PART A - INSPECTION INSTRUCTIONS TO VENDORS

Transcription

1 PART A - INSPECTION INSTRUCTIONS TO VENDORS 1. GENERAL 1.1 This instruction covers the general requirements for shop inspection and testing of equipment and materials (GOODS) to be supplied by the Contractor. Contractor shall be responsible for inclusion of inspection requirements herein and requirements of applicable individual specification as contractual requirements of Sub vendors. 1.2 In addition to the general requirements contained in this specification, the Contractor shall be responsible for all other inspection requirements as defined by documents included in or referenced by the Purchase Order, Requisition, Specification or Data sheets applicable to the Order. 1.3 GOODS for which no individual specification is issued can be inspected and tested in accordance with this instruction and Contractor's standards approved by the Purchaser 1.4 All deviations from this instruction and related inspection specifications shall be previously proposed to the Purchaser in writing and shall be approved by the Purchaser before placement of the order. 1.5 The word "specification(s)" used in this instruction and related inspection specifications often collectively means all technical specifications, drawings, and other technical documents supplied b^ the Purchaser and also specifications and technical documents as may be agreed and/or made by the Contractor and the Purchaser. 2. DEFINITIONS Words used in this instruction and related inspection specifications shall have the following meanings, unless the context requires otherwise : Test Report: Means the individual record or certificate for respective test or inspection. QC Dossier: means the compiled document package consisting of prescribed Purchaser's cover sheet for QC Dossier, Contractor's cover sheet, table of contents, Test Reports, and other necessary documents. Purchaser: means Gujarat Narmada Valley Fertilizer Company limited Purchaser's Inspector: Means inspector(s) dispatched by the Purchaser or inspector(s) of inspection agencies designated by the Purchaser. Owner s Inspector: Means one or combination of inspector(s) dispatched by the Owner and inspector(s) of the inspection agency (agencies) designated by the Owner. Contractor: Sub vendor: Means a supplier or manufacturer of GOODS. Means an organization, company or individual under contract to Contractor for the supply of material, equipment sub-assemblies or services necessary to the completion of Contractor s scope of work. 1

2 3. CODES AND STANDARDS All codes and standards for the inspection of GOODS shall be in accordance with those specified in section 6.1 of the ITB. 4. CLARIFICATION OF CONFLICTS If there is any conflict between the related specifications, codes and standards, the Contractor shall immediately consult with the Purchaser in writing for clarification. Failure of Contractor to seek, in writing, clarification of conflicting requirements prior to acceptance of the Purchase Order shall constitute obligation of Contractor to comply with all of the conflicting requirements at no additional cost, even to the extent that rework and/or retesting may be required. 5. RESPONSIBILITY FOR QUALITY 5.1 Inspection or non-inspection by the Purchaser shall not relieve the Contractor of its obligation for quality control activities and guarantees for the workmanship or performance of the GOODS. 5.2 The Contractor shall be responsible for inspection and testing of the GOODS, including parts and materials supplied by Sub vendors. 5.3 The Contractor shall carry out all inspections and testing specified in the purchase documents. 5.4 All Contractor's fabrication documents, including, but not limited to, welding, nondestructive examination, heat treatment, and major repair procedures, specified in the requisition shall be reviewed and approved by the Purchaser prior to start of fabrication. 6. PRE-INSPECTION MEETING The Purchaser may require holding a pre-inspection meeting(s) at Contractor and/or Sub vendors to resolve questions concerning the compliance with the purchase documents, specifically inspection requirements and related specifications. Final inspection items shall also be defined at the meeting. Contractor shall arrange to provide the following documents for this meeting; 1) Copy (Copies) of Purchaser's requisitions, drawings, specifications of the latest revision and other documents necessary for discussion at the meeting. 2) List of missing documents such as specifications referenced in the Purchaser's requisition, but not received by the Contractor. 3) Questionnaire about Purchaser's documents. 4) Contractor's drawings, diagrams, and schedules. 5) Fabrication procedure 6) Inspection procedure including NDE procedure 7) Written welding documents 8) Major repair procedure 9) Sample of inspection record(s) for a similar jab previously done by the Contractor 10) Other documents considered necessary Contractor shall also arrange for meeting attendance by all Contractor representatives necessary to achieve resolution of technical questions, schedules, 2

3 and inspection requirements. 7. WITNESS INSPECTION NOTICE 7.1 The Contractor shall notify the Purchaser of readiness for witness inspection in writing at least 4 calendar weeks prior to the date when the GOODS will be ready for inspection. The Contractor shall also inform the Purchaser of the definite witness inspection date and time at least 10 working days in advance of the date of the witness inspection. 7.2 Verbal inspection notice is not acceptable. Notice shall be sent to Purchaser by Facsimile (telefax) OR . The inspection notice shall also include the map or the necessary information to reach Contractor's shop, if such information was not given in advance. 7.3 Work shall not proceed beyond "Inspection Hold Points" established by contract correspondence, Specifications or Pre-Inspection Meeting without written authorization of Purchaser. 8. WITNESS INSPECTION Purchaser's and/or Owner's Inspector shall have free entry to those parts or areas of manufacturing shops of the Contractor or its sub vendors where and when work, testing or inspection on the GOODS is being performed. Access shall not be limited to "normal office hours" and escort shall not be required except when agreed for reasons of safety or proprietary work. Where escort restriction is agreed, Contractor and/or Sub vendor shall make escort available during all hours of shop fabrication, testing or inspection. 8.2 Purchaser's and Owner's Inspector reserve the right to monitor, audit, and visit plants or other inspection locations with or without prior notice to the Contractor or Sub vendor. 8.3 For inspection items designated for witness of Purchaser's and/or Owner's inspector, but not designated as inspection hold points, Contractor may, at Contractor's cost and risk, elect to proceed with fabrication after completion of Contractor's in-house inspection, provided that the witness inspection is repeated for witness of the Purchaser's and/or Owner's inspector at time of next inspection visit. 8.4 The Contractor, when so requested, shall provide one additional copy of the latest approved drawings for the use of Owner's Inspector prior to the start of inspection. 8.5 The Contractor shall furnish Purchaser's and/or Owner's Inspector with shop test data, mill certificates, and other materials to verify that each GOODS meets the requirements of the applicable specifications. Free copy, telex, facsimile (tele - fax), and telephone service by the Contractor shall be made available to Purchaser's and/or Owner's Inspector. 8.6 Safety equipment and inspection tools as necessary to safely and expeditiously demonstrate compliance with applicable specifications, as well as assistance from 3

4 Contractor's or Sub vendor's inspection representative shall be made available to Contractor's and/or Owner's Inspectors. 8.7 When requested by the Purchaser, the Contractor shall prepare the required number of QC Dossier, its part, or other documents for Owner's Inspector by the requested date. 8.8 Nothing herein shall preclude Contractor's inspection or contracts representative from accompanying Contractor's and/or Owner's Inspector to Sub vendor locations for inspection purpose. 9. RELEASE FOR SHIPMENT 9.1 Purchaser's Inspector will issue "Inspection Release Note" to the Contractor shortly after the final inspection and review of QC Dossier prepared by the Contractor. 9.2 The Contractor shall not ship any GOODS without securing the Inspection Release Note. 9.3 When the Contractor is permitted to ship on condition to perform the additional work at the work site, the Contractor shall bear all costs and expenses incurred by such work. (1) Special provision for storage or proper care (2) Repair and/or Inspection 10. DOCUMENTATION Incomplete, inaccurate or illegible documentation shall be the cause for rejection of GOODS until such time as satisfactory rectification has been effected Documents to be Submitted All Contractor's inspection and test procedures, including, but not limited to, welding, nondestructive examination, heat treatment, definition of major repairs, and major repair procedures, required for submittal in the requisition shall be reviewed and approved by the Purchaser prior to start of fabrication or prior to use, whichever is the earlier. (1) The Contractor shall submit to the Purchaser 5 white copies for documents such as Contractor's shop inspection and test procedure and welding procedure specification as required. Unless otherwise specified, all these documents shall be prepared in English. The Contractor will be requested to submit these documents prior to fabrication. (2) The Purchaser will need a maximum of fifteen (15) working days, excluding mailing time, from the receipt of the Contractor document to study and accept or give alternative decisions Submittal of QC Dossier (1) The Contractor shall prepare QC Dossier in English and submit 5 white copies to the Purchaser within seven (7) working days after completion of the final inspection of the GOODS. (2) For details of QC Dossier preparation, refer to section 11 of this specification. 4

5 11. PREPARATION OF QC DOSSIER 11.1 Unit of Preparation (1) The QC Dossier of individual pressure vessels, heat exchangers, tanks, and towers shall be prepared for each equipment. (2) The QC Dossier of unit or packaged items such as boiler units, compressor units, etc. shall be prepared for each unit or package including subsidiary equipment and accessories. (3) The QC Dossier of materials, pumps, valves, fittings, instruments, and electrical equipment, which are not included in (1) and (2) above, may be prepared for each order. In case of partial shipment, the QC Dossier may be divided for each shipment Forms To prepare the QC Dossier, the Contractor may use its standard forms Compilation (1) As far as possible, A4 (210mm X 297mm) or 8-1/2 in. x 11 in. size paper shall be used for the test report sheet. For larger sizes, A3 ( 297 mm X 420 mm) may be used, folded to A4 size. When thickness of the QC Dossier is too thick to compile in one package, it can be divided into two or more packages. (2) Construction of QC Dossier As far as possible, Test Reports in the QC Dossier shall be in the following order : (a) List of material certificates with part Nos. and part names (b) Material certificates (c) Nondestructive examination records (d) Visual inspection certificates (e) Dimensional inspection records (f) PWHT chart and thermocouple location map (g) Hydrostatic test records, Leak test records (h) Running test records, Performance test records, Operation test records (i) Nameplate rubbing (j) Cross Sectional Drawings / GA Drawings / Fabrication Drawings, Tolerances for precision parts, etc. (j ) Operation & Maintenance Instructions for machinery Signature Requirements (1) Each document in QC Dossier shall have the verification signature by the Contractor. (2) Signature by Purchaser's Inspector When witness inspection or review of documents is done by Purchaser's Inspector, each respective sheet of the QC Dossier shall bear either witness signature or review signature of Purchaser's Inspector. (3) Each test report sheet shall have the following data or information in addition to signatures : Test data and/or results Date of test Identification of components tested 5

6 11.5 SOFT COPIES Apart from Hard Copies, Soft Copies as per following descriptions shall be submitted by the Contractor: No. Of Copies: 2 Sets. Medium: CD R of reputed make viz. SONY / SAMSUNG / MOSER BAER Formats: All Drawings shall be in AUTO CAD All reports shall be in Editable Format Measuring Units (1) In principle, measuring units on QC Dossier documents shall be metric unit except English unit may be applied for pipe, fitting, flange, flange bolts/nuts, and rating. (2) Units for mill certificates of raw materials may be in accordance with specified codes and standards applicable to such materials Retention of Test Report Contractor shall retain original sheets of Test Report for at least 5 years after shipment of GOODS. 6

7 PART B - INSPECTION PHILOSOPHY FOR PRESSURE VESSELS AND HEAT EXCHANGERS 1. CODES AND STANDARDS The requirements in the following codes and standards also form a part of the requirements of this specification. (1) ASME Code, Section II (2) ASME Code, Section VIII, Division 1 (3) ASME Code, Section V (4) ASME Code, Section IX (5) TEMA (6) Codes, standards & regulations listed at Section 6.1 of the ITB. (7) Other codes, standards and regulations specified in each individual specification 2. Main materials shall be verified to conform to the specified materials by mill test reports. The mill test reports shall include chemical analysis of each lot or heat of material and a statement that it has been tested in accordance with and meets the physical and mechanical requirements of the applicable specification. 3. WITNESS INSPECTION 3.1 Pressure vessels for which ASME official code stamps (U) is required shall be inspected by the ASME Authorized Inspector in accordance with the requirements of ASME Code, Section VIII, Division In addition, all pressure vessels shall be subject to inspection, at the option of the Purchaser or representatives of the Purchaser at all reasonable times and places before, during and/or after fabrication. 3.3 Witness test and inspection agenda shall be in accordance with Table The Owner has the right of access to the Contractor's or Sub vendor's shop for inspection matters. If the Contractor received any instruction from the Owner's Inspector, the Contractor should report to the Purchaser before making any changes. 4. PRINCIPAL REQUIREMENTS All inspection and tests shall conform to the requirements of ASME Code, Section VIII, Division ADDITIONAL REQUIREMENTS TO ASME CODE The following inspections shall be carried out in addition to, but not be limited to, the requirements of ASME Codes. 5.1 Material 1) The following materials for the pressure parts shall be inspected by ultrasonic examination method in accordance with SA-578 Level B of ASME Code, Section II. Test results shall be described in mill test reports. (a) Carbon steel plates of 50 mm (2 inches) thick and over 7

8 (b) (c) Low-alloy steel plates of 25 mm (1 inch) thick and over Low temperature service carbon steel plates of 19 mm (3/4 inch) thick and over Pressure Parts having thickness from 16 mm to 50 mm shall be ultrasonically tested as per SA ) For heat treated materials, test specimens shall be prepared from actual vessel material which has been subjected to an equivalent total thermal treatment as the vessel material in the final fabricated condition. 3) Chemical analysis of weld filler metal shall be certified by the weld filler metal supplier. 5.2 Radiographic Examination 1) In addition to radiographic examination required by the ASME Code or design drawings, the Purchaser reserves the right to take additional exposures as desired to check weld quality. 2) When spot radiography is specified, the radiographic examination shall be made as follows: - For cylindrical vessels, one spot radiograph shall be taken in each circumferential joint and in each longitudinal joint between adjacent circumferential joints at locations designated by the Purchaser's Inspector. - All T joints shall be radiographed. When 100 % or Full Radiography is specified, radiography shall be taken for 100 % of the Butt Joints, including those of Nozzles of all sizes. 3) If any part of a shell or head seam will be covered by a nozzle reinforcing pad or other structural overlay, that portion of the seam shall be spot radio graphed before it is covered. 5.3 Magnetic Particle Examination 1) Magnetic particle examination shall be carried out for all welded joints of low-alloy steel and lifting lugs in accordance with Appendix 6 of ASME Code, Section VIII, Division 1. 2) For 100% radio graphed vessels, all welded joints between nozzles and vessel shell and between nozzles and flanges shall be examined by the magnetic particle method prior to the installation of any reinforcing pads. This examination shall include: - The back side of the root area after the root pass has been back gouged or ground in preparation for the welding required to complete the joint. - Both sides of the complete weld. 3) Final nozzle welds shall be examined by the magnetic particle method after post weld heat treatment, unless these welds are inaccessible. 4) When magnetic particle examination is specified, the DC prod method shall be used prior to final post weld heat treatment, and the AC yoke or coil method after final post weld heat treatment. 8

9 5) Nonmagnetic materials shall be examined by the liquid penetrant method in accordance with Appendix 8 of ASME Code, Section VIII, Division 1 for the same weld joints as defined in above paragraphs, instead of magnetic particle examination. 6) For materials having either: a) a minimum specified tensile strength of 551 MPa (80,000 psi) or greater, or b) a total nominal alloy content greater than 4 percent, or c) a thickness of 38 mm (1-1/2 inches) or greater, All attachment welds and all areas where fit up bars, etc. are temporarily attached shall be examined by magnetic particle method, before final post weld heat treatment (PWHT), and after hydrostatic testing. Austenitic steels and nickel steels are exceptions. 5.4 All forgings except for flanges as per ANSI shall be UT tested as per ASTM A 388 for the thickness greater than 100 mm and shall be procured in normalized/annealed condition. Acceptance standards shall be as per AM of ASME Section VIII Div. 2. In case any defect is found, no repair by welding shall be allowed. 5.5 All forgings including nozzle flanges shall be examined for surface defects by MP/PT testing after machining as per ASTM A Tube sheet and Girth flanges shall of forged quality & ultrasonic tested not have any segmental weld joint. 5.7 All heat exchanger tubes shall be 100% eddy current tested in addition to hydro testing 5.8 Hydrostatic Tests 1) Vessels fabricated in shop shall be subject to hydrostatic test in horizontal position in the fabricator's shop. Water temperature for hydrostatic test shall not be lower than 15 C during the test. Where the ductile-to-brittle transition temperature of steel is known to be, or suspected to be 4 C or higher, it is the fabricator's responsibility to raise the temperature of the water to at least 15 C higher than the transition temperature. Vessels fabricated from solid, clad or lined austenitic stainless steel shall be tested with potable water containing minimum concentration of chloride and not more than 50 ppm chloride. Test gaskets for nozzles connecting to piping or instruments may be of asbestos or other materials. Test gaskets for other than the above shall be of same specification as service gaskets. Such gaskets used for hydrostatic tests shall be shipped in place. In addition, two sets of service gaskets (one for replacing at site and another for construction spare) shall be shipped loose together with the equipment. 2) The test pressure shall be held for one hour or one hour per inch of vessel thickness, whichever longer. 9

10 3) When austenitic stainless steel materials will be exposed to water during hydro testing or water washing, the following shall apply: a) Only treated water or freshwater with less than 50 ppm total chlorides and ph greater than 7 shall be used. b) The water shall be drained immediately after testing or washing and the vessel shall be dried by blowing with dry air or dry nitrogen. 4) Heat Exchanger Testing a) Hydrostatic test methods and sequence shall be established before fabrication and submitted for the approval of the Purchaser. b) Heat exchangers shall be alternately hydro tested on each side with no water in the other side being exposed. c) Girth flange joints taken apart after hydrostatic test shall be reassembled with unused gaskets and retested for tightness by air at the design pressure. 5.9 Leak Tests 1) When specified, pressure vessels shall be leak tested at the air pressure specified on the individual specification and/or drawing. 2) All reinforcing plates shall be tested at air pressure of 1 to 1.4 Kg/cm^ (15 to 20 psig) unless otherwise specified. 3) All tube to tubesheet weld joints of heat exchangers shall be leak tested at the air & with pressure specified on the drawings Impact Tests 1) Materials of each pressure-containing component, welding procedure qualification test plates and production impact test plates shall be impact tested on the basis of individual material specification (class of steel), thickness, and design temperature specified for each item in the individual specification in accordance with ASME Code, Section VIII, Division 1. 2) Shells, heads, nozzles, man ways, reinforcing pads, flanges, skirts, tube sheets, flat cover plates, support lugs, etc., shall be treated as separate components. 3) Results of impact tests shall be incorporated into the vessel records and submitted to the Purchaser. The data shall include specimen size, direction in which material being tested (longitudinal or transverse), test temperature, breaking energy of each specimen, and average values of breaking energy for a set of three specimens Hardness Tests 1) If post weld heat treatment is required, Brinell hardness tests of the base metal, weld metal and heat affected zone (HAZ) shall be made for weld seams of pressure vessels of P-l, P-3, P-4, P-5, P-6, P-7, p-1oa and P-10B materials listed in ASME Code Section IX. The Brinell hardness shall not exceed the limits set in Table

11 Table 5.7 Material P-Number Maximum Brinell Hardness P-l 200 P-3, P P-5, P P P-10a, P-10B 225 2) When hardness test is required by Paragraph 1) above, the detailed requirements for the hardness test shall be in accordance with the following procedure. a) The hardness testing shall be conducted following the completion of all post weld heat treatments. b) The surface hardness test shall be made with a Brinell testing machine or a portable hardness tester such as a Telebrineller using a 10 mm ball. c) The hardness tests for the HAZ shall be made with the ball centered in the HAZ (representing a composite of weld metal, HAZ, and base metal). d) Surface preparation shall consist of filing, grinding, machining, or polishing with abrasive material the areas to be tested so that the edge of the impression shall be clearly defined to permit the measurement of the diameter to mm. Care should be taken to avoid overheating or cold working the surface. Adjacent reading shall be at least 2-1/2 diameter apart, edge to edge. e) Should surface preparation or instrument applicable be difficult, a mockup with identical condition shall be used. f) Where hardness values are determined to be in excess of the allowable limit, sufficient additional reading shall be taken to fully delineate the extent of the deficiency. g) Verification of hardness value shall be performed on the following points. - Each cylinder circumferential seam: one hardness test per seam - Each cylinder longitudinal seam: one hardness test per seam - Sphere seams: - One hardness test per seam at weld line intersection - Fillet weld seam tested by mockup: one hardness test per order for each welding process, filler metal, and technique used 5.12 Dimensional Inspection 1) Dimensional tolerance other than specified in ASME Code Section VIII, Division 1 shall be in accordance with the attached drawings in Figure 1. In addition to the above, the dimensional tolerances specified in TEMA shall be applied to heat exchangers. 2) Nozzle flange dimensions shall be within the tolerance of the pertinent standards for flanges. 3) Agitator mounting flanges shall be machined after welding to shell and the flange face shall be parallel with the indicated plane in any direction Welding Procedure Specifications and Procedure Qualification Records 1) Before starting to weld, welding procedure specification (WPS) and procedure 11

12 qualification record (PQR) shall be submitted to the Purchaser for approval. The formats shall be Form QW-482 and QW-483 of ASME Code Section IX or equivalent. 2) PQR on carbon steel and other materials for which hardness limit is specified shall include hardness measurement across the weld metal, HAZ and base metal to assure that the WPS is adequate for producing the allowable hardness. 3) The WPS/PQR shall meet the requirements of ASME Code Section IX. 4) Weld maps shall be attached to WPS and PQR. The maps shall show the traceability of WPS No. to the weld line of each vessel. 5) Weld repair procedures shall be submitted to the Purchaser for approval, before starting of repair work Surface Finishing When surface finishing such as buff finishing and electro polishing is specified, the finishing of each component shall be visually inspected before assembling by comparing with sample pieces accepted in advance by the Purchaser. Three sample pieces shall be submitted for approval. (Sample piece size : 100 mm x 100 mm x 3 or 6 mm thick, or 4 in. x 4 in. x 1/8 or 1/4 in. thick) 5.15 Tubular Heat Exchangers 1) Actual inside diameter of exchanger shells shall be measured completely around three cross sections of the shell. Maximum diameter shall not exceed design diameter by more than 3.2 mm (1/8 inch) as determined by circumferential measurement. 2) Transverse baffle to shell clearances greater than specified in TEMA Table R-4.3 shall not be used. 3) A template consisting of two discs with diameters equal to baffle diameters, rigidly fixed on a shaft and spaced not less than 304 mm (12 inches) apart, shall pass completely through the shell after completion of all welds and post weld heat treatment(pwht). 4) After fabrication and PWHT, the deviation from a plane for tubesheet and girth flange gasket surface, including peripheral and pass partition sections, shall not exceed 0.8 mm, as measured with dial indicators. 5) All matching nozzle of stacked exchangers must be within 3.2 mm (1/8 inch) in any direction. Matching gasket faces including tubesheet surface must be parallel to within 0.8 mm (1/32 inch). 6) All nondestructive examinations for final welds required by the purchaser shall be performed after PWHT, if PWHT is specified. 7) Shell flanges, channel flanges, channel covers, tube sheets and split rings shall have the manufacturer's serial number applied with steel stencils. 8) Seal welds or strength welds between tubes and tube sheets shall be examined by the liquid penetrant method according to Appendix 8 of the ASME Code, Section VIII, Division PNEUMATIC TESTING All reinforcing plates shall be tested at the air pressure not less than 3.4 bar g. Reinforcing plates and other attachments with vent holes on vessels subject to 12

13 post weld heat treatment shall be pneumatically tested before and after post weld heat treatment Sleeve lined nozzles in clad vessels shall be tested at the air pressure not less than 3.4 bar g Strip lined plates shall be tested at the air pressure specified in the data sheets If specified in the data sheets, vessels shall be subject to a leakage test at the air pressure specified in the data sheets after hydrostatic test. 6. DOCUMENT SUBMITTAL The documents prescribed in the Section A above. 6.1 Detailed Inspection and Test Procedure Unless otherwise specified, the Contractor shall submit the Detailed Inspection and Test Procedure for the Purchaser's approval within 12 weeks after the date of purchase order or by 8 weeks in advance of the date of the first inspection, whichever is earlier. The Procedure shall cover at least the following items and shall meet requirements of all inquiry and purchase documents, including related Contractor's and Purchaser's correspondence. 1) Inspection and test agenda 2) Specific test methods including test equipment 3) Acceptance criteria 4) Test report and test certificate to be submitted (See Table 3) 6.2 Welding Procedure Specifications and Procedure Qualification Records Welding procedure specifications including for the applicable equipment and the procedure qualification records shall be prepared in accordance with Paragraph 5.9 of this specification by the manufacturer. WPS/PQR with Weld Map shall be submitted and approved before starting fabrication and not necessary to be included in QC Dossier. For welding procedures already qualified, the certified records may only be reviewed. 6.3 Fabrication Procedure Fabrication procedure including hot forming procedure and post weld heat treatment procedure shall be submitted for approval of the Purchaser prior to the start of fabrication. 6.4 Welder Qualification Records Welder qualification records and qualified welders list for this job shall be prepared by the manufacturer. They shall be available to Purchaser's Inspector at fabrication shop. 6.5 QC Dossier (Test and Inspection Reports) After final inspection, all test records and/or test certificates for inspection and test given in Table 3 shall be issued as a form of QC Dossier. 13

14 Figure 1a STANDARD TOLERANCES FOR PRESSURE VESSELS (EXCEPT SHELL AND TUBE HEAT EXCHANGERS) 1 PASS 14

15 TRAY SUPPORT Unit. Figure Ib STANDARD TOLERANCES FOR PRESSURE VESSELS (EXCEPT SHELL AND TUBE HEAT EXCHANGERS) DIMENSION TO BE MEASURED TOLERANCES (UNIT mm) (NOTE1) 1. FROM T.L. TO T.L. LARGER OF ± 13 OR 1.5/m MAX. ± FROM T.L. TO C.L. OF MANHOLES INCLINES OF MANHOLE FLANGES FROM 1 Deg INDICATED PLANE IN ANY DIRECTION 4. FROM INSIDE OF VESSELS TO MANHOLE + 10 FLANGES 5. FROM T.L. TO C.L. OF NOZZLES INCLINES OF NOZZLE FLANGES FROM ½ Deg INDICATED PLANE IN ANY DIRECTION 7. FROM OUTSIDE OF VESSELS TO NOZZLE + 5 FLANGES 8. FROM BOTTOM OF DOWNCOMER TO + 3 TRAY FLOORS 9. HEIGHT OF WEIR (ABOVE DOWNCOMER SUPPORT) 10. FROM C.L. OF HEAD TO C.L. OF NOZZLES ORIENTATION OF NOZZLES AND OTHER + 6 ATTACHMENTS 12. FROM TRAY TO TRAY LEVEL OF SUPPORT RINGS (NOTE 2) Upto 1200 mm ID INCL 2 From 1201 to From 2101 to From 4001 to From 6001 to From 8001 to FROM T.L. TO TRAY SUPPORT RINGS FROM TRAYS TO NOZZLE C.L. OF NOZZLES OUT-OF-ROUNDNESS OF CYLINDRICAL SHELL a. VESSELS WITH TRAYS % ID b. VESSELS WITH TIE-ROD TRAYS % ID min + 3 c. VESSELS WITHOUT TRAYS +1 % (Note 3) INSIDE DIAMETER AS MEASURED BY EXTERNAL STRAPPING Upto 1200 mm ID INCL + 3 From 1201 to From 2101 to From 4001 to From 6001 to From 8001 to Head A & B Outside I.D. X

16 Inside I.D. X 0.625% 18. Deviation from Straight applied to LESS THAN 6 PER 6000 AND Shell. LESS THAN 20 PER TOTAL LENGTH 19. Skirt Length From TL to Lug +6 Figure Ic STANDARD TOLERANCES FOR PRESSURE VESSELS (EXCEPT SHELL AND TUBE TYPE SHELL AND TUBE HEAT EXCHANGERS) DIMENSION TO BE MEASURED TOLERANCES (UNIT mm) (NOTE 1) 21. LEVEL OF BASE PATE & SUPPORT Up to 1200 mm ID INCL 3 From 1201 to From 2101 to From 4001 to From 6001 to From 8001 to B.C.D. OF ANCHOR BOLTS UPTO 2100 INCL + 3 Over SUPPORT FOR HORIZONTAL VESSELS a. PITCH OF BOLT HOLES UPTO 2100 INCL + 3 Over b. FROM T.L. TO CENTER OF ANCHOR + 3 BOLTS c. HEIGHT OF SUPPORT FROM T.L. TO FLANGE OF BOTTOM OR TOP NOZZLES FOR LEVEL GAUGES a. PITCH + 2 b. ALIGNMENT LESS THAN 1 c. ALIGNMENT OF ORIENTATION LESS THAN ROTATION OF FLANGES LOCATION OF PLATFORMS, LADDERS, ELE + 10 PIPE SUPPORTS AND LUGS (E.L.) 28. DEVIATION FROM VERTICAL PLANE ON + 20 TRUE CENTER LINE FROM BASE TO TOP OF VESSEL NOTE 1: NOTE 2: NOTE 3: TOLERANCES ARE NOT CUMULATIVE MAX. 6 FOR THE PORTION OF SUPPORT RING THAT WEIR IS ATTACHED. WHEN THE CROSS SECTION PASSES THROUGH AN OPENING, THE PERMISSIBLE DIFFERENCE IN INSIDE DIAMETERS MAY BE INCREASED BY TWO PERCENT OF THE DIAMETER OF OPENING. 16

17 Table 3 INSPECTION & TEST AGENDA AND DOCUMENTS TO BE ISSUED TEST & INSPECTION TEST TEST AGENDA CATEGORY REPORT REMARKS MATERIAL TEST (INCLUDING R REQD BY MILL TEST UT & IMPACT) REPORT (Note 2) FORMED VISUAL INSP & W - TOGETHER WITH HEAD DIMENSIONAL MEAS SHELL ULTRASONIC EXAM R REQD ONLY FOR CLAD WELDED FIT UP, EDGE PREP, W - BY SAMPLING JOINT BACK CHIPPING RADIOGRAPHIC EXAM R REQD FILM CHECK LIQ PEN EXAM W REQD BY SAMPLING M.P. EXAM W REQD BY SAMPLING IMPACT TEST W REQD HARDNESS TEST W REQD VISUAL INSP & DIMENSIONAL MEASUREMENT OF BODY W REQD NOTE 3 VISUAL INSP & DIMENSIONAL MEASUREMENT OF INTERNAL W REQD POST WELD HEAT TREATMENT R REQD BY CHART PNEUMATIC TEST FOR REINF PAD R REQD HYDROSTATIC TESTING W REQD PNEUMATIC TEST W REQD MANUFACTURER S DATA REPORT R REQD ASME FORM RUBBING (COPY) OF NAMEPLATE R REQD. Table 3 INSPECTION AND TEST AGENDA AND DOCUMENTS TO BE ISSUED (Cont'd) Note Note 1) W: Witness Inspection R: Review of the manufacturing test report Test Category: Purchaser's inspection 2) Provide "Sketch of Materials" or "List of Materials" Mill test reports for the following parts, but not limited to, shall be submitted. - Shells, shell flanges, shell covers, channels, and channel flanges - Tube sheets, Tubes - Nozzles, nozzle flanges, and reinforcing plates for nozzles -Parts integrated with the pressure parts 17

18 FEED STOCK CONVERSION SECTION INSPECTION PHILOSOPHY Note -Bolts and nuts for shells, shell covers and channel flanges 3) The following inspection shall be conducted as the interim witness inspection for shell and tube heat exchangers: - Use of specified gaskets and means of holding them in place - Ease of bundle insertion - Bolt makeup and loading - Assembly of stacked exchangers, if any. PART C - INSPECTION PHILOSOPHY FOR COLUMN TRAYS 1. GENERAL Inspection Philosophy for trays shall be read in conjunction with Section A & Section B of the Inspection Philosophy, Section of the ITB. 2 CODES AND STANDARDS 2.1 Only the latest editions of regulations, codes, and standards in force at the time of order placement shall be applied, unless otherwise specified. 2.2 The requirements in the following codes and standards form a part of the requirements of this specification: (1) National standards in regard to materials of the countries from which the materials are supplied. These standards shall, however, be previously approved by the Purchaser. (2) Other codes and standards specified in each individual specification. 3. WITNESS INSPECTION 3.1 All trays shall be subject to inspection, at the option of the Purchaser, under witness by the Purchaser or designated representative of the Purchaser at any reasonable time and place before, during, and after manufacture/fabrication. 3.2 Witness inspection and test agenda shall be in accordance with Table 1, 3.3 The owner has the right of access to the Vendor's or Subvendor's shops for inspection matters. If the vendor received any instruction from the Owner's Inspector, the Vendor should report to the Purchaser before making any changes. 4. INSPECTION AND TEST AGENDA 4.1 Material 1) Material shall be verified to conform to the specified materials by mill test reports or material certificates. 2) Mill test reports or material certificates for such main parts as tray floor, down comer, weir, seal pan and tray support beam and for other specified parts shall be submitted. 3) For other parts than specified above, mill test report or material certificates for corrosion resistant austenitic stainless steel and higher grade material shall be also submitted. 4.2 Visual Inspection 1) All parts shall be visually checked for workmanship. 2) Surface shall be confirmed to have no harmful effect such as creases or chap. 3) Cutting face and punched hole shall be confirmed not to be stripped greatly. 4) Slag and spatter caused by welding shall be confirmed to be removed 5) When surface finishing such as buff finishing and electro polishing is specified, the

19 FEED STOCK CONVERSION SECTION INSPECTION PHILOSOPHY finishing shall be visually inspected by comparing with sample pieces accepted in advance by the Purchaser. Three sample pieces shall be submitted for approval. (Sample piece size : 100 mm x 100 mm x 3 or 6 mm thick, or 4 in. x 4 in. x 1/8 or 1/4 in. thick) 4.3 Dimensional Inspection Dimensional measurement shall be performed against certified dimensional drawings. Unless otherwise specified, tolerances shall be as follows: (1) Tray Floor (a) Length Up to 1000 mm, incl. ±2.0 mm Over 1000 mm - up to 2000 mm, incl. ±2.5 mm Over 2000 mm ±3.5 mm (b) Width ±2 mm (c) Flatness (2) Downcomer and Weir (a) Straightness for upper line of weir and lower line of down comer ±1.5 mm per 1000 mm at any place ±1 mm (b) Length Up to 1500 mm, incl. Over 1500 mm (c) Width (d) Flatness at any place ±2.5mm ±4.5 mm ±1.5 mm ±1.5 mm per 1000 mm (3) Punched hole for perforated tray Diameter +0.3 mm 4.4 Temporary Assembly Inspection All stages of tray shall be temporarily assembled at the Vendor's or Sub vendor's shop to confirm fit-up without trouble about pitch of bolt holes. Main dimensions shall be within the following tolerances. Diameter of Tray (1) Inside diameter specified of tower Up to 2000 mm, incl. +0 mm -4 mm 2001 mm and over +0 mm -5 mm (2) Flatness of tray floor +1.5 mm per 1000 mm at any place (3) Height of weir above the upper surface of tray floor ±1.5 mm 5. DOCUMENT SUBMITTAL The documents prescribed in the following paragraphs shall be submitted in accordance with Section A Inspection Instruction to the Vendors above. 5.1 Detailed Inspection and Test Procedure Unless otherwise specified, the vendor shall submit Detailed Inspection and Test Procedure for the Purchaser's approval within 12 weeks after the date of purchase order or 8 weeks in advance of the date of the first inspection, whichever is earlier

20 FEED STOCK CONVERSION SECTION INSPECTION PHILOSOPHY The procedure shall cover at least the following items and shall meet requirements of all inquiry and purchase documents, including related vendor's and Purchaser's correspondence. 1) Inspection and test agenda 2) Specific test methods including test equipment 3) Acceptance criteria 4) Test report and test certificate to be submitted 5.2 QC Dossier (Test and Inspection Reports) After final inspection, all test records and/or test certificates for inspection and test given in Table 1 shall be issued as a form of QC Dossier. Table 1 INSPECTION AND TEST AGENDA AND DOCUMENTS TO BE ISSUED Inspection & Test Test Category Test Report Remarks Material Test R Required By Mill Test Report/Material Certificate Visual Inspection W Required Incl.inspection of Buff Finishing Dimensional Insp. W Required Temp. Assembly Insp. W Required Note: 1) W: Witness R: Review of manufacturing test report Test Category : Purchaser s Inspection