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JNK HEATERS CO.

LTD.

DOC NO:
TITLE:

DANGOTE OIL
REFINING
COMPANY LIMITED.

A545-JNK-121-XX-XX-XXXX
FABRICATION ENQUIRY OF DUCTS AND DUCT SUPPORT
(121-FF-2001 A/B)

OWNER

DANGOTE OIL REFINING COMPANY LTD.

PMC

ENGINEERS INDIA LIMITED

DEC

JNK HEATERS CO. LTD.

UNIT

: 121-FF-2001 A/B

DOCUMENT SUBMISSION STATUS JNK


DOC. CATEGORY: (USE TICK MARK)
A

REV :
DATE :

0
17-02-2016

REVIEW STATUS - EIL


(1) REVIEWED - NO COMMENTS

(2) REVIEWED, AS COMMENTED, BUT REVISED DRAWING


REQUIRED

ISSUED FOR
(3) NOT MEETING SPECIFICATION, RESUBMIT
INFORMATION

APPROVAL

ENQUIRY

ORDER

CONSTRUCTION

REVIEW

(4) RETAINED FOR INFORMATION / RECORDS

NAME

DISCIPLINE

SIGN.

DATE

Issued for Enquiry

TA

MS

DS

17-02-2016

Rev.

Description

Prepared By

Reviewed By

Approved By

Approved Date

JNK HEATERS CO. LTD. ALL RIGHTS RESERVED


THIS DOCUMENT AND ANY DATA AND INFORMATION CONTAINED THEREIN ARE CONFIDENTIAL AND THE PROPERTY OF JNK HEATERS CO. LTD. (JNK) AND THE COPYRIGHT
THEREIN IS VESTED IN JNK NO PART OF THIS DOCUMENT, DATA, OR INFORMATION SHALL BE DISCLOSED TO OTHERS OR REPRODUCED IN ANY MANNER OR USED FOR ANY
PURPOSE WHATSOEVER, EXCEPT WITH THE PRIOR WRITTEN PERMISSION OF JNK

DANGOTE OIL REFINING


COMPANY LIMITED

JNK HEATERS CO. LTD.


UNIT: PFR HEATER (121-FF-2001 A/B)
COMPONENT: Ducts and Duct Support Modules

Rev: 00
Date: 15-02-2016

1. Introduction:
This doument defines the scope of work for procurement, fabrication, modularization, material
handling (Raw and completed modules) for
PFR HEATER - Ducts and Duct Supports
PFR HEATER (121-FF-2001 A/B)
2. Reference Drawings/ Documents
Sr.
No of
Drawing/ Document No
Drawing Document Title
Rev
Remarks
No.
Pages
1

A545-121-05-42-0100

EIL Documents
Foundation Loading Plan

A545-121-05-42-0201

General Arrangement Cross section & Plan

A545-121-05-42-0202

General Arrangement Long section & Plan

4
5
6
7
8
9
10
11
12

A545-121-05-42-0203
A545-121-05-42-0204
A545-121-05-42-0205
A545-121-05-42-1206
A545-121-05-42-0207
A545-121-05-42-0120
A545-121-05-42-0121
A545-121-05-42-0122
A545-121-05-42-0123

General Arrangement of Plans-I


General Arrangement of Plans-Il
General Arrangement Stack & Plans

B
B
B
B
B
B
B
B
B

1
1
1
1
1
1
1
1
1

13

6-17-0001

Standard Specification for Execution of Fired


Heaters & APH System

13

14

6-17-0002

Standard Specification for Steel Work of Fired


Heater & APH System

12

15

6-17-0003

Standard Specification of Coil Work for Fired


Heater

19

16

6-76-0001

Standard Specification for Erection of


Equipment & Machinery for Fired Heaters

22

17

A 545-999-05-42-SP-12

Standard Specification for Quality checks for


Fabrication Erection and Execution of Fired
Heaters

10

18

7-17-0454 & 7-17-0455

Standard Steel Ladder details

19
20
21

7-17-0461
7-17-0456
6-81-0001 & 6-81-0002

Standard Steel Handrail details


Standard Steel Stair details
Standard Specification of PMI

3
3
2

22

Painting Specification

8
1
5
18
10

23

Inspection and Test Plan for Steel Structure


Fabrication
Inspection and Test Plan for Coil Works

A
A

7
5

24

3. Quantum of Work

Intermediate Tube Sheet & Tube Sheet Bracket

Str Member Configuration Frame Detail


APH System Ducting Layout Plans-1
APH System Ducting Layout Plans-2
APH System Ducting Elevation-1
APH System Ducting Elevation-2

DANGOTE OIL REFINING


COMPANY LIMITED

JNK HEATERS CO. LTD.


UNIT: PFR HEATER (121-FF-2001 A/B)
COMPONENT: Ducts and Duct Support Modules
Sr.
No.

2
4
5
6

Item Description
Steel Structure - Duct casing,
Stiffeners, doors, support saddles
Open Structure - Duct Supports,
APH Supports, Platforms,
Handrails, Ladders
Instrument Nozzles 2"/3"
Refractory Anchors
Retainer Plates
Lifting and Transportation Steel

Material

Rev: 00
Date: 15-02-2016
UOM Quantum Of Work

Remarks

Grade
S275JR
conforming to
EN10025

MT

374

With all Applicable NDT

MT

145

With all Applicable NDT

SS310
SS316L
SS310/304
S275JR

Nos
Nos
MT
MT

50
121030
2.5
52

With all Applicable NDT


With all Applicable NDT
With all Applicable NDT
With all Applicable NDT

4. Scope of Modularization
1 Ducts to be modularised in length of 10-12m
2 Details of Splices to be provided in Details drawings.
3 Open structure to be modularised in portals and loose beams.
4 Assembly of Opem structure into Modules shall be carried out at Port area or at Site on grade.
5 Platforms to be dispatched in panels along with gratings installed.
6 Gratings shall be FIM
Components to be included in Module and Scope Split
Scope of Supply
Sr.
Item Description
No.
JNK
Vendor
X
1 Engineering Drawings
Steel Structure- Casing Plates, stiffeners,
doors, supprt saddles, all attaching
X
component flanges.
2
X
3 RefractoryInsulation Stud/ Anchors Supply
X
4 RefractoryInsulation Stud/ Anchors Welding
X
5 Refractory/ Insulation
X
6 All Doors
X
7 Instrument nozzles including flanges & fittings
X
8 Instruments
X
9 Support Structure for Transportation
X
10 Lifting Gear for Module Handling
X
11 Lifting Steel
12
13

P&M for Job Completion till load out on ship

Enabling Steel

FIM Date

Remarks

Including internal
Transit

Vendor to refer attached drawings for Complete module details. Above mentioned list is not exaustive
All works (Fabrication & Installation) required for completion of the job shall be Vendor's scope.
5. Work Schedule
1. Overall Delivery for all Modules
- 10 Months

10

11

12

13

14

15

16

REFERENCE DRAWING TITLE

REF. DWG. NO.

DATE

REVISIONS

BY

CHKD APPD

(A Govt. of India Undertaking)

COMBINED FEED HEATER (121-FF-1001/1002) & PRODUCT


FRACTIONATOR REBOILER HEATER (121-FF-2001A/B)
FOUNDATION LOADING PLAN
SCALE

1:120
1

10

11

12

13

14

JOB NO.

A 5 4 5
15

UNIT

DIVN. DEPT.

1 2 1 0

DWG. NO.

REV.

1 0

5 4 2 0

16

3-1641-0500 REV.2

A0-1189 x 841

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

REFERENCE DRAWING TITLE

DATE

DIAGRAMMATIC ELEVATION OF CROSS SECTION


SCALE

1:50

REVISIONS

JOB NO.
UNIT

REF. DWG. NO.

NOTES :-

HOLD

BY

DIVN. DEPT.

CHKD APPD

PRODUCT FRACTIONATOR REBOILER HEATER (121-FF-2001A/B)

A 5 4 5 1 2 1 0 5 4 2 0 2 0 1

DWG. NO.

3-1641-0500 REV.2

REV.

A0-1189 x 841

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

REFERENCE DRAWING TITLE

DATE

SCALE

1:50

JOB NO.
UNIT

REF. DWG. NO.

REVISIONS
BY

DIVN. DEPT.

CHKD APPD

PRODUCT FRACTIONATOR REBOILER HEATER (121-FF-2001A/B)

A 5 4 5 1 2 1 0 5 4 2 0 2 0 2

DWG. NO.

3-1641-0500 REV.2

REV.

A0-1189 x 841

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

REFERENCE DRAWING TITLE

DATE

SCALE

1:50

REVISIONS

JOB NO.
UNIT

REF. DWG. NO.

BY

DIVN. DEPT.

CHKD APPD

PRODUCT FRACTIONATOR REBOILER HEATER (121-FF-2001A/B)

A 5 4 5 1 2 1 0 5 4 2 0 2 0 3

DWG. NO.

3-1641-0500 REV.2

REV.

A0-1189 x 841

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

REFERENCE DRAWING TITLE

DATE

SCALE

1:50

REVISIONS

JOB NO.
UNIT

REF. DWG. NO.

BY

DIVN. DEPT.

CHKD APPD

PRODUCT FRACTIONATOR REBOILER HEATER (121-FF-2001A/B)

A 5 4 5 1 2 1 0 5 4 2 0 2 0 4

DWG. NO.

3-1641-0500 REV.2

REV.

A0-1189 x 841

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

REFERENCE DRAWING TITLE

DATE

SCALE

1:50

JOB NO.
UNIT
DIVN.

REF. DWG. NO.

REVISIONS
BY

DEPT.

CHKD APPD

PRODUCT FRACTIONATOR REBOILER HEATER (121-FF-2001A/B)

A 5 4 5 1 2 1 0 5 4 2 1 2 0 5

DWG. NO.

3-1641-0501 REV.2

REV.

A1-841x594

REFERENCE DRAWING TITLE

DETAIL OF INTERMEDIATE TUBE SHEET


1617/201
PATTERN NO. A545/121/1617/201

DETAIL OF WALL TUBE HANGER 1624/201


PATTERN NO. A545/121/1624/201

REF. DWG. NO.

DETAIL OF WALL TUBE HANGER 1624/202


PATTERN NO. A545/121/1624/202

DETAIL OF TUBESHEET SUPPORT BRACKET 1623/205


PATTERN NO. A545/121/1623/205

DETAIL OF INTERMEDIATE TUBE SHEET


PATTERN NO. A545/121/1614/202

1614/202

TUBE SHEET SUPPORT BRACKET 1623/204


PATTERN NO. A545/121/1623/204

DATE

DETAIL OF INTERMEDIATE TUBE SHEET

REVISIONS

BY

CHKD APPD

1614/203

PATTERN NO. A545/121/1614/203


DETAIL OF INTERMEDIATE TUBE SHEET 1614/201
PATTERN NO. A545/121/1614/201
SCALE

1:20

JOB NO.

A 5 4

UNIT

2 1

DIVN.

DEPT.

DWG. NO.

0 5 4 2 1 2

REV.

0 6

3-1641-0501 REV.2

A1-841x594

REFERENCE DRAWING TITLE

1514

REF. DWG. NO.

5914

4172

2000

5888

2949

2939

4200

2100

2100

5888

2939

2949

PLAN @ EL+ 26800

2369

2369

6500

2369

2369

VIEW E-E
6500

6500

OC-35

OC-36

OA-35

2500

2500
OA-36

OC-35

OA-35

OC-36

OA-36

1514

5914

4172

2000
8000

5888

2949

4300

4300
2939

4200

4200

2100

2000

2900

2900

2900

2100

2200

2900

5888

2939

5888

4200

5888

5888

4200

2949

4772

5888

VIEW A-A
VIEW C-C

VIEW B-B

CONVECTION MAIN MEMBER LONGITUDINAL SECTION STEEL FRAME

CONVECTION MAIN MEMBER LONGITUDINAL SECTION STEEL FRAME

4774

CONVECTION MAIN MEMBER CROSS SECTION STEEL FRAME (TYP. ON ALL FOUR COLUMNS)

B
PLAN @ EL+ 24150
CONVECTION PLAN @ EL+ 32700

26

21
26

21
4172

25

22

15

23
11

10078

24
16

15976

23
11

4200

24
16

22

10078

25

12
15

12
DATE

14

13

PLAN @ EL+ 3500 U/S FLOOR / PLATFORM

15

14

11

12

25

16

13

22

24

21

26

23

26

25

24

16

15

14

13

12

11

23

22

REVISIONS

BY

CHKD APPD

21
14

13
PLAN @ EL+ 19450

STRUCTURAL MEMBER CONFIGURATION FRAME DETAIL


SCALE

1:100

JOB NO.

UNIT

DIVN. DEPT.

DWG. NO.

A 5 4 5 1 2 1 0 5 4 2 0 2 0 7
3-1641-0500 REV.2

REV.

A0-1189 x 841

10

11

12

13

14

15

16

REFERENCE DRAWING TITLE

REF. DWG. NO.

NOTES :-

DUCT DETAILS

#
#

CA-1
CA-2
BP-1
HA-1

HA-10

HA-2

HA-4
HA-5
SS

HA-6
HA-7

SS

HA-8
HA-9

HA-9
HA-10

HA-10

HA-7

HA-8

HA-7

SS

HA-10A

HA-8

HA-11
HA-12
HA-12

HA-6

HA-13

HA-5

HA-5

HFG-1

HA-13

HA-11

HA-3

SS

CFG-1

SS

TUBE PULLING AREA


CONVECTION SECTION

RS

BP-1

TAG NO MARKED IN ID/FD FANS,


SAPH & CAPH ARE INDICATIVE ONLY

MAINTENANCE APPROACH

A
123

MAINTENANCE APPROACH

HA-2

CFG-2
SS

LIST OF DAMPERS/SHUT-OFF BLADES

SS

SS

SS

SS

SS

SS

HFG-2
HA-4

HFG-1
CA-1
CA-1

CA-1
RS

CA-1
CA-2
HA-2

HA-1

CA-1

CA-1

BP-1

FS

FS

HA-13
HA-4
HA-5

RS

HA-6

B
122

HA-9
CA-2

DIMENSION MARKED AND DIMENSION NOT


INDICATED ARE TO BE FINALISED BY CONTRACTOR
BASED ON BOUGHTOUT EQUIPMENT

HA-10A
HA-10A

E
122

DATE

REVISIONS

BY

CHKD APPD

D
122

C
122

CFG-2

COMBINED FEED HEATER (121-FF-1001/1002) &


PRODUCT FRACTIONATOR REBOILER HEATER (121-FF-2001A/B)

APH SYSTEM DUCTING LAYOUT PLANS-1


SCALE

1:100
1

10

11

12

13

14

JOB NO.

UNIT

DIVN. DEPT.

DWG. NO.

A 5 4 5 1 2 1 0 5 4 2 0 1 2 0
15

REV.

16

3-1641-0500 REV.2

A0-1189 x 841

(A Govt. of India Undertaking)

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

HA-3

10

11

12

13

14

15

16

REFERENCE DRAWING TITLE

REF. DWG. NO.

SS

SS
SS

SS

SS

SS

SS

SS

NOTES :-

SS

HFG-3

SS

D
E
F
G

F
123

FS

FS

F
122

F
122
SS

SS

FS

HFG-1

CFG-2

FS

SS

SS

SS

CFG-1

CFG-2

REVISIONS

G
122

BY

CHKD APPD

DATE

(A Govt. of India Undertaking)

COMBINE FEED HEATER (121-FF-1001/1002) &


PRODUCT FRACTIONATOR REBOILER HEATER (121-FF-2001A/B)

APH SYSTEM DUCTING LAYOUT PLANS-2


SCALE

1:100
1

10

11

12

13

14

JOB NO.

UNIT

DIVN. DEPT.

DWG. NO.

A 5 4 5 1 2 1 0 5 4 2 0 1 2 1
15

REV.

16

3-1641-0500 REV.2

A0-1189 x 841

G
122

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

SS

SS

SS

SS

10

11

12

13

14

15

CA-1

16

HA-1

REFERENCE DRAWING TITLE

NOTES :-

CA-2

CA-1
FS

FS

CA-1

CA-1

CA-2

CA-2

BP-1

REF. DWG. NO.

VIEW

D
120

VIEW

B
121

E
F

CFG-2
SS

FS

FS

SS

HFG-1

HFG-1
GS

SS

FS

SS

CFG-2

HFG-1

FS

GS

VIEW

F
121

FS

GS

GS

FS

SS

HA-10A
GS

FS

HA-10A
HA-2

GS
BP-1

CFG-1
REVISIONS

BY

CHKD APPD

DATE

HA-11
SS
(A Govt. of India Undertaking)

VIEW

G
121

VIEW

COMBINE FEED HEATER (121-FF-1001/1002) &


PRODUCT FRACTIONATOR REBOILER HEATER (121-FF-2001A/B)

E
120

APH SYSTEM DUCTING ELEVATION-1


SCALE

1:100
1

10

11

12

13

14

JOB NO.

UNIT

DIVN. DEPT.

DWG. NO.

A 5 4 5 1 2 1 0 5 4 2 0 1 2 2
15

REV.

16

3-1641-0500 REV.2

A0-1189 x 841

0475

CFG-2

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

C
120

VIEW

10

11

12

13

14

15

16

REFERENCE DRAWING TITLE

REF. DWG. NO.

C
D

NOTES :-

FS

HFG-2

SS

SS

SS

F
G

SS

F
121

HA-4

HA-9

HA-3

VIEW

HA-10

HA-3

HA-5

HA-5

FS
K

HA-13
FS

HA-2

HA-10A

HA-10A

HA-5

HA-5

GS

GS

GS

RS
HA-7

RS

HA-8

HA-11

RS

HA-6

A
120

DATE

REVISIONS

BY

CHKD APPD

VIEW

COMBINE FEED HEATER (121-FF-1001/1002) &


PRODUCT FRACTIONATOR REBOILER HEATER (121-FF-2001A/B)

APH SYSTEM DUCTING ELEVATION-2


SCALE

1:100
1

10

11

12

13

14

JOB NO.

UNIT

DIVN. DEPT.

DWG. NO.

A 5 4 5 1 2 1 0 5 4 2 0 1 2 3
15

REV.

16

3-1641-0500 REV.2

A0-1189 x 841

(A Govt. of India Undertaking)

The drawing, design and details given on this format are the property of ENGINEERS INDIA LIMITED. They are merely loaned on the borrower's express agreement that
they will not be reproduced, copied, exhibited or used, except in the limited way permitted by a written consent given by the lender to the borrower for the intended use.

SS

HA-9

SS

Page 444 of 2175

Page 445 of 2175

Page 446 of 2175

Page 447 of 2175

Page 448 of 2175

Page 449 of 2175

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Page 451 of 2175

Page 452 of 2175

Page 453 of 2175

Page 454 of 2175

Page 455 of 2175

Page 456 of 2175

ENGINEERS
INDIA 1JMITED
Govt of Ind.a Undelfakingt

STANDARD SPECIFICATION
FOR STEEL WORK OF FIRED
HEATERS & APH SYSTEMS

th-rzrd treT afr<


wvf

STANDARD SPECIFICATION No.

6-17-0002 Rev. 5
Page 1 of 12

r~4.1

fwg

Trrw rcifgi

STANDARD SPECIFICATION FOR


STEEL WORK OF
FIRED HEATERS AND
APH SYSTEMS

20.03.14

06.09.10

02.04.07

30.01.02

Rev.
No

Date

REVISED AND ISSUED AS STANDARD


SPECIFICATION
REVISED AND ISSUED AS STANDARD
SPECIFICATION
REVISED AND ISSUED AS STANDARD
SPECIFICATION
REVISED AND ISSUED AS STANDARD
SPECIFICATION

Purpose

44
KJHN

AP

SC

MK

KJHN/DK

AKG

ND

AP

KJHN/DK

AKG

VC

VM

DC/SKK

Prepared
by

Checked
by

RKA
Standards
Committee
Convenor

GRR
Standards
Bureau
Chairman

Approved by
Format No. 8-00-0001-F1 Rev. 0
Page 476 of 2175

Copyright

All rights reserved

Iloizi

$'gz:rr ;Me5
17117R

ENGINEERS
INDIA LIMITED
CA Govt oftl,aunde^aking)

STANDARD SPECIFICATION FOR


STEEL WORK OF FIRED
HEATERS & APH SYSTEMS

STANDARD SPECIFICATION No.

6-17-0002 Rev. 5
Page 2 of 12

Abbreviations:
APH :
:
AS
ASTM :
BIS
:
BOM :
CS
EIC
ETS :
HMTD :
:
IS
ITP

SS
UON
VDR

Air Preheater
Alloy Steel
American Society for Testing and Materials
Bureau of Indian Standards
Bill of Materials
Carbon Steel
Engineer-in-Charge
End Tube Sheet
Heat & Mass Transfer Division
Indian Standard
Inspection & Test Plan
Stainless Steel
Unless Otherwise Noted
Vendor Data Requirements

Heat & Mass Transfer Standards Committee


S/Shri Amit Prakash
Mandip Kapoor
Inder Kumar
Ratan Lal (Projects)
GK Iyer (Construction)
Format No. 8-00-0001-F1 Rev. 0

Page 477 of 2175

Convener
Member
Member
Member
Member
Copyright EIL All rights reserved

fa2es
2.1-~ 1,151 JWITA

ENGINEERS
INDIA LIMITED
A Govi of Inda Undeflak,o9)

STANDARD SPECIFICATION FOR


STEEL WORK OF FIRED
HEATERS & APH SYSTEMS

STANDARD SPECIFICATION No.

6-17-0002 Rev. 5
Page 3 of 12

CONTENTS

1.0

SCOPE

2.0

GENERAL

.4

3.0

CODES & STANDARDS

.4

4.0

MATERIALS

5.0

DESIGN AND DETAILING

6.0

FABRICATION DRAWINGS

7.0

FABRICATION

8.0

ERECTION

10

9.0

GROUTING UNDER STEEL STRUCTURES

12

10.0

INSPECTION AND TESTING

12

Format No. 8-00-0001-F1 Rev. 0


Page 478 of 2175

Copyright EIL All rights reserved

ENG1NEERS
INDIA LIMITED
Govt of indo Undertakog)

STANDARD SPECIFICATION FOR


STEEL WORK OF FIRED
HEATERS & APH SYSTEMS

STANDARD SPECIFICATION No.

6-17-0002 Rev. 5
Page 4 of 12

1.0

SCOPE

1.1

This specification covers requirements towards residual design, detailing, supply,


fabrication and erection of steel works for Fired Heaters and connected APH systems.

2.0

GENERAL

2.1

Steel work broadly consists of columns, beams, bracings, portals, casing plates, floor,
arch, header boxes, end tube sheets, breeching, off-takes, ducts, stacks, all appurtenances
and fabricated auxiliaries, retainer plates, sleeves, platforms, ladders, stair case, hand
railing etc. and other connected works, including miscellaneous items of AS / SS
wherever required.

2.2

Steel work shall be in accordance with the applicable drawings, standard details,
specifications, and relevant Codes & Standards.

2.3

Approval of Contractor design / documents / drawings and shop / site work at any stage
shall not relieve the Contractor of his responsibilities / guarantees and correctness of work
in any way.

3.0

CODES & STANDARDS

Compliance shall be ensured to the following Codes & Standards. Equivalent international
codes & standards can be used when specifically permitted in the job specifications :
IS: 210
IS: 513
IS: 800
IS: 808
IS: 813
IS: 814
IS: 816
IS: 1239
IS: 1363
IS: 1364
IS: 1367
IS: 1852
IS: 2016
IS: 2062
IS: 2266
IS: 2315
IS: 2361
IS: 2629
IS: 2633
IS: 3063
IS: 3121
IS: 3138
IS: 3502
IS: 4000
IS: 5372
IS: 5374
IS: 5504
IS: 6745
Format No. 8-00-0001-F1 Rev. 0

Page 479 of 2175

Cast iron
Cold rolled low carbon steel sheets and strips
Code of practice for general construction in steel
Dimensions of hot rolled steel sections
Scheme of symbols for welding
Covered electrodes for manual metal arc welding
Code of practice for use of metal arc welding for general construction
in steel
Mild steel tubes, tubulars and other mild steel pipe fittings
Hexagon head bolts, screws and nuts
Precision hexagonal bolts, screws, nuts and lock nuts (M6 to M39)
Technical supply conditions for threaded steel fasteners
Tolerance on dimension of individual rolled steel components
Specification for plain washers
Steel of general structural purposes
Steel wire ropes for general engineering purposes
Thimbles for wire ropes
Bulldog grips
Recommended practice for hot dip galvanizing of iron & steel
Method for testing uniformity of coating on zinc coated iron & steel
articles
Spring washers for bolts, nuts & screws
Specification for rigging screws & stretching screws
Hexagonal bolts and nuts (M42 to M150)
Chequered plates
Code of practice for assembly of structural joints using high tensile
friction grip fasteners
Taper washers for channels
Taper washers for I beams
Specification for spiral welded pipes
Method for determination of mass of zinc coated iron & steel articles
Copyright EIL All rights reserved

$'gar fffieg

ENGINEERS
INDIA LIMITED
IA Govt of InOw Undenaking)

IS: 7215
IS: 12778
ASTM A53
ASTM A105
ASTM A193
ASTM A194
ASTM A240
ASTM A283
ASTM A479

STANDARD SPECIFICATION FOR


STEEL WORK OF FIRED
HEATERS & APH SYSTEMS

STANDARD SPECIFICATION No.

6-17-0002 Rev. 5
Page 5 of 12

Tolerances for fabrication of steel structures


Dimensions & section properties for hot rolled parallel flange steel
sections for beams, columns and bearing piles
Specification for seamless & welded black and hot dipped pipes (use
for pipes for sleeves)
Couplings, plugs, pipe caps
Alloy and stainless steel bolting for high temperature service
Carbon and alloy steel nuts for bolts for high pressure, high
temperature service
Specification for stainless steel plates
Low and intermediate strength CS (use Grade C for ETS UON)
Specification for stainless steel bars and shapes (use for pipe spindle)

4.0

MATERIALS

4.1

All materials shall be new and conform to their respective specifications of BIS, ASTM or
applicable standards and supported with mill test certificates. The use of equivalent or
alternate materials will be considered a deviation which will need prior written approval.

4.2

All materials shall be sourced from approved Vendors as per Vendor List attached
elsewhere in the Package.

4.3

All grating and grating clamps shall be hot dip galvanized.

4.4

Structural steel shall confirm to IS2062 Gr.A/B or ASTM A36 UON. For metal
temperatures exceeding 425 degC, alloy or stainless steels shall be used.

5.0

DESIGN AND DETAILING

5.1

Design and detailing shall be in accordance with IS: 800. The Contractor shall have
established standard details in line with International norms and good engineering
practices.

5.2

Requirements given in this paragraph shall be followed, unless indicated otherwise in job
drawings. Details shall be provided to show all dimensions, weld sizes, bolt sizes and
proper reinforcement requirements, gussets, stiffeners, bearing plates, pad plates etc. to
develop complete strength of members and also account for local stresses.

5.3

All connections shall be in line with actual design requirements and shall be full strength
connections. Where actual loads are available, the connections may be designed
accordingly. Shop connections shall be of welded type and field connections may be either
welded or bolted, as approved by EIL.

5.4

Connections shall be arranged with due regard to eccentricity of welds or bolts.

5.5

All skewed beam to girder connections which support stacks shall have stiffened seat
connections with bent plate connecting beam webs. At deep blocks, the remaining `tee'
section of the beam shall be checked for flexure.

5.6

The minimum size of bolts shall be M16, except where flanges prohibit the use of this
size. Minimum M12 size bolts shall be used for splicing of panels.

5.7

Beam to column connections shall be arranged to facilitate erection without the tilting of
columns. Where seated connections are used, the bottom flange of the beam shall be
connected with a seat angle. In connections to column flanges, `knifed' connections may
be used. At any seat connections, the beam set back shall not exceed 12 mm.

Format No. 8-00-0001-F1 Rev. 0


Page 480 of 2175

Copyright EIL All rights reserved

$2zir22'
,--,oloaa, eg
0,1 3~1 I

ENGINEERS
INDIA LIMITED
iA Go, of Ind,o UnoloOak,f,g)

STANDARD SPECIFICATION FOR


STEEL WORK OF FIRED
HEATERS & APH SYSTEMS

STANDARD SPECIFICATION No.

6-17-0002 Rev. 5
Page 6 of 12

5.8

In welded construction, the ends of angle, channel, beam etc. are to be preferably notched
to suit the profile of connecting members. All welded moment resisting connections shall
necessarily have profile cutting.

5.9

Provide minimum 10 mm diameter drain holes at all water traps at suitable locations so as
to ensure effective draining of water without affecting integrity of the structure.

5.10

All flange bolts to straddle principal centerlines.

5.11

Stiffeners on radiant shell (including ones at bracket / knee brace, terminal anchor
locations etc.) convection wall, ducts and at openings shall be provided based on
stiffening requirement and detail engineering.

5.12

All welding on heater casing / ducting shall be continuous on outside and intermittent 50100 on inside. Welds on horizontal channel stiffeners to be continuous on topside and
discontinuous on bottom side. Vertical stiffeners shall be provided with continuous
welding on both sides. Minimum fillet size shall be 5 mm, unless otherwise noted.

5.13

Base plates shall be shop welded to columns.

5.14

Minimurl thickness of gussets shall be 6 mm.

5.15

Splice Connection

5.15.1

All splice connections shall be submitted for approval indicating locations as well as
details. Splice joints shall be full strength butt welded, single `V' for thickness <16 mm
and double `V' for thickness >16 mm. Additional splice plates shall be provided for 40%
strength of member. These joints shall not be located at maximum bending moment and /
or maximum shear force location.

5.15.2

In case of built-up section, each individual component shall be spliced at different


(staggered) location. Also splicing for adjacent columns in the same structure shall not be
at same elevation but staggered by minimum 1.0-meter w.r.t. each other.

5.15.3

Flange plate on beams, columns and plate girders shall be shop welded with continuous
fillet welding on all sides. Where beam, column or girder flange exceeds 300 mm, plug
welds shall be used in addition to the above fillet welds to prevent warping of the cover
plates. Plug welds, when required, shall be spaced at a maximum of 450 mm on centers.

5.16

Horizontal Bracing

5.16.1

Wherever possible, bracing shall be connected to both column and beam where the inside
face of the column is used as a working point.

5.16.2

Where the center of a column is used as a working point with beams framing to the flange
and the web of the column, bracing shall be connected to both beams.

5.16.3

Welds in gussets shall be arranged to eliminate eccentricity. Gusset plates in same truss or
girder shall be of uniform thickness.

5.17

Vertical Bracing

5.17.1

At the inter-section of a column, beam and brace, the brace shall be connected to both
beam and column. At the connection to a column flange, the working point shall be the
face of the column flange & the top or bottom of the beam flange, depending upon
whether the brace is above or below the beam. At the connection to a column web, the

Format No. 8-00-0001-F1 Rev. 0

Page 481 of 2175

Copyright EIL All rights reserved

ENGINEEFZS
rt_r) INDIA
LIMITED
Og-ar 02-dg
' C

31

1~1el,9,71,151~1)

IA Govt of lneha undertaking)

STANDARD SPECIFICATION FOR


STEEL WORK OF FIRED
HEATERS & APH SYSTEMS

STANDARD SPECIFICATION No.

6-17-0002 Rev. 5
Page 7 of 12

working point shall be the centerline of the column web and the top or bottom flange of
the beam.
5.17.2

For the connection of bracing to beam 300 mm or smaller at the mid-span, the working
point shall be the inter-section of the horizontal centerline of the beam and the centerline
of the bay.

5.17.3

For connection of underlying bracing to beams 350 mm and larger at the mid-span, the
working point shall be taken as 125 mm above the bottom flange of the beam. Similarly,
the working point of overlying bracing for such beams shall be 125 mm below the top
flange of the beam.

5.17.4

Vertical bracing connections shall be as described for horizontal bracing.

5.17.5

At wind moment connections, allowance shall be made for mill overrun in beam depth by
allowing for shims to facilitate erection.

5.18

Trusses

5.18.1

On welded trusses, splices to ship the largest possible shop assembled units shall be
detailed. Splices for welded or bolted joints shall also be detailed. All splice details to be
submitted.

5.19

Platforms and Ladders

5.19.1

Unless shown in prefabricated sections on drawings, top rail, middle bar and toe plates
shall be supplied in random length for field welding to handrail posts. Bent section and
posts shall be shop fabricated. Removable sections of handrails shall be furnished with
posts at each end of the removable sections for bolting to supporting clips.

5.19.2

Toe plates shall be provided on walkways and platforms along with all edges protected by
railing, around openings in platforms under equipment where no railing is provided; under
the bottom treads of all stairways which rine from landings; across ladder access openings
and around all openings where the normal clearance between the edge of the floor plate
and the equipment or piping is 50 mm or more.

6.0

FABRICATION DRAWINGS

6.1

EIL steelwork drawings wherever issued are design drawings showing structural member
configuration and sizes. These along with job specifications indicate complete engineering
requirements towards the construction of fired heaters & APH system.

6.2

After completion of the residual design & engineering work, Contractor shall submit the
fabrication drawings for approval, along with supporting calculations wherever asked for.

6.3

The fabrication drawings shall contain the complete information about the fabrication
work to be carried out including connections, splices, welding, BOM, other details etc.

6.4

If deemed necessary, the EIC may ask for review or modification of any drawing,
document or procedure of the Contractor, without any cost / time implications.

6.5

Completion of fabrication or erection shall be carried out as per the approved drawings.
This however, does not prevent the Contractor from going ahead with arrangements for
procuring the required material, or making other arrangements required for fabrication and
erection.

Format No. 8-00-0001-F1 Rev. 0


Page 482 of 2175

Copyright EIL All rights reserved

$1g"a[22dg
'

ENGINEERS
INDIA LIMITED
IA GovI al Intlta

underiak.g)

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


STEEL WORK OF FIRED
6-17-0002 Rev. 5
HEATERS & APH SYSTEMS
Page 8 of 12

6.6

If any modification is made in the design drawings during the execution of the job, revised
design drawings will be issued to the Contractor. Contractor shall revise his fabrication
drawings and seek re-approvals as required.

6.7

Fabrication in the form of modules / pre-fabricated assemblies at shop is preferred. Details


such as individual module drawings, assembled module drawings, module markings, site
joints / joint lines, splices, lifting arrangement of modules, procedures and sequence of
erection etc. shall all be shown in the detailed drawings. Job requirements, facilities
available at shop / site, transportation and handling etc. shall all be considered. The
complete details shall be got approved from EIL.

6.8

After the completion of all works, as-built details shall be marked in EIL drawings,
incorporated in Contractor fabrication drawings and submitted to the EIC for certification
& approval of all revisions made before submission of requisite number of copies as per
VDR.

6.9

For detail requirement of fabrication drawing submission refer VDR given in tender
document.

7.0

FABRICATION

7.1

Fabrication shall be in accordance with IS: 800 and standard fabrication practices as
approved by the EIC.

7.2

Fabrication shall be done as per design drawings in conjunction with details / drawings
approved by EIL-HMTD / EIC.

7.3

Welding shall be done as per the requirements of IS: 800, IS: 814 and IS: 816. Surfaces to
be welded shall be free from oil, grease, dirt, scale and other foreign materials.
Composition of welding filler materials shall be in accordance with the base materials
being joined.

7.4

Welding shall be done only by fully trained and experienced welders as qualified and
approved by EIC. Qualification tests for welders as well as tests for approval of electrodes
will be carried out as per IS: 823. The nature of test shall be as advised by EIC.

7.5

Steel work shall be delivered to site in sub assembled units or components as shown in the
detailed drawings. Prior to dispatch, fabricated sections are to be trial assembled in the
shop to ensure correct fit and erection. All mating parts shall be match-marked properly.
All the fabricated and delivered items shall be suitably packed for protection from any
damage during transportation and handling. Fabricated segments and modules liable for
distortion during handling, transportation and erection shall be temporarily cross-braced to
prevent distortion. Temporary stoppers shall prevent movement of tube assemblies
relative to steelwork / housing. The handling direction shall be prominently marked on the
packing to avoid any mishandling during transportation and erection.

7.6

Column bottom / top welded to base plates / cap plates shall be ground fine to bear
uniformly on the connected surface and fitted exactly at 90 degrees.

7.7

All built-up sections are to be fabricated and erected in one piece. Drilling of through
holes in the built-up section to be done after building up the section.

7.8

Platforms, ladders, panel plates and stacks shall be shop assembled in the largest unit
suitable for handling, transportation and erection.

7.9

All welds in stack and shell, both horizontal and vertical are to be full-penetration buttwelds. For plate thickness upto 12 mm thickness single `V' butt weld & for 14 mm and

Format No. 8-00-0001-F1 Rev. 0


Page 483 of 2175

Copyright EIL - All rights reserved

("ENGINEERS
2151-egWr INDIA LJMITED

31

1.1R7r 2.1~70,
1~1)

IA Govt of India Undertaking)

STANDARD SPECIFICATION FOR


STEEL WORK OF FIRED
HEATERS & APH SYSTEMS

STANDARD SPECIFICATION No.

6-17-0002 Rev. 5
Page 9 of 12

above double `V' butt weld shall be used. Longitudinal welds shall not be in the same
line. Welds shall not be in line with any opening in stack. No welding shall be carried out
during poor weather condition. For stack shell plate more than 38 mm thick, preheat &
stress-relieving requirement shall be applicable as per ASME code.
7.10

A11 steel surfaces shall be cleaned of all rust, dirt and loose mill scale by wire brushing or
other approved method. Use of box sections for main columns and beams shall be
avoided. While using box or tubular section, the ends shall be properly sealed using end
caps against ingress of moisture. Also before sealing, the inside surface shall be ensured
as dry and shall be primer painted.

7.11

A11 fabrication shall be of rigid construction and care shall be taken against welding
deformation.

7.12

A11 bolt holes shall be sheared only and not gas cut. For matching parts, bolt holes shall be
match marked and holes drilled.

7.13

A11 erection bolts shall be left in position.

7.14

Fabricated structures shall be given primer coat compatible with the final painting as per
painting specification, immediat,Aly after completion at site or before dispatch from shop.

7.15

Channels that require rolling / bending may be fabricated out of plates or angles as
approved by EIC.

7.16

For base plate sizes above 300 x 300 mm, grouting holes may be provided at suitable
locations. Such holes shall be indicated in the base plate drawing submitted for EIL
approval.

7.17

Tolerances (in mm) on steel work fabrication shall be as follows unless noted otherwise
on the job documents. Tolerances of all other fabrication shall be as per IS: 7215.
a.

Marking

1.0

b.

Flame cutting

1.5

c.

Shearing (plates)

1.0

d.

Machining (column ends etc.)

0.5

e.

Cold-forming
short radius upto 25 mm
medium radius upto 75 mm
large radius beyond 75 mm

0.5
1.0
1.5

f.

Hot forming - short radius upto 25 mm

0.5

g.

Holes and internal surfaces:

0.4

h.

Shafts and external surfaces:

0.4

i.

C/C holes: (this tolerance is non-cumulative)

0.2

j.

Longitudinal straightness of beams

Length/1500

k.

Lateral straightness of beams

Length/1500

Format No. 8-00-0001-F1 Rev. 0


Page 484 of 2175

Copyright EIL All rights reserved

$'fg-u112- g

ENGINEERS
INDIA LIMITED
IA Govt ot Inct. Unclertak.g)

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


STEEL WORK OF FIRED
6-17-0002 Rev. 5
HEATERS & APH SYSTEMS
Page 10 of 12

1.

Length/1000
Straightness of columns (with cap/base plate)
Outer & inner intermediate columns about XX axis 6
Outer & inner intermediate columns about YY axis 3.0
3 .0
Outer & inner end columns about XX axis
3 .0
Outer & inner end columns about YY axis
-

m.

Twisting (with respects to any two sections at a


distance of L) measured on point farthest from c.g.

Length/1000
5 (maximum)

n.

Twisting of cross section measured in its own plane

2.5

o.

Flatness of base plates from mean surface


Size upto 250 mm
Size above 250 mm
-

1.0
1.5

Overall length on fabricated members


beams with shear connections
beams with moment end connections
columns with splices (including cap and plates)
columns without splices (including cap and plates)
trusses, between supports/rockers

2.0
1.0
3.0
2.0
3.0

P.

1/o
5.0 (maximum)

q.

Quality (stack, radiant shells)

r.

Overall height of heater segments (non-cumulative)


upto 5 m height
5 m to 15 m height
-

3
6

Misalignment of plates at any weld

1.5 (maximum)

s.

7.18

The flatness of individual furnace casing plates after welding of stiffeners shall conform to
the following:

7.18.1

A straight edge (or taut string) shall be laid along the edges and across diagonally opposite
corners of the casing plate. The maximum permissible camber shall not exceed 2 mm per
meter.

7.18.2

The camber at various points on the plate shall be checked with a straight edge (min.
length 500 mm). The maximum permissible camber over a length of 500 mm at any
location and measured in any direction shall not exceed 1 mm.

8.0

ERECTION

8.1

Erection shall be in accordance with IS: 800 and standard erection practices as approved
by the EIC.

8.2

Contractor shall appraise himself completely with the facilities and constraints at site.

8.3

Before preparation of detail drawings / starting erection work, sequence and procedure of
erection shall be prepared and got approved from the EIC.

8.4

The Contractor shall satisfy himself about the levels, alignment etc. for the foundations
well in advance before starting the erection. Minor rectification, if required, shall be
carried out at no extra cost.

8.5

The erection work shall be started only after obtaining permission form the EIC.

Format No. 8-00-0001-F1 Rev. 0


Page 485 of 2175

Copyright EIL All rights reserved

ENGINEERS
INDIA LIMITED

Re.j1 054-3
1~29~=~11

GuN Wlndia Undertak.91

STANDARD SPECIFICATION FOR


STEEL WORK OF FIRED
HEATERS & APH SYSTEMS

STANDARD SPECIFICATION No.

6-17-0002 Rev. 5
Page 11 of 12

8.6

Grouting below base plates shall be done as per clause 9.0 of this specification.

8.7

The positioning and leveling of the structure, alignment and plumbing of the stanchions
and fixing every member of the structure shall all be in accordance with the drawings.

8.8

Care shall be taken at all slotted holes connections while tightening of bolts to allow
freedom for expansion. Check nuts with suitable washers shall be used in all such cases.

8.9

Heater shall be of air tight construction and welded throughout, except wherever called for
otherwise. All casing splicing shall be seal welded after erection. In order to minimize air
infiltration into heater, extreme care must be taken to ensure closing of all openings and
crevices after assembly of heater is complete.

8.10

The following erection marking systems shall be followed:

8.10.1

All structural steel and sub-assemblies shall be clearly identifiable and suitably marked to
provide an easy means of erection in the field.

8.10.2

On vertical cylindrical heaters, all columns, and sections shall be marked clockwise from
the 'N' direction.

8.10.3

Wherever there is possibility of erecting the member inverted, the members to be marked
`Top'.

8.10.4

Where a member is shipped in two or more pieces, each piece shall have the same mark
suffixed by a, b, c etc.

8.10.5

All marks shall be painted on the steel in a legible fashion with letters and numerals of at
least 40 mm height.

8.10.6

All rods, turnbuckles etc. are to be tagged and wired firmly together.

8.10.7

All bolts, washers etc. shall be shipped in bags or crates and tagged or clearly marked as
to MOC, size, diameter and length.

8.10.8

Galvanized members (if required) shall be tagged with a metal plate having raised letters
so that the mark will be visible after galvanizing. This metal plate shall be tack welded to
the number prior to galvanizing.

8.11

Tolerances (in mm) for steel work erection shall be as follows:


a.

Verticality of stack (w.r.t. stack base)


(w.r.t. 0.000 level)

b.

Verticality on centerline of assembly / centerline of


columns
top of the heater (U/S stack)
HT/1000 but max. 5
assembled radiant section-box heater
HT/1000 but max. 5
HT/1000 but max. 5
assembled radiant section-VC heater

c.

Horizontality on stack support beams

1.0

d.

Levels of connecting piping manifolds

2.0

e.

Distance connecting piping manifolds

3.0

Format No. 8-00-0001-F1 Rev. 0

Page 486 of 2175

HT/1000 but max. 20


HT/1000 but max. 25

Copyright EIL All rights reserved

5gar 92e5
1.1-2,1 cwer,r,

f.

ENGINEERS
INDIA LIMITED
IA Govt ot Inolta Unclettatungt

Clear spans
at beam connection
at Radiant section and columns
Radiant section intermediate columns
-

g.

STANDARD SPECIFICATION FOR


STEEL WORK OF FIRED
HEATERS & APH SYSTEMS

Convection section, all columns

Levels of U/S base plate (on C.L.)

STANDARD SPECIFICATION No.

6-17-0002 Rev. 5
Page 12 of 12

1.0
Span/1000 but max.6
Span/1000 but 6
(max.) from CL
Span/1000
1.0

9.0

GROUTING UNDER STEEL STRUCTURE

9.1

The grouting material shall solidly fill the spaces to be grouted and permanently retain its
original volume so that the base plate will be held firmly in the set position. The amount
of water used in mixing shall be kept to a minimum such that the grout shall not flow.

9.2

After final alignment and plumbing of the structure, the forms shall be constructed allround and joints made tight to prevent leakage. Grouting (under the base plates/shoe
plates including grouting of sleeves & pockets) shall be done with non-shrink grout
having compressive strength (28 days) not lens than 40N/sq. mm Non shrink grout shall be
of free flow premix type and of approvel quality and make.

9.3

The grout shall cover all shims that are to be retained.

9.4

Preparation for grouting shall be undertaken as follows:

9.4.1

All anchor boltholes shall be completely filled with grout.

9.4.2

The finished surface shall be floated smooth and shall be suitably sloped away from base
plate.

9.4.3

After the initial set is over the grout shall be kept thoroughly wetted for a minimum of 5
days.

9.4.4

Care is to be taken during grouting so that the base plate Level and alignment are not
disturbed.

10.0

INSPECTION AND TESTING

10.1

A11 inspection will be done in accordance with the relevant codes including IS: 800 and
with the specific requirements of the job specifications.

10.2

Contractor shall prepare a detailed ITP for steel work and get it approved from E1L.

10.3

For inspection at any stage of the job, the EIC or his representative shall have free access
to the Contractor's or his sub-contractor's shop as well as in the field for proper execution
of the job.

10.4

Weld joints in stack and shell of shell-designed cylindrical heaters will be subject to 2%
radiography test. Selection of radiography spots and acceptance limit will be as decided by
the EIC / Inspector depending upon the quality of welding required. However, all the `T'
joints shall necessarily be covered for radiography.

Format No. 8-00-0001-F1 Rev. 0

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Oziei
ria
itge.n

99:5,s,

ENGINEERS
INDIA LIMITED

STANDARD SPECIFICATION
FOR ERECTION OF EQUIPMENT
& MACHINERY

STANDARD SPECIFICATION No

6-76-0001 Rev. 3
Page 1 of 22

6*k-cm vd zit *r TWIT


tq &Hot Far4t2T
STANDARD SPECIFICATION
FOR
ERECTION OF EQUIPMENT &
MACHINERY

03.09.2008

Revised & Reissued

DM

PKR

AA

VC

30.05.2008

Revised & Reissued

DM

PKR

AA

VC

25.04.2001

Issued as Standard Specification

DM

AM

MR

MI

Checked
by

Standards
Committee
Convenor

Standards
Bureau
Chairman

Rev.
No

Date

Purpose

Prepared
by

Approved by
Format No. 8-00-0001-F1 Rev. 0
Page 583 of 2175

Copyright EIL All rights reserved

zier
SiglIT

far

ENGINEERS
INDIA LIMITED
IA Gobi of India Undetakingi

STANDARD SPECIFICATION FOR


ERECTION OF EQUIPMENT &
MACHINERY

STANDARD SPECIFICATION No.

6-76-0001 Rev. 3
Page 2 of 22

Abbreviations:
ASME

American Society of Mechanical Engineers

EC

Erection Contractor

EIC

Engineer-in-charge

ELCB

Earth Leakage Circuit Breaker

GAD

General Arrangement Drawing

IS

Indian Standard

NDT

Non Destructive Testing

SS

Stainless Steel

General Engg. Standards Committee


Convenor :
Members :

Mr. Vinay Kumar


Mr. S. Chanda
Mr. J.M. Singh
Mr. D. Khare
Ms.Vartika Shukla
Mr. M.P. Jain
Ms. N.P. Guha
Mr. Rakesh Nanda

Format No. 8-00-0001-F1 Rev. 0

Page 584 of 2175

Copyright EIL All rights reserved

fazieT to

Ogelf laliteS

ENGINEERS
INDIA LIMITED

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


ERECTION OF EQUIPMENT &
6-76-0001 Rev. 3
MACHINERY
Page 3 of 22

CONTENTS

1.0

SPECIFICATION FOR ERECTION OF EQUIPMENT AND MACHINERY

2.0

ERECTION OF COLUMNS, TANKS, VESSELS AND DRUMS ETC

3.0

ERECTION OF MECHANICAL EQUIPMENT

4.0

HEAT AND MASS TRANSFER EQUIPMENT

10

5.0

ERECTION OF ROTATING EQUIPMENT

16

6.0

EQUIPMENT GROUTING

19

7.0

REFERENCE EIL STANDARDS/ SPECIFICATIONS

22

Format No. 8-00-0001-F1 Rev. 0


Page 585 of 2175

Copyright EILAll rights reserved

ENGINEERS
INDIA LIMITED
A O,l of India underlakPrigi

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


ERECTION OF EQUIPMENT &
6-76-0001 Rev. 3
MACHINERY
Page 4 of 22

1.0 SPECIFICATION FOR ERECTION OF EQUIPMENT AND MACHINERY


1.1

Scope
This specification covers technical requirements for erection of all static and rotating
equipment by erection contractor at site. This specification is applicable for all the erection
tenders operated by EIL.

1.2

General

1.2.1

All necessary handling equipments, tools, tackles and precision instruments for carrying out
the works as specified shall be provided by the Erection Contractor (EC) at his cost. EC must
provide all tools and gauges for erection and alignment. Special tools, if any, received as part
of machinery, will be given to EC for erection purposes, which shall be returned in good
condition after use. Suitable deductions will be made by the Engineer-in-Charge (EIC) in
case of loss or damage of the special tools. The value of such loss or damage will be decided
by the EIC and EC shall be bound by such a decision.

1.2.2 Equipment Manufacturer's recommendations regarding preservation during storage at site and
detailed specifications for the installation alongwith layout drawings, general
arrangement/equipment outline drawings and sub-assembly drawings of the various equipment
and machinery will be provided to EC during the performance of work. The requirements
stipulated in these shall be fulfilled by EC in addition to what is stated in this specification.
Erection shall be carried out as per the instructions and supervision of Machinery
manufacturer's representative, wherever such supervisory services are applicable.
1.2.3 All the items of work covered in the tender shall be carried out as per this Specification and
However, EIC reserves the right to give
EC.
other details to be furnished to
additional/alternative specifications and instructions, at any time, for execution of any
particular work and EC shall execute such works in accordance with such
additional/alternative specifications and instructions of the EIC. Such a step taken by the EIC
shall not constitute a breach of the contract.
1.3

Preparation for Erection

1.3.1

EC shall be responsible for organising the lifting of the equipment in the proper sequence, so
that orderly progress of the work is ensured and access routes for erecting the other equipment
are kept open.
Rigging procedure for all the major lifts (above 10 MT) and at maximum crane capacity shall
be submitted by EC for the approval of EIC. However, approval to rigging procedure
proposed by EC shall not relieve EC from his responsibility in following the proper
lifting/erection methods on ensuring orderly .

1.3.2 Orientation of all foundations, elevations, length and disposition of anchor bolts and diameter
of holes in the supports saddles shall be checked by EC, well in advance. Minor rectifications
including chipping of foundations as the case may be, shall be carried out by EC after
obtaining prior approval of EIC. EC shall also be provided with the necessary structural
drawings and piping layouts etc. wherever required for reference. EC shall crosscheck such
piping and structural drawings with actual construction at site and in case of any mismatch
inform the EIC before taking up the erection.

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Copyright EILAll rights reserved

5fgar fakres

ENGINEERS
INDIA LIMITED
IA Govl 01 haw undeptakingl

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


ERECTION OF EQUIPMENT &
6-76-0001 Rev. 3
MACHINERY
Page 5 of 22

1.3.3 During the performance of the work, EC shall keep structures, materials or equipments
adequately braced by guys, struts or otherwise approved means which shall be supplied and
installed by EC as required till the installation work is satisfactorily completed. Such guys,
shoring , bracing, strutting, planking supports etc. shall not interfere with the work of other
agencies and shall not damage or cause distortion to other works executed by him or other
agencies.
2.0 ERECTION OF COLUMNS, TANKS, VESSELS AND DRUMS ETC.
2.1

Scope of work of Erection Contractor


(a) Preparation of erection scheme and rigging procedure and obtaining its approval from
EIC wherever necessary.
(b) Withdrawal of equipments from Owner's storage point, checking and reporting its
conditions, transporting the same to EC's stores of work site including unloading etc.
(c) Erection on foundations furnished by Owner including aligning, levelling and grouting.
(d) Assembly and fixing of demisters, grids, internal distributors and other internal fittings in
Columns, Vessels etc.
(e) Filling of Columns, Reactors, Vessels/Drums etc. with Raschig rings, supporting
elements, sand, concrete etc. as required.
(0 Welding of washers for equipments, erection of pipe davit & minor welding of their parts
as per specifications and instruction of EIC.
(g) Assembly & erection of Agitator (Mixer) along with drive unit (Motor) including all
accessories for vessels/drums/reactors (wherever indicated) as per specification drawings
& instructions of EIC.
(h) Flushing, cleaning and drying of Columns, Vessels/Drums etc.
(i) Completing the equipments in all respects for commissioning the plant as per drawings,
specifications & instructions of EIC.
0) Any modification in the erected Columns, Reactors, Vessels/Drums to the complete
satisfaction of EIC.

2.2

General Conditions of Erection

2.2.1

Unless otherwise specified Columns, Vessels, Drums etc. will be generally supplied to the
Erection Contractor in single piece and EC will not be required to carry out any assembly or
welding. In case column is supplied in multiple pieces and erection of the equipment is not
possible in single piece, EC shall be responsible for lifting the pieces, for aligning, welding
and hydrotest etc. in vertical position under the supervision of column Supplier (Fabricator).
However, EIC shall be responsible for coordination between Erection Contractor &
Fabricator. The schedule of quantities (SO()) for equipment erection enclosed with the tender
document outlines details of each equipment such as diameter, overall height, type of support
(saddle/skirt/leg/bracket), position (horizontal or vertical) and approximate erection weight
etc. However the erection elevation and location of equipment shall be as per the piping
layout drawing enclosed with the tender.

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Copyright EIL All rights reserved

INIFEzie?
SIgt-IT "keg

ENGINEERS
INDIA LIMITED
0 Gov' of Indra Undettakingl

STANDARD SPECIFICATION FOR


ERECTION OF EQUIPMENT &
MACHINERY

STANDARD SPECIFICATION No.

6-76-0001 Rev. 3
Page 6 of 22

2.2.2 Rigging procedures and erection schemes for all the heavy lifts weighing 10 MT & above
shall be prepared by EC and got approved by EIC. Approval by EIC shall not relieve EC of
his responsibilities. The details to be submitted will include the location of equipment from
where it will be lifted, location of crane(s), details of crane(s) (like configuration, boom
length, operating radius, boom point elevation, clearance underside the boom and the
equipment, lifting capacity, counter weights to be deployed, holds on any neighbouring
foundations, structures, equipments etc.), the load chart of the crane(s), design of the lifting
tackles like spreader beam, D-shackles, wire rope slings etc. Unless the erection scheme and
rigging procedures are approved by EIC, erection of such equipments shall not be undertaken
in any case by EC.
2.2.3 Before starting the erection of Columns, Vessels etc., top surface of the foundations is to be
cleared/chipped, roughened to obtain proper bond, while grouting. Also the sleeves are to be
cleaned before erecting the equipments. Line (orientation) and levels are to be marked on all
the foundations to facilitate checking of alignment.
EC shall also check the correct elevation and orientation of civil, structural foundations, before
proceeding with the erection work. Discrepancy, if any, shall be brought to the notice of EIC.
However, minor rectifications and chipping of foundations upto a thickness of 15 mm in
foundation height shall be carried out at no extra cost, by the EC. EC shall be responsible for
supply of levelling plates, (if required) and shall carry out levelling of equipment under the
directions of EIC.
2.2.4 While handling, transporting or erecting the equipments, care shall be taken not to damage the
nozzles, instrument connections, structural clips etc. EC shall also take care of the orientation
of the nozzles and other connections of the equipments while erecting the same and ensure
compliance with the drawings and specifications supplied. Discrepancy, if any, in the
number/orientation of the nozzles, cleats etc. should be brought to the notice of the EIC before
actual erection is started.
2.2.5 Verticality of the Columns, ReactorsNessels shall be checked with theodolites. After erection
the equipment shall be levelled and properly aligned with necessary shims and wedges
supplied by EC, at his cost. After the level, alignment and verticality etc. are checked and
approved by EIC, EC shall carry out grouting.
2.2.6 EC shall produce recent test certificates of the slings which they will be using for erection
work. However, retesting of the slings shall be done at site by EC at his cost, as and when
required by EIC. The weights of test loads shall be as per IS-807. The test loads shall be
supplied by EC at his cost. Tested slings will be punched for test loads and date of testing as
directed by EIC.
2.2.7 EC shall also carry out the assembly, erection, levelling and alignment of all types of weir
plates, baffles, distributors, collectors, spray nozzles, demisters, grids and other internal
fittings etc. Work shall be carried out as per manufacturer's standards/specifications which
shall be made available to EC at the time of erection. Raschig rings, molecular sieves, intalax
saddles packing and other types of tower packings such as sand, catalyst etc. and SS wire
mesh shall be loaded into sections of Vessels, Columns as per specifications and drawings.
Details for internals to be installed by EC shall be as per separate schedule of quantities
enclosed with the tender document. All packings except clay and lime stone shall be washed
with water before filling. Bottom layers, if required, shall be arranged as directed and random
filling shall be done afterwards with equipment filled with water. Installation of packings,
shall be done only after flushing and cleaning of Columns/Vessels and completed to the
satisfaction of EIC.

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Copyright EIL All rights reserved

laratlei
* la g,

ENGINEERS
INDIA LIMITED

STANDARD SPECIFICATION FOR


ERECTION OF EQUIPMENT &
MACHINERY

STANDARD SPECIFICATION No.

6-76-0001 Rev. 3
Page 7 of 22

2.2.8 EC shall carry out minor welding for attachment of prefabricated pipe davit parts such as rain
covers, handles etc. with pipe davit, during or after erection of the same as per the
manufacturer's specifications, at no extra cost to the Owner.
2.2.9 EC shall execute erection of wooden pillow for saddle support for cold horizontal vessels
wherever necessary as indicated on the drawings/ EIL STD 7-12-0003 and as per the
instructions of EIC.
2.2.10 EC shall execute assembly & erection of agitator/mixer along with drive unit including all
accessories as per supplier's instructions, specification drawings & instructions of EIC.
2.3

Flushing & Cleaning of Columns, Vessels, Drums etc.

2.3.1 After the erection, alignment and grouting of these equipments are complete, flushing and
cleaning shall be carried out by EC as per specifications and instructions of EIC.
2.3.2 After flushing, cleaning and draining, equipments shall be dried by compressed air at the
pressure and for duration decided by the EIC. The Vessel interior shall be thoroughly
inspected to the complete satisfaction of EIC before it is finally boxed up. Boxing up of
manholes and handholes shall be leak proof. All joints which need remaking, shall be remade.
Compressed air for drying shall be arranged by EC.
2.4

Inspection and Acceptance Limits for Level and Alignment

2.4.1 Co-ordinates of foundations/supporting structures/mounting holes etc. shall be checked with


respect to the plot plans by EC.
2.4.2 Before equipments are placed on foundations, orientations shall be checked with respect to
piping drawings.
2.4.3 When equipments are firmly bolted down but prior to grouting, verticality of all the Columns,
vertical vessels etc. shall be checked by using theodolite. Tolerances for equipment after
erection shall be as per EIL Standard 7-12-0001. The allowable deviation from plumb line
shall be 1 mm per metre height, subject to maximum of 15 mm unless otherwise stated on the
drawings.
2.4.4 Horizontal Vessels shall be checked for level across machined face of nozzle flanges with
precision level.
2.5

Additional requirements for Underground buried vessels

2.5.1 Underground vessels for operating temp upto 60C


The vessels shall be supplied at site with one coat of inorganic zinc silicate primer duly
applied on its external surfaces as per Spec. 6-79-0020. All other works such as application of
coaltar enamel, as per 6-79-0020 & wrapping and coating as per EIL Spec. 6-79-0011 shall be
carried out by EC. This shall include necessary materials, tools and tackles to complete the Job
in all respect as per the instructions of EIC.
2.5.2 Underground Vessels for operating temp. Above 60C and upto 300C
The vessels shall be supplied at site with one coat of inorganic zinc silicate primer as per Spec.
6-79-0020 duly applied on its external surfaces. EC shall be required to carryout touch-up and
repair of outside primer before erection of equipment.

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Copyright EILAll rights reserved

afarm a ENGINEERS
slig2li EVIeg UINDIA LIMITED
IA Gori al India undenakrnyi

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


ERECTION OF EQUIPMENT &
6-76-0001 Rev. 3
MACHINERY
Page 8 of 22

2.5.3 EC shall do the necessary excavation, backfilling and removal of surplus earth at the site as
per the directions of the EIC. EC's rate shall include the excavation, blast cleaning, painting,
wrapping by kraft paper, placing and fixing of Vessels, backfilling and removal of excess
earth.
3.0 ERECTION OF MECHANICAL EQUIPMENT
3.1

Scope of Work of Erection Contractor


The scope of EC shall consist of withdrawal and transportation of equipments and accessories
from Owner's stores to site, assembly of loose supplied components/parts erection of
equipment on foundations, levelling, aligning and grouting, preparation of equipments for trial
runs and hand over in fit condition for the start up of the plant as per instructions of EIC.

3.2

Details of Owner Supplied Equipments


Equipments to be erected shall be supplied by the owner. Equipments may be supplied in any
of the following conditions.
Single equipment such as filter, static mixer, silencer etc.
Skid mounted equipment, fully assembled.
Skid mounted equipment with some items supplied loose or as subassemblies involving
interconnections also.
System comprising of many equipments, skids with interconnected piping & hook up.

3.3

Technical Requirements

3.3.1 All equipment/machinery erection shall be done by experienced fitters. For this purpose EC
shall employ an experienced erection supervisor and crew who have done similar jobs.
3.3.2 EC shall study the layout drawings, for the machineries and equipments with their auxiliaries,
controls defining scope of supply.
3.3.3 Equipments shall be checked for any damages as a result of transport, handling and defects, if
any, shall be reported to the EIC. Rectification of defects shall be carried out in accordance
with approved procedure.
3.3.4 Correct procedures for handling of equipment & installation on the foundation shall be
followed as given in the manufacturer's manual. In case of non-availability of such
procedures, EC shall develop & submit handling procedures for all equipment weighing more
than 10 metric tonnes. The handling procedure shall be approved by the EIC.
3.3.5 EC shall check the correctness of equipment foundations or supporting structures as per the
drawings. Equipment/Skid foot print dimensions shall be verified to match with the
foundation. Minor chipping of foundation, pockets if required shall be carried out by EC.
3.3.6 All accessories like pressure gauges, seal oil, cooling water & Lube oil headers etc., shall be
tagged and separately kept in Contractor's stores till erection. All flanged connections and
openings shall be kept blanked with dummies, plugs to prevent entry of foreign particles.
3.3.7 Equipments shall be installed on the foundations in proper sequence. Incase the equipments
are delivered in subassemblies, EC shall do the assembly work as per manufacturer's
instructions.
3.3.8 Equipments shall be installed in the correct orientation and alignment.

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filPA; ENGINEERS
5ittif EffileS 71? INDIA LIMITED
GoN at India Undenakg,91

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


ERECTION OF EQUIPMENT &
6-76-0001 Rev. 3
MACHINERY
Page 9 of 22

3.3.9 After installation and levelling the equipment shall be grouted with the specified grouting
applied to the baseplate and support.
3.3.10 EC shall remove all the packing and protective devices used during transport and handling
from the equipment such as shock absorbent materials from machined faces, blocking of shafts
or rolling bearings & restraining devices from instruments, safety devices and protective
equipments.
3.3.11 After the grouting is set & cured, the foundation bolts shall be checked to make sure that they
are in straight and vertical position and properly tightened. Shims, if used, shall be on either
side of the foundation bolts.
3.3.12 Desiccant, catalyst where supplied loose shall be loaded on to the respective vessels in
specified quantities as per the suppliers instructions.
3.3.13 Internals, where supplied loose shall be assembled as per the drawings and manufacturer's
instructions.
3.3.14 Unless otherwise specified, all the instruments such as pressure gauges, sight glasses
temperature recorders etc. including instrument panels, if any, supplied along with the
equipment with necessary connections, shall be installed by EC as part of Equipment erection.
3.3.15 Equipments shall be checked for final cleanliness before boxing up.
3.3.16 Any interconnected piping & ducting shall be properly installed and supported. EC shall
connect the gas, steam, air, utility piping, instruments, oil piping etc. as per manufacturer's
drawings, specifications and instructions of the EIC.
3.3.17 Safety devices shall be correctly installed.
3.3.18 Ladders, platforms, walkways shall be correctly installed with handrails, and flooring shall be
properly secured.
3.3.19 Field welding, where specified shall be in accordance with the specified procedures and NDT
tests where specified shall be carried out. Results of NDT tests shall be recorded.
3.3.20 Equipment alignment & couplings shall comply with tolerances specified in manufacturer's
drawings and manuals. Provisions of dowel pins or similar arrangements for retaining the
alignment shall be carried out.
3.3.21 After the piping has been connected, the alignment shall be checked by EC again, to ensure
that piping connections do not induce any undue stresses on the Equipments. After making
necessary corrections on the piping, if any, realignment shall be done by EC to ensure that no
undue stresses are induced on the equipment.
3.3.22 Painting, insulation & fireproofing where specified shall be carried out in accordance with the
applicable specifications attached in the tender document.
3.3.23 Any alterations, deviations made during equipment erection with respect to manufacturer's
drawings or instructions shall be duly recorded and approval shall be taken from the EIC.
3.3.24 Any special tools, tackles supplied along with the equipment and used during installation shall
be returned to the stores through the EIC.
3.3.25 Any protection of the equipment after installation, if required shall be carried out in
accordance of the instructions of the EIC.
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Page 591 of 2175

Copyright ELAll rights reserved

apA ENGINEERS

Sigar talegWINIDIA LIMITED


.Rn el7mTV aezmil

3.4

IA

Govt of India uncienakiv

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


ERECTION OF EQUIPMENT &
6-76-0001 Rev. 3
MACHINERY
Page 10 of 22

Trial Runs

3.4.1 Wherever specified, Machinery & Equipment erected & installed by EC under the supervision
of Machinery/Equipment supplier shall be subjected to trial runs in accordance with clause 5.4
of this specification. Job specific trial run procedure, if specified, supersedes the trial run
procedure as described in clause 5.4.
3.5

System Start-up
During this phase of work, EC shall provide as part of his work necessary skilled personnel as
per requirement of EIC. Any defects noticed in the Equipment shall be made good by EC at
his cost if such defects are attributable to him.

4.0 HEAT AND MASS TRANSFER EQUIPMENT


This section covers the minimum requirements for erection of the following equipment by the
EC.
Deaerator
Trays/tower Internals And Tower Packings
Separators And Internals
Shell And Tube Heat Exchangers
Double Pipe Exchangers
Electric Heaters
Plate Exchangers
Plate Fin Exchangers
Sulphur Recovery Unit Equipment like Combustion Chambers, Waste Heat Boilers,
Sulphur Condensers, Incinerators, Burners, Etc.
Waste Heat Recovery Units
- Desalters
Vacuum Ejectors
Ejector Condensers
4.1

Scope of Work of Erection Contractor

4.1.1 Preparation of erection scheme and rigging procedure and obtaining its approval from EIC
wherever necessary.
4.1.2 Withdrawal of equipment from Owner's storage point, checking and reporting its conditions,
transporting the same to EC's stores and work site including unloading etc.
4.1.3 Preparation of foundation by chipping & installation of base plates for foundations. Minor
rectifications & chipping of foundations up to a thickness of 15 mm due to error in foundation
height, shall be carried out by the EC at no extra cost
4.1.4 Before starting the erection, top surface of the foundations are to be
cleaned/chipped/roughened to obtain proper bond while grouting. Line (Orientation) & Levels
are also to be marked on the respective foundations prior to erection to facilitate checking of
alignment.
4.1.5

Supply of necessary shims, levelling plates, wedges, sliding base plate.

4.1.6 Erection on foundations furnished by Owner including aligning, levelling and grouting.

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Page 592 of 2175

Copyright Ell - All rights reserved

lociMewl
5gTzIT felf5lt
,

ENGINEERS
INDIA LIMITED
A GOY, 0( India Undett.,ng)

STANDARD SPECIFICATION FOR


ERECTION OF EQUIPMENT &
MACHINERY

STANDARD SPECIFICATION No.

6-76-0001 Rev. 3
Page 11 of 22

4.1.7 Assembly and fixing of trays, tower internals (distributor, bed limiter, support plate, chimney
trays, vapour distributor etc.), demisters, grids, internal distributors and other internal fittings
in columns, vessels etc.
4.1.8 Installation of transformers on desalters and their electrical connection to electrode grid etc.
4.1.9 Welding of chimney trays, lattice girders, beams etc. wherever required.
4.1.10 Carrying out minor adjustments, modifications, seal welding of seal plates etc. wherever
necessary during installation.
4.1.11 Checking of installed trays & tower internals and filling of installation formats as referred in
6-14-0016.
4.1.12 Filling of columns, vessels/drums etc. with Raschig rings/Pall rings/ Structured packing, as
required.
4.1.13 Welding of washers for equipment, erection of pipe davit & minor welding of their parts as
per specifications and instruction of EIC.
4.1.14 Hydrotesting of shell and tube heat exchangers if the time gap between last hydrotest is more
than six months or in case it is found to be necessary by EIC. Procedure is given in para 4.3 &
4.4 below. EC to note that any equipment which are refractory lined at shop shall not be
hydrotested.
4.1.15 Flushing, cleaning and drying of equipment using compressed air and blinding to prevent
ingress of rain, dust etc.
4.1.16 Installation of refractory lining, brick lining, ceramic boards etc., as per specifications,
recommendations of manufacturer and instructions of EIC.
4.1.17 Mounting of instruments like safety valves, rupture disks, sight glasses etc as required.
4.1.18 Completing the equipment in all respects for the commissioning of the plant as per drawings,
specifications & instructions of EIC.
4.1.19 Any modification in the equipment to the complete satisfaction of EIC.
4.1.20 In addition to the above EC may be called upon to do other jobs like rectification of defects
etc. as per instructions of EIC.
4.2

General Conditions of Erection

4.2.1 All carbon steel components of trays/tower internals shall be cleaned to remove rust
preventive coating.
4.2.2 All welding shall be done by qualified welders only. The electrodes/filler material to be used
shall be compatible with the metallurgy of component and shall be used only after prior
approval of EIC.
4.2.3 A proposed Welding Procedure Specification (WPS) shall be submitted to EIL/ Owner's
Inspector for his approval. On approval, a Procedure Qualification Test (PQT) shall be
conducted which shall be witnessed by EIL/Owner's Inspector. On acceptance of all tests as
per ASME Section IX, a final WPS along with Procedure Qualification Record (PQR) shall be
submitted. Production welding shall start only after approval of final WPS/PQR and

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lardaeg (Lt
Sit ENGINEERS
SIgof latiregW INDIA LIMITED
.2/7 erenw7 nnn

IA Gcnn ol India Undenavingi

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


ERECTION OF EQUIPMENT &
6-76-0001 Rev. 3
MACHINERY
Page 12 of 22

qualification of welders as per ASME Section IX. EIL/Owner's Inspector may accept
previously qualified WPS/PQR at his sole discretion.
4.2.4 Lattice girders wherever provided for supporting tray & tower internals have been designed in
such a way that various components pass through column manway. Components/parts of
lattice girders are to be welded inside the column as per respective drawings. EC shall also
ensure that all parts of lattice girder are properly welded & levelness of the lattice girder shall
be checked before & after the welding. The limits of levelness as mentioned in GA drawings
shall be adhered to.
4.2.5 The rigging procedure shall include the following as a minimum:
Location of equipment from where it will be lifted, location of crane(s), details of crane(s)
(like configuration, boom length, operating radius, boom point elevation, clearance underside
the boom and the equipment, lifting capacity, counter weights to be deployed, holds on any
neighbouring foundations, structures, equipment etc.), the load chart of the crane(s), design of
the lifting tackles like spreader beam, D-shackles, wire rope slings etc. Unless the erection
scheme and rigging procedures are approved by the EIC, erection of equipment shall not be
undertaken in any case by the EC.
4.2.6 While handling, transporting or erecting the equipment, care shall be taken not to damage the
nozzles, instrument connections, structural clips, refractory lining etc. EC shall also take care
of the orientation of the nozzles and other connections of the equipment while erecting the
same and ensure compliance with the drawings and specifications supplied. Discrepancy, if
any, in the number/orientation of the nozzles, cleats etc. should be brought to the notice of the
EIC before actual erection is started.
4.2.7 After erection, the equipment shall be levelled and properly aligned with necessary shims and
wedges supplied by EC, at his cost. After the level, alignment and verticality etc. are checked
and approved by EIC, EC shall carry out grouting.
4.2.8 EC shall produce recent test certificates of the slings which they will be using for erection
work. However, retesting of the slings shall be done at site by the EC at his cost, as and when
required by the EIC. The weights of test loads shall be as per IS-807. The test loads shall be
supplied by EC at his cost. Tested slings will be punched for test loads and date of testing as
directed by ETC.
4.2.9 EC shall also carry out the assembly, erection, levelling and alignment of all types of weir
plates, baffles, distributors, collectors, spray nozzles, demisters, grids and other internal
fittings etc. Work shall be carried out as per manufacturer's standards/specifications which
shall be made available to EC at the time of erection. Raschig rings/Pall rings/Structured
packing, molecular sieves, intalox saddles packing and other types of tower packing such as
sand, catalyst etc. and SS wire mesh shall be loaded into sections of vessels, columns as per
specifications and drawings. Details for internals to be installed by EC shall be as per separate
schedule of quantities enclosed with the tender document. All packing except clay and lime
stone shall be washed with water before filling. Bottom layers, if required, shall be arranged as
directed and random filling shall be done afterwards with equipment filled with water.
Installation of packing, shall be done only after flushing and cleaning of columns/vessels and
completed to the satisfaction of EIC.
4.2.10 EC shall carry out minor welding for attachment of prefabricated pipe davit parts such as rain
covers, handles etc. with pipe davit, during or after erection of the same as per the
manufacturer's specifications, at no extra cost to the Owner.
4.2.11 EC shall install base plate over the sliding end foundation before erection of shell and tube
exchangers.
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sitZ r laigleg NIP INDIA LIMITED
IA Gent 01 Inda Undenaing)

STANDARD SPECIFICATION FOR


ERECTION OF EQUIPMENT &
MACHINERY

STANDARD SPECIFICATION No.

6-76-0001 Rev. 3
Page 13 of 22

4.2.12 Levelling and plumbness shall be approved by EIC and shall be checked using theodolite
before grouting and final finishing of the foundations. The record of the same shall be
maintained.
4.2.13 EC to ensure that shell and tube exchangers shall be firmly bolted down to foundations at the
fixed end. Further EC to ensure that foundation bolts at the sliding saddle end are at the centre
of slotted holes & nuts at sliding end are only hand tightened. Projected bolt threads shall be
properly protected by application of grease etc. to avoid rusting and for facilitating free
movement of nuts.
4.2.14 EC shall ensure that no equipment is subjected to any corrosion during any stage during his
period of work till handling over to EIC/Client.
4.2.15 Instruments, as required, shall be mounted by EC. On instructions of EIC, EC shall also
remove and hand over the instruments to EIC for calibrations. During this period, EC shall
cover all openings to protect the equipment.
4.2.16 Before transportation to site, EC shall check and report to EIC on the condition of equipment,
specifically highlighting the nitrogen pressure indicated in the nitrogen gauges and the absence
of blinds on any of the nozzles.
4.2.17 In case the shell and tube exchangers are to be stacked, but have been stored as single shells at
the store, then EC shall erect the bottom most shell, then erect other shell(s) sequentially using
the nozzle gaskets/bolting and saddle bolting supplied by owner. Additional shims, if
necessary, shall be supplied by EC. If the exchangers do not have interconnecting nozzles,
then nozzle elevations shall be maintained as per piping GAD.
4.2.18 All equipment, consumable and other accessories required for completion of the job shall be
arranged by the EC. This would include but not limited to cranes, tools and tackles,
manpower etc; machinery for cutting, grinding , drilling etc. of base plates; instruments like
dumpy level, plumb lines, Engineer's levels, precision levels, theodolite, straight edges etc. for
checking the alignment/erection accuracy, hydrostatic testing pumps, potable water for
hydrotesting, necessary materials including making the arrangements for hydro-testing, hoses,
compressed air supply, pressure gauge, sealing taps, blinds, shims and wedges for alignment
etc.
4.2.19 EC shall execute the erection of wooden pillows for saddle supports for cold equipment as
indicated in schedule of quantities, EIL standard 7-12-002 and instructions of EIC.
4.2.20 For bought out items like plate exchangers, plate fin exchangers, electric heater, etc. vendor's
instructions shall be followed.
4.2.21 For erection of piping of ejector system, EC shall follow relevant erection specification of
piping for the project.
4.2.22 EC shall check the health of the equipment refractory lined at shop on receipt and shall report
any defect or damage in the same to EIC. During installation all precautions shall be taken to
avoid any damage to refractory lining. Any damage to refractory during erection shall be
repaired by EC at his own cost without loss of time.
4.2.23 Wherever equipment with refractory are bolted or welded at the girth joints, the gaps between
the refractory shall be suitably filled with ceramic fiber of suitable grade as given in the
drawings or other relevant documents of the equipment.
4.2.24 Refer section 1.0 (General) for additional requirements.

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Page 595 of 2175

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it rth

INDIA LIMITED
IA Govt ol India Underlaying)

STANDARD SPECIFICATION FOR


ERECTION OF EQUIPMENT &
MACHINERY

STANDARD SPECIFICATION No.

6-76-0001 Rev. 3
Page 14 of 22

4.3

Hydrotesting of Shell and Tube Exchangers including Condensers

4.3.1

These shall hydrotested at site using potable water. Hydrotesting of both shell and tube sides
shall be carried out as per procedure given below or as per instructions of EIC. For
exchangers fitted with SS bellow or SS part, potable water with max. 25 ppm chlorides shall
be used for hydrotesting.

4.3.2 Suitable pump set, piping, test pressure gauges and other instruments, water-hoses, temporary
gaskets, metallic blinds, bolts, nuts, consumable and other temporary arrangements and
equipment for testing shall be provided by the EC at his cost. Test pressure gauges shall be
calibrated by the EC and got approved from EIC.
4.3.3 Stacked exchangers shall be hydrotested in stacked conditions.
4.3.4 Test pressure shall be as indicated in the name plates mounted on each exchangers. Duration
of hydrotest shall be at least one hour. Test pressures and duration of hydrotest may be
reduced by EIC. Minimum test water temperature shall be 20C.
4.3.5 Any defects noticed during hydrotesting shall be repaired by EC as per the procedure
approved by EIC. Cost for rectifying defects, not attributable to the EC shall be paid
separately.
4.3.6 No equipment shall in general form part of the piping loop during hydrotesting and shall be
blinded off, except when instructed otherwise by EIC.
4.3.7 EC to take adequate care during pressurising & depressurising the equipment. EC shall also
take care of any instruction given regarding hydrotest in the exchanger drawing.
4.4

Hydrotesting Procedure

4.4.1

Shell side & tube side shall be hydrotested separately, unless specified otherwise. If both sides
are to be tested together, a warning plate would be fixed to the exchanger, and the instructions
given therein are to be followed.

4.4.2 The side, shell or tube which ever to be tested at higher pressure shall be taken first.
4.4.3 During hydrotest all gasket joints should be checked for any leakage. In case of leakage from
any gasket joint, bolting at that joint shall be further tightened following proper tightening
sequence (bolts should not be overtightened or tightened by hammering). In case it is not
possible to stop leakage by bolt tightening, drain the water in exchanger & replace gasket at
that joint by new gasket (gasket will be supplied by owner). After replacing gasket exchanger
must be again hydrotested with same procedure to ensure leak tightness.
4.4.4 In case of floating head heat exchangers, if it is found during hydrotest that the pressure is
dropping, while the external gasketed joints are not leaking, this could be due to floating head
gasket joint leakage. This shall be further investigated, by removing shell cover &
pressurising tube side to check the floating head gasket joint leakage. In case of leakage
observed at floating head flange joint, replace floating head gasket by new gasket. After
replacing gasket exchanger must be again hydrotested first on tube side & then on shell side
with same procedure to ensure leak tightness of gasket joints.
In case of heat exchangers with shell side hydrotest pressure higher than tube side, it is
possible that above procedure (with tube side hydrotest to detect floating head gasket leakage)
may not help. Absence of leakage during this test is not conclusive in such a case, as the shell
side pressure was dropping during hydrotest. In such a case, floating head gasket shall in any
case be replaced and then equipment retested to ensure leak tightness.

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Page 596 of 2175

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Ogal" laMeg W INDIA LIMITED
+nen eixanvmoan)
T. Gort ol Intha Undertaing)

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


ERECTION OF EQUIPMENT &
6-76-0001 Rev. 3
MACHINERY
Page 15 of 22

4.4.5 When hydrotested as per above procedure after floating head gasket replacement, if it is
observed that test pressure is still dropping, this could mean leakage from tube to tubesheet
joint. For such cases matter shall be reported to EIC for further investigations/instructions.
4.5

Flushing & Cleaning

4.5.1 After the erection, alignment and grouting of these equipment are complete, and after
hydrotest if any, flushing and cleaning shall be carried out by EC as per specifications and
instructions of the EIC.
4.5.2 After flushing, cleaning and draining, equipment shall be dried by compressed air at the
pressure and for duration decided by EIC. The equipment interior shall be thoroughly
inspected to the complete satisfaction of EIC before it is finally boxed up. Boxing up of
manholes and handholes shall be leak proof. All joints which need remaking, shall be remade.
Compressed air for drying shall be arranged by EC at his cost.
4.6

Inspection and Acceptance Limits for Level & Alignment

4.6.1 Co-ordinates of foundations/supporting structures/mounting holes etc. shall be checked with


respect to the plot plans by EC.
4.6.2 Before equipment are placed on foundations, orientations shall be checked with respect to
piping drawings.
4.6.3 When equipment are firmly bolted down but prior to grouting, verticality of all equipment
shall be checked by using theodolite. Tolerances for equipment after erection shall be as per
EIL Standard 7-12-0001. The allowable deviation from plumb line shall be 1 mm per metre
height, subject to maximum of 6 mm.
4.6.4 Horizontal equipment shall be checked for level across machined face of nozzle flanges with
precision level.
4.6.5 Difference in elevation of centerline from one end to the other end shall not be more than 1
mm per meter and limited to 3 mm maximum. Further elevation difference shall be such as
to ensure complete draining of equipment.
4.6.6 Survey of column inside and checking the levelness of support rings, location of bolting bars
to ensure that the same are as per column drawings and within tolerances specified in standard
7-14-0001. In case these are not within permissible tolerances, the same shall be reported to
EIC for necessary rectification/modification.
4.7

Safety, Health & Environment


EC shall install an exhaust fan for exhaling welding/ cutting fumes etc. and to maintain
adequate oxygen level, before any work is started inside confined spaces (i.e. columns).
Adequate ventilation shall be maintained at all times. Gas/LPG cylinders shall not be taken
inside confined space. When a worker/supervisor enters a confined space, it shall be
mandatory to have a second man as standby. Safety belts shall be worn while entering
columns, if there is a danger of falling. All ladders/stair cases shall be in place before any item
is offered to owner's inspectors. Rope ladders/scaffolding shall be provided inside the column
in case tower internals are not easily approachable from column manhole. Low voltage (24 V)
lamps equipped with guards shall be used to prevent accidental contact with bulb. All
electrical connections shall be through ELCB's and proper earthing shall be ensured. Acids
and other materials used for pickling shall be disposed off to a designated place as directed by
owner/EIL. All statutory Regulations and owner's safety, health and environment requirements

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INDIA LIMITED
G.v, 1^dia Undertak.11

STANDARD SPECIFICATION FOR


ERECTION OF EQUIPMENT &
MACHINERY

STANDARD SPECIFICATION No.

6-76-0001 Rev. 3
Page 16 of 22

shall be complied with. Inspection aids for carrying out the inspection of internals shall also be
provided.
5.0 ERECTION OF ROTATING EQUIPMENT
5.1

Scope of Work of Erection Contractor


The scope of work shall consist of transportation of Rotating Equipments and accessories from
Owner's stores to site, assembly of sub-assemblies/parts, erection of Rotating Equipments on
foundations, levelling, aligning and grouting, preparation of Rotating Equipments for trial
runs, carrying out no load/trial runs, return of any unused material to the owners stores and
hand over in fit condition for the start- up of the Plant, as per instructions of EIC.
Defects due to EC's fault noticed during trial runs shall be rectified by him. Schedule of
Quantities, indicate estimated numbers, dimensions and weights of the Rotating Equipments.
The actual data on dimensions and weights will be in the vendor data manuals.
The term 'Rotating Equipment' includes all pumps, compressors, steam & gas turbines, fans
and blowers, diesel engine/steam turbine/gas turbine generator sets along with drivers
accessories & auxiliary systems.

5.2

General Conditions of Erection

5.2.1 All Rotating Equipment erection shall be done by experienced fitters. For this purpose EC
shall employ experienced and suitably qualified erection supervisor and crew who have done
similar jobs.
5.2.2 The Rotating Equipment manufacturer's instructions as available regarding installation and
trial runs will be passed on to EC during the course of work. The requirements prescribed
therein shall be met in addition to what is stated in this specification. Erection shall be carried
out as per instructions of the Rotating Equipment manufacturer's representative and under
their supervision whenever the manufacturer is present at site. In all other cases instructions
of the EIC, regarding procedure/sequence of erection shall be binding on EC.
5.2.3 For all Rotating Equipment, EC shall follow the proper sequence for assembly and erection.
For Rotating Equipment received along with driver in coupled condition, the coupling bolts
shall be dismantled by EC, and alignment shall be rechecked. Realignment, if required, shall
be done before recoupling.
Where drivers and couplings are provided separately, drilling and tapping of holes in the base
plates for fixing drivers, fixing of couplings on shafts, after enlarging the pilot bores to the
correct size with key way etc. and dowelling including provision of dowel pins, alignment
screws, jack-up screws or similar arrangements for retaining the alignment shall be carried out
by EC as part of erection work. Shims & wedges as required for alignment shall be supplied
by EC.
5.2.4 Process and utility (such as cooling water, steam flushing, quenching, lubricating oil, sealing
etc.) connections connected with rotating equipment and its auxiliaries shall be fabricated
and/or installed by EC from materials supplied by the Owner as per drawings, specifications
and instructions of the EIC.
5.2.5 Piping and accessories supplied with the rotating equipment such as seal oil/Gas system,
cooling water system & Lube oil system etc. shall be tagged separately and kept in EC's stores
till erection. All flanged connections and openings shall be kept blanked with dummies/plugs
to prevent entry of foreign matter.

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aarG,

ENGINEERS
INDIA LIMITED
IA Gan of India UndettaMingl

STANDARD SPECIFICATION FOR


ERECTION OF EQUIPMENT &
MACHINERY

STANDARD SPECIFICATION No.

6-76-0001 Rev. 3
Page 17 of 22

5.2.6 The local mounted instruments such as pressure gauges, sight glasses, temperature gauges etc.
and Local instrument panels, if any, with necessary connections, shall be installed by EC as
part of rotating equipment erection.
5.2.7 After initial alignment, the Rotating Equipments shall be properly grouted. Grouting shall be
carried out as per this specification. Wherever grout holes are provides in the base plates,
grout shall be filled through them also.
Epoxy grout where recommended by the rotating equipment manufacturer, shall be provided
by EC and shall be as specified in this standard.
5.2.8 Alignment between the Driver and driven equipment shall be done without connecting the
equipment nozzles to respective piping. After completion of alignment, the equipment shall
be connected to Piping. After the piping has been connected, the alignment shall be rechecked by EC, to ensure that piping connections do not induce any undue stresses on the
Rotating Equipments. After making necessary corrections on the piping, if any, re-alignment
shall be done by EC and he will ensure that no undue stresses are induced on the Rotating
Equipment.
5.3

Special Instructions

EC in addition to general instructions for erection as out lined in para 5.2 above, shall also
follow the following special instructions.
5.3.1

Pumps

Depending upon the size of equipment, Pump train will be supplied for erection in any of the
following modes :
(a) Pumps with drivers and accessories fully assembled on a common skid (Base plate).
(b) Pumps mounted on base plate and couplings and driver supplied loose in separate packs.
(c) Various major components such as pump, drivers, couplings, gear boxes & base plates
auxiliary systems like lube, seal flush equipment in separate packs.
5.3.2

Reciprocating Type Compressors

5.3.2.1 Reciprocating compressors may be supplied for erection in knocked down condition in
multiple packaged subassemblies such as frame assembly, distance pieces, fly wheels, cylinder
block assemblies, valve assemblies etc. and other accessories such as, drivers, couplings, gear
boxes (if any), control panels, gauge boards, coolers, lube oil systems, cooling water systems,
etc. would be in separate packages.
Besides the above there would be other packages for loose supplied items such as instruments,
pre-fabricated piping, and piping/tubing in commercial lengths.
Lifting devices for erection shall be arranged by EC depending on the weight of packages and
elevation of installation.
5.3.2.2 In case of Rotating Equipments received in knocked down condition, the various parts shall be
assembled as per instructions of the EIC and as per manufacturer's instructions. All parts of
the Compressor shall be thoroughly cleaned with solvents to remove protective compounds if
any, before assembly.

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Page 599 of 2175

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t
aT
r fd9:
idg

ENGINEERS
INDIA LIMITED
IA GUN Q1 India UndelaKingi

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


ERECTION OF EQUIPMENT &
6-76-0001 Rev. 3
MACHINERY
Page 18 of 22

5.3.2.3 The compressor, driver and other accessories shall be erected on their respective foundations
and the compressor, couplings, gear box and driver shall be aligned and grouted as per the
manufacturer's instructions and instructions of EIC and the manufacturers supervisor (when
present). There-after all process and utility, drain & vent connections shall be completed as
per the relevant drawings/instructions of equipment manufacturer and advice of EIC.
5.3.2.4 Final alignment shall be done after all the piping connections such as water, steam, drains and
Tolerances for alignment shall be maintained as
connection to coolers etc. are made.
specified in the Manufacturer's Instruction Manual. To ensure that piping connections do not
induce any undue stresses on the Rotating Equipment, the alignment shall be checked once
again by EC after the piping has been connected. Any correction necessary for proper
alignment shall be done by EC.
5.3.2.5 EC shall carefully study the vendor drawings, manuals and other data before start of the job to
ensure correct erection, alignment and commissioning.
5.3.3

Centrifugal Compressors & Expanders

5.3.3.1 Centrifugal Compressors are supplied for erection in multiple packages such as,
Compressor casings
Drivers (Electrical motors, Steam/Gas turbines -.)
{. : Steam/Gas turbines would be further supplied in multiple packages}
Base plates (or skids)
Lube oil/control oil systems
Sealing systems
Air filters (for gas turbines & compressors for air service)
Temporary strainers
Couplings
Gear boxes
Coolers
Gauge boards
Control panels
Lube & Seal Oil tanks
Fire systems (for gas turbines)
Condensers (for steam turbines)
Condensate systems (for steam turbines)
Loose supply items
Pre-fabricated & Commercial lengths piping, tubing.
Other miscellaneous packages
5.3.3.2 Other requirements shall be same as defined in para's 5.3.2.2 to 5.3.2.5 above.
5.4

Trial Runs of Machinery

5.4.1

Any construction defects shall be intimated to EIC before start-up. All protective and safety
guards shall be installed and rotating equipment shall be checked for free movement by
manual barring over. All foundation bolts and alignment shall be checked before starting the
trial runs, if damaged, rotating equipment may have to be opened and repaired as directed by
EIC. Prior to carrying out the trial runs, the rotating equipment will be subjected to necessary
checks by the EIC and the trial runs shall be commenced only after the approval of the EIC.

Format No. 8-00-0001-F1 Rev. 0


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INDIA LIMITED
IA Gov/ 0/ India llndenalong/

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


ERECTION OF EQUIPMENT &
6-76-0001 Rev. 3
MACHINERY
Page 19 of 22

5.4.2 Unless otherwise specified, all the rotating equipment will be subjected to trial runs for a
continuous operation of 72 hours. In case of motor driven rotating equipments, motors shall
be decoupled and turned over to other agencies doing electrical work for testing and no load
running of motors. After the no load runs of motors are satisfactorily completed, EC shall
recouple the motors to the rotating equipment and recheck the alignment. The trial run of the
rotating equipment shall be started only after the above is completed. EC shall provide, as part
of his work, necessary skilled personnel (excluding the operating personnel) for conducting
the trial runs round the clock during the trial runs period. The duration of trial run may be
extended if it is considered necessary in the opinion of EIC and EC shall provide personnel for
such extended period also. Final inspection of bearing etc. shall be carried out by EC after the
Machinery had gone through the trial run and defects, if any, shall be made good for rendering
the rotating equipment ready for start up.
5.4.3 During the trial runs, readings of bearing temperature, cooling water inlet and outlet
temperatures, lube oil inlet/outlet temperature and pressure, rotating equipment discharge
pressure and temperature, starting in current, no load/full load current etc. shall be recorded,
wherever necessary, by EC. Trial reports shall be prepared in the approved proforma by EC
containing all the above details and submitted to the EIC as part of completion documents.
5.4.4 EC shall also provide necessary improvised fencing and watch & ward personnel as safety
measures during trial runs.
5.5

System Start up
During start-up, EC shall provide necessary skilled personnel as per requirement of EIC, to
rectify defects noticed in the rotating equipment, if such defects are attributed to him.

6.0 EQUIPMENT GROUTING


All anchor bolt sleeves/pockets and space under Base plates/machine base frames/shoe plates,
etc. shall be grouted with either free flow non shrink cementitious or epoxy grout as per the
following categorisation:
Sr.
No.
1

Type of Grout
Non shrink
cementitious grout

Application
All static and rotating equipments, unless covered in 2)
below, viz Static equipments like tall columns, vertical silo,
blender etc. and horizontal vessel, drum, sphere, bullets,
filter, heat exchangers, coolers etc. and other similar
equipments, steel stack/chimney, furnace etc.
Low frequency, medium frequency, high frequency rotating
machines like compressors (centrifugal, reciprocating,
diaphram, screw, gear type etc.). Induced draft fan, forced
draft fan, air blowers, pumps (centrifugal, reciprocating,
diaphram, gear type etc.), expanders, turbine, generator,
diesel generator, air coolers (fin fan cooler) and other
similar equipment.
Machine like screen vibrator, extractor, centrifuge
pulverizer, dryer, drop hammer, ball mill, crushers, bagging
machine and general workshop equipment.

Epoxy grout

Format No. 8-00-0001-F1 Rev. 0


Page 601 of 2175

Specifically if requested by the Machine Vendor.

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Se7 ?Mtg
.

6.1

INDIA LIMITED
Grm of India uncienalong)

STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


ERECTION OF EQUIPMENT &
6-76-0001 Rev. 3
MACHINERY
Page 20 of 22

Grout (Material)
All material used for grout shall be in EC's scope. Only approved grout material shall be
used. EC shall submit details of grout materials for prior approval of EIC.

6.1.1 Non-Shrink Grout


Non-shrink grout shall be premix type of cementitious (cement pregraded fibre and additive)
non-shrink, ready to use grout in dry powder form. It shall have free flow property when
mixed with required quantity of water. It shall have initial setting time of 30 minutes.
It shall have the following features:
-

Non corrosive to anchor bolts, base plate/saddle/frame, sliding plate.


Not harmful to concrete and reinforcing steel.
Non toxic
Frost, oil and fire resistant
Require normal curing
Suitable to use under restraints and grout thickness required
Expansive to counteract initial shrinkage
Ensure high early strength without surface crack.
Suitable for temperature of above 0 deg.0 to 200 deg.C.
Maximum flow distance is compatible to the dimensions of base plate/ saddle/frame.
It should be resisted to the chemicals, gases etc. being handled in equipment/machines.

It should have the following physical properties:


Min. Compressive strength at

3 days
7 days
28 days

25 N/mm2
2
30 N/mm
40 N/mm2

Min. Tensile strength at

28 days

3.5 N/mm2

Min. Bond strength at

7 days

12 N/mm2

Max. Onstrained Expansion in

2 hours

4%
2000 kg/m3

Min. Density
6.1.2 Epoxy Grout

Epoxy grout shall consist of epoxy resin base, hardener and filler component like graded and
blended aggregate. Components of epoxy grout shall be of desired grade and mixed in
proportion recommended by manufacturer such that it is injectable under base
plate/frame/saddle etc., has low viscosity to meet the flow distances according to dimensions
of base plate saddle/frame, it is suitable for the desired thickness, it is homogenous, free from
segregation, attains high early and high final strength. It shall have minimum Pot life of 30
minutes. It shall have all the features as specified in clause 6.1.1 except for expansive
properties.
It should have the following physical properties :
Min. compressive strength at

1 day
7 days

75 N/mm2
85 N/mm2

Min. Flexural strength

7 days

25 N/mm2

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6.2

Grouting (Placement)

6.2.1

Surface Preparation

STANDARD SPECIFICATION FOR


ERECTION OF EQUIPMENT &
MACHINERY

STANDARD SPECIFICATION No.

6-76-0001 Rev. 3
Page 21 of 22

Prior to positioning of equipment/machine etc. over concrete pedestal, foundation, slab, beam,
etc. all laitance & loose material shall be removed by wire brushing & chipping. The bearing
concrete surface shall be sufficiently levelled, hacked with flat chisels to make it rough, clean
(using compressed air). Additional chipping, if required, to suit level of base plate and/or
minimum thickness of grout shall also be done. In case of use of cementitious grout surface
shall be thoroughly wet. All pockets for anchor bolts shall also be similarly cleaned. Any
excess water shall be removed. In case of use of epoxy grout, it shall be ensured that
surface/pocket to receive grout is totally dry. After erection, alignment/plumbing of
equipment/machine in required level, orientation and plumb and installation of sliding plate.
Forms shall be constructed around and joints made tight to prevent leakage of the grout.
6.2.2

Preparation of Grout

6.2.2.1 In case of premix type of grout water shall be added in required quantity as specified by
supplier and/or EIC. Any specific instruction of manufacturer will be strictly followed.
6.2.2.2 In case of epoxy grout required quantity of all constituents shall be mixed in proportion
recommended by manufacturer/supplier and/or EIC. All specific requirements of
manufacturer/ supplier shall be strictly followed.
6.2.2.3 Required quantity of grout shall be made considering initial setting/pot life of grout. Any
grout not used within initial setting time/pot life shall be rejected and in no case used for
grouting.
6.2.3

Placement of Grout

6.2.3.1 Placing of grout shall be taken up only after level, orientation, alignment of
equipment/machine has been approved by EIC and anchor bolts are placed in pocket.
6.2.3.2 In case of epoxy grout EC shall give details of grouting scheme and get approval of EIC.
6.2.3.3 The grout mixture shall be poured/injected continuously (without interruption till completion)
by grouting pump/injecting gun from one side of base plate and spread uniformly with flexible
steel strip and rammed with rods till the space is filled solidly and grout mixture carried to the
other side of base plate and fill all pockets. Any specific requirement of manufacturer/
supplier shall be strictly followed. Epoxy grout shall be done by or under supervision of
manufacturer/supplier and/or agency having adequate experience in this field as per direction
of EIC.
Total work shall be done under supervision and direction of EIC and care shall be taken that
alignment of equipment/machine is not disturbed.
6.2.3.4 Grout mixture shall be allowed to harden for a period of minimum 7 days or as required by
manufacturer/supplier of grout and/or as decided by EIC. At the end of this period, the
shims/edges/pack plate may be removed and anchor bolts tightened uniformly. Alignment of
equipment/machine shall be rechecked and if found correct, the voids left by the removal of
shims/wedges/pack plate (if removed) must be filled up with a similar mixture of grout. In
case after checking, serious misalignment is indicated, the grout shall be removed completely
and fresh grouting is done after making appropriate correction of alignment.
6.2.3.5 Minimum thickness of grout shall be 25mm for all types of grout and maximum thickness
shall be 40mm for non-shrink grout. For epoxy grout the maximum thickness shall be as per
manufacturer's recommendation and/or as specified in drawing.
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STANDARD SPECIFICATION FOR STANDARD SPECIFICATION No.


ERECTION OF EQUIPMENT &
6-76-0001 Rev. 3
MACHINERY
Page 22 of 22

7.0 REFERENCE EIL STANDARDS/ SPECIFICATIONS


6-14-0003

Installation Procedure for Trays & Tower Internals

6-14-0011

Specification for Packing the Column

6-14-0016

Standard Specification for Review of Site Installation of Column


Internals.

6-79-0011

Standard Specification for Corrosion Protection Tape Coating for


Underground Steel Piping.

6-79-0020

Standard Specification for Surface Preparation and Protective Coating


(New Construction)

7-12-0001

Vessel Tolerances.

7-12-0002

Support for Horizontal Vessel

7-12-0003

Wooden Pillow for Saddle Support

7-12-0004

Skirt Base Details

7-12-0024

Lifting Lug Top Head Type

7-14-0001

Construction Tolerance for Welded Supports for Tray / Tower


Internals

Format No. 8-00-0001-F1 Rev. 0

Page 604 of 2175

Copyright EILAll rights reserved

SPECIFICATION FOR
QUALITY CHECKS FOR
FABRICATION ERECTION AND
EXECUTION OF FIRED
HEATERS

EMPLOYER :
PROJECT

0
Rev.
No

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0
Page 1 of 45

DANGOTE OIL REFINING COMPANY (DORC)

: DANGOTE REFINERY & PETROCHEMICALS PROJECT


(DRPP)

07.03.2015
Date

ISSUED WITH TENDER


Purpose

AS
Prepared
by

RP
Checked
by

AP
Approved
by

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SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

Page 2 of 45

CONTENTS

S.NO.

DESCRIPTION

1.0

PURPOSE4

2.0

REFERENCES4

3.0

DEFINITIONS............................4

4.0

SCOPE5

5.0

ATTACHMENTS / FORMATS ...10

ANNEXURE-I - DOCUMENTATION CHECK LIST (2 SHEETS)


ANNEXURE-II HEATER QUALITY CHECK REPORTING FORMATS
ANNEXURE III- CHECKLIST FOR SHOP/ SITE CHECKS OF HEATER SYSTEM
ANNEXURE IV- ADDITIONAL QUALITY CHECKS FOR HEATER SYSTEMS
FABRICATED IN MODULES

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SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
1.0

Page 3 of 45

PURPOSE
This document covers the minimum inspection requirements and quality checks for
Fired Heater Systems during the construction & prior to commissioning of heater
systems.
In order to ensure overall quality during execution, it is Package Vendors
responsibility to meet the specified technical requirements and execute the job as
per applicable documents issued by PMC as well as PMC approved documents
prepared by the Package Vendor. Records of all quality checks shall be maintained
by the Package Vendor duly counter checked by Engineer-in-Charge.

2.0

REFERENCES
Following shall be considered as reference documents for carrying out the work:
i)
All Technical documents issued along with Tender & Agreed Variations (if
any).
ii)

All referred Standards Codes and Drawings (issued for construction /


engineering).

iii)

Quality Assurance Plans / ITPs (developed by Package Vendor) as agreed


with PMC / Employer.

iv)

Documents originated by Package Vendor (listed in Document Index) and


approved by PMC wherever required.

3.0

DEFINITIONS

3.1

Package Vendor means the person(s), firm, company, organization from whom
PMC procured products/services on behalf of Employer.

3.2

Engineer-in-Charge means the authorized engineer either from Employer / PMC


site / Inspection Agency responsible to interact with Package Vendor carrying out
stage wise inspection and getting the jobs done under his survPMClance and
inspection.

3.3

Specialist means the nominated personnel of PMC from Heater group / SMMS
Refractory group, assigned to perform the review of Heater System site execution at
identified stages.

3.4

Punch List means a list of comments given by Specialist after shop / site review
which needs to be attended for necessary rectifications by the Package Vendor
under direction of Engineer-in-Charge.

4.0

SCOPE

4.1

PACKAGE VENDOR

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CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

Page 4 of 45

4.1.1

Execution of work defined in Scope para of job specification and specification 6-170001 issued with tender document. The detail concerning different portions of work
are covered in separate technical specifications e.g. Steel Work, Coil, Refractory etc.
Inspection & Test requirements for different portions of work are covered in these
separate Technical Specifications and the compliance of the same is Package
Vendors responsibility.

4.1.2

Prior to usage, Package Vendor shall ensure that all the material / sub-assemblies
being used for Job execution are in good condition & meeting the specification
requirements.

4.1.3

Tolerances on fabrication and assembly of various works are also specified in


technical specifications for Steel work, Coil work & Refractory work. These shall be
strictly complied during execution of work. Deviation from these is not permitted
unless authorized by a Deviation Note.

4.1.4

Maintaining the Records of all Tests & Inspections in line with requirements of
Technical Specifications shall be Package Vendors responsibility. Wherever
required the same shall be got witnessed / counter checked from Engineer-inCharge. Tests / Inspection Records shall include but not limited to following:
i)

Steel work fabrication tolerances as per para 7.17 of Spec. 6-17-0002.

ii)

Steel work erection tolerances as per para 8.11 of Spec. 6-17-0002, UON.

iii)

Steel work weld joint inspection as per para 10.4 of Spec. 6-17-0002.

i) Coil assembly tolerance as per para 2.3 of Specification 6-17-0003.


v)

Hydrotest at site for Coil Assembly - indicating test pressure, holding time and
remarks, if any.

vi)

Radiographic examination of coil welds as per para 4.3 of specification 6-170003.

vii)

Skin point thermocouple welding - as per Appendix V of 6-17-0003 to ensure


complete welding length of 50 mm both side & clamp.

viii)

All material test reports including special tests such as WPS/PQR, hardness
tests, radiography, DP / MT test, UST etc.

Prior to erection of tube support castings Package Vendor shall re-verify at shop /
site, that Tube support casting (including Convection Intermediate Tube supports)
are as per para 5.1 of Spec 6-17-0007, UON.
4.1.5

HOLD POINTS
Clearance to be sought from Engineer-in-Charge at following critical stages of job:
i)

Prior to starting refractory lining of Radiant Shell (to avoid hot work after lining
and to ensure check stage A).

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SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

Page 5 of 45

ii)

Prior to start of refractory lining of Convection Box (to avoid hot work after
lining).

iii)

Prior to Erection of Coil within Radiant Box (to inspect refractory lining).

iv)

Prior to start of refractory in the convection section but after erection of


Intermediate tube sheets (to inspect Tube sheet clearances with the Steel
works and Specialist check stage C(i)).

v)

Prior to start of tubing of Convection Section (to inspection refractory and


specialist check stage C(ii).

vi)

Prior to lifting of tubed & lined convection box wherever the same is envisaged
(to ensure readiness of convection box, completion of convection supporting
steel work & adequacy of lifting arrangement).

vii)

Prior to connecting jump overs / cross-overs in Radiant & Convection Coil


passes (for witnessing of cold pull requirements).

viii)

Prior to Stack Erection (to ensure completion of stack support steel work and
adequacy of lifting arrangement).

ix)

Prior to removal of internal scaffoldings from the heater (to facilitate


inspection stage B & C(iii).

x)

Prior to providing various seals on tubes, sleeves, spigots etc. (to ensure
correct positioning of coil parts in cold condition).

xi)

Prior to erection of flue gas ducts connected to Heater (for ensuring support
requirements at both ends).

xii)

Prior to installation of Burners (to ensure readiness & to ensure safety /


protection of burners).

xiii)

Prior to box up of heater (i.e. closing of all doors, header boxes, panel covers
etc.) (to ensure completeness check).

4.1.6

Provide all the facilities for inspection / review by Engineer-in-Charge / Specialist.

4.1.7

Conduct a smoke test (pressure test) for furnace & ducting to check for all leakage
points.

4.2

ENGINEER-IN-CHARGE

4.2.1

Maintaining a list of all applicable documents, drawings etc. with Revision Nos.
which are being followed for execution of heater work and ensuring that the same
are as per PMC drawings / vendor drawing index. (A typical documentation check list
is enclosed for reference - Annexure-I).

4.2.2

Stage wise & final inspection of execution of site work in compliance with applicable
specifications and drawings.

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CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

Page 6 of 45

4.2.3

Ensuring that all hot work is performed on steel work surfaces before the same is
released for refractory lining.

4.2.4

Counter checking of various dimensions / tolerances / tests as recorded by Package


Vendor as per para 4.1. These records shall be maintained at site and shown to
Specialist for his review.

4.2.5

In case of any deficiency found by Engineer-in-Charge during stage-wise / final


inspection, the directions shall be provided to Package Vendor for necessary
rectification / modification or examine the Package Vendors proposal for
rectification.

4.2.6

Review & approval of Package Vendors Quality Assurance Plan for stage wise /
final inspection & the same shall be sent to Heater Specialist for information.

4.2.7

Review of sequence of various activities & the erection scheme proposed by


Package Vendor vis--vis crane capacity, crane availability and schedules. Activities
sequence to be reviewed by Engineer-in-Charge and forwarded to specialist for
concurrence.

4.2.8

Organizing specialists Stage wise / final checks and providing all facilities e.g.
approach, lighting, safety gadgets for conducting site checks.

4.2.9

Attending to Punch Lists provided by specialist at the end of his review and ensuring
that these are attended to by the Package Vendor. Engineer-in-Charge shall intimate
the specialist through Projects, when all points listed in punch list are attended to.

4.2.10 Any problem, if faced during rectification, may be referred to specialist for opinion.
4.2.11 It is the responsibility of the Engineer-in-Charge to see that the heater is constructed
strictly to the design requirements. Proper inspection requires regular checks as it
progresses.
Following Inspection / Checks shall also be carried out and recorded:
i)

Identification and inspection of materials of construction and sub-assemblies.

ii)

Approval of welding procedures in accordance with tender specifications /


code requirements.

iii)

Carrying out of welder qualifications tests as per code.

iv)

Ensuring that approved welding procedures, welders and welding


consumables are employed & proper storage of welding consumables is done
by Package Vendor.

v)

Ensuring that proper preheating and post weld heat treatment are carried out,
wherever specified.

vi)

Checking the quality of welding by radiographic and other NDT techniques as


required.

vii)

Checking of the layout and dimensions of all parts strictly as per the drawing.

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ERECTION AND EXECUION OF
FIRED HEATERS

Page 7 of 45

viii)

Witnessing the hydrotest of coil assembly / sub-assemblies according to


requirements.

ix)

Ensuring that all structurals, specially the load bearing structurals are in
accordance with approved drawings.

x)

Checking the quality of external insulation material and weather proofing (i.e.
aluminum cladding etc.).

xi)

Ensuring that all painting jobs are done after adequate surface preparation
and the paints meet the specifications.

xii)

Ensuring that explosion doors are seating properly and are operable without
hindrance.

xiii)

Witnessing of cold condition placement of all terminals before and after


connection to piping to ensure cold pull as per requirements.

xiv)

All checks as per formats enclosed (Annexure-II).

4.2.12 For all refractory related work, following are some of important checks which shall be
carried out by Engineer-in-Charge and a record shall be kept for reference:
i)

Verify the refractory lining material & thicknesses during application.

ii)

Verify the tie back anchors details e.g. material, shape, dimensions etc.

iii)

Verify the retainers are provided as per approved refractory drawings.

iv)

Verify proper welding of tie back anchors/studs on furnace casing and ducting,
prior to lining.

v)

Verify anchors layout, pitching, orientations etc.

vi)

In case of castable lining ensure proper mixing & application as per


manufacturers recommendations. Verify the date of manufacture and the
shelf life of castable.

vii)

Where brick lining is used, the laying of brick & quality of mortar should be
ensured as per PMC approved procedure.

viii)

Verify that adequate provision is given in lining for thermal expansion as


detailed in the drawings.

ix)

Verify that castable lining is free of voids/cracks/bulges. Proper shuttering and


ramming techniques to be applied. Hammer tests after curing to be used to
detect voids.

x)

In case of ceramic fiber blankets lining verify that edge distance of top blanket
layer from the first stud is not more than 76 mm / 50 mm as permitted in
drawings.

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ERECTION AND EXECUION OF
FIRED HEATERS

Page 8 of 45

xi)

Verify the overlap of top most blanket layer with respect to flow direction so
that it does not permit flue gas ingress within the lining.

xii)

Verify that the Ceramic fiber module orientations are as per approved
refractory drawings.

xii)

Ensure that Refractory Dry Out is done as per PMC approved procedure.
During dry out check heater casing and stack shell temperatures and record
for verification by Specialist.

4.2.13 Engineer-in-Charge shall also ensure that all checks are made as per CHECK LIST
Annexure-III, by Package Vendor and witnessed by Engineer-in-Charge as routine
checks and same are kept as RECORD. Heater specialist shall review the same and
carry out some random checks.
4.2.14 A critical review by Engineer-in-Charge is required at following stages of work:
(A)

When Package Vendor informs the readiness to begin Radiant Section lining.

(B)

After Radiant Coil erection work including jump-overs between Radiant Tubes
is completed but the approach scaffoldings inside radiant shell are not
removed

(C)

i)

Convection section modules after erection of Tube support casting


inside the modules but before refractory lining.

ii)

After the Erection of Intermediate Tube Sheets in Convection Box is


done and also the castable lining of convection wall is completed and
coil erection in convection box is to be started. (approach scaffoldings
inside upto Convection Area should not be removed).

iii)

After all coil work is completed and Convection to Radiant Crossovers


are connected but approach scaffoldings inside radiant shell are not
removed.

(D)

After Mechanical Work Completion is informed by Package Vendor.

(F)

Witnessing of Smoke / Leak test of system.

4.2.15 REFRACTOR CHECKS


(1)

The Review / Checks by SMMS-Refractory Specialist are not covered in this


Specification. Engineer-in-Charge shall coordinate with SMMS Specialist
through Projects for Refractory site review.

(2)

C(ii) review is recommended also for Convection Refractory checks (by


SMMS specialist).

4.2.16 The stage wise/ final checks by PMC-Heater specialist at site are defined in this
specification. For Stage wise review / check listing by PMC- Heater specialist at
shop in case of modular construction are as defined below:
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ERECTION AND EXECUION OF
FIRED HEATERS

i)
ii)
iii)

Page 9 of 45

For convection section modules after erection of Tube support casting inside
the modules before refractory lining.
When modules with coils are nearing completion at shop / fabrication yard.
Completely modularized Fired Heater where major fabrication activities are to
be performed at shop.

PMC- Heater specialist checking shall be done after confirmation that all checks
as per requirements of specifications have already been carried out by the
Package Vendor as per the various defined stages. In case the actual dimensions
/ tolerances are not meeting the tender requirements the same shall be rectified
by Package Vendor before offering the Heater for PMC- Heater specialist
checking.
4.2.17 For the fabrication work carried out at shop outside the refinery premises, all the
quality formats shall be duly signed by Package Vendor and the inspection agency.
And the same shall be made available along with the Inspection Release Note at the
time of bringing the modules / panels inside the refinery premises.
4.2.18 Incase of modular construction it shall be the responsibility of the Package Vendor to
prepare and transport the foundation templates to the Package Vendors shop so as
to ensure correct interfacing / seating of the modules at foundations.
4.3

SPECIALIST shall carry out following checks and reviews:


i)

Review of various test reports, observations, tolerances, checks made on site.

ii)

Random checks on fabrication, erection, assembly tolerances and their


correctness.

iii)

Review of correct installation of tube supports.

iv)

Review of correct seating of tubes on the supports.

v)

Review of refractory soundness and ensuring correct thickness and grades of


refractory material, date of manufacture and shelf life.

vi)

Listing out the discrepancies observed. If specialist finds it necessary to


discuss with head office, it shall be referred to HO for decision. Jobs which
need rectification shall be reported to Engineer-in-Charge through a Punch
List. These shall be attended to by Engineer-in-Charge.

vii)

Punch List shall be handed over to Engineer-in-Charge. One copy of Punch


List shall be submitted to Head Office.

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CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

Page 10 of 45

ANNEXURE I

REFERENCE DOCUMENTS CHECK LIST

FOR

HEATER JOB EXECUTION

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ERECTION AND EXECUION OF
FIRED HEATERS
S. No.
1.

DOCUMENT

Page 11 of 45

DOCUMENT NO.

REMARKS

Tender Document including :


(a)

Job Specification

(b)

Other Technical Specification

(c)

Referred Standard Drawings

(d)

Referred Standard Specification

(e)

Quality Documents 6-78-0001,


6-78-0002

(f)

Referred latest rev PMC Job Drawings


Issued for Engineering / Construction

2.

Addendum to Tender Specification

3.

Latest rev PMC Job Drawings Issued for


Engineering / Construction

3.1

Index of Drawings

4.

Agreed variations to Tender


Approved Erection Sequence

5.

Burner Vendor drawing (PMC approved) +


Operating / installation instructions

6.

Soot Blower Vendor drawings (PMC approved)


+ Operating / Erection Manual

7.

Tube Support Casting PR drawings/Vendor


drawing if applicable

8.

Spring Supports PR drawings (if applicable) /


Vendor drawings and Manual

9.

Damper Vendor drawings (PMC approved) +


Operating / Erection Manual

10.

Package Vendor documents latest Revisions


(PMC approved) (along with Document Index
updated on monthly basis)

11.

PMC Operating Manual along with approved


Dry-out Procedure

12.

Design change notes, deviation permits

Document

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CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

Page 12 of 45

ANNEXURE - II

HEATER QUALITY CHECKS

REPORTING FORMATS

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ERECTION AND EXECUION OF
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JOB NO. . . . . . . . . . . . . . . . .
....

Page 13 of 45

PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

STRAIGHTNESS OF STRUCTURAL COLUMNS( For Panels , modules and assembled


Heater Structure ) FORMAT NO: A
INSPECTION STAGE

REFERENCE SPEC./PARA :
COLUMN GRID NO.

STRUCT. MEMBERS FABRICATION


6-17-0002/7.17(l) , UON.

OUT OF STRAIGHTNESS OVER FULL LENGTH


ABOUT X-X AXIS

PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

REMARKS

ABOUT Y-Y AXIS

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .

..
Notes:

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1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of fabrication (panels, modules
and at site ).
JOB NO. . . . . . . . . . . . . . . . .
....

PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

STRAIGHTNESS OF STRUCTURAL BEAMS, FORMAT NO: B


INSPECTION STAGE

REFERENCE SPEC./PARA :
BEAM GRID PLANE

STRUCT. MEMBERS FABRICATION


6-17-0002/7.17(j&k)

ELEVATION

OUT OF STRAIGHTNESS
LONGITUDINAL

PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

REMARKS

LATERAL

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .

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EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of fabrication (panels, modules
and at site ).
JOB NO. . . . . . . . . . . . . . . . .
....

PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

VERTICALITY OF ASSEMBLY / CENTRELINE OF COLUMNS, FORMAT NO: C


INSPECTION STAGE

REFERENCE SPEC./PARA :
ELEVATION

ERECTION
6-17-0002/8.11(b)
OUT OF VERTICAL (mm)
w.r.t. GRADE

REMARKS

(CENTRELINE U/S STACK)


(CENTRELINE U/S ARCH)
(CENTRELINE COL. GRIDS)

PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........

Engineer in Charge . . . . . . . . . . .

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FIRED HEATERS
(SIGNATURE)

Page 16 of 45

(SIGNATURE)

NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .

..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of fabrication (panels, modules
and at site ).
JOB NO. . . . . . . . . . . . . . . . .
....

PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

LEVEL OF HEARTH FLOOR, FORMAT NO: D


INSPECTION STAGE

ERECTION OF FLOOR PLATE

REFERENCE SPEC./PARA :
ORIENTATION

LEVEL CHECK REMARK

REMARKS

0o
45o
90o
135o
180o
225o
270o
315o
Note: 1. Level shall be measured along all defined Radial lines with respect to floor centre in
case of VC heater & with respect to centre of each floor segment in case of Box heaters.
2. Level must be achieved perfect across the burner cut out openings.

Page 180 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

Page 17 of 45

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .

..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of fabrication (panels, modules
and at site ).

JOB NO. . . . . . . . . . . . . . . . .
....

PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

VERTICALITY OF STACK, FORMAT NO: E


INSPECTION STAGE

REFERENCE SPEC./PARA :
DEGREE

STACK ERECTION
6-17-0002/8.11(a)

MAX. DEVIATION OF TOP OF


STACK w.r.t. STACK BASE

DEVIATION OF TOP STACK


w.r.t. GROUND LEVEL

REMARKS

0o
45o
90o
135o
180o
225o
270o
315o

Page 181 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

Page 18 of 45

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .

..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of fabrication (modules and at
site).

JOB NO. . . . . . . . . . . . . . . . .
....
HEATER NO. . . . . . . . . . . . .

PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

OVALITY OF RADIANT SHELL (VC HEATERS) / STACK, FORMAT NO: F


INSPECTION STAGE

REFERENCE SPEC./PARA :
DEGREE

SHELL FABRICATION
6-17-0002/7.17 (q)

INSIDE DIAMETER (mm)

REMARKS

0o
30o
60o
90o
120o
150o
180o

Page 182 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

Page 19 of 45

210o
240o
270o
300o
330o

PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .

..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of fabrication (panels, modules and
at site).
JOB NO. . . . . . . . . . . . . . . . .
....
HEATER NO. . . . . . . . . . . . .

PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

TUBES CENTRELINE TO CENTRELINE DISTANCE, FORMAT NO: G


INSPECTION STAGE

REFERENCE SPEC./PARA :
PITCH NO.

COIL FABRICATION/ERECTION
6-17-0003/2.3

REQUIRED AS PER
DRAWING (mm)

MEASURED POINT (mm)


1

REMARKS

Page 183 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

Page 20 of 45

NOTE:

1.

Pitch Nos. shall be counted starting from 0 and moving in clock wise direction for
VC heater.
For Box heaters pitch no. shall be counted starting from bottom most pitch.

2.

Pitch must be measured at least 4 locations along tube length.

PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .

..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
fabrication & erection.

JOB NO. . . . . . . . . . . . . . . . .
....

PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

TUBES CIRCLE DIA OF CYLINDRICAL HEATERS, FORMAT NO: H


INSPECTION STAGE

REFERENCE SPEC./PARA :
ORIENTATION

COIL FABRICATION/ERECTION
6-17-0003/2.3

REQUIRED DIMENSION MEASURED POINT LOCATION


(mm)
(mm)

REMARKS

Page 184 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
1

Page 21 of 45

0o
45o
90o
135o
180o
225o
270o
315o
NOTE:

1.

TCD shall be measured at least at four locations along the height of Radiant
Section.

2.

This Format is applicable for Vertical as well as Helical Tube Radiant Section.

PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .

..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
fabrication & erection.
JOB NO. . . . . . . . . . . . . . . . .
....

PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

TUBES CLEARANCE TO REFRACTORY WALL SURFACE, FORMAT NO: I


INSPECTION STAGE

COIL ERECTION

Page 185 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
REFERENCE SPEC./PARA :

6-17-0003/2.3

REQUIRED
DIMENSION
(mm)

ORIENTATION

MEASURED POINT LOCATION


(mm)
1

NOTE:

Page 22 of 45

REMARKS

1.

Tube No. in case of VC heater shall be counted clockwise starting from 0o. For Box
heater Tube No. to be counted from Bottom to Top.

2.

Four No. equi-spaced point location for measurement shall be selected along tube
length.

PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .

..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
erection.

Page 186 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
JOB NO. . . . . . . . . . . . . . . . .
....

Page 23 of 45

PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

OUT OF PLUMB FOR VERTICAL TUBES, FORMAT NO: J


INSPECTION STAGE

REFERENCE SPEC./PARA :
TUBE NO.

NOTE:

1.
2.

COIL ERECTION
6-17-0003/2.3
OUT OF PLUMB (mm)

REMARKS

Readings shall be recorded in coil free condition before restraining the spigots.
Readings shall be recorded after removal of all temporary supports (if used) e.g.
incase of CCR heater coils.

PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .

..
Notes:

Page 187 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

Page 24 of 45

1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
erection.

Page 188 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
JOB NO. . . . . . . . . . . . . . . . .
....

Page 25 of 45

PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

STRAIGHTNESS OF TUBES, FORMAT NO: K


INSPECTION STAGE

REFERENCE SPEC./PARA :
TUBE NO.

PRIOR TO FABRICATION / DURING FABRICATION


6-17-0003/2.3
STRAIGHTNESS DEVIATION ON
OVERALL LENGTH (mm)

PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

REMARKS

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .

..
Notes:

Page 189 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

Page 26 of 45

1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up for various stages of modular construction and at
site.
HEATER NO. . . . . . . . . . . . .
PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

COIL SUPPORT CASTINGS LOCATION, FORMAT NO: L


INSPECTION STAGE

REFERENCE SPEC./PARA :
SUPPORT CASTING
S.NO.

AFTER CASTING ERECTION/COIL ERECTION


6-17-0001/4.3

ALIGNMENT OF
CASTING

PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

TUBE RESTING
CHECK

REMARKS

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 190 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

Page 27 of 45

EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .
..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
erection.

JOB NO. . . . . . . . . . . . . . . . .
....
HEATER NO. . . . . . . . . . . . .

PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

VERIFICATION OF TERMINAL LOCATIONS, FORMAT NO: M


INSPECTION STAGE

REFERENCE SPEC./PARA :
TERMINAL
/
PASS NO.

INLET/
OUTLET

FIELD WELDING/ERECTION OF TERMINAL PIECE


OF COIL
HEATER GENERAL ARRANGEMENT DRAWINGS

CENTRELINE
ELEVATION

DIST. OF FACE OF
LATERAL POSITION OF
FLANGE
TERMINAL
FROM HEADER
BOX/SHELL
BEFORE
AFTER
BEFORE
AFTER
COLD PULL COLD PULL COLD PULL
COLD
PULL

Page 191 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

Page 28 of 45

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .

..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
erection.

JOB NO. . . . . . . . . . . . . . . . .
....
HEATER NO. . . . . . . . . . . . .

PMC DRG.NO(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PACKAGE VENDOR . . . . . . . . . .
.............

PACKAGE VENDOR DRG.NO(S) . . . . . . . . . . .

VERIFICATION OF INTERMEDIATE TUBE SHEETS (ITS), FORMAT NO: N


INSPECTION STAGE

REFERENCE SPEC./PARA :
ITS
NO.

PRIOR TO REFARCTORY IN CONVECTION


SECTION BUT AFTER TUBE SUPPORT
INSTALLATION
HEATER GENERAL ARRANGEMENT DRAWINGS

LENGTH OF ITS (
outer edge to outer
edge )

Steel Column to Steel Clearance of ITS Clearance of ITS


column convection
edge from Steel edge from Steel
width at ITS location column A ( at edge
column A ( at
of ITS )
other edge of ITS
)

Top Middle Botto


of of ITS m of
ITS
ITS

Top of Middl Bottom Top Middl Botto Top Middl Botto


ITS
e of
of ITS of ITS e of m of of
e of m of
ITS
ITS
ITS ITS ITS
ITS

Page 192 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

Page 29 of 45

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .

..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.

ANNEXURE - III

CHECK LIST

FOR

SITE CHECK OF HEATER SYSTEMS

Page 193 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
PROJECT: . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 30 of 45

NAME OF CHECKER: . . . . . . . . . . . . . .
...

HEATER: . . . . . . . . . . . . . . . . . . . . . . . . . . .
S. No.

DESCRIPTION

A.

SITE OFFICE DOCUMENTS

1.

Check the availability of documents and


Rev No. with index for fabrication
drawings,
engineering
drawings,
standard drawings, specifications and
vendor equipment drawings, equipment
manuals with PMC-specialist group's
authentication.
Package Vendor shall ensure that all the
formats, as per annexure II, are filled up
and maintained for each and every stage
of the fabrication. The formats shall be
duly signed and verified by the Package
Vendors Engineer in charge.
Some of the points mentioned below are
applicable for the Fabrication carried out
at shop also depending on the extent of
work carried out at the shop. It I Package
Vendors responsibility to check and
verify the points which becomes
applicable for shop fabrication.
COIL WORK
Orientation of the bolt holes of the
flanges
Check projection of the terminals outside
Check position of the terminals whether
they are in line with GADs (pass details).
Are the terminals/manifolds free to take
the expansions as indicated in the
drawings Axial/sideways w.r.t. steel work
& concrete pedestals.
Freeness of defined movements shall
also be verified w.r.t first piping support in
transfer line.
Check position of the coil on the coil
brackets w.r.t. GA drawings. This will
give idea whether the supports are
erected properly and tube is supported.

2.

B.
1.
2.
3.
4.

5.

CHECK LIST STAGE


(As defined in para 4.2.14
of Spec.)

REMARKS/
COMMENTS

ALL

B, D
D
B, D
B, D

B, D

Page 194 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
S. No.

6.

7.

8.
9.

10.

11.

12.

13.

14.

15.

16.
17.

DESCRIPTION

Page 31 of 45

CHECK LIST STAGE


(As defined in para 4.2.14
of Spec.)
Check whether the ends of the studded
C, D
tubes have been provided with castable
lining as per Standard 7-17-0313 before
installation.
Check if any permanent drain connection
D
is installed below the coil drain. If yes, is
there adequate slotting provided for the
movement of drains along with coil in the
grating as platform member.
Check all crossovers / jump overs are
D
provided with insulation and Al cladding.
Check all crossover points for convection
to radiant and radiant to radiant have
been provided for their free expansion
(considering external insulation) through
the gratings.
Check all VC heater radiant bottom guide
(spigot) having been provided with
cooling holes in case of SS 304 guides.
In case of SS-310 guide tubes, the hole
shall not be provided.
Check all VC heater bottom guides are
free for expansion and remain clear of
any obstruction below.
Check the projection of spigots underside
floor plate. The same to be measured
prior to dry out and during dry out.
Check that all bottom spigot sleeves are
sealed against air leakage (cloth seal or
end caps to be provided as per
requirement).
Check coil anchors and cross guides
have been provided as indicated in the
drawings.
Check all tubes or the bends rest
properly on the support casting unless
noted otherwise on GAD.
Check cast lugs are resting properly on
supports and not jumped or lifting up.
Check studded tube banjos are erected
in the proper position and not got
interchanged. Observe in Header Box &
check studs by counting.

REMARKS/
COMMENTS

B, D

B, D

B, D

B
D

Page 195 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
S. No.

18.

19.
20.
21.

22.

DESCRIPTION

Page 32 of 45

CHECK LIST STAGE


(As defined in para 4.2.14
of Spec.)
If the coil in the radiant section is
B
changing in size, check location of the
reducer/expander.
Check location of coil tube w.r.t. sight
B
door opening.
Ensure that all tubes are free for thermal
B, D
expansion as envisaged.
Ensure none of the opening provided for
B
the probe type instrument/SS tapings are
facing the tube or have the possibility of
facing/obstructing the tubes after their
expansion.
Check cold pull has been provided as per
B, D
drawings.
= Radiant/Radiant jumpovers
=

Convection/convection jumpovers

Convection/Radiant crossovers

23.

24.

25.

26.

27.

Inlet/Outlet
terminal
before
connecting to transfer line.
(The above can be ensured by checking
the positioning of connected tubes before
and after cold pull duly recorded and
signed as per prescribed Format).
Check all coil tubes coming out of the
furnace are having their openings sealed
using asbestos/ceramic cloth as per
Standard 7-17-0322. Also ensure that
slotted sleeves on End tube sheets are
also provided with sealing inside Header
boxes.
Check convection section studded tubes
are straight, do not foul/touch with the
refractory on the sides, specially on
corbel side.
Check projection of Thermowell flange
connection in the coil for weldolet type
connection. (min 200 mm above tube OD
is required).
Flange rating of Thermowell and
Pressure gauge tapping to be same as
coil process rating. Check flange facings
also.
Check for all other tapping points like

REMARKS/
COMMENTS

B, D

B, D

B, D

Page 196 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
S. No.

DESCRIPTION

Page 33 of 45

CHECK LIST STAGE


(As defined in para 4.2.14
of Spec.)

REMARKS/
COMMENTS

steam injection etc. as per GAD.


28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

Verification of the cast plug header for


their ratings and clearances on Header
Box.
Check clearance between U/S bottom
bend and floor refractory. Ensure no
refractory bricks obstructing below
bends.
Check LR bends locations, if provided in
drawings.
If Cast return bend are present, ensure
that ends are not grinded at site with out
HMTD approval to suit welding. The
thickness at ends shall be ensured as per
GADs
Check external surface of tubes for
deposits and cracks.

B, D

Verification of Record for tubes Central


Butt Welding Procedure Qualification as
per ASTM A-422.
Verification of Records for Weld
Procedure Qualification w.r.t. Hardness
requirement of the Specification.
Check
whether
instruments
other
auxiliary connection nozzles in coils are
temporarily covered with blind to avoid
foreign body entering (e.g. material / rain
water). Instruct site to put caution tags at
these locations for instrument mountings.
Check tube skin thermocouples are
placed correctly w.r.t loop orientation and
coil expansion direction indicated in
GAD.
For tubular APH (on board) check that
one end of tube is welded to the tube
sheet and other end is free to move in
the gland arrangement.
Check convection section studded tubes
are straight; do not foul/touch with the
refractory on the sides, specially on
corbel side.
Check that in no case temporary
structural supporting (tacking of platform
member etc.) is permitted from the heater

B, D

B, D

B, D

B, D

C, D

C, D

C, D

C,D

C,D

Page 197 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
S. No.

DESCRIPTION

Page 34 of 45

CHECK LIST STAGE


(As defined in para 4.2.14
of Spec.)

REMARKS/
COMMENTS

coil or cross overs.


C.

TUBE SUPPORT CASTINGS

1.

Check the proper brackets are provided


at the outlet tubes on the proper side of
the heater.
Check supports are not obstructing the
cold pulled tubes of the crossover.

2.
3.

4.

5.

6.
7.

8.
9.
10.
11.

12.

13

Check all bends and lugs are supported


on the brackets except otherwise noted
in GADs. Also verify adequate gaps on
brackets at lugs location w.r.t. cross over
thermal expansion
Any special supports for crossover if
shown in GAD have been provided in the
heater. Sliding supports to have limit
stops and Teflon layer.
Check alignment/spacing/levels of all
brackets. (For VC heaters hangers tip to
tip distance also to be checked).
Check bolt material for T/sheet support
bracket (SS required).
Check all bends and lugs are supported
on the brackets. Also verify lugs location
w.r.t. cross over thermal expansion.
Check intermediate guide where shown
on GAD are provided.
Check all locking bars are assembled
properly.
Verify all nut/bolts are tightened and tack
welded for fixing of tube support castings.
Verify that Intermediate tube sheets are
free to expand sideways. Proper
expansion gaps for length expansion and
between support and refractory must be
available. In case, support flange is other
than bottom flange, all round expansion
gap to be ensured. (including sideways)
Verify that all the pins used for Tube
support assemblies are tack welded after
assembly as per requirement.
In case of dimensionally identical tube
sheets, but different MOCs, check that
they are installed at the correct location.

D
A

B, C

B,D

C
B, D

B
B
B, D
B

Page 198 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
S. No.

14.

DESCRIPTION

CHECK LIST STAGE


(As defined in para 4.2.14
of Spec.)
B
For top supported vertical tube cabin
heaters, check that the top tube supports,
which in turn are supported from arch
members outside fire box , are having
positive contact with the arch members
for ensuring proper tube load transfer to
the arch members.

D.

REFRACTORIES

1.

Check for expansion joints at all grid


locations in cabin heater as detailed in
GAD.
Check for expansion joints below all
brackets and on two sides and above the
brackets.
Check expansion joints are not packed
too tight.
Check for expansion joints around all
instrument/auxiliary openings for brick
lined heaters.
Check expansion/movement slots and
sleeves are not packed with ceramic
fiber. These are to be sealed through
details as per PMC Std. 7-17-0322.
Ceramic packing between end tube sheet
break points on side wall insulations.
No ceramic packing to be given in the
tertiary air space for the burners and also
ensure no tile is damaged. Refer Burner
drawing.
Check height of floor castable around
burner. It should not be higher than
burner tile. Also refer Burner suppliers
drawings.
Check tar paper is provided where
indicated.
Check all pack areas :

2.

3.
4.

5.

6.
7.

8.

9.
10.

Page 35 of 45

Floor radiant wall after drying out

Expansion joints

Around burner if specified

REMARKS/
COMMENTS

B, C

B, C

D
D

C, D
D

D
D

Page 199 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
S. No.

11.

12.

13.

14.

15.

DESCRIPTION

All auxiliary openings

Below sight door lining

= around support / brackets


All auxiliary connection in case of
ceramic fiber lining should be visible from
heater inside. Ensure all openings have
collar / washer (SS) at refractory face
from inside heater.
Check IFB + Block/Castable Lining go
upto the support level and only
expansion gap are packed as per
drawing.
Ensure all access doors/observation
doors/ explosion door etc. are lined as
per PMC standard.
VC heater floor access door to be
preferably lined with ceramic fiber /SS foil
to have minimum weight and easy
handling.
Check proper insulation on ID Fan casing
and associated ducting.

CHECK LIST STAGE


(As defined in para 4.2.14
of Spec.)

B, C

B,D

Castable lining may be checked for


compactness by knocking method and
checking the sound (damp sound
refractory is NOT OK)

17.

Refractory detailing around vacuum


formed sight door to be as per approved
drawing.
Check that brick walls have been
provided with horizontal and vertical
expansion joints
as per approved
drawing.
Check that verticality of the bridgewall.

19

E.

REMARKS/
COMMENTS

16.

18

Page 36 of 45

B, C

B, C

REFRACTORY TIE BACK MATERIALS

1.

All retainer plates to have notch as per


the standard requirement.

2.

Check a few tie back pitches and

A, B, C

Page 200 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
S. No.

DESCRIPTION

Page 37 of 45

CHECK LIST STAGE


(As defined in para 4.2.14
of Spec.)

REMARKS/
COMMENTS

orientation if lining not already done.


3.

Check that correct anchor/lugs are used


at various locations.

A, B, C

4.

In case of blanket lining check the edge


distance of anchor randomly.

5.

In case of brick lining check that shelf


flats are provided as per lining drawing

B, C

F.

STEEL WORK

1.

All opening in the casings for probe type


instruments/ auxiliaries shall not be
directly in front of coil work inside.
Floor refractory around burner with
tertiary air openings all-round to be
provided with SS retainer all-round for
retaining castable. Ensure leading edges
of retainers are notched to provide
expansion slot.
Check all outside welding is continuous
so that there is no chance of water
ingress causing corrosion.
Check (semicircular 25mm dia) drain
holes flushing with casing are provided
for all water traps.
Check for all openings and its orientation
as per GAD.
Check all ladders and stair for free
approach and convenience including
grade level entry to staircase.
All bolts shall be provided and properly
tightened.
All splice joints on heater casing to be
seal welded.
Check all fixed and sliding supports for
ducting are properly done with adequate
provisions for movements.
Check all the platforms for proper
walkways and safety.
Ensure all railings, gratings, floors are
safe and necessary toe plates/ safety
chains/ self closing gates are provided at
openings / ladder locations as envisaged.

2.

3.

4.

5.
6.

7.
8.
9.

10.

ALL

ALL

ALL
D

B, C, D
D
D

ALL

Page 201 of 2175

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Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
S. No.

11.

12.

13.

14.
15.

16.

17.

DESCRIPTION

CHECK LIST STAGE


(As defined in para 4.2.14
of Spec.)
Check damper, SOB and expansion joint
D
installation
/orientation
w.r.t.
flow
direction.
Check linkage/chain position and their
D
accessibility and free movement for
damper, SOB etc.
Check manual operation winches have
D
been installed conveniently at ground
level or platform level as applicable for
damper & SOB.
Check all openings with gasketted
D
closure are sealed properly.
Soot blower installation and cold lift as
D
per approved Soot blower vendor
drawing.
Verify that all ETS support blocks have
C
been provided and all ETS bolts
tightened. Check for slotted and
oversized bolt holes in ETS.
Verify stand alone wall tube hangers and
B
ITS supports (if applicable) locations
have been adequately stiffened.

18.

Taper washers are provided and tack


welded for convection brackets as per
applicable standards

19.

Verify shear blocks have been provided


under ITS Brackets & vertical tube
hanger.
Verify the lap plate in between top &
bottom End tube sheets are properly
fixed with welding on top ETS and proper
lap on the lower ETS.
Verify all holding down stud bolts for
stack support.
Verify the integrity of welding on all
critical load bearing steel work :
- Stack support structure
- Convection portal columns

B, C

20.

21.
22.

Page 38 of 45

REMARKS/
COMMENTS

D
ALL

- Radiant portals for box heaters


- Convection column base stools
23.

Verify manual operation for movement of


soot blowers lance, shut off blades,
dampers including counter weight.

Page 202 of 2175

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Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
S. No.

24.

25.

DESCRIPTION

CHECK LIST STAGE


(As defined in para 4.2.14
of Spec.)
Verify full opening and closing of self
D
closing peep holes, sight door &
convection observation doors and its
operation & visibility.
Check all leak points noted have been
sealed as per recommended procedure.
-

Check coil floor guide spigot has been


provided with sealing (cloth type) or
the caps as per GAD.
Check sight door mounting plates has
been fully welded to the heater casing
and there is no leakage from gasket
seating locations.
Check all panels have been boxed
correctly to make them air tight.

Check APH modules have been seal


welded together if recommended by
APH supplier.
Check all erection splices on ducts
and heater casing have been seal
welded externally.
Check ducts splices accessible from
inside have been seal welded from
inside.

Check at stiffener locations where


plate is lapped from inside and
welded have full weld on all sides on
outside.
Check for leak tightness of all
gasketted joints such as Damper
flanges. APH flanges, Header boxes
and Duct flanges for maintenance.
Check stack off-take has been seal
welded to stack floor angle or a
stuffing detail has been provided as
per detail of heater drawing.
Check all drain points are plugged

ALL

Check no leakage through auxiliary


openings (cloth type bellow to be
provided).

Check all the guide vanes/deflector

26.

Page 39 of 45

REMARKS/
COMMENTS

Page 203 of 2175

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DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
S. No.

27.

28.

29.
30.

31.

32.

33.
34.
35.
36.
37.

38.

39

DESCRIPTION

plates/ splitter inside ducting are properly


fixed (i.e. welded or bolted properly with
nuts tack welded afterwards).
Check that all holes in End tube sheets
for future tubes are filled up with castable
and covered with a cover plate from
Header Box side.
Check that ETS is not bent or deformed.
This can be judged by observation of
convection tubes projections outside ET
sheet.
Check that all soot blower shield plates
are installed with expansion provision.
Check proper sealing & operating of
Explosion (Pressure Relief) Doors by
opening and free drop. Ensure rigidizer
spray around explosion door opening as
per standard.
Ensure suitable protection around
explosion door for personnel safety in
case of door opening.
For vertical coil entry and exits suitable
protection to be provided to prevent rain
water ingress.
Check sight door projection not fouling
with casing stiffener/members.
Check, no knee brace support to be
taken directly from un stiffened casing.
Check in general casing straightness (i.e.
no deformations)
Ensure burner hot air ducts are not
fouling with the concrete pedestals
Ensure that stiffener plates have been
provided in column at heavy type ITS
bracket location as per PMC std. 7-170406
Ensure
that
key
type
locking
arrangement has been provided in
breeching access door as per PMC std.
7-17-0418
Check that removable grating is provided
and for opening / access to arch tube
pulling door and breeching access doors
as per drawing.

Page 40 of 45

CHECK LIST STAGE


(As defined in para 4.2.14
of Spec.)

REMARKS/
COMMENTS

C, D

C
D

ALL

D
D
D
D
D

Page 204 of 2175

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Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
S. No.

40

41

DESCRIPTION

Page 41 of 45

CHECK LIST STAGE


(As defined in para 4.2.14
of Spec.)
Ensure that for heaters
where the
D
columns/ beams are passing through the
fire box / ducting zone are open from
either side.
It is to be ensured that during
D
construction
stage
also
structural
members are not subjected to loads
other than design loads. e.g. :
a) VC heater floor members are
provided with central post (if
mentioned in the drawing) before
internals erection activities are
started.
b) In case of CCR heater bottom
manifolds supported by spring
hangers, these are not to be
temporarily supported from floor
members.

G.

MISCELLANEOUS

1.

Check location of Control Panels for


location and approach convenience in
case of :
- FD/ID fans

REMARKS/
COMMENTS

- Dampers
- Soot Blowers
Ensure all major equipment dimensions /
locations are as per layout/ drawings.
2.

Check Burner installation/alignments

3.

Check access and operability of air


register dampers, oil guns, pilot burners
etc.
Check proper access to all operating
points such as instruments, dampers,
sight doors, convection observation
doors, access door is available.
All fabric type expansion bellows in
ducting to be checked for leakage.
Ensure support fixed point, sliding point
details as per approved APH eqpt.
vendor drawings.

4.

5.
6.

D
D

Page 205 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
S. No.

7.

8.

9.
10.

11.

12.

13.

14.
15.

16.

17.

DESCRIPTION

Page 42 of 45

CHECK LIST STAGE


(As defined in para 4.2.14
of Spec.)
Ensure that all construction equipments,
D
tools & tackles, scaffolding etc. are
removed before heater dry out.
Ensure that all temporary members /tie
D
rods / spiders / erection aids provided for
transportation and erection purpose are
removed and Equipment finished as per
drawing.
Check
CFD
recommendation
as
D
applicable, are being taken care off.
Ensure that requirement of piping
D
supports/ cut outs/ marked platform /
local
structural
stiffening
is
communicated to heater Package Vendor
as per Piping comments and the same is
being taken up by Heater Package
Vendor under site/piping supervision.
In case of long projected instruments like
D
pitot tube sufficient support is provided at
the free end of the instruments.
Calibration nozzles where ever required
D
shall be provided before external /internal
insulation
as
per
the
drawing
requirements.
Ensure that painting (internal/external) /
D
coating and weather proofing of
equipment / structure is done as per
tender.
Ensure local draft gauge instruments are
D
provided at arch.
Check that no heater support structure
D
member
has
box
type
(closed)
configuration for hot air entrapment.
IF spring supports are present, the stops
D
shall be removed after hydro test as per
spring support vendor recommendation
and connection of transfer line/ erection
of springs on transfer line.
Verification/clearing of points of Punch
F
Lists at previous stages & witnessing of
Smoke Test for checking leakage. Dry
out to be monitored by site and post dry
out observation, if any critical reported to
HMTD.

REMARKS/
COMMENTS

Page 206 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
PACKAGE VENDOR . . . . . . . . . . . . . . . . . . . . . .
.........
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..

Page 43 of 45

Engineer in Charge . . . . . . . . . . .
(SIGNATURE)
NAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMP. NO. . . . . . . . . . . . . . . . . . . . . . . . .

..
Notes:
1. This format shall be filled up by Heater Package Vendor & Counter Checked by
Engineer in Charge.
2. Separate forms shall be filled up in case of modular construction and at site after
erection.

Page 207 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS

Page 44 of 45

ANNEXURE - IV

ADDITIONAL QUALITY CHECKS


FOR HEATER SYSTEMS FABRICATED IN
MODULES
S. No.

QUALITY CHECK

DESCRIPTION

Remarks

Following checks shall be performed by the Heater Package Vendor before final dispatch of the
Modules to site. Package Vendor to prepare requisite format duly approved by Engineer in
Charge/ specialist / Inspection agency.
1
Verification of Module to As a minimum following is to be
module match marking
included:
-Match marking of base plate
of module with
foundation
template
-Match marking / trial assembly
for interfacing modules
-Flatness of the interfacing
flanges / members connecting
two modules.
2
Verification of Numbering Modules shall be numbered for -Packing list shall be
of modules
easy identification at site.
prepared
with
proper
identification of modules.
-Document of Rigging /
erection
scheme
shall
identify the modules with
part numbers.
2
Verification of Erection
For
lifting, -Package Vendor is
aids (like spreader
transportation/shipment
and responsible for design
beams/lifting frames/ lugs erection as per the rigging / adequacy
etc.)
erection scheme proposed by -Document of Rigging /
Package Vendor
erection scheme shall also
identify the erection aids
which are to be removed
after erection.
3
Verification of
Preservation for refractory / To avoid damage from
preservation procedure
insulation, pressure parts
handling
during
adopted for safe transit of
transportation /shipment &
modules and safe storage
erection and weather
till erection.
4
Verification of provision of Module to module connection in Duly
approved
Sealing
sealing arrangement.
erected condition at site.
arrangement.

Page 208 of 2175

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DOCUMENT No.
A545-999-05-42-SP-12 Rev. 0

SPECIFICATION FOR QUALITY


CHECKS FOR FABRICATION
ERECTION AND EXECUION OF
FIRED HEATERS
S. No.

QUALITY CHECK

Verification of dryout of
castable lined module
before dispatch

Verification of modular
stacking /placement
scheme for transportation
/ shipment of modules.

DESCRIPTION

Page 45 of 45

Remarks
As per duly approved dry
out procedure

Page 209 of 2175

Format No. EIL 1641-1924 Rev. 1

Copyright EIL All rights reserved

STANDARD No.

LADDER AND CAGE DETAILS


(SIDE STEP TYPE)

PlafAieENONEERS
a taRegwe INDIA LIMITED

7-17-0454 Rev. 3

IA Gan. of India Undenalongi

0412M

Page 1 of 5

FOR TOP LEVEL


DETAIL-5
FOR INTERMEDIATE
LEVELS
DETAIL-6

HANDRAIL

0 00
0 0

HANDRAIL
STANDARD
PLATFORM

ir

o
CD
z
rD

FOR TOP LEVEL


DETAIL-3
FOR INTERMEDIATE
LEVELS DETAIL-4

0
0

5 STEEL CHAIN
COMPLETE WITH
6 EYE BOLT AND
SAFETY SNAP HOOK
(REFER NOTE-5)
PROVIDE 2300 HIGH
ACCESS OPENING AT
INTERMIDIATE LEVELS

PLAN-CC

C
A

75X10,
FLAT tit
;)

INTERMEDIATE BRACING

IF REQUIRED SEE
DETAIL-13

DETAIL-10

tsi

DETAIL-1

PLAN-BB

DETAIL-2

741)

U S OF
LADDER BASE 1

SID
z

460

NOTE: LADDERS SHALL NOT BE CONTINUOUS


FOR MORE THAN 9000
M12 ROUND
HEAD BOLTS
(HEAD INSIDE CAGE

30X6 FLAT
TYP

TOP LEVEL
DETAIL I 1
INTERMEDIATE

LEVEL DETAIL-12
M
M

HOOPS 50x6
CONTINUOUSE
FLAT (TYP.)

RUNGS

PLAN-AA

TOP &
BOTTOM

REFERENCE NOTES :THE FOI I OWING INFORMATION TO APPEAR ON STFFI


ARRANGEMENT DRAWINGS.

POSITION OF LADDERS
ELEVATION OF PLATFORMS SERVED

STAIR DETAILS
CIRCULAR PLATFORMS (CHEQ. PLT.)

7-17-0455
7-17-0456
7-17-0457

RECTANGULAR PLATFORMS (CHEQ. PLT.)


CIRCULAR PLATFORMS

(OPEN TYPE FLOORING)


RECTANGULAR PLATFORMS
(OPEN TYPE FLOORING)
HANDRAIL DETAILS

3
2

30.01.2012
17.11.2006

Rev.
No.

Date

7-17-0458
7-17-0459
7-17-0460

Format No. 8-00-0001-F4 Rev.0


Page 375 of 2175

PLAN-BB

GENERAL NOTES:ALL DIMENSIONS AND MEMBER SIZES ARE IN


MILLIMETRES.

3. FOR POSITION OF LADDERS AND ELEVATION OF


PLATFORMS SERVED SEE ARRANGEMENT DRAWING.
4 CAGES SHALL NOT BE PROVIDED FOR LADDERS TO
PLATFORMS WHICH ARE LESS THAN 4000 ABOVE
GRADE.
5. CONTRACTOR TO DEVELOP & PROVIDE SELF
CLOSING ARRANGEMENT IN CASE SPECIFIED IN
TENDER.

7-17-0461

REVISED & ISSUED AS STANDARD


REVISED & ISSUED AS STANDARD
Purpose

ALTERNATI

ALL MATERIAL TO BE CARBON STEEL U.O.N. ALL


MATERIAL SUPPLIED BY STEELWORK VENDOR.

COMPANION STANDARDS:
LADDER (STEP THROUGH)

NTINU
MEMBER
(FOR USE AT CORNERS OF PLATFORMS)

SS $1.
SS

Prepared
by

\er...*/1QH \\-0V, QtaitAl


DM
MK/DK
AKG
VC
Stds.
Committee
Stds.
Bureau
Checked
Convenor
Chairman
by
Approved by
Copyright EIL - All rights reserved

lafteLrah ENGINEERS

aar 11Wieg ir INDIA LIMITED


g

mom maw ana ocni

STANDARD No.

LADDER AND CAGE DETAILS


(SIDE STEP TYPE)

7-17-0454 Rev. 3

(A Gov' at intha undenaingl

Page 2 of 5

STRINGER

22 DIA. SLOTTED

HOLE

18 DIA HOLE
PLUG WELD
AND GRIND
FLUSH
ISA150X75X10/1
45

16 DIA. NUT
AND WASHER

24 DIA. HOLE M20


HOLDING DOWN
BOLTS AT GRADE

DETAIL-2

DETAIL-1

TOE P LT. CONTINUOUS


ACROSS LADDER
ACCESS

STRINGER

HANDRAIL
STAND RAD

16 DIA. NUT
AND WASHER

DETAIL-3
REFERENCE NOTES :

DETAIL-4
GENERAL NOTES:
FOR GENERAL NOTES AND UST OF COMPANION
DRAWINGS SEE SHEET NO. 1.

SEE SHEET NO. 1

COMPANION STANDARDS:
SEE SHEET NO. 1

tikPACJH \\err
Pri

30.01.2012

REVISED & ISSUED AS STANDARD

SS/K

17 11 2006

REVISED 8 ISSUED AS STANDARD

SS

MKIDK

Rev.
No.

Date

Prepared
by

Checked
by

Format No. 8-00-0001-F4 Rev.0


Page 376 of 2175

Purpose

C=Son-4---

Aialt3--.

AKG
Stds. Committee

DM
VC
Stds. Bureau

Convenor
Chairman
Approved by

Copyright EIL - All rights reserved

18ffil-aq Ea ENGINEERS
51gZIT Mieg giLY INDIA LIMITED
(+Merl elEteReetniAl
IA Geri of India Undertakongj

STANDARD No.

LADDER AND CAGE DETAILS


(SIDE STEP TYPE)

7-17-0454 Rev. 3
Page 3 of 5

STRINGER

STRINGER

Irmo
"
2M16

21 1
2 rI

HANDRAIL
STANDARD
6
RUNGS

6 THK. BENT PLT.

16 DIA. NUT
AND WASHER

DETAIL-6

DETAIL-5

(FOR FURTHER INFORMATION SEE DETAIL-5)


10 DIA NUT
/AND WASHER
12 DIA. HOLE

CAGE HOOP

CAGE HOOP

2M12 ROUND
HEAD BOLTS

14 DIA. SLOTTED
HOLE
2s

12 DIA. WASHE R
d 12 DIA.
ROUND HEAD

DETAIL-8

DETAIL-7

(FOR FURTHER INFORMATION SEE DETAIL-7)

GENERAL NOTES:

REFERENCE NOTES :

FOR GENERAL NOTES AND LIST OF COMPANION

SEE SHEET NO. 1

DRAWINGS SEE SHEET NO. 1.

COMPANION STANDARDS:

,-,

SEE SHEET NO. 1

30.01.2012

REVISED & ISSUED AS STANDARD

". (16./KJH
54,1111....)

17.11.2006

REVISED & ISSUED AS STANDARD

SS

MK/OK

Prepared
by

Checked
by

Rev.
Date
No.
Format No. 6-00-0001-F4 Rev.0
Page 377 of 2175

Purpose

AK
AK

2 wi...-

DM

AKG
VC
Stds. Committee
Stds. Bureau
Convenor
Chairman
Approved by

Copyright EIL - All rights reserved

lalen ERMI7M3O111)

STANDARD No.

LADDER AND CAGE DETAILS


(SIDE STEP TYPE)

r
8111=
4-44 th
ENGINEERS
zfga tViewer WA LIMITED
IA Go .4 of lochs Undedalong)

7-17-0454 Rev. 3
Page 4 of 5

3 SIDES

TOP AND BOTTOM


OF L ONLY
rr

50 X50 X 6L
S.O. P.

rn

RUNGS
50 X50 X6L

La

P T.
6 la
GUSSET

2M16 BOLTS
PLATFORM
MEMBER

DETAIL-10

6 THK. BENT
PLT. GUSSET

32 II 12

DETAIL-9

0
N

PLATFORM MEMBER /
(EXTENDED)

.--6-1

OP FLANGE
AND WEB IF
PLATFORM
MEMBER

22 DIA. SLOTTED
HOLE

DETAIL-12
DETAIL-11
REFERENCE NOTES :
SEE SHEET NO. 1

(FOR FURTHER INFORMATION SEE DETAIL-11)

GENERAL NOTES:
FOR GENERAL NOTES AND LIST OF COMPANION
DRAWINGS SEE SHEET NO. 1.

COMPANION STANDARDS:
SEE SHEET NO. 1
3
30.01.2012
REVISED & ISSUED AS STANDARD
2
17.11.2006
REVISED & ISSUED AS STANDARD
Rev.
Date
Purpose
No.
Format No. 8-00-0001-F4 Rev.0
Page 378 of 2175

ir
S4/ /54,/KJH Woe

SS
Prepared
by

MK/DK
Checked
by

l(1

AKG
Stds. Committee

Z411-4-VC
Stds. Bureau

Convenor
Chairman
Approved by

Copyright EIL - All rights reserved

Safrae?ift ENGINEERS
Meg',"If WA UNITED
Govt M India undeareng)

16 DIA. NU
AND WASHER

LADDER AND CAGE DETAILS


(SIDE STEP TYPE)

STANDARD No.
7-17-0454 Rev. 3
Page 5 of 5

22 DIA
HOLE

HOLE

II 6 THK. PLT.

TYP. CONNECTION TO CASING PLT.

(.6

CASING PLATE
(MAY BE FLAT
OR CURVED)

IX 0
J Z
Ls1 L. LI
IJJ

0
z

< 7

Ia
sl CC
CC

RUNGS
6

_q_LADDER

1111
114
DETAIL-13 (PLAN)
(INTERMEDIATE BRACE TO BE USED
IF DISTANCE BETWEEN PLATFORMS
EXCEEDS 6100)

REFERENCE NOTES
SEE SHEET NO. 1

:-

TYP. CONNECTION TO LADDER


GENERAL NOTES:FOR GENERAL NOTES AND

UST OF COMPANION
DRAWINGS SEE SHEET NO. 1.

COMPANION STANDARDS: SEE SHEET NO. 1


3
30.01.2012
REVISED & ISSUED AS STANDARD
2
17.11.2006
REVISED & ISSUED AS STANDARD
Rev.
Date
Purpose
No.
Format No. 8-00-0001-F4 Rev.0
Page 379 of 2175

SSI**'

SS
Prepared
by

WP/KJH
MK/DK
Checked
by

I"

AKG
AKG
Stds. Committee

.27t14-CDM
VC
Stds. Bureau

Chairman
Convenor
Approved by

Copyright EIL - All rights reserved

lafrae et ENGINEERS

FIRrumir INDIA IJMITED

173Mar=
111

INRl1Ramiu)

IA Gov' of India UNIatalungl

HANDRAIL
STANDARD
PLATFORM

UM* r:

7R

DETAIL-3

TOP RUNG LEVEL


WITH TOP OF
GRATING

7-17-0455

Rev. 3

Page 1 of 3

DETAIL-4
U
C

STANDARD No.

LADDER AND CAGE DETAILS


(STEP THROUGH TYPE)
HANDRAIL

0
re
0_
0_

B
0
ce

0
0

(f)
00
0
0
0
L0
0

50 STEEL CHAIN
COMPLETE WITH
60 EYE BOLT AND
SAFETY SNAP HOOK
(REF. NOTE-6)

PLAN C-C

0En

U
A

INTERMEDIATE BRACIN
IF REQUIRED SEE
DETAIL-5

75X10 FLAT

RUNGS

ox

DETAIL-2

HOOPS 50x6 CONT.


FLAT TYP.
M12 ROUND HEAD
BOLTS HEADS
INSIDE CAGE)

330

DETAIL-1

lul

30X6 FLAT
(TYP.)
U/S OF LADDER BASE

NOTE: LADDERS SHALL NOT BE CONTINUOUS FOR


MORE THAN 9000
REFERENCE NOTES :THF FDI J OWING INFORMATION TO APPFAR ON STFFL
ARRANGEMENT DRAWINGS:-

POSITION OF LADDERS
ELEVATION OF PLATFORMS SERVED
COMPANION STANDARDS:
LADDER & CAGE DETAILS (SIDE STEP TYPE) 7-17-0454
STAIR DETAILS
7-17-0456
CIRCULAR PLATFORMS
7-17-0457
(CHEQ. PLT. FLOORING)
7-17-0458
RECTANGULAR PLATFORMS
(CHEQ. PLT. FLOORING)
CIRCULAR PLATFORMS
7-17-0459
(OPEN TYPE FLOORING)
RECTANGULAR PLATFORMS
7-17-0460
(OPEN TYPE FLOORING)
HANDRAIL DETAILS
7-17-0461

TOP &
BOTTOM

PLAN A-A

GENERAL NOTES:ALL DIMENSIONS ARE IN MILLIMETRES.


ALL MATERIAL TO BE CARBON STEEL U.O.N. ALL
MATERIAL SUPPLIED BY STEEL WORK VENDOR.
FOR POSITION OF LADDERS AND ELEVATION OF
PLATFORMS SERVED SEE ARRANGEMENT DWG.
CAGES SHALL NOT BE PROVIDED FOR LADDERS TO
PLATFORMS WHICH ARE LESS THAN 4000 ABOVE
GRADE.
TOP RUNG LEVEL SHOULD MATCH WITH TOP OF
TOE PLATE & ALL RUNG SPACINGS MUST BE EQUAL.
CONTRACTOR TO DEVELOP & PROVIDE SELF
CLOSING ARRANGEMENT IN CASE SPECIFIED IN
TENDER.

30.01.2012

REVISED B ISSUED AS STANDARD

S81/

17.11.2006

REVISED 8 ISSUED AS STANDARD

SS

MK/DK

Rev.
No.

Date

Prepared
by

Checked
by

Format No. 8-00-0001-F4 Rev.0

Page 380 of 2175

Purpose

YAID/KJH \NeriAK

AKG
Stds. Committee

(2i!b2,1_

DM
VC
Stds. Bureau

Convenor
Chairman
Approved by
Copyright EIL - All rights reserved

agtzleitl-h ENNEERS
GI

STANDARD No.

LADDER AND CAGE DETAILS


(STEP THROUGH TYPE)

lableZ IOW INDIA LIMITED


51gai
men mew egaworn)
IA Got. d ha Undertaking,

7-17-0455 Rev. 3
Page 2 of 3

22 DIA. SLOTTED
HOLE

PLUG WELD
AND GRIND
FLUSH

18 DIA. HOLE

20 DIA RUNG

ISA 150x75x10/
24 DIA. HOLE FOR
M20 BOLTS OR
HOLDING DOWN
BOLTS AT GRADE

DETAIL-1
100x6 THK. TOE PLT.
CONTINUOUS ACROSS
LADDER ACCESS

16 DIA. HUT
AND WASH
Ir

71.

DETAIL-2
STRINGER

ns.

6 THK. PLATE

PLATFORM MEMBER,
2M16 DIA BOLTS

RUNGS
HANDRAIL
STANDRAD
HANDRAIL
STANDRAD

2M16 BOLTS

DETAIL-4

DETAIL-3

REFERENCE NOTES :-

GENERAL NOTES:-

SEE SHEET NO. 1

FOR GENERAL NOTES AND LIST OF COMPANION


DRAWINGS SEE SHEET NO. 1.

COMPANION STANDARDS:

SEE SHEET NO. 1


\-eit"/KJH \\..tsr

30.01.2012

REVISED & ISSUED AS STANDARD

SS

17.11.2006

REVISED & ISSUED AS STANDARD

SS

MK/DK

Rev.
No.

Date

Prepared
by

Checked
by

Format No. 8-00-0001-F4 Rev.0

Page 381 of 2175

Purpose

_An^

AK 4 . V

AKG
Stds. Committee

C)erIA

DM

VC
Stds. Bureau

Chairman
Convenor
Approved by

Copyright EIL - All rights reserved

STANDARD No.
airaegallE
a NGINEERS
laIWIeu/iffir INDIA LIMITED
b Gov

India Undertak.9)

LADDER AND CAGE DETAILS


(STEP THROUGH TYPE)

7-17-0455 Rev. 3
Page 3 of 3

tc.1

M16 DIA. NUT


AND WASHER
12
18 DIA. HOLE

cn

75

TYP. CONNECTION TO CASING PLATE

18 DIA. HOLE

STRINGER /

i 22 DIA. HOLE

SHOULDER BOLT\
NUT AND WASHER
AS ABOVE

TYP. CONNECTION TO LADDER

LADDER

DETAIL-5 (PLAN)
(INTERMEDIATE BRACE TO BE USED IF DISTANCE
BETWEEN PLATFORMS EXCEEDS 6100)

GENERAL NOTES:-

REFERENCE NOTES:-

FOR GENERAL NOTES AND LIST OF COMPANION


DRAWINGS SEE SHEET NO. 1.

SEE SHEET NO. 1

COMPANION STANDARDS SEE SHEET NO. 1


3
2
Rev.
No.

30.01.2012
17.11.2006

REVISED & ISSUED AS STANDARD


REVISED & ISSUED AS STANDARD

Date

Format No. 8-00-0001-F4 Rev.0

Page 382 of 2175

Purpose

DM
4:W/KJH.\rGler I "
MK/DK
AKG
VC
SS
Stds.
Committee
Stds.
Bureau
Prepared
Checked
Convenor
Chairman
by
by
Approved by
Copyright Ell- All rights reserved

STANDARD No.

OlfragfitENGINEERS
EitAewer INDIA IJMTED
NPR eRMIPJ9m1

IA Goo

7-17-0461 Rev. 3

HANDRAIL DETAILS

1nata Uncienakongj

Page 1 of 1

1830 MAX. SPACING


OF HANDRAIL STANDARD

1830

41

33 0/D X3.2 THK.


"'HANDRAIL

0
0
In

HANDRAIL STANDARD
ISA 50x50x6

AT TOE PLT.
JOINT

50x6 MID RAIL

100X6 TOE PLT. TYP

FLOORING

TOE PLT. SHOWN


FOR CHEQ. PLT.
FLOORING

DETAIL OF HANDRAIL

(CONNECTION TO I PLATFORM MEMBER SHOWN)

10 THK.
L CLEAT

M16 DIA

3 CLEAR
BOTTOM OF TOE
PLT. LEVEL WITH
TOP OF FLOORING

CHEQ. PLT. OR
OPEN FLOORING

CHEQ. PLT. FLOOR


M16 DIA BOLTS
PLATFORM
MEMBER

PLATFORM MEMBER

HANDRAIL STANDARD

HANDRAIL
STANDRAD

II

M16 DIA BOLTS

PLATFORM MEMBER

DETAIL OF TOE PLATE


DETAIL OF CONNECTION
(FOR
OPEN TYPE FLOORING)
TO L PLATFORM MEMBER
1675 MAX.

DETAIL OF CONNECTION
TO I OR 3 PLATFORM MEMBER

(TOE PLATE SHOWN FOR CHEQ. PLT. FLOORING)

HANDRAIL MITRE CUT AND


BUTT WELDED.(TOE PLT. &
MID RAIL BENT OR WELDED)

DETAIL OF RETURN OF HANDRAILING


ON PLATFORM CORNERS
REFERENCE NOTES :
THF F011 OWING INFORMATION TO APPEAR ON THE
ARRANGEMENT DRAWING:R I . EXTENT OF HANDRAIL

COMPANION STANDRAD:
7-17-0454
LADDER (SIDE STEP)
7-17-0455
LADDERS (STEP THROUGH)
STAIR
7-17-0456
7-17-0457
CIRCULAR PLATFORM (CHEQ. PLATE)
7-17-0458
RECTANGULAR PLATFORMS (CHEQ. PLATE)
CIRCULAR PLATFORM (OPEN TYPE FLOORING) 7-17-0459
RECTANGULAR PLATFORM (OPEN TYPE FLOORING) 7-17-0460

GENERAL NOTES:-

ALL DIMENSIONS ARE IN MILLIMETRES.


ALL MATERIAL TO BE CARBON STEEL U.O.N.
ALL MATERIAL SHOWN ON THIS DRAWING TO BE
SUPPLIED BY STEELWORK VENDOR UNLESS NOTED
ON ARRANGEMENT DRAWING.
FOR EXTENT OF HANDRAIL SEE ARRANGEMENT DWG.
FOR PAINTING AND OR GALVANISING SEE ARRANGEMENT DRAWING / TENDER.
FOR GALVANISED HANDRAILS, SITE JOINTS ARE TO BE
BOLTED.

30.01.2012 REAFFIRMED & ISSUED AS STANDARD

SS

17 11 2006

SS

MKJDK

Rev.
No.

Date

Prepared
by

Checked
by

REVISED & ISSUED AS STANDARD

Format No. 8 -00-0001 - F4 Rev.0

Page 394 of 2175

Purpose

AKG

DM

AKG
VC
Stds. Committee
Stds. Bureau
Chairman
Convenor
Approved by

Copyright EIL - All rights reserved

(an oliftof(eityzasn)

STANDARD No.

STAIR DETAILS
(FOR USE WITH CHEQUERED
PLATE OR GRATING PLATFORMS)

aRZIeTa ENGINEERS
1ga faReZWIll INDIA LIMITED
IA Govt of Ind* Unciedalang)

7-17-0456 Rev. 3
Page 1 of 5

DETAIL
DETAIL-7

fogy
Pr

OBSTRUCTION

DETAIL-5

tt

760

1..305

(MIN.)

DETAIL-2

o
0
r DETAIL-1
(TREAD)

GRADE LEVEL V

V a

ELEVATION

ELEVATION

gam*
PLAN
PLAN

(STRAIGHT RUN OF
STAIR WITH LANDING)

(DOG LEG STAIR)

REFERENCE NOTES :-

GENERAL NOTES:FOR GENERAL NOTES SEE SHEET NO. 5

SEE SHEET NO. 5

COMPANION STANDARDS:-

SEE SHEET NO. 5

30.01.2012

REAFFIRMED & ISSUED AS STANDARD

SS

/KJH

17.11.2006

REVISED & ISSUED AS STANDARD

SS

MKJDK

Rev.
No.

Date

Format No. 8-00-0001-F4 Rev.O

Page 383 of 2175

Purpose

Prepared
by

Checked
by

DM
AKG
VC
Stds. Committee
Stds. Bureau
Chairman
Convenor
Approved by
Copyright EIL - All rights reserved

Isv-ziet
ENGINEERS
9 t 04z)
.
!ND)"
A , LIMITJD

400x75x6 TOE PLT.


WELDED TO GRATING
0
0
Pe)

STANDARD No.

STAIR DETAILS
(FOR USE WITH CHEQUERED
PLATE OR GRATING PLATFORMS)

7-17-0456 Rev. 3
Page 2 of 5

2111__

?-
CHECKEREAD PLATE
NOSING

750

DETAIL-1

33 0 D 3.2 THK.

01

12
20
POST
L-50x50x6
MID RAIL
50x6 THK. FLAT

TYPICAL FOR
HANDRAIL STDS.

SECTION A-A

SETTING OUT LINE


(FOR EDGE OF
TREADS)

N
750
MC 200
STRINGER

"N,L-50x50x6
36.8'
(MAX.)

. 4 65

2M20 DIA
BOLTS

.
H.D. BOLT
L-100X75X10 CLEAT 1-24 DIA
HOLE FOR M20 DIA HOLDING
DOWN BOLT.

150 1 254
t HOLD NG
DOWN BOLTS

V 11;.

DETAIL-2

REFERENCE NOTES :

GENERAL NOTES:
FOR GENERAL NOTES SEE SHEET NO. 5

SEE SHEET NO. 5

COMPANION STANDARDS: SEE SHEET NO. 5


3

30.01.2012 REAFFIRMED & ISSUED AS STANDARD

4 *QH

17.11.2006

SS

MK/DK

Rev.
No.

Date

Prepared
by

Checked
by

REVISED & ISSUED AS STANDARD

Format No. 8-00-0001-F4 Rev.0

Page 384 of 2175

Purpose

Z1/2"--`
AKG
VC
Stds. Committee
Stds. Bureau
Convenor
Chairman
Approved by
Copyright EIL - All rights reserved

Gat 0

kicha

STANDARD No.

STAIR DETAILS
(FOR USE WITH CHEQUERED
PLATE OR GRATING PLATFORMS)

INWIE4iSENONIEERS
5gar laigIeglit INDIA LIMITED
Unclenakm

7-17-0456 Rev. 3
Page 3 of 5

SETTING OUT j

LINE

S0P

65

SAME

AS TREAD

S.O.P.

STRINGER

STRINGER/

FULL
STRENGTH

DETAIL-4

2 M16 DIA BOLTS

3 SIDES
115i

NOSING SAME
AS TREAD

DETAIL-3

(MOMENT CONNECTION)
65

S0P

S.O.P.
NOSING SAME

AS TREAD

NOTCH STRINGER
NOTCH

INTO PLATFORM
MEMBER

STRINGER /

STRINGER

PLATFORM
MEMBER

PLATFORM
MEMBER

ANGLE CLEAT
(SIZE TO SUIT)
2M20 DIA BOLTS
ANGLE CLEAT
(SIZE TO SUIT)
2M20 DIA BOLTS

DETAIL-5

(WITH JOIST OR REVERSED


CHANNEL PLATFORM MEMBER)

DETAIL-5

(WITH CHANNEL PLATFORM MEMBER)

REFERENCE NOTES :SEE SHEET NO.5

GENERAL NOTES:FOR GENERAL NOTES SEE SHEET NO.5

COMPANION STANDRADS:- SEE SHEET NO.5


3
30.01.2012 REAFFIRMED & ISSUED AS STANDARD
2
17.11.2006
REVISED & ISSUED AS STANDARD
Rev
Date
Purpose
No.
Format No. 8-00-0001-F4 Rev.0
Page 385 of 2175

Seit1/4-4./

SS
Prepared
by

DM
V.DXP/KJH\c\47,r,
Arr
AKG
VC
MK/DK
Stds.
Committee
Stds.
Bureau
Checked
Convenor
Chairman
by
Approved by

Copyright EIL - AN rights reserved

lain Man alS9m)

STANDARD No.

STAIR DETAILS
(FOR USE WITH CHEQUERED
PLATE OR GRATING PLATFORMS)

aRZIeYgla ENGINEERS
lig-adaMagWVINDIA LIMITED
IA Goa of lode Undedaking)

7-17-0456 Rev. 3
Page 4 of 5

SETTING
OUT LINE

,/

POST L-50x50x6
100x6 TOE PLATE
WELD TO STRINGER
BOTH SIDES

0
o
to

STRINGER

MID RAIL 50x6 FLAT


ASETTING OUT LINE

3 SIDES
ANGLE CLEAT
ASIZE TO SUIT)
__Fh7-M20 DIA BOLTS

MC 200
STRINGER

DETAIL-6
(WITH CHANNEL MEMBER)

100x6 TOE PLATE


WELD TO STRINGER
BOTH SIDES

90x60x6 THK.
PLATE

\ \ STRINGER

S.O.P

ANGLE BOTTOM FACE


TO BE GROUND FLUSH

DETAIL-7

10 THK .PLATE
WELDED TO TOES
OF JOIST

3 SIDES
ANGLE CLEAT
SIZE TO SUIT)
/2-M20 DIA BOLTS

DETA L-6
(WITH JOIST MEMBER)

RFFERENCE NOTES :-

GENERAL NOTES:FOR GENERAL NOTES SEE SHEET 5

SEE SHEET 5

COMPANION STANDARDS:3
2

SEE SHEET

30.01.2012 REAFFIRMED & ISSUED AS STANDARD


17.11.2006
REVISED & ISSUED AS STANDARD

Rev.
Date
No.
Format No. 8-00-0001-F4 Rev.0
Page 386 of 2175

Purpose

4-SS
Prepared
by

\\CNN G
MK/DK
Checked
by

"

GywA-

DM

AKG
VC
Stds. Committee
Stds. Bureau
Convenor
Chairman
Approved by

Copyright EIL - All rights reserved

zSi1151-aget ENGINEERS
$1g-9 tafaeg we iDIA LIMITED
Goof of Inda Undertalongl

STAIR DETAILS
(FOR USE WITH CHEQUERED
PLATE OR GRATING PLATFORMS)

STANDARD No.
7-17-0456 Rev. 3
Page 5 of 5

33 0 D 3.2 TH1

L-50x50x6 STIFFENING
BRACING TO BE PROVIDED
FOR STAIR WITH MORE
THAN 20 RISERS

NOSING SAME AS

S Al:

BRACING
L-50x50x6

DETAIL-8

1.

REFERENCE NOTES :-

GENERAL NOTES:-

WHEN VERTICAL RISE EXCEEDS 4500 STAIR IS TO BE


BROKEN BY AN INTERMEDIATE LANDING. LANDING TO
BE 760 MIN. IN DIRECTION OF STAR.

ALL DIMENSIONS ARE IN MILLIMETRES.

THE FOI I OWING INFORMATION IS TO APPEAR ON


ARRANGEMENT DRAWING:

POSITION OF STAIRS.
DIMENSIONS OF RISES AND TREADS.
DIMENSIONS OF SETTING OUT POINTS.
TYPE OF TREAD IF OTHER THAN GRATING.
R5. TYPE OF PAINTING AND/OR GALVANISING.

COMPANION STANDRADS:
CIRCULAR PLATFORMS WITH
CHEQUERED PLATE FLOORING
RECTANGULAR PLATFORMS WITH
CHEQUERED PLATE FLOORING
CIRCULAR PLATFORMS WITH
OPEN TYPE FLOORING
RECTANGULAR PLATFORMS WITH
OPEN TYPE FLOORING
3
2
Rev.
No.

30.01.2012
17 11 2006

7-17-0457
7-17-0458

Format No. 8-00-0001-F4 Rev.0

Page 387 of 2175

FOR POSITION OF STAIRS, AND ELEVATION OF


PLATFORM SERVED SEE ARRANGEMENT DRAWING.
SETTING OUT POINTS ARE ALL TO TOP OF FLOORING.
5. FOR PAINTING AND/OR GALVANISING SEE ARRANGEMENT DRAWING / TENDER.
6 MAXIMUM PRE FABRICATION TO BE CARRIED OUT
BY STEEL VENDOR.
TOE PLATE SHALL BE PROVIDED ALLROUND LANDING.
MAXIMUM SINGLE RUN IN ONE DIRECTION SHALL BE
12M. ABOVE 12M, EITHER STAGGERING IN
THE STAR SHALL BE PROVIDED OR DIRECTON SHALL
BE CHANGED.

7-17-0459
7-17-0460

REAFFIRMED & ISS UED AS STANDARD


REVISED & ISSU ED AS STANDARD

Date

ALL MATERIAL TO BE CARBON STEEL. ALL MATERIAL


SUPPLIED BY STEELWORK VENDOR UNLESS NOTED
ON ARRANGEMENT DRAWING.

Purpose

SS I,
SS
Prepared
by

0/KJH
MK/DK
Checked
by

91,in.A
AK
DM
AKG
VC
Stds. Committee
Stds Bureau
Convenor
Chairman
Approved by
Copyright EIL - NI rights reserved

tg

si

151fRiseA
at efaleg

ENGINEERS

INI NA LIMITED
/A nul

na. Lnden.,),

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS

STANDARD SPECIFICATION No.

6 - 81 - 0001 Rev. 2
Page I of 8

covingii 4
,flcomoict) TIPTth LI 111
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STANDARD SPECIFICATION
FOR
POSITIVE MATERIAL
IDENTIFICATION
(PMI)
AT SUPPLIER'S WORKS

40D ., 15,
2

20.10.11

REVISED AND RE-ISSUED

15.07.08

REVISED AND RE-ISSUED

07.12.00

Rev.
No

ISSUED AS STANDARD SPECIFICATION

Date

Formal No. 8-00-0001-F1 Rev. 0

Page 1193 of 2175

Purpose

NKR

SSL

AKC

AKB

Prepared
by

Checked
by

AKC

DM

SKP

VC

AKB

MI

Standards Standards
Committee
Bureau
Convenor
Chairman
Approved by

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- le.' ENGINEERS

151Mae?

imegver INDIA LIMITED

yin eRaWanJelwill

Govl of India Undertakno

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PM I) AT
SUPPLIER'S WORKS

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2
Page 2 of 8

Abbreviations:
American Petroleum Institute
Alloy Steel
Lump Sum Turn Key
Positive Material Identification
Schedule
Stainless Steel
Third Party Inspection Agency

API
AS
LSTK
PMI
Sch
SS
TPI or TPIA

Inspection Standards Committee


Convenor:

Mr.AK Chaudhary

Members:

Mr. SS Lotay
Mr. SC Gupta
Mr. RK Singh
Mr. Rajeev Kumar
Mr. Anoop Goel
Mr. G Suresh
Mr. G Poornachandra Rao
Mr. MP Jain (Projects)

Format No. 8-00-0001-F1 Rev. 0


Page 1194 of 2175

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151M4-e?fte ENGINEERS
Ogrir tfigtegW INDIA LIMITED
Gorl of India undertaking}

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2
Page 3 of 8

CONTENTS

SCOPE

2.0

REFERENCE DOCUMENTS

3.0

DEFINITIONS

4.0

PMI EXAMINATION

5.0

ACCEPTABLE METHODS FOR PMI

6.0

EXTENT OF PMI EXAMINATION

7.0

RECORDING AND DOCUMENTATION

8.0

MARKING

1.0

Format No. 8-00-0001-F1 Rev. 0


Page 1195 of 2175

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'- -1 INDIA LIMITED


beire,altateg 60

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PMT) AT
SUPPLIER'S WORKS

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2
Page 4 of 8

1.0 SCOPE
1.1

This specification applies to the requirements for Positive Material Identification (PMI) to be
performed at the Supplier's works on Metallic Materials procured either directly by the
Owner/EIL/ LSTK contractor or indirectly through the sub-Suppliers.

1.2

Any post order deviation from this specification must be approved by Owner/EIL in the
Deviation/ Waiver Permit format (No. 5-0000-0180-F1) enclosed with Material Requisition.

1.3

This specification covers the procedures and methodology to be adopted to assure that the
chemical composition of the material is consistent with the material specifications as specified
in purchase documents using 'Alloy Analyzer' at the time of final inspection before dispatch.

1.4

The scope of this specification shall include but shall not be limited to Positive Material
Identification (PMI) to be performed on Materials listed below:

1.4.1

For alloy Steel materials as below:


Alloy Steel Pipes including Clad Pipes
Alloy Steel Flanges & Forgings
Alloy Steel Fittings including Clad Fittings
Alloy Steel Fasteners
Alloy Cast & Forged steel valves
Alloy Steel Instrumentation Items (Control Valves, Safety Valves etc.)
Longitudinal Pipe & Fittings Welds.
Gaskets (for Ring Type Joints)

1.4.2

For Carbon Steel materials as below:


All Carbon Steel Piping items under NACE or HIC or H2
Carbon Steel flanges and valves (Rating 900# and above)
Carbon Steel Pipes & fittings for following thicknesses:
: Sch 160 & above
Size 1"- 2" NB
: Sch XS & above
Size 3" NB
: Sch 120 & above
Size 4" - 12" NB
Following items shall be excluded from scope of PMI examination.
Gaskets other than for Ring Type Joints
Internal Components of Valves

1.5

All grades of material supplies including Stainless Steels shall be liable for PMI test at site. In
case of any defective materials being found at site, the Supplier shall be responsible to effect
replacement of such defective materials at project site without any delays to the satisfaction of
EIL site RCM (Resident Construction Manager).

2.0

REFERENCE DOCUMENTS

2.1

API Recommended Practice 578 (First Edition, May 1999) - Material Verification Program for
New and Existing Alloy Piping Systems.

3.0

DEFINITIONS

3.1

Supplier: Any Supplier or Manufacturer on whom an order is placed for the supply of referred
items. This definition shall also include any sub-Supplier or manufacturer on whom a sub-order
is placed by the Supplier.

Format No. 8-00-0001-F1 Rev. 0


Page 1196 of 2175

Copyright EIL All rights reserved

SaIRCIELM; ENGINEERS
Par taiReZ VW INDIA LIMITED

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PM I) AT
SUPPLIER'S WORKS

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2
Page 5 of 8

3.2

Inspection Lot: A group of items offered for inspection covered under same size, Heat and
Heat treatment lot.

3.3

Alloy Material: Any metallic material (including welding filler materials) that contains
alloying elements such as chromium, nickel, molybdenum or vanadium, which are intentionally
added to enhance mechanical or physical properties and/or corrosion resistance.

4.0

PMI EXAMINATION

4.1

The Supplier shall submit a procedure of PMI to comply with the requirements of this
Specification Approval of PMI Procedure shall be obtained from Owner/EIL/TPIA prior to
commencing manufacture/ inspection of product.

4.2

PMI examination of materials is independent of any certification, markings or colour coding


that may exist and is aimed at verifying that the alloy used are as per specified grades.

4.3

The Supplier shall identify all incoming alloy materials and maintain full traceability of all alloy
materials, including all off-cuts. Transfer of identification marks shall be undertaken prior to
cutting to ensure maintenance of identification on off-cuts.

4.4

The Supplier shall ensure that all alloy materials are segregated and stored in separately
identified locations to prevent the mix up of materials of different alloy specifications or alloy
material with carbon steel. Non ferro-magnetic materials shall be segregated at all times from
ferro-magnetic materials.

4.5

PMI examination is subject to surveillance inspection by Owner/EIL/TPIA.

5.0

ACCEPTABLE METHODS FOR PMI

5.1

The method used for PMI examination shall provide a quantitative determination of the alloying
elements like chromium, nickel, molybdenum or vanadium in Alloy Steel items.

5.2

Instruments or methods used for PMI examination shall be able to provide quantitative,
recordable, elemental composition results for positive identification of alloying elements
present.

5.3

The acceptable instruments for alloy analyzer shall be either "Portable X-Ray fluorescence" or
"Optical Emission" type each capable of verifying the percentage of alloy elements within
specified range.

5.4

Chemical spot testing, magnets, alloy sorters and other methods using eddy current or
triboelectric testing methods are not acceptable for PMI examination.

5.5

The PMI instrument used shall have the sensitivity to detect the alloying elements in the
specified range.

5.6

All PMI instruments shall have been serviced within a 6 month period of the time of use to
verify the suitability of batteries, sources etc., and the data of the last service shall be stated on
the PMI Report Form (Sample enclosed).

5.7

Each analyzer must be calibrated according to the manufacturer's specification at the beginning
and end of each shift. Instrument must be checked against known standard for each alloy type
to be inspected during the shift.

Format No. 8-00-0001-F1 Rev. 0


Page 1197 of 2175

Copyright EIL All rights reserved

ISillaZreq e ENGINEERS
INDIA UMITED
s'Ig7e2eg
Govt a Inaa Undenakingi

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2
Page 6 of 8

5.8

Certified samples, with full traceability, of a known alloy materials shall be available for use as
a random spot check on the instrument calibration.

5.9

The surfaces to be examined shall be prepared by light grinding or abrasive paper and solvent
cleaner. Evidence of Arc burn resulting from examination shall be removed by light grinding or
abrasive paper. No permanent marks, which are injurious to the usage of product in service, are
acceptable.

5.10

Alloy Steel ring type joint Gaskets shall be inspected by using portable X-Ray fluorescence
instrument.

5.11

Testing shall be done as per the procedures outlined by the manufactures of alloy analyzer
being used. Modification of these procedures if any must be approved by Owner/EIL.

5.12

The persons performing PMI shall demonstrate their capabilities to the satisfaction of
Owner/EIL/TPIA visiting engineer. If the Supplier has qualified operator on their rolls, he may
perform the examination. Otherwise PMI examination shall be sub-contracted to an independent
testing agency approved by EIL.

5.13

Whenever material is identified as not meeting requirements by the visiting engineer a rejection
note shall be issued.

6.0

EXTENT OF PMI EXAMINATION


Following sampling plans shall be applicable for PMI examination of various items.
Flanges, Fittings
Valves, RTJ Gaskets

100%

Pipes

100% (for pipes procured from traders).


2 random samples drawn from each
Size/Heat/Lot (for pipes procured directly from mills)

Fasteners

C.

Lot Size

Sample Size

Upto 100
101 to 500
501 and above

2% (Min 2)
1% (Min 3)
0.5% (Min 5)

Note:
For Welded Pipes and Fittings, PMI shall be performed on Base Metal as well as
weldments.
Whenever any sample drawn to PMI test on the basis of percentage selection in B & C
above, fails to meet specification requirements, 100% of items of lot shall be tested for
PMI.

Format No. 8-00-0001-F1 Rev. 0


Page 1198 of 2175

Copyright EIL All rights reserved

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ogrir EiRtegi
7.0

ENGINEERS
INDIA LIMITED
IA Go' at India Undertaking)

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2
Page 7 of 8

RECORDING AND DOCUMENTATION

The results of PMI examination shall be recorded in a Report Format as enclosed with this
specification.
8.0

MARKING

8.1

All alloy materials tested by PMI shall be identified using either of the following methods by
indicating "PMI OK"
Bar Code/Hologram Sticker
A low stress stamp marking

Format No. 8-00-0001-F1 Rev. 0


Page 1199 of 2175

Copyright EIL All rights reserved

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st",ar &Reg W INDIALIMTED


GOA Of India

undertakng)

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION (PMI) AT
SUPPLIER'S WORKS

STANDARD SPECIFICATION No.

6-81-0001 Rev. 2
Page 8 of 8

Page

POSITIVE MATERIAL IDENTIFICATION REPORT


BULK MATERIALS

of

Job No.

Project:

Client

PMI Report No.

Supplier/Sub-Supplier

Purchase Order No.

Testing Agency

Purchase
Requisition No:

PMI Location

Bulk Item Type (as per Requisition)


Material Specification/Grade
Number of items in Lot
Requisition Item No./ Description

Major content, Weight Percent

Element

Cr

Mo

Ni

Remarks
Accept/Reject

Specified Range
Actual observations

Instrument Type / ID
Last Service Date

Format No. 8-00-0001-F1 Rev. 0


Page 1200 of 2175

Inspection Agency

Witnessed By

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,t *Peg '4IW INDIA LIMITED
II

6-1 S "ea " .""

19Trfur

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES

STANDARD SPECIFICATION No.

6-82-0002 Rev. 2
Page 1 of 9

T2,T1 717 *i ch I *lei ch

WIN *

keR 4-111ch Fir4ki

STANDARD SPECIFICATION
FOR
POSITIVE MATERIAL
IDENTIFICATION
AT
CONSTRUCTION SITES

14/11/2011

Revised and updated

02/01/2007

0
Rev.
No

9i7w-A

1,1"141t
)!

SM

SM

Mk-t

DM

Revised and updated

AS

MPJ

VNP

VC

22/07/2002

Issued as Standard Specification

MPJ

MPJ

Date

Purpose

RSG
Standards
Committee

GRR
Standards
Bureau

Format No. 8-00-0001-F1 Rev. 0

Page 1201 of 2175

Prepared Checked
by
by

Convenor

Chairman

Approved by

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sig:ar ElfakegiS
INDIA LIMITED
Gov't of India underlain%)

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES

STANDARD SPECIFICATION No.

6-82-0002 Rev. 2
Page 2 of 9

Abbreviations:
API

American Petroleum Institute

ASM

American Society for Metals

ASME

American Society of Mechanical Engineers

ASTM

American Society for Testing and Materials

BV

Bureau Veritas

CELL

Certification Engineers International Limited

DNV

Det Norske Veritas

EIL

Engineers India Limited

ITP

Inspection Test Plan

PMI

Positive Material Identification

RTJ

Ring Type Jacket

TPI/TPIA

Third Party Inspection /Third Party Inspection Agency

Construction Standards Committee


Convenor :

Sh. MK Garg, DGM (Construction)

Members :

Sh. SK Kaul, DGM (C&P)


Sh. M.P. Jain, DGM (Projects)
Sh Rakesh Nanda, DGM (Piping)
Sh. S Mukherjee, AGM (Construction)
Sh. B Chakraborty, AGM (Construction)

Format No. 8-00-0001-F1 Rev. 0


Page 1202 of 2175

Copyright EIL All rights reserved

ISM-a-daft ENGINEERS

Igiar ElfglegW INDIA LIMITED


IA CoN InSa

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES

STANDARD SPECIFICATION No.

6-82-0002 Rev. 2
Page 3 of 9

CONTENTS
1.0

SCOPE

2.0

DEFINITIONS

3.0

SPECIFIC APPLICABILITY

4.0

REFERENCES

5.0

GENERAL REQUIREMENTS

6.0

EXTENT OF PMI

7.0

PMI OF PIPING AND HEATER COIL COMPONENTS

8.0

TESTING METHODOLOGY

9.0

CHARACTERISTIC ELEMENTS

10.0

CALIBRATION

11.0

SITE VERIFICATION OF ANALYZER

12.0

PERSONNEL QUALIFICATION

13.0

ACCEPTANCE CRITERIA

14.0

REJECTION CRITERIA

15.0

DOCUMENTATION

ATTACHMENT (REPORTING FORMAT)


FORMAT FOR PMI TEST REPORT - 6-82-0002-F1 (1 SHEET)

Format No. 8-00-0001-F1 Rev. 0

Page 1203 of 2175

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- ENGINEERS
LIMITED
EA G., d the. Und.t..9)

cif miaowINDIA

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES

STANDARD SPECIFICATION No.

6-82-0002 Rev. 2
Page 4 of 9

1.0

SCOPE

1.1

This specification applies to metallic alloy materials as well as carbon steel materials as
defined in this document used in piping, heater coils, storage tanks, vessels etc. at
construction sites. Positive Material Identification (PMI) is to be carried out on Owner
supplied material as well on materials purchased by the contractor.

1.2

Any deviation from this specification must be approved by Owner/EIL in the prescribed
format.

2.0

DEFINITIONS

2.1

Positive Material Identification (PMI)


The term Positive Material Identification (PMI) refers primarily to determination/verification
of alloy type or its composition using portable or mobile spectrometer/alloy analyzer. For the
purpose of this specification, some carbon steel materials as defined in this document are
also included for PMI checking to avoid mix up with Alloy steel during installation.
Chemical spot checking, resistivity testing, eddy current testing, electromagnetic alloy sorting,
thermoelectric testing shall not be considered as PMI for the purpose of this specification.

3.0

SPECIFIC APPLICABILITY

3.1

The following items require PMI unless specifically exempted through a Concession/
Deviation permit by Owner/EIL.

3.1.1

All pressure containing piping components including, thermowells instrument manifolds, RTJ
gaskets, fasteners etc..

3.1.2

Tubular products used in the fabrication of heaters.

3.1.3

Pressure - containing instrument housings (e.g. gauge glass housings, orifice meter tubes).

3.1.4

Internal metallic linings/cladding, and weld overlay, done at site, used for protection against
corrosive environments.

3.1.5

Tubing

3.1.6

Stud, bolts and nuts

3.1.7

Plates

3.1.8

All pressure containing welds.

3.1.9

a) Carbon steel piping components of rating 900# and above


b) Carbon steel piping items under H2 and NACE service.

3.1.10 any other components or materials specifically designated for PMI on the purchase
order/contract.
3.2

Exclusions
The following items are exempted unless specifically designated for PMI in the purchase
order/contract:

Format No. 8-00-0001-F1 Rev. 0

Page 1204 of 2175

Copyright EIL All rights reserved

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09eu WV

ENGINEERS
INDIA LIMITED
IA Govt of India

uneensmg)

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES

STANDARD SPECIFICATION No.

6-82-0002 Rev. 2
Page 5 of 9

3.2.1

Gaskets (spiral wound or carbon steel only).

3.2.2

Internal instrument parts.

3.2.3

Internal machinery parts.

3.2.4

Internal non pressure - containing baffles, trays, tray clips, supports, pall-rings, support rings,
etc.

3.2.5

Electrical components.

3.2.6

Internal valve components.

3.2.7

Compression-type ferrules and fittings for use with 3/4 inch (19mm) outside diameter and
smaller tubing.

3.2.8

All carbon steel piping components (including carbon steel pipe supports) other than those
specified at 3.1.9.

3.2.9

All carbon steel Studs/bolts/nuts.

4.0

REFERENCES
American Society of Mechanical Engineers (ASME) BPV Code Section-II Part A, B, C and D
ASME B 31.3
American Society for Testing and Materials (ASTM): As applicable
Material Verification Program for New and Existing Alloy Piping Systems: API RP 578
Any other material specification referenced by the Purchase Order/Contract.
IS 1239, IS 3589 and other relevant BIS codes.

5.0

GENERAL REQUIREMENTS

5.1

The test methods outlined in this specification are intended to identify the nominal
composition of alloy/Carbon steel materials. These test methods are not intended to establish
the conformance of a material to a particular specification.

5.2

PMI shall not be considered as a substitute for required mill test reports listing chemical
composition. In addition, mill test reports shall not be considered as confirming
alloy/composition verification.

5.3

The PMI activity shall be included in the overall quality plan and Inspection & Test Plan for
fabrication/erection. The contractor shall submit to EIL/Owner, a procedure for PMI to
comply with the requirements of this specification. Approval of PMI procedure shall be
obtained from Own er/EIL prior to commencement of fabrication/erection as the case may be.

5.4

Contractor shall engage reputed TPIA (BV, Lloyds, CEIL, DNV) with prior approval to
witness inspection at site prior to hydrotesting, and accordingly submit ITP for review of
owner/EIL.

5.5

A copy of daily PMI records shall be submitted to Owner/EIL

Format No. 8-00-0001-F1 Rev. 0

Page 1205 of 2175

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5`Ig7 Wag WY INDIA LIMITED
GOA at roam UncleflOong)

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES

STANDARD SPECIFICATION No.

6-82-0002 Rev. 2
Page 6 of 9

5.6

After installation, but prior to hydrostatic testing/painting/insulation, the contractor shall


examine all components requiring PMI for proper compliance to this specification. A record
of this final check duly endorsed by TPIA, as specified below, shall be submitted to
EIL/Owner and made part of the permanent inspection records.

5.6.1

Owner Supplied Material


Records signed by contractor and duly certified by TPIA (engaged by contractor)/ and
reviewed by EIL/ Owner at Contractor's warehouse as part of the receiving inspection at
warehouse.

5.6.2

Contractor Supplied Material


Records signed by contractor and certified by an approved third party inspection agency.

5.7

After acceptance, all components shall be marked with a suitable paint mark. Markings must
be permanent and readily visible. These markings are in addition to markings required by
other codes/specifications/Technical Notes.

5.8

Controls shall be established to keep the non conforming items identified till proper resolution
of non conformity.

5.9

EIL/Owner shall have the right to witness the performance of any PMI test.

6.0

EXTENT OF PMI

PMI shall be done on each component (100 percent PMI inspection) including welds, unless
specifically exempted by Owner/EIL
PMI shall be done on pipe supports (welded/bolted) such as pads, saddles, dummy pipes etc.
(100 percent PMI inspection) in all piping systems of alloy material
PMI shall be done on all bolts and nuts (100 percent PMI inspection) of flange joints in all
piping systems of alloy material.
7.0

PMI OF PIPING AND HEATER COIL COMPONENTS

PMI testing (irrespective of PMI done at earlier stages) shall be carried out when piping
loops/heater coils have been cleared for hydrostatic testing by EIL/Owner. Hydrostatic
Testing shall be carried out only when non conforming components have been
replaced with conforming components and subsequent Non Destructive Testing, Post Weld
Heat-Treatment, Hardness checking etc., as required by specifications have been completed.
PMI records shall form a part of piping/heater inspection records. Contractor shall
demonstrate to EIL that each & every component of the piping system and heater coils has
been subjected to PMI by providing line wise records of PMI duly endorsed by TPIA
8.0

TESTING METHODOLOGY

8.1

The method used for PMI examination shall provide a quantitative determination of the
alloying elements like chromium, nickel, molybdenum or vanadium in alloy steel items for the
characteristic elements specified in clause 9.0

Format No. 8-00-0001-F1 Rev. 0

Page 1206 of 2175

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CA GOA

of Inclo Undept009)

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES

STANDARD SPECIFICATION No.

6-82-0002 Rev. 2
Page 7 of 9

8.2

Instruments or methods used for PMI examination shall be able to provide quantitative,
recordable, elemental composition results for positive identification of elements.

8.3

The acceptable instruments for alloy analyzer shall be either "portable X-ray Fluorescence" or
"optical Emission type each capable of verifying the percentage of elements within specified
range The instruments must have the printout facility and sensitivity to detect the elements in
the specified range.

8.4

Chemical spot testing, magnets, alloy sorters and other methods using eddy current or
triboelectric testing methods are not acceptable for PMI examination.

8.5

All PMI instruments shall have been serviced within a 6 month period of the time of use to
verify the suitability of batteries, sources,etc, and the date of the last service shall be stated on
the PMI report form.

8.6

The surfaces to be examined shall be prepared and cleaned by suitable means before PMI so
that surface be free from grease, oil, paint or oxides. Testing shall be done after proper
surface cleaning and other requirements as outlined by the manufacturer of the portable alloy
analyzer. Modification, if any, of these procedures must be approved by Owner/EIL.

8.7

Alloy steel ring type joint gaskets shall be inspected by using portable X-ray fluorescence
instrument.

9.0

CHARACTERISTIC ELEMENTS
Material Specification

ASTM A 335

ASTM A 312

Gr P1 1
! (Jr P5
! GrP22
t Gr p9
Type 304
Type 316
Type 321
Type 347

Characteristic Elements

Cr, Mo

_Cr, Ni
Cr, Ni, Mo
I Cr, Ni, Ti
Cr. Ni, Columbium, Tantalum

9.1

Carbon Steel materials shall be checked for Cr, Ni, Mo, Cu and Va as per clause no: 13 .3.

9.2

Characteristic elements for materials not listed above shall be proposed by the contractor for
approval of the Owner/EIL

10.0

CALIBRATION

10.1

Instruments used for PMI shall have the sensitivity to detect the alloying elements in the
specified ranges. Instruments or methods used for examination shall be of the type that will
provide quantitative, recordable, elemental composition results for positive identification of
the alloy elements present.

10.2

Each alloy analyzer shall be calibrated using known alloy standards for intended materials to
be checked by PMI. A calibration certification from the Manufacturer or his authorized
agency shall be submitted to EIL/Owner for records.

Format No. 8-00-0001-F1 Rev. 0

Page 1207 of 2175

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lgt-9 ENegviiir INDIA LIMITED
IA GAN of XIda

unaenakam

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES

STANDARD SPECIFICATION No.

6-82-0002 Rev. 2
Page 8 of 9

10.3

EIL/Owner shall review the procedure and qualification and witness sample alloy/carbon steel
materials verification tests to confirm that the procedures, equipment and personnel are
capable of providing consistent and accurate results. Certified samples, with full traceability,
of a known alloy materials/carbon steel materials shall be available for use as a random spot
checking on instrument calibration.

11.0

SITE VERIFICATION OF ANALYZER


Verification using Standard samples supplied by institutes such as ASM (American Society of
Metals) for the intended materials type and grade shall be performed each day before using the
analyzer. Such verification shall be done again if PMI test is to be performed on different
grade or type of material.

12.0

PERSONNEL QUALIFICATION
The persons performing the PMI test should be knowledgeable about properties of material,
all aspects of operation of PMI equipment including the method of testing.
Qualification/experience documents of the person performing the PMI test including his
training and experience shall be submitted to EIL/Owner for review and approval.

13.0

ACCEPTANCE CRITERIA

13.1

Base Metal
PMI test results showing presence of characteristic elements upto 10% less than the minimum
specified value in the material specification and upto 10% more than the maximum specified
value in the material specification shall be acceptable.

13.2

Deposited Weld Metal


For deposited weld metal between base metals of the same specification using matching
consumables, the recorded presence of characteristic elements upto 12.5% less than the
minimum specified value in the welding consumables specification and upto 12.5% more than
the maximum specified value in the welding consumable specification shall be acceptable.

13.3

Carbon Steel Material


The cumulative percentage of chemical composition of Cr, Ni, Mo, Cu and Va shall
maximum be 1% for acceptance of material.

14.0

REJECTION CRITERIA

14.1

If the PMI test results fall outside the acceptable range as given in 13.0 above, the contractor
shall obtain a quantitative check analysis performed by a laboratory acceptable to EIL/Owner
for a complete chemical analysis. Results of this analysis shall be submitted to EIL/Owner,
with contractor's recommendation, for final decision.
Decision of EIL/Owner shall be final in this regard.

14.2

If any material component or weld is found unacceptable, all other represented materials ( e.g.
in case of fasteners, supports) or welds shall be considered suspect. In such cases, the
contractor has the following options:

14.2.1 Scrapping all those represented materials or components and replacing with new components
or welds.
Format No. 8-00-0001-F1 Rev. 0

Page 1208 of 2175

Copyright EIL All rights reserved

OM-a-Eta ENGINEERS
seigTrr Wag's, INDIA LIMITED

I ^ G" btu. unonk.s

STANDARD SPECIFICATION
FOR POSITIVE MATERIAL
IDENTIFICATION AT
CONSTRUCTION SITES

STANDARD SPECIFICATION No.

6-82-0002 Rev. 2
Page 9 of 9

14.2.2 Performing 100% examination of the remainder of the represented materials/ components and
replacing each item that fails the PMI check.
14.2.3 If the performance of any verification activity is unacceptable to EIL/Owner or if any material
has been incorrectly identified, all further tests shall be subject to EIL/Owner approval until
the problem is corrected.
15.0

DOCUMENTATION

15.1

Print out from alloy analyzer, in original, duly certified by the contractor/ PMI agency.

15.2

PMI report as per format No. 6-82-0002-FI

15.3

Basis and action for resolving and documenting PMI non conformances.

15.4

Contractor shall demonstrate to EIL/Owner that all components requiring PMI have been
subjected to PMI testing and accepted.

Format No. 8-00-0001-F1 Rev. 0

Page 1209 of 2175

Copyright EIL All rights reserved

15IrazIeqtt ENGINEERS
Ig7E1PreglilW INDIA LIMITED
Gow II16a thlthillSONO

DOCUMENT NO.

POSITIVE MATERIAL
IDENTIFICATION TEST REPORT

Page 1 of 1

REPORT NO:
Contractor

Date of PMI

Project

Inspection Agency

Location

PMI Agency

Job No.

PMI Equipment Model

Line No. /ISO Drg. No


/Heater No./Drawing No

Make & Serial No.

Sr.
No.

Part Identification

(PMI AGENCY)

Material
As per Drg./spec

(CONTRACTOR)

Material
as per PMI

Result
(Accepted/Rej ected/
Retest)

(TPI AGENCY)

(EIL/OWNER *)
*When material is supplied by Owner

Format No. 6-82-0002-F1 Rev. 2

Page 1210 of 2175

Copyright EIL All rights reserved

JNK HEATERS
CO. LTD.

DOC NO:
TITLE:

DANGOTE OIL
REFINING
COMPANY
LIMITED.

PAINTING SPECIFICATION

OWNER

DANGOTE OIL REFINING COMPANY LTD.

PMC

ENGINEERS INDIA LIMITED

DEC

JNK HEATERS CO. LTD.

UNIT

152-FF-1001A/B, 1002A/B, 1003A/B


151-FF-1001
121-FF-1001/1002, 2001A/B
101-FF-1001A/B

DOCUMENT SUBMISSION STATUS


JNK
DOC. CATEGORY: (USE TICK MARK)
A

ISSUED FOR

0
15/02/2016

REV :
DATE :

REVIEW STATUS - EIL


(1) REVIEWED - NO COMMENTS
(2) REVIEWED, AS COMMENTED, BUT REVISED DRAWING
REQUIRED
(3) NOT MEETING SPECIFICATION, RESUBMIT

INFORMATION

APPROVAL

ENQUIRY

ORDER

CONSTRUCTION

REVIEW

(4) RETAINED FOR INFORMATION / RECORDS

NAME

DISCIPLINE

SIGN.

DATE

Issued for Enquiry

TA

MS

DS

15/02/16

Rev.

Description

Prepared By

Reviewed By

Approved By

Approved Date

JNK HEATERS CO. LTD. ALL RIGHTS RESERVED


THIS DOCUMENT AND ANY DATA AND INFORMATION CONTAINED THEREIN ARE CONFIDENTIAL AND THE PROPERTY OF JNK HEATERS CO. LTD. (JNK) AND THE COPYRIGHT
THEREIN IS VESTED IN JNK NO PART OF THIS DOCUMENT, DATA, OR INFORMATION SHALL BE DISCLOSED TO OTHERS OR REPRODUCED IN ANY MANNER OR USED FOR ANY
PURPOSE WHATSOEVER, EXCEPT WITH THE PRIOR WRITTEN PERMISSION OF JNK

JNK HEATERS
CO. LTD.

DOC NO:
TITLE:

DANGOTE OIL
REFINING
COMPANY
LIMITED.

PAINTING SPECIFICATION

REV :
DATE :

0
15/02/2016

TABLE OF CONTENT

Section

DESCRIPTION

PAGE NO.

Introduction

Reference Documents

Scope of Work

Surface Preparation

Storage of Painting Material

Mixing & Thinning

Painting

Inspection & Testing

Documentation

JNK HEATERS CO. LTD. ALL RIGHTS RESERVED


THIS DOCUMENT AND ANY DATA AND INFORMATION CONTAINED THEREIN ARE CONFIDENTIAL AND THE PROPERTY OF JNK HEATERS CO. LTD. (JNK) AND THE COPYRIGHT
THEREIN IS VESTED IN JNK NO PART OF THIS DOCUMENT, DATA, OR INFORMATION SHALL BE DISCLOSED TO OTHERS OR REPRODUCED IN ANY MANNER OR USED FOR ANY
PURPOSE WHATSOEVER, EXCEPT WITH THE PRIOR WRITTEN PERMISSION OF JNK

JNK HEATERS
CO. LTD.

DOC NO:
TITLE:

PAINTING SPECIFICATION

DANGOTE OIL
REFINING
COMPANY
LIMITED.
REV :
DATE :

0
15/02/2016

1. Introduction
This specification covers the minimum requirements for the Painting of Fired Heaters of Dangote Refinery and
Petrochemicals Project for Dangote Oil Refining Company Ltd., Nigeria.
This document briefly specifies scope of work, requirements for surface preparation, selection and application of
paints on equipment, piping and steel structures etc.

2. Reference Documents
Specification for Surface Preparation and Protective Coating A545-000-07-41-SP-01121-Rev 0

3. Scope of Work
3.1. Extent of Work & Supply
The following surfaces and material shall require shop, post-erection and field painting
3.1.1. All uninsulated carbon steel and low alloy steel and related piping, fittings and valves (including
painting of identification marks), Heater ducts and stacks, Heaters etc.
3.1.2. All insulated parts of piping & ducting.
3.1.3. All structural steel work, pipe, structural steel supports, walkways, handrails, ladders, platforms etc.
3.1.4. Identification of colour bands on all piping as required.
3.1.5. Supply & application of all types of primers, Intermediate/finish paints as per Annexure-1 with paint
required for repair at site.
3.1.6. Painting under insulation for carbon steel, alloy steel and stainless steel as specified.
3.1.7. Quality control, testing and inspection during all stages of work (surface preparation, application of
coating and testing of furnished coating).
3.1.8. For fabricated box section & construction of similar nature, primer coat shall be given in the inside
surfaces before fabrication.

4. Surface Preparation & Application


Specification for Surface Preparation and Protective Coating A545-000-07-41-SP-01121-Rev 0

5. Storage of Painting Material


5.1. Paints, varnishes, thinner, additives and other volatile substances shall be stored in a flame proof
enclosure, away from heat.

JNK HEATERS CO. LTD. ALL RIGHTS RESERVED


THIS DOCUMENT AND ANY DATA AND INFORMATION CONTAINED THEREIN ARE CONFIDENTIAL AND THE PROPERTY OF JNK HEATERS CO. LTD. (JNK) AND THE COPYRIGHT
THEREIN IS VESTED IN JNK NO PART OF THIS DOCUMENT, DATA, OR INFORMATION SHALL BE DISCLOSED TO OTHERS OR REPRODUCED IN ANY MANNER OR USED FOR ANY
PURPOSE WHATSOEVER, EXCEPT WITH THE PRIOR WRITTEN PERMISSION OF JNK

JNK HEATERS
CO. LTD.

DOC NO:
TITLE:

PAINTING SPECIFICATION

DANGOTE OIL
REFINING
COMPANY
LIMITED.
REV :
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5.2. Fire extinguishers or sand and water for emergency firefighting operations shall be provided near storage
area at easily accessible place for use, in case of fire.
5.3. Warning Boards and signs shall be exhibited around the storage area.
5.4. Also Refer Specification for Surface Preparation and Protective Coating A545-000-07-41-SP-01121Rev 0

6. Mixing & Thinning


6.1. Mixing and thinning of paints shall be carried out as per manufacturers recommendations.
6.2. Mixing and thinning operations shall be carried out in well ventilated rooms.
6.3. Only that quantity of paint which is sufficient to cover the required area within the specified painting time
shall be mixed at a time.
6.4. Mixed paints shall be used within the time span as recommended by manufacturer. Mixed paints, for
which standing time specified has elapsed, shall not be used.
6.5. Ready-mixed paints containers shall be opened only at the time of painting.
6.6. Containers shall be closed air tight after drawing paint from it.
6.7. Ready-mixed paints shall be stirred well before drawing from the storage container as well as during
painting operations.
6.8. Ready-mixed paints shall be thinned only if absolutely necessary by using thinners recommended by
manufacturer. Balance of ready-mixed paints shall not be poured back into the main container after use,
but shall be kept in a separate air tight container.

7. Painting

7.1. General Requirement


7.1.1. Painting of equipment, piping and structural shall be carried out at shop or site as prescribed in the
respective equipment data sheets, piping line schedule or structural detail drawing.
7.1.2. Painting shall not be carried out on surfaces not prepared and not meeting the requirements of clause
4.0.
7.1.3. Painting shall be carried out only under favorable conditions. Painting shall not be carried out in dusty
and draught conditions in damp areas and during rainy seasons or cold atmosphere.
7.1.4. During painting, adjacent equipments or surfaces shall be protected from paint sprays, splashes or drips.

JNK HEATERS CO. LTD. ALL RIGHTS RESERVED


THIS DOCUMENT AND ANY DATA AND INFORMATION CONTAINED THEREIN ARE CONFIDENTIAL AND THE PROPERTY OF JNK HEATERS CO. LTD. (JNK) AND THE COPYRIGHT
THEREIN IS VESTED IN JNK NO PART OF THIS DOCUMENT, DATA, OR INFORMATION SHALL BE DISCLOSED TO OTHERS OR REPRODUCED IN ANY MANNER OR USED FOR ANY
PURPOSE WHATSOEVER, EXCEPT WITH THE PRIOR WRITTEN PERMISSION OF JNK

JNK HEATERS
CO. LTD.

DOC NO:
TITLE:

PAINTING SPECIFICATION

DANGOTE OIL
REFINING
COMPANY
LIMITED.
REV :
DATE :

0
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7.1.5. A Caution board indicating wet paint shall be posted after painting is over and kept till the curing time is
completed.
7.1.6. For painting of multiple coating, each coat shall be applied only after sufficient curing time has elapsed
after the previous coat, as recommended by manufacturer.
7.1.7. All painted surfaces shall have a uniform and smooth regular finish.
7.1.8. The surfaces shall be free from foreign particles, brush marks, bristles, ridges, waves, laps wrinkles etc.
If such surface defects occur, the same shall be removed by using abrasive paper/cloth and re-painted.
7.1.9. Surfaces inaccessible after assembly shall be painted to requirement before assembly.
7.1.10. Any imperfect or damaged layer/coat shall be repaired before subsequent coating.
7.1.11. At places where welding is to be carried out at field after assembly, a space of 100 to 200 mm width
shall be left unpainted on both sides of the welding joint.
7.1.12. Field welded areas shall be thoroughly cleaned as required in clause 4.0 and painted in the same
manner as the remaining area.
7.1.13. When successive coat of same color have been specified, alternate coat should be tinted sufficiently to
produce enough contrast to indicate complete coverage of the surface.
7.1.14. Pipes shall be painted only after mechanical completion and testing.
7.1.15. Also Refer Specification for Surface Preparation and Protective Coating A545-000-07-41-SP-01121Rev 0

7.2. Shop Painting/ Priming


7.2.1. Shop painting/priming shall be carried out as specified in the respective data sheets/line schedule etc.
and shall meet all the requirements of this specification.

7.3. Painting at Field/ Site


7.3.1. Field/site painting shall be carried out as specified in the data sheets/painting schedule and shall meet
all the requirements of this specification for painting.
7.3.2. Where equipments/piping/structures have already received shop painting/priming, the painted/primed
surfaces shall be thoroughly cleaned and inspected for any damage or defects. Such damages or
defects shall be repaired before starting the filed/site painting.

JNK HEATERS CO. LTD. ALL RIGHTS RESERVED


THIS DOCUMENT AND ANY DATA AND INFORMATION CONTAINED THEREIN ARE CONFIDENTIAL AND THE PROPERTY OF JNK HEATERS CO. LTD. (JNK) AND THE COPYRIGHT
THEREIN IS VESTED IN JNK NO PART OF THIS DOCUMENT, DATA, OR INFORMATION SHALL BE DISCLOSED TO OTHERS OR REPRODUCED IN ANY MANNER OR USED FOR ANY
PURPOSE WHATSOEVER, EXCEPT WITH THE PRIOR WRITTEN PERMISSION OF JNK

JNK HEATERS
CO. LTD.

DOC NO:
TITLE:

PAINTING SPECIFICATION

DANGOTE OIL
REFINING
COMPANY
LIMITED.
REV :
DATE :

0
15/02/2016

7.4. Codification of Painting Material & Scheme of Painting


Refer Annexure-1 for detailed description of painting requirements for different heater components. Vendor to
cross verify the details in Annexure-1 before purchase / application of paint as per Specification for Surface
Preparation and Protective Coating A545-000-07-41-SP-01121-Rev 0, discrepancy shall be noticed to JNK, if
any.

8. Inspection & Testing


8.1. General
8.1.1. All painting materials and related items shall be inspected to check the suitability of the same for the
specified purposes.
8.1.2. Painting surfaces are to be inspected after cleaning operation, to ensure that the surfaces are fit for
painting.
8.1.3. Finished surfaces shall be checked for uniformity in colour, finish and appearance as well as for
defects.
8.1.4. Thickness of each coat of paint shall be checked after curing time. The total thickness of multiple coats
shall be as specified in the data sheets/piping line schedules/painting schedules, Annexure-1.
8.1.5. Paint thickness gauge shall be either mechanical or electronic. The gauges shall be calibrated
regularly. Defective gauges shall not be used.
8.1.6. A detailed quality / inspection report shall be made for each equipment / line / structure separately.
8.1.7. The record of inspection shall be maintained.
8.1.8. Stages of inspection shall be as follows
a. Surface preparation
b. Primer Application
c.

Each coat of Intermediate paint

8.1.9. Final inspection of finished coating shall consist of measurement of:


a. Paint dry film thickness (DFT)
b. Adhesion
c.

Holiday detection check as well as for finish and workmanship

8.1.10 Test mentioned in Specification for Surface Preparation and Protective CoatingA545-000-07-41-SP01121-Rev 0

JNK HEATERS CO. LTD. ALL RIGHTS RESERVED


THIS DOCUMENT AND ANY DATA AND INFORMATION CONTAINED THEREIN ARE CONFIDENTIAL AND THE PROPERTY OF JNK HEATERS CO. LTD. (JNK) AND THE COPYRIGHT
THEREIN IS VESTED IN JNK NO PART OF THIS DOCUMENT, DATA, OR INFORMATION SHALL BE DISCLOSED TO OTHERS OR REPRODUCED IN ANY MANNER OR USED FOR ANY
PURPOSE WHATSOEVER, EXCEPT WITH THE PRIOR WRITTEN PERMISSION OF JNK

JNK HEATERS
CO. LTD.

DOC NO:
TITLE:

PAINTING SPECIFICATION

DANGOTE OIL
REFINING
COMPANY
LIMITED.
REV :
DATE :

0
15/02/2016

8.2. Thickness & Adherence Check


As per Specification for Surface Preparation and Protective Coating-A545-000-07-41-SP-01121-Rev 0

9. Documentation
Following documents shall be prepared and maintained:
Painting Inspection Report.

Attachment
Annexure 1 Painting Specification Table

JNK HEATERS CO. LTD. ALL RIGHTS RESERVED


THIS DOCUMENT AND ANY DATA AND INFORMATION CONTAINED THEREIN ARE CONFIDENTIAL AND THE PROPERTY OF JNK HEATERS CO. LTD. (JNK) AND THE COPYRIGHT
THEREIN IS VESTED IN JNK NO PART OF THIS DOCUMENT, DATA, OR INFORMATION SHALL BE DISCLOSED TO OTHERS OR REPRODUCED IN ANY MANNER OR USED FOR ANY
PURPOSE WHATSOEVER, EXCEPT WITH THE PRIOR WRITTEN PERMISSION OF JNK

Annexure 1
Painting Specification Table (As per Specification A545-000-07-41-SP-01121-01-Rev 0)

PRIMER 1

Table

10.3

10.2

Sr.
No

Radiant
Section,
convectio
n Section
& Stack

All Steel
Structure,
Platforms,
Duct/APH
, Supports
etc

3
8.1

10.2

Surface
of
Applicati
on

Handrails,
Posts, toe
Guard,Sta
irways,
Gartings
and
Ladders
Cold Air
Duct
(Internal)

10.2

Cold Air
Duct
(External)

15.1.2

APH by
pass air
duct

15.1.1

Hot Air
Duct from
SAPH to
CAPH
(External)

Material

Grade
S275 JR

Grade
S275 JR

Grade
S275 JR

Grade
S275 JR

Grade
S275 JR

Grade
S275 JR

Grade
S275 JR

Service
Temper
ature
Range
in o C

81 to
400

-14 to
80

Up to 60

-14 to
80

-14 to
80

121 to
540

-45 to
120

Surface
Prepara
tion

SSPCSP-10

SSPCSP-10

SSPCSP-10

SSPCSP-10

Type

Two Component
Inorganic zinc
silicate coating (F9)

Two Component
Inorganic zinc
silicate coating (F9)

N
o.
O
f
C
o
at
s

DFT
Each
Coat
(Micro
ns)

Two Component
Inorganic zinc
silicate coating (F9)

Two Component
Inorganic zinc
silicate coating (F9)

SSPCSP-10

Two component
Heat resistant
Silicone Aluminium
paint (F12) (*)

Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15) (*)

N
o.
O
f
C
o
at
s

DFT
Each Coat
(Microns)

FINISH COAT 1
DFT
Each
Coat
(Micr
ons)

Type

HEATER STRUCTURE
Two component
Heat resistant
silicone
Aluminium paint
(F12)

65-75

65-75

Two
component
Epoxy Zinc
Phosphate
Primer cured
with polyamine
hardener (P6)

Hot Dip Galvanizing to 80-85


microns (600-610 gm/m2) as per
IS 4759, 2629, 4736, 2633

SSPCSP-10

SSPCSP-10

PRIMER 2

Two
component
Epoxy Zinc
Phosphate
Primer cured
with polyamine
hardener (P6)

65-75

65-75

Two
component
Epoxy Zinc
Phosphate
Primer cured
with polyamine
hardener (P6)

20

75

Two
component
Epoxy
phenolic
coating cured
with
Polyamine
adduct
hardener
system (F15)

40

High Build Epoxy


finish coating
cured with
polyamine
hardener
(F6-A)

40

Two component
Acrylic
Polyurethane
finish paint (F2)

High Build Epoxy


finish coating
cured with
polyamine
hardener
(F6-A)

40

High Build Epoxy


finish coating
cured with
polyamine
hardener
(F6-A)

Two component
Heat resistant
Silicone
Aluminium paint
(F12).

75

Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15)

FINISH COAT 2

No.
Of
Coat
s

DFT
Each
Coat
(Micro
ns)

DFT
Each
Coat
(Micro
ns)

Total Avg
DFT in
Microns

Colour Shade

Type

No.
Of
Coat
s

20

105-115

Heat resistant
aluminium

100

Two
component
Acrylic
Polyuretha
ne finish
paint (F2)

40

345-355

Heater StructuresSteel Grey


P.form-Steel Grey

40

160-165

100

Two
component
Acrylic
Polyuretha
ne finish
paint (F2)

50

215-225

Black

100

Two
component
Acrylic
Polyuretha
ne finish
paint (F2)

40

345-355

Black

20

60

Black

Hold

Hold

Duct/APH/Piping
Supports- Black

Handrail-Signal
Red
Stairways, Grating,
Ladder- Black

Remarks

Hold

Hold

Hold

Hold

Hold
2

75

300

Black

15.1.2

15.1.1

10
10.2

Hot Air
Duct from
CAPH to
Burner
(External)

Cold Flue
Gas Duct
(External)

Hot Flue
Gas Duct
(External)

Grade
S275 JR

Grade
S275 JR

Grade
S275 JR

121 to
540

-45 to
120

-14 to
80

SSPCSP-10

SSPCSP-10

SSPCSP-10

Two component
Heat resistant
Silicone Aluminium
paint (F12) (*)

Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15) (*)

Two Component
Inorganic zinc
silicate coating (F9)

20

75

65-75

Two
component
Epoxy
phenolic
coating cured
with
Polyamine
adduct
hardener
system (F15)
Two
component
Epoxy Zinc
Phosphate
Primer cured
with polyamine
hardener (P6)

Two component
Heat resistant
Silicone
Aluminium paint
(F12).

20

60

Black

75

Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15)

75

300

Black

40

High Build Epoxy


finish coating
cured with
polyamine
hardener
(F6-A)

100

Two
component
Acrylic
Polyuretha
ne finish
paint (F2)

40

345-355

Black

Hold

Base

HEATER PIPING

11
15.1.1

12

Fuel (Oil)
Piping
(Main &
Pilot)

CS

15.3.2

Fuel
(Gas)
Piping
(Main &
Pilot)

Stainles
s Steel

15.1.2

Process
Inlet/
Outlet

CS/ Low
Alloy
Steel

13

15.3.3
14

15.3.4

15.1.2

15

16

-45 to
120

0 to 125

121 to
540

SSPCSP-10

Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15) (*)

SSPCSP-10

Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15) (*)

SSPCSP-10

Two component
Heat resistant
Silicone Aluminium
paint (F12) (*)

20

125

125

Process
Inlet/
Outlet

SS

126 to
400

SSPCSP-10

Engineered Epoxy
poly Siloxane
Coating or high
build cold applied
inorganic copolymer based
aluminium coating
(F16) (*)

Process
Inlet/
Outlet

SS

401 to
600

SSPCSP-10

Amercoat 738 (*)

SSPCSP-10

Two component
Heat resistant
Silicone Aluminium
paint (F12) (*)

Snuffing
Steam

CS

121 to
540

Two
component
Epoxy
phenolic
coating cured
with
Polyamine
adduct
hardener
system (F15)
Two
component
Epoxy
phenolic
coating cured
with
Polyamine
adduct
hardener
system (F15)

75

80

20

75

Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15)

80

Two component
Epoxy phenolic
coating cured with
Polyamine adduct
hardener system
(F15)

Hold

Hold

Band

Hold
2

75

300

Black

1 Yellow

Hold
1

80

240

Orange

1
Aluminiu
m

20

60

Dark
admiralty
Grey

1 Red

125

250

Dark
admiralty
Grey

1 Red

Amercoat 738

125

250

Dark
admiralty
Grey

1 Red

Hold

Two component
Heat resistant
Silicone
Aluminium paint
(F12)

20

60

Off white/
Aluminiu
m

1 light
green

Hold

Two component
Heat resistant
Silicone
Aluminium paint
(F12).
Engineered
Epoxy poly
Siloxane Coating
or high build cold
applied inorganic
co-polymer based
aluminium coating
(F16)

Hold

Hold

15.1.2

17

Cross
Over

Cross
Over

15.3.3

CS/ Low
Alloy
Steel

Stainles
s Steel

121 to
540

126 to
400

SSPCSP-10

Two component
Heat resistant
Silicone Aluminium
paint (F12) (*)

SSPCSP-10

Engineered Epoxy
poly Siloxane
Coating or high
build cold applied
inorganic copolymer based
aluminium coating
(F16) (*)

SSPCSP-10

Two component
Heat resistant
Silicone Aluminium
paint (F12) (*)

18

15.1.2

10.2

19

20

Soot
Blower,
Atomizing
steam

CS

Instrumen
t Air

CS

121 to
540

20

125

20

Two component
Heat resistant
Silicone
Aluminium paint
(F12)

20

Engineered
Epoxy poly
Siloxane Coating
or high build cold
applied inorganic
co-polymer based
aluminium coating
(F16)

125

Two component
Heat resistant
Silicone
Aluminium paint
(F12)

20

Galvanized pipes shall be coated with zinc by hot dip process conforming to ASTM A 153

60

Dark
admiralty
Grey

1 Red

250

Dark
admiralty
Grey

1 Red

60

Off white/
Aluminiu
m

1 Red

Hold

Sea
Green

1 Black

Hold

HEATER STRUCTURE & PIPING REPAIR WORKS


Two Component
All
Grade
-90 to
SSPC7.2.1
Inorganic zinc
1
65-75
As applicable for individual heater components mentioned in serial no 1,2,4,5 & 10above
Surface
S275 JR
400
SP-3
21
silicate coating (F9)
Note 1: After repair of damaged galvanized coating by Cold Galvanized, the repaired area shall be top coated with paint system as given in Table 8.1 above (i.e., 1 coat of P-6 @ 40 DFT/coat + 1coat of F-2 @ 40 DFT/coat).
Note 2: One coat of F-9 shall be applied wherever damage was observed on pre-erection/ pre fabrication or shop primer of inorganic zinc silicate coating (F-9).
Note 3: one coat of F-12 shall be applied wherever damage observed on pre-erection / prefabrication shop primer of silicone aluminium (F-12).
Note 4: one coat of F-15 shall be applied wherever damage observed on pre-erection / prefabrication shop primer of (F-15).
Note 5: one coat of F-16 shall be applied wherever damage observed on pre-erection / prefabrication shop primer of (F-16).
Note ( *): Primer shall be suitable for minimum 400 C temperature.

Hold

Hold

Hold

Hold

DANGOTE OIL REFINING


COMPANY LTD.

JNK INDIA PVT. LTD.

REV : A

TITLE: INSPECTION TEST PLAN FOR STEEL STRUCTURE FOR RADIANT, CONVECTION, STACK & DUCTS AT SHOP
ITP NO: -

DATE : 15-02-2016

OWNER

DANGOTE OIL REFINING COMPANY LIMITED

PROJECT

DANGOTE REFINERY AND PETROCHEMICALS PROJECT

CONSULTANT

ENGINEERS INDIA LIMITED

LSTK CONTRACTOR

JNK HEATERS CO.LTD

CONTRACTOR'S PROJECT NO

XXXX

REF. NO.

XXXX

DORCL JOB NO.

XXXX

DORCL PO NO.

XXXX

TPIA

XXXX

INSPECTION CATEGORY

CATEGORY A

DOCUMENT SUBMISSION STATUS - JNK

APPROVAL STATUS CLIENT / CONSULTANT

DOCUMENT CATEGORY : (USE TICK MARK)

R
ISSUED FOR

A
INFORMATION
INQUIRY
CONSTRUCTION

LEGENDS :

I
APPROVAL
ORDER

REVIEW

Existing approved WPS/PQR/WPQ will be submitted to EIL for review & approval.
HP - Hold Point, W - Witness Point, Rw- Review Of Contractor's documentation, S - Surveillance Inspection by Ower/EIL, WC- 100% Examination by Contractor.
WPS - Welding Procedure Specification, PQR - Procedure Qualification Record, WPQ - Welder Performance Qualification

ISSUED FOR REVIEW

AJ

CL

DS

15-Feb-16

REV

DESCRIPTION

PRPD BY

CHKD BY

APRD BY

DATE

Page 1 of 4

SR. NO.

ACTIVITY DESCRIPTION

REFERENCE DOCUMENT

EXTENT OF INSPECTION
MFG

1
2

PRIOR TO FABRICATION
Incoming Material Inspection
Welding Filler Material Approval/Qualification
a) Review of materials test certificate/ Documents
b) Laboratory testing, if any
i) Carbon Steel
ii) Alloy Steel/ Stainless Steel

TPI

ITP No: 6-82-1010

INSPECTION BY

REMARKS

MFG

JNK

TPI

EIL/ DORCL

100%

100%

HP

WC

Rw

HP *

100%

100%

HP

WC

Rw

100%

100%

HP

WC

100%

100%

HP

WC

Rw

HP

100%

100%

HP

WC

HP

100%

100%

HP

WC

HP

100%

100%

HP

WC

HP

100%

100%

HP

WC

Rw

HP

As per ASME Sec IX

100%

100%

HP

WC

As per welder Certificates

100%

100%

HP

WC

Rw*

HP

Test Certificates
Test Certificates/ Project
Specs
Test Certificates/ Project
Specs

Note 1

WPS/PQR
a) Review of Proposed Procedure

As per ASME Sec IX and


Project Spec

b) Welding of Test Coupons and subsequent testing


i) Carbon Steel
ii) Alloy Steel/ Stainless Steel
iii) All other materials icluding CS for H2 Service
c) Approval of final WPS/PQR
4

Welder Performance Qualification Test

Certification & Approval of welders before deployment


on job

As per ASME Sec IX and


Project Spec
As per ASME Sec IX and
Project Spec
As per ASME Sec IX and
Project Spec
As per ASME Sec IX and
Project Spec

Page 2 of 4

Note 2

SR. NO.

ACTIVITY DESCRIPTION

b) Witnessing proposed Procedure Testing


c) Approval of Qualified Procedure
7

Layout Checking

Welding Equipment and accessories

Preparation and approval of Fabrication drawings

FABRICATION ACTIVITIES
Materials as per design drawing
Check straightness and non-warping of members
Dimensional & fit-up checks including provision of
slopes for deflection wherever required
Visual check for welding

NDT

EXTENT OF INSPECTION

INSPECTION BY

REMARKS

MFG

TPI

MFG

JNK

TPI

EIL/ DORCL

100%

100%

HP

WC

Rw

HP

100%

100%

HP

WC

100%

100%

HP

WC

Rw

HP

100%

HP

WC

Test Certificates

100%

100%

HP

WC

Rw

As per drwaings and Project


Specs

100%

100%

HP*

Rw

Rw

As per approved drawing


As per approved drawing

100%
100%

100%
10%

HP
HP

WC
WC

Rw
W

Rw
S

As per approved drawing

100%

10%

HP

WC

As per Spec.

100%

10%

HP

WC

ASME Sec-V Article 2 & ASME


Sec VIII Div 1

100%

HP

WC

100%

100%

HP

WC

100%

10%

HP

WC

100%

10%

HP

WC

NDT Procedure Qualification


a) Review of Proposed Procedure

1
2

REFERENCE DOCUMENT

As per ASME Sec V and


Project Specs
As per ASME Sec V and
Project Specs
As per ASME Sec V and
Project Specs
As per drawings and Project
Specs

a) Radiography Testing (as applicable)


i) RT Marking ( for random/spot radiography only)

ii) RT Interpretation
b) Ultrasonic Testing (as applicable)
c) Penetrant Testing (as applicable)

ASME Sec-VIII Div 1 UW 51 &


UW 52 & ASME Sec-V Article
2
ASME Sec-V Article 4 and
Project Specs
ASME Sec-V Article 6 and
Project Spec

Page 3 of 4

Note 3

SR. NO.

ACTIVITY DESCRIPTION

REFERENCE DOCUMENT

EXTENT OF INSPECTION

INSPECTION BY

REMARKS

MFG

TPI

MFG

JNK

TPI

EIL/ DORCL

As per Spec.

100%

10%

HP

WC

As per Spec / Test


Certificates

100%

100%

HP

WC

Rw

As per Project Spec.

100%

10%

HP

WC

Grinding including surface preparation for painting and


application of primer

Checking paint as per specs, shelf life etc

Application of specified paint, painting thickness, etc

Module assembly inspection

As per drawings

100%

100%

HP

WC

10

Trial Assembly of all adjecent parts with Match marking

As per drawings

100%

10%

HP

WC

11

Final Dimensional & Visual Inspection

As per drawings

100%

10%

HP

WC

As per drawings

100%

100%

HP

WC

Rw

Rw

As per PO
As per PO

100%
100%
100%

100%
100%
-

HP
-

Rw
Rw
-

Rw
Rw
HP

Rw
Rw

12
12

Lifting Arrangements including test certificates of lifting


tackles
Packing & Final
a) Final Marking, stamping quantity check
c) ITP Signed off
d) IRN Issue

Notes:
1)
For Alloy Steel & Stainless steel welding filler metals chemical analysis to be carried out for every batch.
2)

Review of TPI for existing WPQ

3)

JNK will prepare and approve fabrication drawings.

4)

10% Extent of Inspection for TPI means,10% of each item (Radiant, Convection, Stack, Duct).

Page 4 of 4

DANGOTE OIL REFINING COMPANY


LTD.

JNK INDIA PVT. LTD.

REV : A

TITLE: INSPECTION TEST PLAN FOR STEEL STRUCTURE FOR APH, PIPE & OPEN SUPPORTS AT SHOP
ITP NO: OWNER

DATE : 15-02-2016

: DANGOTE OIL REFINING COMPANY LIMITED


: DANGOTE REFINERY AND PETROCHEMICALS PROJECT

PROJECT
CONSULTANT

: ENGINEERS INDIA LIMITED


: JNK HEATERS CO.LTD

LSTK CONTRACTOR
CONTRACTOR'S PROJECT NO

: XXXX
: XXXX

REF. NO.
DORCL JOB NO.

: XXXX
: XXXX

DORCL PO NO.
TPIA

: XXXX
: CATEGORY B

INSPECTION CATEGORY
DOCUMENT SUBMISSION STATUS - JNK

APPROVAL STATUS CLIENT / CONSULTANT

DOCUMENT CATEGORY : (USE TICK MARK)

R
ISSUED FOR

A
INFORMATION
INQUIRY
CONSTRUCTION

LEGENDS :

I
APPROVAL
ORDER

REVIEW

Existing approved WPS/PQR/WPQ will be submitted to EIL for review & approval.
HP - Hold Point, W - Witness Point, Rw- Review Of Contractor's documentation, S - Surveillance Inspection by Ower/EIL, WC- 100% Examination by Contractor.
WPS - Welding Procedure Specification, PQR - Procedure Qualification Record, WPQ - Welder Performance Qualification

ISSUED FOR REVIEW

AJ

CL

DS

15-Feb-16

REV

DESCRIPTION

PRPD BY

CHKD BY

APRD BY

DATE

Page 1 of 3

SR. NO.

ACTIVITY DESCRIPTION

REFERENCE DOCUMENT

EXTENT OF INSPECTION

INSPECTION BY

REMARKS

MFG

TPI

MFG

JNK

TPI

EIL/ DORCL

100%

100%

HP

WC

Rw

HP

100%

100%

HP
-

WC
-

Rw
-

S
-

PRIOR TO FABRICATION
1

a) Review of calibration certifactes/testing euipments

Test Certificates

b) Field Calibration, if any


Incoming Material Inspection
Welding Filler Material Approval/Qualification
a) Review of materials test certificate/ Documents
b) Laboratory testing, if any
WPS/PQR

Test Certificates
Test Certificates
As per ASME Sec IX

100%
100%
100%

100%
100%
100%

HP
HP
HP

WC
WC
WC

Rw
Rw
W

Rw
W
HP

Welder Performance Qualification Test

As per ASME Sec IX

100%

100%

HP

WC

W*

Layout Checking

As per drawings and Project


Specs

100%

100%

HP

WC

Rw

Welding Equipment and accessories

Test Certificates

100%

100%

HP

WC

Rw

Preparation and approval of Fabrication drawings

As per drwaings and Project


Specs

100%

100%

HP*

Rw

Rw

As per approved drawing


As per approved drawing

100%
100%

100%
10%

HP
HP

WC
WC

Rw
W

Rw
S

As per approved drawing

100%

10%

HP

WC

As per Spec.

100%

10%

HP

WC

2
3

FABRICATION ACTIVITIES
Materials as per design drawing
Check straightness and non-warping of members
Dimensional & fit-up checks including provision of slopes for
deflection wherever required
Visual check for welding

NDT

1
2
3

ITP No: 6-82-1010

a) Radiography Testing (as applicable)

Page 2 of 3

Note 1

Note 2

SR. NO.

ACTIVITY DESCRIPTION

REFERENCE DOCUMENT

EXTENT OF INSPECTION

INSPECTION BY

REMARKS

MFG

TPI

MFG

JNK

TPI

EIL/ DORCL

ASME Sec-V Article 2 &


ASME Sec VIII Div 1

100%

100%

HP

WC

ASME Sec-VIII Div 1 UW 51


& UW 52 & ASME Sec-V
Article 2

100%

100%

HP

WC

b) Ultrasonic Testing (as applicable)

ASME Sec-V Article 4 and


Project Spec

100%

10%

HP

WC

c) Penetrant Testing (as applicable)

ASME Sec-V Article 6 and


Project Spec

100%

10%

HP

WC

As per Spec.

100%

10%

HP

WC

As per Spec / Test


Certificates

100%

100%

HP

WC

Rw

As per Project Spec.

100%

10%

HP

WC

i) RT Marking ( for random/spot radiography only)

ii) RT Interpretation

Grinding including surface preparation for painting and


application of primer

Checking paint as per specs, shelf life etc

Application of specified paint, painting thickness, etc

Trial Assembly of all adjecent parts with Match marking

As per drawings

100%

10%

HP

WC

10

Final Dimensional & Visual Inspection

As per drawings

100%

10%

HP

WC

As per drawings

100%

100%

HP

WC

Rw

Rw

As per PO
As per PO

100%
100%
100%

10%
100%
-

HP
-

WC
Rw
-

W
Rw
HP

Rw
Rw

11
12

Lifting Arrangements including test certificates of lifting


tackles
Packing & Final
a) Final Marking, stamping quantity check
b) ITP Signed off
c) IRN Issue

Notes:
1)
Review of TPI for existing WPQ .
2)

JNK will prepare and approve fabrication drawings.

3)

10% Extent of Inspection for TPI means,10% of each item (APH, Pipe & Open Supports).

Page 3 of 3

DANGOTE OIL REFINING


COMPANY LTD.

JNK INDIA PVT. LTD.

REV : A

TITLE: INSPECTION TEST PLAN FOR PRESSURE PART COIL WORKS (HEATER INLET FLANGE TO OUTLET FLANGE)
ITP NO: -

DATE : 15-02-2016

OWNER

DANGOTE OIL REFINING COMPANY LIMITED

PROJECT

DANGOTE REFINERY AND PETROCHEMICALS PROJECT

CONSULTANT

ENGINEERS INDIA LIMITED

LSTK CONTRACTOR

JNK HEATERS CO.LTD

CONTRACTOR'S PROJECT NO

XXXX

REF. NO.

XXXX

DORCL JOB NO.

XXXX

DORCL PO NO.

XXXX

TPIA

XXXX

INSPECTION CATEGORY

CATEGORY A

DOCUMENT SUBMISSION STATUS - JNK

APPROVAL STATUS CLIENT / CONSULTANT

DOCUMENT CATEGORY : (USE TICK MARK)

R
ISSUED FOR

INFORMATION

APPROVAL

INQUIRY

ORDER

CONSTRUCTION

LEGENDS :

REVIEW

Existing approved WPS/PQR/WPQ will be submitted to EIL for review & approval.
HP - Hold Point, W - Witness Point, Rw- Review Of Contractor's documentation, S - Surveillance Inspection by Ower/EIL, WC- 100% Examination by Contractor.
WPS - Welding Procedure Specification, PQR - Procedure Qualification Record, WPQ - Welder Performance Qualification

ISSUED FOR REVIEW

AJ

CL

DS

15-Feb-16

REV

DESCRIPTION

PRPD BY

CHKD BY

APRD BY

DATE

Page 1 of 5

SR. NO.

ACTIVITY DESCRIPTION

EXTENT OF INSPECTION

REFERENCE DOCUMENT

MFG
1
2

PRIOR TO FABRICATION
Incoming Material Inspection
Welding Filler Material Approval/Qualification
a) Review of materials test certificate/ Documents
b) Laboratory testing, if any
i) Carbon Steel
ii) Alloy Steel/ Stainless Steel

TPI

ITP No: 6-82-1010

INSPECTION BY

REMARKS

MFG

JNK

TPI

EIL/ DORCL

100%

100%

HP

WC

Rw

HP *

100%

100%

HP

WC

Rw

100%

100%

HP

WC

100%

100%

HP

WC

Rw

HP

100%

100%

HP

WC

HP

100%

100%

HP

WC

HP

100%

100%

HP

WC

HP

100%

100%

HP

WC

Rw

HP

As per ASME Sec IX

100%

100%

HP

WC

As per welder Certificates

100%

100%

HP

WC

Rw*

HP

100%

100%

HP

WC

Rw

HP

100%

100%

HP

WC

100%

100%

HP

WC

Rw

HP

100%

100%

HP

WC

Rw

Test Certificates
Test Certificates/ Project
Specs
Test Certificates/ Project
Specs

Note 1

WPS/PQR
a) Review of Proposed Procedure

As per ASME Sec IX and


Project Spec

b) Welding of Test Coupons and subsequent testing


i) Carbon Steel
ii) Alloy Steel/ Stainless Steel
iii) All other materials icluding CS for H2 Service
c) Approval of final WPS/PQR
4

Welder Performance Qualification Test

Certification & Approval of welders before deployment


on job

NDT Procedure Qualification


a) Review of Proposed Procedure
b) Witnessing proposed Procedure Testing
c) Approval of Qualified Procedure

Joint Numbering for coils/Pressure Parts

As per ASME Sec IX and


Project Spec
As per ASME Sec IX and
Project Spec
As per ASME Sec IX and
Project Spec
As per ASME Sec IX and
Project Spec

As per ASME Sec V and


Project Specs
As per ASME Sec V and
Project Specs
As per ASME Sec V and
Project Specs
As per drawings and Project
Specs

Page 2 of 5

Note 2

SR. NO.

ACTIVITY DESCRIPTION
FABRICATION OF COIL
a) Materials as per specification ( check w.r.t.
approved colour coding procedure) and material
traceability
b) Dimensional checks
c) Fit-up checks for butt joints and socket joints
d) Fit-up checks for branch joints

EXTENT OF INSPECTION

REFERENCE DOCUMENT

As per approved drawing


and Project Specs
As per approved drawing
ASME B 31 & As per
approved drawing
ASME B 31.3 & As per
approved drawing

INSPECTION BY

REMARKS

MFG

TPI

MFG

JNK

TPI

EIL/ DORCL

100%

10%

HP

WC

100%

10%

HP

WC

100%

10%

HP

WC

100%

10%

HP

WC

Pre-heat (if any)

As per approved WPS & Preheat chart

100%

100%

HP

WC

Rw

Certificate of purity of purging/shielding gas (if any)

As per approved WPS & Test


Certificates

100%

100%

HP

WC

Rw

Purging rate ( if any) and arrangement

As per approved WPS

100%

HP

WC

Shielding rate ( if any)

As per approved WPS

100%

HP

WC

Baking of Electrodes

As per Project Specs

100%

HP

WC

Inter pass cleaning and Tempreature check

100%

10%

HP

WC

Rw

Visual Checks of completed welds

100%

10%

HP

WC

a) Monitoring of PWHT Cycle

100%

100%

HP

WC

Rw

As per approved WPS & Preheat chart


ASME B31.3 and Approved
Drawings
As per approved WPS

Page 3 of 5

SR. NO.

ACTIVITY DESCRIPTION

b) Review of Time-Tempreature graph

Hardness check
i) For CS Coils
ii) For AS Coils

10

EXTENT OF INSPECTION

REFERENCE DOCUMENT

As per approved WPS

As per ASME B31.3 &


Project Spec
As per ASME B31.3 &
Project Spec

INSPECTION BY

REMARKS

MFG

TPI

MFG

JNK

TPI

EIL/ DORCL

100%

100%

HP

WC

Rw

100%

10%

HP

WC

100%

10%

HP

WC

NDT
a) Penetrant Testing/ Magnetic Particle Testing ( as
applicable).

As per ASME Sec V &


Project Spec

100%

10%

HP

WC

b) Radiography Marking (for Random Radiography


only)

As per ASME Sec V Article 2


and Project Spec

100%

10%

HP

WC

ASME B31.3

100%

100%

HP

WC

HP

c) Radiography Interpretation/Review
d) Check Shot for Radiography, if applicable

ASME Sec V Article 2

100%

10%

HP

WC

Rw

ASME Sec V Article 4 and


Project Spec

100%

10%

HP

WC

As per Project Specs

100%

10%

HP

WC

HP

As per approved drawings

100%

10%

HP

WC

As per Project Specs


As per Project Specs

100%
100%

100%
100%

HP
HP
HP

WC
WC
WC

W
Rw
Rw

S
HP
Rw

As per Project Specs

100%

100%

HP

WC

Rw

HP

PMI Reports

100%

100%

HP

WC

Rw

Rw

e) Preparation of Punch list

As per Project Specs

100%

HP

WC

f) Review of Puch list prepared by Contractor

As per Project Specs

100%

100%

HP

WC

Rw

Rw

e) Ultrasonic Testing (as applicable)


11

Positive Material Identification for base material and


welds, as applicable

12

Final visual and dimensional tolerance

13

Hydrotest
a) Procedure Review
b) Correctness of Testing Arrangements
c) Scrutiny of test Packs for Mechanical & NDT
Clearance
d) PMI as per specifcation after completion of
installation

Page 4 of 5

SR. NO.

ACTIVITY DESCRIPTION

REFERENCE DOCUMENT

EXTENT OF INSPECTION

INSPECTION BY

REMARKS

MFG

TPI

MFG

JNK

TPI

EIL/ DORCL

As per Project Specs

100%

100%

HP

WC

Rw

HP

h) Review of Calibration Certificates of Pressure


Gauges

Test Certificates

100%

100%

HP

WC

Rw

HP

i) Field Calibration, if any

Test Certificates

100%

10%

HP

WC

j) Air/Water Flushing ( preliminary)

As per Project Specs

100%

10%

HP

WC

k) Visual inspection of all joints during


Hydro/Pnuematic Testing

As per Project Specs

100%

10%

HP

WC

HP

l) Draining of water and Air drying

As per Project Specs

100%

10%

HP

WC

m) Removal of Temporary Blinds/Supports

As per Project Specs

100%

10%

HP

WC

n) Boxing up including reinstallation of flappers of


check valves

As per Project Specs

100%

HP

WC

Test Certificates/ Project


Specs

100%

100%

HP

WC

Rw

Rw

p) Torque tightening/tensoning of flange joints,


wherever applicable

As per Project Specs

100%

10%

HP

WC

q) Modification of Tested lines

As per Project Specs

100%

100%

HP

WC

Rw

Rw

As per drawings

100%

10%

HP

WC

100%

100%

Rw

Rw

Rw

HP

Rw

g) Liquidation of check list, if applicable

o) Review of records and fasteners & gaskets

14

Final Marking, stamping quantity check, match marking

15

ITP Signed off

16 IRN Issue
100%
Notes:
1)
For Alloy steel & Stainless steel welding filler metals, chemical analysis to be carried out for every batch.
2)

Review of TPI for existing WPQ

3)

10% Extent of Inspection for TPI means,10% of each item ( Radiant Coils, Convection Coils, Crossovers, Inlet and Outlet Manifolds.)

Page 5 of 5