L. Mehta/ R.

Otto MECHANICAL

05-Oct-06
PLEASE CLARIFFY FOR WHICH EQUIPMENT NO. DOES THIS DOCUMENT INCLUDE MB-AYZ221-F01/F02 ? IF SO PLEASE INCLUDE.

0 0 0

PLEASE CLARIFFY AND MATCH SERVICE NAME, ITEM NO. AND DRAWING NUMBER. FOR EXAMPLE: DWG NO. F-06-1883-02-03 ITEM: MB-AYZ221-F01 SERVICE: CHARGE HEATER

PCK' s Do c . No . KIC' s Do c . No . Sheet No .

: K1053 - HFP- 0 02 : 20 06 L- DOC- 10 1 : 2 of 7

TABLE OF CONTENTS
1. SCOPE

PAGE
4

2. REFERENCES 2 . 1Req uisitio n 2 . 2Spec if ic a tio n 2 . 3Co d es a nd Sta ndard s

4 4 4

3. MATERIALS 3 . 1General 3 . 2Storag e o f Materials 4. FABRICATION 4 . 1General 4 . 2Pre- fabric atio n 4 . 3Straig htening 4 . 4Ma rking 4 . 5Cutting 4 . 6Bo lt Holes 4 . 7Bend ing 4 . 8Tolera nc es 5. WELDING 5 . 1General 5 . 2Co ntro l of Welding Consum ab les 5 . 3Weld ing Wo rks 5 . 4Rep air Wo rks f o r Weld ing Def ec ts 5 . 5Tolera nc es 5 . 6Co ntro l of Distortion and Shinkag e D ue to Weld ing

4 4 4 4 4 4 5 5 5 5 5 6 6 6 6 6 7 7 7

6. PAINTING 6 . 1Surfa c e Prep aratio n 6 . 2Painting Ap plic ation 6 . 3Painting Inspec tio n

7 7 8 8

7. PACKING 8. MARKING

8 8

PCK' s Do c . No . KIC' s Do c . No . Sheet No .

1. SCOPE

: K105 3- HFP- 002 : 2 00 6L- DOC- 1 01 : 3 of 7

This p roc ed ure d esc rib es the genera l req uirem ents f or Fab ric a tio n proc ed ure f or Steel Struc ture & End Tube Supp o rt f o r Charge Hea ter (F18 83), Strip p er Reb o iler (F1883), Charge, # 1 & # 2 Interhea ter (F188 3), whic h a re sup plied to Relianc e Jam nag er Ref inery o f RELIANCE PETROLEUM LIMITED in INDIA 2. REFERENCES req uirem ents o f this p ro c edure ; 2. 1P. O No. (1 )F0 61883 85- 0 6 2. 2Spec if ic ation No . (1 )229 60- 3PS- SS- 001 (2 )2- 1 2- 4 (3 )229 60- 3PS- GAW- 0 05 (4 )251 94- 3PS- GAW- 0 01 2. 3Cod es and Stand ards (1 )Steel Materials (2 )Bo lts and Nuts (3 )Weld ing Materia ls (4 )Weld ing Proc ess (5 )Pa inting (6 )API 560 3. MATERIALS 3. 1General New m aterial shall b e used. Old m a terials having any loss o f the ef fec tive thic kness d ue to rust o r po c km ark o n the surf ac e shall no t be used . Materials shall b e used ac c urately a s p er d im ensio n and shap es indic ated o n the ap p lic a ble d rawing s. 3. 2Sto ra ge of Materials Material sha ll b e stored o n the a dequate p la tf o rm in tidy and so und c o nd itions in o rd er to avo id d ef o rm ations, ero sions o r c orro sio ns and to prevent them f ro m m ixing with o ther unrelated m aterials. 4. FABRICATION 4. 1General Exec ution in this Item c overs yard o r worksho p f a bric atio n o f the vario us m em bers, c om po nents, f ram es, units, p arts etc . , tha t m ake up the req uired steel struc tures. 4. 2Pre- f ab ric a tio n Prior to proc eed ing with fa bric ation, la yout wo rk sha ll b e p erf orm ed in ac c o rda nc e with the sho p d etail d ra wing s. Cut size and length, lo c ation o f ho les, loc atio n o f stif f eners etc . , shall b e trac ed ac c urately o n pattern p la tes a nd/ o r steel strap s. The tap e line, to be used f o r la yout work, shall be a f irst c la ss ta pes. : : : : : : ASTM and / or JIS & KS JIS, KS, A NSI and ISO ASME, JIS and/ or AWS AWS D1. 1 - Struc tural Welding Co d e SSPC / ISO 8501 - 1: 1 98 8 / SIS- 0 5- 5 90 0 Fired Heaters f or General ref inery servic e Rev. No . 0 Rev. No . 7 4 12 1

The f ollo wing c o d es, sta ndard s and sp ec if ic atio ns o f the latest ed itons shall be ap p lied to and fo rm a part o f the

PLEASE CLARIFFY AND MATCH SERVICE NAME, ITEM NO. AND DRAWING NUMBER. FOR EXAMPLE: DWG NO. F-06-1883-02-03 ITEM: MB-AYZ221-F01 SERVICE: n Desc riptio CHARGE HEATER
Co nvec tio n. Mo dules & RAD. X- Over Pipes Desc riptio n Steel Struc ture Convec tion Sec tio n UOP Fired Hea ter Spec ific atio n Painting Sho p & Field Vend or Weld ing Proc ed ure

PCK' s Do c . No . KIC' s D o c . No . Sheet No .

4. 3Straig htening

: K105 3- HFP- 002 : 2 00 6L- DOC- 1 01 : 4 of 7

B ef o re m arking- of f , steel whic h enters the sho p f or f ab ric atio n sha ll be c hec ked fo r c onf o rm ity w ith the stand ard s. Any d am a ged o r d isto rted m ateria l sha ll b e rep lac ed. 4. 4Marking The m arking with pa ttern p lates and / o r stra ps whic h were p rovid ed at la yout work, shall be p erf orm ed a c c urately o n the steels. 4. 5Cutting 4 . 5 . 1The f ollo wing eq uip m ent are suita bly used fo r the purp ose o f c utting and f ab ric ation. (1)Cutting Mac hine (2)Shea ring Mac hine (3)Auto Oxyg en Cutter (4)Oxyg en Cutter : : : : Ang les, Channels and H- beam Shap es Plates and Flat bars of Pro p er thic kness Plates and Flat bars of Pro p er thic kness Misc ellaneo us, Multi p urpo se

4 . 5 . 2Cutted edg e shall b e straig ht a nd f ree f ro m slag and no tc h. Def ec ts in c utted ed g e sha ll be rep aired b y weld ing and / o r g rind ing . 4 . 5 . 3Wa rp ing and bending shall be rem o ved a fter c utting. 4 . 5 . 4Plate c utting arrang em ent shall be m ad e so c arefully that m ain weld lines shall no t c o m e to the lo c ation of op ening s. 4. 6B olt Ho les 4 . 6 . 1The f ollo wing eq uip m ent are suita bly used fo r the purp ose o f fa bric atio n. (1)Multi Boring Mac hine (2)Punc hing Mac hine (Plate Thic kness 12m m o r Under) (3)Hand y Bo ring Mac hine 4 . 6 . 2The spec ified size of ho les shall b e drilled and / o r punc hed ac c urately a t c learly m arked on the steel. 4 . 6 . 3Bo lt ho les in adjointing f lang es, jo ints and sp lic es shall be drilled as p o ssib le as to gether. 4 . 6 . 4The rim s of ho les shall b e c lea ned c o m p letely b y grind ing. 4. 7B end ing 4 . 7 . 1The f ollo wing eq uip m ent are used f o r b end ing p rop erly. (1)Hig h f req uenc y b end ing m ac hine (2)Oil p ress m ac hine (3)Oil jac k 4 . 7 . 2As a rule b end ing shall b e p erf orm ed by c o ld b end ing m etho d . Bending o f steel b y a hot proc ess m ay be a pproved if it is dem onstrated that the pro c ess will no t red uc e the prop erties of the steel b elow those sp ec if ied. Ho t b end ing sha ll b e d o ne in the tem perature ra nge o f 900 thro ug h 1, 100 .

4 . 7 . 3The m inim um insid e b end ing rad ius of steel plate shall b e 3 tim es the p late thic kness. 4. 8To leranc es Struc tural c o m p onents shall satisfy the to lera nc e lim its o f ATTA CHMENT # 1 " Fabric ation Toleranc es" , unless sp ec if ied otherwise on the Desig n Drawing s.

PCK' s Do c . No . KIC' s Do c . No . Sheet No .

5. WELDING 5. 1General WPS/ PQR shall be subm itted f or a pproval.

: K1 05 3- HFP- 002 : 2 006L- DOC- 1 01 : 5 of 7

A ll struc ture weld ing shall b e do ne in ac c o rd anc e with AWS D 1. 1 and a pp ro ved WPS. Weld ing w orks shall b e p erf orm ed by weld er only who has p assed p erf orm anc e q ualific atio n tests with AWS D1 . 1. A nd a weld er list whic h c ertif ies the qualif ic atio n of eac h weld er sha ll be subm itted f or ap p ro val b ef o re weld ing is started. Weld ing elec tro d es shall have a c hem ic al c om po sitio n m atc hing that o f the b ase m etals b eing joined . Weld ing elec tro d es shall c onf orm to the req uirem ents of a pp ro ved WPS. 5. 2Contro l of Welding Co nsum ab les (1 )Elec trod es sha ll be c learly identif iab le in c olo r c lassif ic atio ns and und isting uishab le elec trod es shall no t b e used. (2 )All c onsum ab les shall b e sto red and hand led with c a re. (3 )Elec trod es, f iller wires that show sig ns of dam ag e o r d eterio ra tion, i. e. c rac ked o r f laked c o atings on c overed elec tro d es, rust o r d irty elec tro des shall b e d isc a rded . (4 )If the c overed elec tro d e ha s b een exp osed to the am bient a ir f or m ore than f our ho urs, they shall b e d ried ag ain p rior to use. (5 )Rem ained elec trod es sha ll be returned to sto ra ge at the end o f welding work. 5. 3Welding Wo rks (1 )Slag, m o isture, dust, rust or o ther fo reig n m aterials on the surf ac es to be weld ed shall be rem oved b y p rop er m etho d suc h a s grind er or wire brush. (2 )In c ase o f b utt weld ing joint, ed ge p repa ratio n sha ll be d o ne ac c urately in ac c o rd anc e with the req uirem ents of WPS and relevant draw ings. Plate over 6m m thic kness shall b e b eveled f o r butt- weld ing. (3 )Edge p rep aration shall be m a de b y g ouging, g as c utting a nd g rind ing. Ed g e prep aration shall b e finished b y grind ing . (4 )Butt weld sha ll sec ure f ull weld ing penetration so that the f ro nt and b ac k weld ing ha ve to m a ke full alignm ent. (5 )Co m plete joint p enetratio n groo ve weld s to b e m a de witho ut the use of bac king shall b e roo t g o ug ed b ef o re the b ac kside weld ing . (6 )Fillet weld shall b e p erf o rm ed in ac c ord anc e with AWS D1 . 1 and WPS. (7 )In p rinc ip le, weld ing p osition shall b e p erf o rm ed b y typ e o f flat, horizontal or vertic al a s p rac tic able. In vertic al po sition, only up- hill p ro g ressio n shall b e ap p lied . (8 )Weld ing m etho d and wo rking sequenc e shall be d ec id ed so as to m inim ize residual stress, and welding shall b e p erf orm ed witho ut c ausing any defec ts and d efo rm atio ns. (9 )In any c a se c rac ks should oc c ur to the tac k- w eld ed b ea d, they sho uld be rem oved up to the bo tto m o f d epo sit m etal and weld ed . (10 )For straig htening up o f distortio n af ter welding , the d isto rtion c aused in weld ing wo rk sha ll b e c orrec ted in the fo llowing trea tm ents. a. Mec ha nic al Treatm ent b . Heating Trea tm ent :b y m ea ns o f press :b y m ea ns o f gas b urner as m ea sured by therm o- m elt c rayon o r suitable m eans.

Heat treatm ent sha ll be p erf o rm ed the tem p erature whic h do es not injure the m a terial. Heating tem p erature shall not exc eed 6 50

PCK' s Do c . No . KIC' s Do c . No . Sheet No .

5. 4Rep air Works fo r Weld ing Def ec ts

: K105 3- HFP- 002 : 2 00 6L- DOC- 1 01 : 6 of 7

A f ter the c o m p letio n o f weld ing, slag and spatter shall b e rem o ved and c leaned up b y prop er m etho d . In c ase defec t is f ound out it sha ll b e rep aired b y the fo llowing m ethod . Repair Method Kind o f Def ec ts Surfac e f laws of base m etal Lam ina tio n c ra c ks Arc strikes Crac ks in weld (inc lud ing tac k weld) and b ase m etal Overlap and exc essive c o nvexity Exc essive c onc a vity o f weld o r c rater und ersized welds, und erc utting Exc essive weld p o ro sity, exc essive slag inf usio n inc o m p lete f usion 5. 5To leranc es Workm anship to leranc es in assem bly o f weld ed jo ints and q uality of the weld s shall satisfy the req uirem ents o f AWS D1. 1. 5. 6Contro l of Distortio n and Shinka ge Due to Weld ing (1 )Disto rtio n and shrinkage shall b e c o ntro lled in stric t ac c o rda nc e with the p ro visio ns of the ap plic ab le weld ing c o d e. Spec ia l c are shall b e taken to m inim ize p la tework d isto rtio n d ue to stiff ener weld ing. (2 )Entities d istorted by weld ing shall b e straightened in the sho p , in ac c o rd anc e with the provisions o f the ap p lic a ble weld ing c o de. 6. PAINTING Painting wo rks shall b e do ne in ac c o rd a nc e with req uirem ents of p ainting p ro c ed ure 2006 L- DOC- 10 5 / Painting and Rust Preventio n Proc ed ure 6. 1Surfac e Prepa ra tio n 6. 1 . 1All c o nvec tio n m o dule o f steel struc tures shall be b last c lea ned in ac ord anc e with g ra de o f SSPC- SP1 ~ 10 . 6. 1 . 2Pro file ro ughness should be 25 1)G40 - G80 steel grit 2)S110 - S23 0 steel sho t 6. 1 . 3High pressure a ir b lo wing sha ll be d one to rem o ve d usts and residues af ter b lasting . 6. 1 . 4Prio r to blasting o il, g rease etc shall be soaked with so lvent c o m p letely. 6. 1 . 5Blasted surf ac es should b e c oated a s so o n as p ossib le and shall not b e allowed to rem ain un- c o ated m o re than 4 hours. 7 5 m ic rons pro p erly. Treatm ent Af ter surfac e f laws are rem o ved b y air a rc go uging o r grinding a nd w elded , the weld m eta l shall be gro und . The base m etal with lam ina tio n c rac ks sha ll b e c hanged to new b ase m eta l Cra c ks o r b lem ishes c aused by a rc strikes shall be gro und to a sm o oth c o nto ur a nd c hec ked to ensure sound ness. The extent o f c rac ks sho uld be asc ertained and rem o ved inc lud ing 50m m fro m eac h side o f them by air c a rb on go uging o r g rind ing and re- weld ed. Exc ess weld m etal shall be rem o ved b y grind ing. Surfac e shall b e ground and ad ditio nal weld m etal shall be depo sited . Unac c ep table po rtion shall be rem o ved b y air c arb on arc go uging o r g rind ing and re- weld ed.

For ab ove p ro f ile suita ble a brasives sha ll b e selec ted as f ollo ws :

PC K' s D o c . No . KIC' s Do c . No . Sheet No .

6. 2 Pa inting Ap p lic atio n 6. 2. 1Painting works shall no t b e d o ne und er f ollowing weather c ond itio ns : (1 )When am bient tem p erature is ab ove 4 9 and belo w - 5 . . (2 )When steel surfac e' s tem p erature is ab o ve 54 (3 )When surf ac e s tem perature is no t higher than 3 (4 )When hum idity is 5 0~ 95% . and b elow - 5

: K1 053 - HFP- 0 02 : 2 006 L- DOC- 1 01 : 7 of 7

ab ove dew po int tem p erature.

6. 2. 2Airless sp ray m etho d shall b e used in p ainting exc ept d if fic ult area where no t to be c o vered b y spray g un.

These areas sho uld b e c o ated by b rush p rio r to sp ray c o ating .

6. 3 Pa inting Insp ec tio n The f ollow ing insp ec tio ns shall b e d one d uring p ainting wo rks. 6. 3. 1Paint Materia ls 1)Batc h Num ber 2)Shelf Lif e 3)Co lo r 6. 3. 2Surf ac e Prep aratio n 1)Surfac e Prof ile (Anc ho r Pattern) 2)Prep aration Grad e 6. 3. 3Painting Wo rk 1)Finished surf ac es shall b e unif o rm and sm o o th f ree from d ro p s, run, rid g es, w aves, lap s, wrinkles, b rush m arks, and o ther defec ts. 2)Finished surf ac es shall b e unif o rm c o lors that p resent g oo d ap p earanc e without sp ots, stains and d isc o loratio n. 3)D ry f ilm thic kness shall b e c hec ked in ac c o rd anc e with spec ified DFT b y m a gnetic typ e o f ga uge. 7. PACKING Fab ric a ted steel shall be pac ked with spec ial c are to avo id any d am ages d uring transpo rtation. Eac h c ased type m o d ules shall b e reinf orc ed stric tely in ac c o rd anc e with relevant d rawing a nd instruc tio ns. Pac king item s shall b e stric tly c hec ked with supp ly list. Up o n c om pletion of pac king , witness inspec tion shall b e g iven. 8. MARKING Ac c ording to the typ e designated b y stenc il o r m etal level shall be p ut a s ship ping m a rk. Tag Plate shall b e attac hed a t the end of c ased typ e m o dules and eac h pa c kag e.