Fabrication, Testing & Supply of the Tube Bundle for Heat

exchanger EA2006/EA42006

Specification No: Revision

MRPL/HCUI/EA2006/EA42006

Spare Tube Bundle for EA2006/EA42006

Scope of Supply of vendor/Manufacturer:

Fabrication, Testing & Supply of the Heat Exchanger Tube Bundle for First Stage
Intercooler EA42006. Detailed Fabrication Dimensions are as per Drawing No.:-GA-
3090 Rev 3. .(dummy shell used for hydro test shall be supplied along with tube
bundle)

Please Note that Material of Construction are as per the enclosed Sheet
Sl Description Qty
1 Tube Bundle for Heat Exchanger EA42006
No of Tubes – 118 U Tubes
Tube Sizes: 19.05 mm ODx2.11mm thk (Min) –
6000mmLg.
Tube Matl: ASTM A179/ ASME SA179 One
Tube Sheet Matl:SA350 LF2
Dimensions as per Enclosed Drawing : GA-3090 Rev
3.
Material of Construction As per Enclosed
Dwg.(dummy shell used for hydro test shall be
supplied along with tube bundle)

Inspection by Third party agencies at vendor/Manufacturer shop completely in

the scope of vendor/manufacturer :
Stage wise Inspection by one of the following Third Party Like M/s EIL,M/s LRIS ,M/s
BVIS,M/s TUV ,M/s IRS, M/s DNV only.

Extent of Third Party inspection for EA2006/EA42006 is as follows

a. Review of Quality Assurance Plan (QAP). Approval of QAP shall be by MRPL.
b. The drawing shall be approved by MRPL before manufacturing.
c. Review of test certificate for traceability of material meeting original material
specification for all pressure parts
d. Review of Heat Treatment report as per material specification.
e. If the material is sourced from vendor other than manufacturer, then selection of
samples (minimum two samples from each heat/lot) for mechanical and
chemical (product analysis) test. All Mechanical test required as per the
applicable material specification shall be carried out and witnessed by TPI.
Product chemical analysis report shall be reviewed.
f. Review of hydro test certificate of tubes.
g. Inspection of tube sheet after machining.
h. Witnessing shear load test and approval of tube expansion procedure. Review of
procedure, if already developed/approved procedure is available.

Page 1
 Fabrication, Testing & Supply of the Tube Bundle for Heat
exchanger EA2006/EA42006

Specification No: Revision

MRPL/HCUI/EA2006/EA42006

i. Review of WPS/PQR
j. Stage wise inspection during fabrication as per QAP.
k. Inspection for dimensional conformance.
l. Witness hydro-test of tube bundle assembly and shell (dummy) test.
m. Issue product release note giving details of inspections carried-out.
n. The raw material used for manufacturing tube bundle shall be from the
mills/shops of INDIA/USA/JAPAN or EUROPE.

LIST OF DRAWINGS ATTACHED

a) GA-3090 REV 3/ GA-2973 REV 5.
b) Spec, 00-ES-4005 Rev1
c) Inspection and Test Plan for Heat Exchanger Tube Bundles

Page 2
 INSPECTION AND TEST PLAN
FOR HEAT EXCHANGER TUBE BUNDLES
 Scope of Inspec!on
Sl. Inspec!on Method of Quantum of Reference Acceptance Manufactur-
No. Ac!vity/ Stage Component Characteris!c Check Check Document Criteria Record er TPI
1 General
ASME Sec!on VIII. ASME Sec!on VIII.
Drawing & Div.1 Ed.2017/ TEMA Div.1 Ed.2017/ Drawing &
Calcula!on 9th Ed./ API 660 TEMA 9th Ed./ API Calcula!on
1.1 Approval Ed.2015 660 Ed.2015/ PO Document H H
Inspec!on and Inspec!on and
1.2 Test Plan Review of ITP Test Plan H H
2 Procedure
ASME Sec!on IX
Welding Review of WPS, PQR Ed.2017/ Approved ASME Sec!on IX WPS/ PQR/ New-H,
2.1 Procedure and WPQ 100% Drawing Ed.2017 WPQ H Old-R

ASME Sec!on V & VIII ASME Sec!on V &

Non Test Procedure, Ed.2017/ TEMA-R/ VIII Ed.2017/
Destruc!ve Requirement and PO/ TEMA-R/ PO/ New-H,
2.2 Tes!ng Parameters 100% Approved Drawing Approved Drawing Test Procedure H Old-R

ASME Sec!on II Part ASME Sec!on II Part

% Expansion, A/B/C/D, TEMA-R/ A/B/C/D, TEMA-R/
Desctruc!ve Mock-Up Hardness, Pull Test, API 660 Ed.2015/ API 660 Ed.2015/ New-H,
2.3 Tes!ng Coupon Impact Test 100% Approved Drawing Approved Drawing Test Procedure H Old-R

ASME Sec!on II Part ASME Sec!on II Part

Heat Requirement, Cycle, A/B/C/D, TEMA-R/ A/B/C/D, TEMA-R/ Heat
Treatment Temperatures and API 660 Ed.2015/ API 660 Ed.2015/ Treatment New-H,
2.4 (If Applicable) Parameters 100% Approved Drawing Approved Drawing Procedure H Old-R

ASME Sec!on II Part ASME Sec!on II Part

Test Procedure, A/B/C/D, TEMA-R/ A/B/C/D, TEMA-R/
Requirement and API 660 Ed.2015/ API 660 Ed.2015/ New-H,
2.5 Pressure Test Parameters 100% Approved Drawing Approved Drawing Test Procedure H Old-R

INSPECTION AND TEST PLAN Rev.0 2018

HEAT EXCHANGER TUBE BUNDLES Page 1 of 4

 Scope of Inspec!on
Sl. Inspec!on Method of Reference Acceptance Manufac-
No. Ac!vity/ Stage Component Characteris!c Check Quantum of Check Document Criteria Record turer TPI
3 Raw Material Inspec!on/ Iden!fica!on
Marking and
All Pressure Correla!on with
Parts (Plates/ TC, Marking
Raw Material Tubes/ Transfer and PO & Material PO & Material Inspec!on
3.1 Inspec!on Forgings) Review of TC Visual 100% Specifica!on Specifica!on Report W H
All Pressure
Parts (Plates/
Raw Material Tubes/ Visual and PO & Material PO & Material Inspec!on
3.2 Inspec!on Forgings) Dimensional Check Visual 100% Specifica!on Specifica!on Report W H
Spectro,
Tensile,
Hardness,
Chemical & Fla#ening, ASME SA450/ ASME SA450/
Destruc!ve Mechanical Flaring, Material Material Laboratory
3.3 Tes!ng Tubes Proper!es IGC Test (SS) 2 Tubes at Random Specifica!on Specifica!on Report W H
2 Tubes (Highest
Destruc!ve Thickness & Highest
Tes!ng (For Corrosion Carbon/ Heat Laboratory
3.4 Stainless Steel) Tube Proper!es IGC Test Treatment lot) ASTM A262 ASTM A262 Report W H
Marking and
All Non- Correla!on with
Raw Material Pressure Parts TC, Visual and PO & Material PO & Material Inspec!on
3.5 Inspec!on (Plates/ Tubes/ Dimensional Check Visual 100% Specifica!on Specifica!on Report W R
4 In-Process
Tube-hole
Diameter, Surface
Finish, Groove
Depth, Spacing,
Ligament Check PO, Approved PO, Approved
Machining/ and Posi!onal Bore Gauge/ Drawing and Drawing and Inspec!on
4.1 Drilling Tubesheet Accuracy Vernier 100% TEMA-R TEMA-R Report H W

INSPECTION AND TEST PLAN Rev.0 2018

HEAT EXCHANGER TUBE BUNDLES Page 2 of 4

 Scope of Inspec!on
Sl. Inspec!on Method of Reference Acceptance Manufac-
No. Ac!vity/ Stage Component Characteris!c Check Quantum of Check Document Criteria Record turer TPI
Hole Diameter and
Surface Finish, Lig- PO, Approved PO, Approved
Machining/ ament Check and Bore Gauge/ Drawing and Drawing and Inspec!on
4.2 Drilling Baffles Posi!onal Accuracy Vernier 100% TEMA-R TEMA-R Report W W/R
Tube Bundle
Skeleton As- Completeness of
semby - Before Assembly, Spacing, Visual & PO & Approved PO & Approved Inspec!on
4.3 Tube Inser!on Tube Bundle Dimension Dimensional 100% Drawing Drawing Report W W/R
Tube Bundle Alignment,
Assemby - A'er Completeness of Visual & PO & Approved PO & Approved Inspec!on
4.4 Tube Inser!on Tube Bundle Assembly Dimensional 100% Drawing Drawing Report H W
PO & Approved PO & Approved
% Expansion, Bore Gauge/ Drawing, Material Drawing, Material
Hardness, Shear Vernier, Pull 100%/ Min. 3 Tests Specifica!on, Specifica!on,
Desctruc!ve Mock-Up Strength, Impact Test, Impact per Coupon ASME Sec.VIII, ASME Sec.VIII, Laboratory
4.5 Tes!ng Coupon Proper!es Test (Pull Test) API 660 Ed.2015 API 660 Ed.2015 Report W H
Approved Approved
Tube-to- Soundness, Procedure, Procedure, Inspec!on
4.6 Welding Tubesheet Weld Workmanship Visual 100% Approved Drawing Approved Drawing Report H W
Post Weld Heat Heat Treatment
Treatment Tube-to- Cycle (Time & Furnace PO & Material PO & Material Inspec!on
4.7 (If Applicable) Tubesheet Weld Temperature) Recorder 100% Specifica!on Specifica!on Report W R
Destruc!ve PO, Approved PO, Approved
Tes!ng (If PWHT Tube-to- Mechanical Random (10%), Drawing & Material Drawing & Materi- Laboratory
4.8 is applicable) Tubesheet Weld Proper!es Hardness Test Minimum 10 tubes Specifica!on al Specifica!on Report W H
% Thinning, % and PO, Approved PO, Approved
Tube-to- Length of Bore Gauge/ Random (10%), Drawing and Drawing and Inspec!on
4.9 Expansion Tubesheet Expansion Vernier Minimum 10 tubes TEMA-R TEMA-R Report W H
PO, Approved PO, Approved
Tube-to- Drawing, API 660 Drawing, API 660
Tubesheet Pneuma!c Ed.2015 and Ed.2015 and Inspec!on
4.10 Leak Check Welds Leak Check Test 100% TEMA-R TEMA-R Report W H

INSPECTION AND TEST PLAN Rev.0 2018

HEAT EXCHANGER TUBE BUNDLES Page 3 of 4

 Scope of Inspec!on
Sl. Inspec!on Method of Reference Acceptance Manufac-
No. Ac!vity/ Stage Component Characteris!c Check Quantum of Check Document Criteria Record turer TPI
5 Final Inspec!on
Surface Condi!on,
Dimensions,
Completeness of Visual, PO & Approved PO & Approved Inspec!on
5.1 Final Inspec!on Tube Bundle Equipment Dimensional 100% Drawing Drawing Report W H

Inspec!on
Hydrotes!ng PO & Approved PO & Approved Report/ Hy-
5.2 (Shell Side) Tube Bundle Leak Check Visual 100% Drawing Drawing drotest Graph W H
Equipment Dryness, PO & Approved PO & Approved Inspec!on
5.3 Drying Tube Bundle Cleaniness Visual 100% Drawing Drawing Report W R
An!-Corrosion PO & Approved PO & Approved Inspec!on
5.4 Coa!ng Tubesheet Workmanship Visual 100% Drawing Drawing Report W W
Tube Bundle +
Dummy Shell PO & Approved PO & Approved Inspec!on
5.5 Nitrogen Filling Assembly Gas Pressure Visual 100% Drawing Drawing Report W W
Stamping Details PO & Approved PO & Approved Rub-Off of
5.6 Final Stamping Tube Bundle Verifica!on Visual 100% Drawing Drawing Stamping W W
6 Documenta!on
Verifica!on/
Compila!on of Purchase Order & Purchase Order & Documents
Inspec!on & Test Vendor Vendor as per PO and
6.1 Documenta!on Records Requirements Requirements Vendor W H
Legend: R:Review, W:Witness, H: Hold (Offer for Witness and Obtain Clearance)
In case of conflict between Purchase Specifica!on, Contract documents and ITP, more stringent condi!ons shall be applicable.

INSPECTION AND TEST PLAN Rev.0 2018

HEAT EXCHANGER TUBE BUNDLES Page 4 of 4