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HRPU/NFC/PT/ENG/11432 SCOPE Procurement of raw materials & welding consumables, fabrication, inspection, testing and supply at Central Stores, NFC, Hyderabad for NZSP of the following item as per the technical specification mentioned herein & as per the drawing:
Description
Drawing No.
Qty (Nos.) 14
1.1 210004872 Reduction Retort B-NZSP-DWS-872 R2 Top Closure 2. 0 Applicable standards and codes:
a) a) ASME Boiler and pressure vessel code Sec VIII Div I, for fabrication, inspection and testing of the equipment including radiography etc. b) b) ASME Boiler and pressure vessel code Sec V for inspection & testing standards and procedures. c) c) ASME Boiler and pressure vessel code Sec IX for welder and welding procedure qualification. d) d) ASME Boiler and pressure vessel code Sec II for specifications and testing of materials of construction and consumables. e) e) ASTM A 262 for inter granular corrosion testing. f) f) ASME Section-V SA 578 for ultrasonic testing of plates. 3.0 Materials of construction. 3.1 3.1 The stainless steel plates shall conform to SA-240 & SA-480 of ASME Section-II Part A & the additional requirements specified in the drawings and shall be in solution annealed and pickled condition. The restriction on minimum carbon of 0.04%, Grain size, requirement of IGC test as per ASTM A262-practice-E, Ultrasonic testing as per ASME SA 578-Level-B etc shall be as specified in the respective drawings. 3.1.1 3.1.1 The plates shall be free from surface defects like pits, cracks, laminations and inclusions. If any grinding is done to remove these defects, it shall be ensured that there is a smooth merger of the ground surface with the remaining surface and thickness is within the tolerance limits of ASME SA 480.
3.2 3.2 The cooling jacket pipes need to be checked for chemical composition alone & shall conform to SA 312 of ASME section-II., All pipes /tubes shall be in the solution Annealed & pickled condition Each air cooling coil (part no 4,5&6 of drawing no B-NZSP DWS-872 R2) shall be Seamless and of single piece without welding .It shall confirm to SA312 of ASME Sec ll. The pipes shall satisfy the eddy current testing requirements confirming to SA-999 of ASME Section V with reference standard as through and through drilled holes of 0.8 mm dia , at 120 degs .apart and separated by appropriate distance .The holes should not have any burrs. 3.3 3.3 All the welding consumables used for welding shall conform to SFA 5.4 / 5.9 of ASME Sec II C and shall be of standard make like Advani, L&T, D&H, Rajratna, ESAB etc.
3.3.1
E 317/ ER 317 welding consumables shall be used for welding AISI 317 to AISI 317 & AISI 304. E 308/ ER 308 welding consumables shall be used for welding AISI 304 to AISI 304.Welding consumables for welds between shell and bottom plates shall be either ER NiCr3 or E NiCr3. welding consumables for welds and flanges shall be ER317/E317. . 4.0 4.0 Pre-Fabrication requirements: 4.1 4.1 The vendor shall submit a detailed manufacturing procedure, any additional working drawings, QC plan & stage wise check lists and documentation formats along with time schedules to the purchaser for approval before fabrication. 4.2 Manufacturing procedure shall include the detailed procedure of manufacture, the equipment used and the tolerances that are maintained at various stages of manufacture to achieve the final required specifications. 4.3 QC plan shall detail the procedures for carrying out inspection and testing at various stages. 4.4 Templates, metrology instruments and testing consumables used in DP test, etc. shall need to be approved by the purchaser. 4.5 The welder and welding procedure shall be qualified as per ASME Sec IX. However, if valid documents of welder and welding procedure qualification carried out as per ASME Sec IX by QA, NFC or any other agency acceptable to the purchaser are already available with vendor, clearance for welding will be given on the basis of these documents. Fabrication 5.1 The fabricated components shall be numbered as per the identification number given by the purchaser, The number shall be legibly marked by welding on the edge of the bolted flange. 5.2 The edges/ surfaces to be welded shall be cleaned thoroughly using acetone/ TCE before welding. Wire brush, if used for cleaning, shall be of stainless steel only. D.P. check shall be conducted on the weld chamfers, root pass, back gouged surface & final passes of all the welds.. 5.3 After completion of welding, the inside weld reinforcement of all the welds shall be ground flush with the parent material if specified in the drawing.
4.2
4.3
4.4
4.5
5.2
5.3
5.4 The components after fabrication shall be free from injurious defects such as dents, Pits, handling marks, remain of fixtures etc. 5.5 Repairs: If the number of repairs on any weld during entire fabrication is more than three, the welder and welding procedure shall be re-qualified. The vendor shall not carry out any weld repairs without the prior approval of the repair procedure from the purchaser. 6.0 6.0 Inspection & Testing: Inspection & documentation by the vendor shall include the following checks before, during and after fabrication:
6.1
6.1 Inspection of materials of construction ie ( visual, dimensional, chemical, mechanical. IGC, grain Size & U.T )wherever required on the samples taken. 6.2 Accuracy of templates / Marking / cut-outs.
6.2
6.2.1 Dimensional checks / Alignment / Ovality /Skew ness/Flatness/Finish before & after (a) Assembly (b) Welding (c) Machining & (d) Final fabrication.
6.3
D.P. Inspection of edge preparation , root pass, back gouged surface & final welds. DP test shall be carried out by colour contrast penetrant technique using solvent removable penetrant systems. 100% DP test shall be carried out on all the welds. Any unacceptable defect shall be corrected as per the procedure approved by the purchaser followed by re-test to ensure that the defects are within acceptable limits. The dye , developer and cleaner used for DP test shall be of reputed brands like Megnaflux , P Met (or any other brand approved by the purchaser ) and spray type only and shall confirm to the specifications given in ASME Sec V .
6.4 6.5
Pressure test of cooling jacket and cooling coils as specified in the drawing. Leak test .of the completely fabricated top cover along with retort at pneumatic pressure of 200 mm Hg(gauge ) and a vacuum of 700 mm Hg The leak rate shall be restricted to less than 0.1 torr lit / sec. This will be carried out NFC Welding consumables; one sample / specimen of welding consumables / weld deposit from each heat; nominal diameter and batch shall be tested for chemical composition / mechanical properties as specified in SFA 5.4 / 5.9 of ASME section II. Test certificates pertaining to the chemical compositions /mechanical properties shall be furnished by the vendor to the purchaser . Welder and welding procedure, qualification: Welder and welding procedure qualification shall be in accordance with ASME section IX . Welding of the test coupons shall be done in the presence of the Representative of the approved third party QA agency and all the documents connected with the qualification, including formats (duly filled) and evaluation reports counter signed by the QA agency, shall be submitted by the fabricator to the purchaser for verification. Production welding shall be taken up only after clearance from the purchaser.
6.6
6.7
6.8
Hold points for inspection. Following shall be the hold points for stage wise inspection.
6.8.1 Pre-fabrication : a) Raw material clearance b) consumable clearance c) approval of manufacturing engineering Instructions and QC plans . d) Welders and welding procedure qualification 6.8.2 In process clearance: a) Shells inspection. b) Flange clearance
c) Fit up at all assembly stages. d) Final inspection of all welds. e) Leak testing of cooling jacket 6.8.3 Documentation: a) a) At Pre-fabrication stage b) b) In process c) c) Post fabrication Note: The above are only indicative . The actual hold points shall be as per the QC plan submitted by the Vendors and approved by the purchaser. 7.0 7.1 GENERAL: All the materials of construction shall be procured from the manufacturers/ authorized agents of manufacturers. Local traders shall be avoided The material shall be neatly stocked by the vendor with proper identification marks to avoid mix-up and to ensure correct usage . The vendor shall give the details of Sub-contractor in case of any sub-contract and the sub-contractor shall be approved by the purchaser before subcontracting. Final approved drawings with / without minor revisions will be given to the vendor on placement of order. The vendor shall strictly comply with the approved drawings , specifications and codes and shall maintain and submit complete documentation of fabrication, inspection and testing at every stage up to the final product. Inspection shall be carried out at various stages by NFC representatives as per agreed QA plan , and authorized for final clearance to the vender . Quantity may be split among parties while making recommendation . Minimum order Qty shall be clearly mentioned by the vender in his offer.
7.2
7.3
7.4
7.5
7.6