Professional Documents
Culture Documents
E1461 Dossier.
E1461 Dossier.
E1461 Dossier.
SURIA ENGINEERING
DOSSIER FOR E1461 Re-tubing
ENGRO POLYMER
CLIENT:
KARACHI - PAKISTAN
www.suriaengineering.com
2|Page
TABLE OF CONTENTS
DOC NO.:-QC-FIL-001
5. UFD OF CONNECTION 17
1. QUA
LITY
INPE
CTIO
N
PLA
N
5|Page
S U R IA E N G IN E E R IN G
W E L D IN G P R O C E D U R E S P E C IF IC A T IO N (W P S )
C li e n t: EPCL D a te :
W e ld in g P r o c e d u r e S p e c ific a tio n N o .: S E -Q C -W P S -E 1 4 6 1 -0 1 P ro je c t
R e v is io n : S u p p o r tin g P Q R N o .: S E - Q C - P Q R - E 1 4 6 1 -02
W e ld in g P r o c e s s ( e s ) : G TAW T y p e (s ) : M anual
C ode / STD : A s p e r A S M E S e c tio n IX
N o te :
a = 1 .5 m m
t = 2 .0 m m
A c c e p ta b le w e ld jo i n ts w h e r e a is n o t le s s t h a n 1 . 4 t
W e ld J o i n t T y p e a n d D e t a ils : S t r e n g t h W e ld , t u b e t o t u b e s h e e t
B A S E M E T A L (Q W .4 0 3 )
P .N O . 1 G ro u p N o . 1 to P .N o . 1 G ro u p N o . 2
O R
S p e c ific a tio n ty p e a n d G r a d e A 17 9
to S p e c ific a tio n ty p e a n d G r a d e S A -5 16 G r 7 0
O R
B a s e M e t a l: T u b e : 2 0 m m T u b e S h e e t: 3 2 m m th ic k n e s s F ille t A ll th ic k n e s s
D ia m e te r o f T u b e : A ll O th e r
T u b e H o le s : 2 5 m m T r ia n g u la r P itc h
F IL L E R M E T A L S PO STW ELD H E A T TR E A TM EN T
( Q W .4 0 4 ) (Q W .4 0 7 )
G TAW SM AW
R O O T H O T PA SS F IL L /C A P R O O T F IL L CA P T e m p e ratu re R a n g e : N /A
S p e c . N o . (S F A ) 5 .1 8 5 .1 8 T im e R a n g e : N /A
A W S N o . ( C la s s ) E R -7 0 S -3 E R -7 0 S -3 S o a k in g T im e a t M a x T e m p : N /A
F .N o . 6 6
A .N o. 1 1
S iz e o f F ille r M e t a ls 1 .6 m m 1 .6 m m G AS
W e ld M e ta l G T A W -0 7 4 8 2 4 G T A W -0 7 4 8 2 4 (Q W -4 0 8 )
F ille t A ll T h ic k n e s s A ll T h ic k n e s s S h ie ld in g G a s ( e s ) : A rgo n
E le c tr o d e F lu x (C la s s ) BAR E M ETAL P e r c e n t C o m p o s itio n ( m ix tu r e ) : 9 9 .9 0 %
F lu x T ra d e N a m e M A G M A W E L D /L IN K O N / E SS A B F lo w R a t e : 8 - 1 0 L I T / P .M
C o n s u m a b le I n s e r t ` G a s B a c k in g : N /A
O th e r T r a i li n g S h i e l d in g G a s C o m p o s i t i o n : N /A
E a c h b a s e & f ille r m e t a l c o m b in a t io n s h o u ld r e c o r d in d iv id u a lly
Q W .4 8 2
P O S I T I O N S ( Q W .4 0 5 ) P O S T W E L D H E A T T R E A T M E N T ( Q W .4 0 7 )
P o s itio n ( s ) o f G r o o v e S p e c ia l T e m p e ra tu re R a n g e
W e ld in g P o s itio n : 5F T im e R a n g e -
P o s it io n ( s ) o f F ille t t u b e s h e e t v e r t ic a l, t u b e h o r iz o n t a l
P R E H E A T ( Q W .4 0 6 ) G A S ( Q W .4 0 8 )
P e r c e n t C o m p o s itio n
P r e h e a t T e m p . M in . 1 0 D e g C G a s(e s) ( M ix tu r e ) F lo w R a te
I n te r p a s s T e m p M a in t a in . 2 5 0 D e g C S h ie ld in g A R G O N 9 9 .9 0 % 8 -1 0 L IT / M .P
P r e h e a t M a in te n a n c e ( I f R e q u ir e d ) B y P r o p a n e T o r c h T r a ilin g - - -
B a k i n g o f e le c t r o d e B a c k in g - - -
E L E C T R I C A L C H A R A C T E R I S T I C S ( Q W .4 0 9 )
C u rren t A C or D C D C SM AW
P o la r ity
A m p s. (R a n g e ) SMAW GTAW R E V (E P )
GTAW 8 0 -14 0 V o lts (R a n g e ) 18 -2 8
E le c tr o d e w ir e fe e d s p e e d r a n g e
T u n g s t e n E le c tr o d e S iz e a n d T y p e D ia 1 .6 m m 2 % T H O R A T E D
T E C H N I Q U E ( Q W .4 1 0 )
S tr in g o f W e a v e B e a d A ll S tr in g
O r ific e o r G a s C u p S iz e 4 - 6 m m
I n i t i a l a n d in t e r p a s s C le a n in g ( B r u s h in g , G r i n d in g , e tc .) B r u s h in g & G r in d in g / P o w e r g r in d in g
M e th o d o f B a c k G o u g in g P ow er B rush
O s c i lla t io n P o w e r G r in d in g
C o n ta c t T u b e to W o r k D is ta n c e
N /A
M u lt ip le o r S in g le P a s s ( p e r s id e ) M u lt ip le s ( if R e q )
M u lt ip le o r S in g le E le c t r o d e s S in g le
T ra v e l S p e e d (R a n g e ) 1"-2 "
P e n n in g
O th e r
F ille r M e ta l C urren t
W e ld T ype A m p V o lt O th e r
L ayers P ro cess C la s s D ia . P o la r R ange R ange T ravel S p eed
R O O T G TA W E R 70 S -3 1 .6 D .C 90 - 120 18 -2 8 1 " -1 .5 "
FILLING (if req) G TA W E R 70 S -3 1 .6 D .C 90 - 120 18 -2 8 1"-2 "
C A P P I N G ( if r e q ) G TA W E R 70 S -3 1 .6 D .C 8 0 -2 0 0 18 -2 8 1"-2 "
S U R IA E N G IN E E R IN G
W E L D IN G P R O C E D U R E S P E C I F IC A T IO N (W P S )
C lie n t: EPCL D a te :
W e ld in g P r o c e d u r e S p e c ific a tio n N o .: S E -Q C -W P S -E 1 4 6 1 -0 2 P r o je c t: E -1 4 6 1
R e v is i o n : S u p p o r tin g P Q R N o .: S E -Q C -P Q R -E 1 4 6 1 -0 1
W e l d in g P r o c e s s ( e s ) : G TA W & SM A W T y p e (s ) : M anual
C ode / STD : A s p e r A S M E S e c tio n IX
N o te:
R o o t to b e d o n e b y G T A W p r o ce ss
F illi n g a n d c a p p in g to b e d o n e b y S M A W
p r o c e s s P la te T h ic k n e s s M a x im u m 12 0 m m
S h e ll t o t u b e s h e e t
B A S E M E T A L (Q W .4 0 3 )
P .N O . 1 G ro u p N o . 2 to P .N o . 1 G ro u p N o . 2
O R
S p e c i f ic a t i o n t y p e a n d G r a d e A STM A -5 16 G r. 7 0
to S p e c ific a tio n ty p e a n d G r a d e A STM A -5 16 G r. 7 0
O R
F IL L E R M E T A L S PO STW E LD H E A T TR EA TM E N T
(Q W .4 0 4 ) ( Q W .4 0 7 )
G TAW SM A W
R O O T H O T PA SS F IL L /C A P R O O T F IL L C A P T e m p era tu re R a n g e : N /A
S p ec. N o . (S F A ) 5 .1 8 5 .1 5 .1 T im e R a n g e : N /A
A W S N o . ( C la s s ) E R -7 0 S -3 E -70 18 E -70 18 S o a k in g T im e a t M a x T e m p : N /A
F .N o . 6 4 4
A . N o. 1 1 1
S iz e o f F ille r M e ta ls 1 .6 m m / 2 .4 m m 3 .2 / 4 3 .2 / 4 G A S
W e ld M e ta l F /C -E 70 18 F / C -E 7 0 1 8 (Q W -4 0 8 )
F ille t A ll T h i c k n e s s A ll T h i c k n e s s A ll T h ic k n e s s S h ie ld in g G a s ( e s ) : A rgon
E le c tr o d e F lu x (C la s s ) BAR E M ETAL P e r c e n t C o m p o s itio n ( m ix tu r e ) : 9 9 .9 0 %
F lu x T ra d e N a m e M A G M A W E L D /L IN K O N / E SS A B F lo w R a t e : 8 - 1 0 L I T / P .M
C o n s u m a b le I n s e r t ` G a s B a c k in g : N /A
O th e r T r a ilin g S h ie ld in g G a s C o m p o s it io n : N /A
E a c h b a s e & f ille r m e t a l c o m b in a t io n s h o u ld r e c o r d in d iv id u a lly
Q W .4 8 2
P O S I T I O N S ( Q W .4 0 5 ) P O S T W E L D H E A T T R E A T M E N T (Q W .4 0 7 )
P o s itio n (s ) o f G r o o v e H O R T e m p e ra tu re R a n g e
W e ld in g P o s i tio n : U p F 5 T im e R a n g e -
P o s itio n ( s ) o f F ille t A L L
P R E H E A T ( Q W .4 0 6 ) G A S ( Q W .4 0 8 )
P e r c e n t C o m p o s itio n
P r e h e a t T e m p . M in . 10 D eg C G a s(es) ( M ix tu r e ) F lo w R a te
I n t e r p a s s T e m p M a in t a i n . 150 D eg C S h i e ld in g A R G O N 9 9 .9 0 % 8 -1 0 L IT / M .P
P r e h e a t M a in te n a n c e ( I f R e q u ir e d ) B y P r o p a n e T o r c h T r a ilin g - - -
B a k i n g o f e le c t r o d e 250 D eg C B a c k in g - - -
E L E C T R I C A L C H A R A C T E R I S T I C S ( Q W .4 0 9 )
C u rren t A C or D C D C SM AW S T -(E N )
P o la r ity
E le c tr o d e w ir e fe e d s p e e d r a n g e
T u n g s te n E le c tr o d e S iz e a n d T y p e D ia 2 .4 m m 2 % T H O R A T E D
T E C H N I Q U E ( Q W .4 1 0 )
S trin g o f W e a v e B e a d A ll S tr in g
O r ific e o r G a s C u p S iz e 4 - 6 m m
I n it i a l a n d in t e r p a s s C le a n in g ( B r u s h in g , G r i n d in g , e t c .) B ru s h in g & G r in d in g / P o w e r g r in d in g
M e th o d o f B a c k G o u g in g P ow er B ru sh
O s c i lla t i o n P o w e r G r in d in g C o n ta ct
T u b e to W o r k D is ta n c e N /A
M u ltip le o r S in g le P a s s ( p e r s id e ) M u lt ip le s
M u lt i p le o r S i n g le E le c t r o d e s S i n g le
T ra vel S p eed (R a n g e) 3 " -6 " P e n n in g
O th e r
F ille r M e t a l C u rren t
W e ld T ype A m p V o lt T ravel O th e r
L ayers P ro cess C la s s D ia . P o la r R an ge R an ge Speed
R O O T G T A W E R 70 53 2 .4 / 3 .2 D .C 9 0 - 120 18 -2 8 3 " -4 "
F IL L IN G 1 SM A W E 70 18 3 .2 / 4 D .C 8 0 -2 0 0 18 -2 8 4 "- 6 "
FILLING 2(If Req.) SM A W E 70 18 3 .2 / 4 D .C 8 0 -2 0 0 18 -2 8 4 "- 6 "
C A P PIN G SM A W E 70 18 3 .2 / 4 D .C 8 0 -2 0 0 18 -2 8 4 "- 6 "
Page 01 of 03
1.0 Scope.
This Procedure Provides a System of general conditions and Specific Instructions to perform Liquid
Penetrant Examination in accordance with the applicable ASME code edition for Examination of
Carbon Steel, Stainless Steel, Welds and on Porous Material.
2.1 Penetrant Material used Shall be water Washable, Visible Colour contrast of the
Following Specifications
2.1.1 Brand
Magnaflux Spot Check
2.1.2 Material Specifications
Penetrant SLK-SPI in aerosol can.
Cleaner SKC-S in aerosol can.
Developer SKD-S2 in aerosol can.
2.2 Any change in Material from the above list shall require requalification of Procedure
2.3 Intermixing of Penetrant Materials of different manufacturers is not permitted.
3.0 Procedure.
3.2.1 Prior to Penetrant application the Surface to be Examined and all the adjacent Areas
Within 25mm Shall be Cleaned by Mechanical Means and Solvent to remove dirt, grease
Scale, Welding flux or other matter which could interfere with the Examination
3.2.2 Operations that may Close the opening and Compromise the integrity of the Examination
Such as sand blasting are not recommended when these operations are being performed.
3.2.3 A Minimum of five minutes Shall be allowed for drying the surface to be Examined
Accomplished by evaporation before applying Penetrant.
Page 02 of 03
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3.3.1 The Temperature of the Penetrant and the Surface of the part to be Examined Shall
not be below 5˚c nor above 52˚c, Local Heating or Cooling is permitted.
The Penetrant Shall be Applied by Spraying, so that all Surface under Examination
Shall be Thoroughly and uniformly covered by Penetrant.
After Application excess Penetrant is drained out from the part allowing suitable Dwell
Time of minimum 5 minutes. The area to be examined Shall remain covered by Penetrant
throughout the Dwell time.
3.4.1 After Dwell time the Penetrant on the Surface Shall be Removed by using Clean with
Cloth This operation Shall Continue until most traces of Penetrant on the surface is
Removed.
3.4.2 The Remaining Traces of Penetrant Shall be Removed be wiping the Surface Clean
with Cloth moistened with solvent remover, to Minimize removal of Penetrant from
discontinues, care Shall be taken to avoid excess Solvent Remover.
3.4.3 Flushing the surface with solvent remover following application of the penetrant and
prior to developing is strictly prohibited.
3.5.1 The developer is of Solvent, Suspended wet type and shall be applied as soon as possible
after excess penetrant has been removed and part is dried Developer Shall be Sprayed in
such a manner to assure complete coverage with a thin uniform film. The Second coat
may be applied across the first coat.
Page 03 of 03
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5.1 The Following acceptance standards shall apply which have been referred from ASME
Sec-I, Sec VIII Division -I
5.2 All Welds Such as Longitudinal and Circumferential seams, including fillet weld
Pressure Parts. Joining of Nipples. Header Shall be Free of all relevant Indication
5.2.1 All Cracks. Lack of fusion and relevant imperfections
x______________________________________x
REV: 00
SURIA ENGINEERING
LIQUID PENETRANT EXAMINATION REPORT DATE: 01-11-2019
Page: 01 of 01
Client: Project: Manufacture No. Procedure No.
Engro Polymer Exchanger Re-tubing E1461 NDE, PR-016
Component: Report No.:
Drawing No.: - T07801-1400FE20-0400
Shell, Shell Window E1461-08-20
S.NO 14 | P aPART-PART
ge WELDED JOINTS DIMENSION
NO. OF TEST
ACCEPT REJECT
JOINTS RESULT
Shell dia.600mm -
01 Shell Window to Shell Shell to Shell window 8mm
350mmx400mm
01 Satisfactory —
Acc Std. PWHT: N/A
NDT Ref. Code: ASME SECTION V Material Specification: SA-36
ASME SEC-V
Penetrant SLK-SPI Make Magnaflux Spot Check Test Temperature °c Light Equipment
(i)
R Root
FC Filling Capping
REV: 00
SURIA ENGINEERING
LIQUID PENETRANT EXAMINATION REPORT DATE: 01-11-2019
Page: 01 of 01
Client: Project: Manufacture No. Procedure No.
Engro Polymer Exchanger Re-tubing E1461 NDE, PR-016
Component: Report No.:
Drawing No.: - T07801-1400FE20-0400
Shell To Tube sheet, Tube sheet to Tubes E1461-08-20
Acc Std. PWHT: N/A
NDT Ref. Code: ASME SECTION V Material Specification: SA-36
ASME SEC-V
Penetrant SLK-SPI Make Magnaflux Spot Check Test Temperature °c Light Equipment
(i)
R Root
FC Filling Capping
5. UFD REPORT
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6. TUBE EXPANSION
/HYDROSTATIC TESTING
PROCEDURE AND REPORT
SURIA ENGG.
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Suria Engineering
Following processes will done for re-welding and expansion of tube to tube sheet joints.
4- Hydrostatic Testing
This Procedure describes and specifies the technique, acceptance standards, and
documentation requirement for tube expansion in heat ex-changers.
Reference.
The current edition or addenda of the following documents has been referenced in the
preparation of this procedure and shall be considered a part of this procedure as applicable
1. Pneumatic Expansion unit shall be used for carrying out the expansion.
2. The roller to be used shall have a generous radius at both the ends so as to ensure that
there are no sharp steps on the expanded tube ID & to ensure that there is a smooth
transition from expanded to unexpanded zone of the tubes.
3. Measuring instrument like Dial gauge & outside Micrometer / Vernier.
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4. Take 300 x 300 mm sides mock up block with thickens equal to tube sheets with same
material as that of tube sheet. Drill the tube holes in the mock up block, of diameter &
pitch as per Tube sheet drawing.
5. Measure and record the tube hole inside diameter (ID).
6. Cut tube 150 mm long other than tube sheet thickness and tube projection length as per
drawing from the same material & wall thickness to be used in job.
7. Measure & record tube ID & tube OD.
8. Put mandrel of proper length, based on required expansion length.
9. Carry out expansion of tube of at least of 09 nos. Tube by mechanical expansion (Tube
rolling).
10. Measure & record increase in the tube ID.
11. Calculate % of thinning of tube using the following formula.
Notes:
- 100% tubes shall be inspected to ensure that the tubes are expanded.
- Tube to tube sheet joint shall be examined during hydro test to detect leakage, if any.
- In the event of leakage, the tube shall be re – expanded. Care shall be taken to ensure
that there is no excessive thinning of the tubes.
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M.R G.M
Prepared By
Approved By
CONTENTS
1) Purpose
2) Scope
3) Preparation
4) Storage of Water
5) Water Quality
6) Procedure
7) Safety
9) Reference document
2) PURPOSE
3) SCOPE
This procedure is applicable to all hydrostatic tests of vessels being performed by
Suria Engineering.
PREPARATION:
Vessel shall be placed in horizontal position on bags filled with fine sand.
Test shall be carried out after completion of all welding activities, Radiographic
tests, and DPT (if applicable) but before surface treatment.
It shall be insured that 100% welding has been completed and all weld seams
shall visually be inspected from inside with proper lighting arranged.
All cleats, erection attachments, remaining weld tacks near weld seam shall be
removed by proper grinding. In case of excessive grinding during removal of
attachments, that portion shall be built-up by tack welds.
One vent shall be provided to remove the air pockets/ bubbles. (Filling shall be
continued till the over flow from the vent.)
Two calibrated pressure gauges shall be installed out of which one will be at
the highest point of the vessel.
4) WATER QUALITY:
Sweet water shall be used for leak test. In case of stainless-steel vessel, the
chloride content of the water shall not be exceedingly more than 50 ppm (mg/l). The
water shall also be clear of any solid particles.
PROCEDURE:
Blind flanges of all the highest point nozzles and vents shall be kept loose.
Water shall be filled through any nozzle until it starts to overflow from all the nozzles to
remove entrapped air.
Loose blind flanges shall be tightened and air shall be removed from filling point.
Pressure shall be increased gradually. Test pressure should be 1.3 times of working or
design pressure.
During Hydrostatic Test metal surface temperature should neither be below 16 0C nor
above 480C.
Once the pressure is increased to the working/ design pressure and all tubes, nozzles,
bolting and the weld seams should be checked for any leek.
After satisfactory result the pressure shall be increased to the required mark.
Once the pressure is reached to the required mark it should be maintained for 30
minutes or for the time specified by the vessel designer.
Gradually release the pressure to avoid bulging of the vessel caused by sudden
vacuum created upon rapid release of water.
All the highest points nozzles blind covers shall be loosen before draining of
water from the column. After that water to be drained from any suitable nozzle as
per physical situation.
Sign shall be displayed to indicate the pressure test is in progress and the area shall
be barricaded.
INSPECTION AND RECTIFICATION:
Any leak shall be identified and marked on the vessel. The area shall be documented.
The vessel shall be completely drained and defective welds / joints shall be repaired.
All leaks shall be repaired by approved weld repair procedure. Dye Penetrate test of all
repairs shall be carried out.
Applicable forms and documents shall be filled which will become part of the
Manufacturer’s Data Report to be submitted to the client at the time of delivery.
REFERENCE DOCUMENTS
Fabrication codes: ASME VIII div. 1.
Client’s/ Designer’s procedural documents.
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Painting Procedure
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10) General:
This procedure covers the outline of procedure adapted for the sand blasting
and primer application for structure.
3) Surface Preparation:
Sand blasting could be done in late hours of a day but subject to weather condition.
Sand blasting shall not be done when surface temperature is less than 3°C above
the dew point and relative humidity is greater than 85% or there is a possibility that
blasted surface shall be subject to wetting before application of primer.
Before blasting, oil, grease or other oily objects, if any, shall be removed with the
help of any detergent wash.
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4) PAINT APPLICATION:
Base will be stirred thoroughly to homogenize. Then hardener will be added to base
in recommended ratio as mentioned in “Manufacturer's Data Sheet” with constant
stirring. A
recommended solvent shall be mixed for required thinning of primer.
Roller and or brush shall be used for application of Primer, if not restricted by Primer
Specification Sheets” by manufacturer.
After sand blasting primer shall be applied within 3 to 4 hours of blasting activity.
After each coat, surface will be left for a period recommended for drying and recoating.
Such quantity of primer shall be removed from containers and mixed with
hardeners and thinner, which must be consumed same day and with-in the Pot-life
time.
While applying the primer care shall be taken that paint should not be dripped,
sagged, skipped or dripped-off during application or immediately after application, if
these defects are detected then immediately be dressed with brush. If defect is not cured
then primer shall be removed completely and re-coated with the same system.
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5) INSPECTIONS:
During surface preparation and primer application following inspection shall be carried out.
DFT of each coat shall be 80-100 Microns and should be measured at 5 spots per 9
SQ.M, and for area less than 9 SQ.M; at least 3 spots shall be measured.
5) Paint System:
Following paint system shall be adopted for structure including (ladder /Platforms):
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7. RANDOM PICTURES
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