NHT CHARGE HEATER PRESSURE PARTS FABRICATION

SHEET 1 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

NHT CHARGE HEATER PRESSURE

PARTS FABRICATION
REQUIREMENTS

A 11-APRIL-2018 FIRST ISSUE SGI SAR AP

REV. ISSUE DATE REASON FOR ISSUE PREPARED BY CHECKED BY APPRVEDO BY

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 NHT CHARGE HEATER PRESSURE PARTS FABRICATION
SHEET 2 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

1. GENERAL REQUIREMENTS:

1.1. APPLICABLE CODES, STANDARDS AND PROJECT SPECIFICATIONS:

 API 560 5th Edition (2016) “FIRED HEATERS FOR GENERAL REFINERY SERVICE”.
 API 530 7th Edition (2015) “CALCULATION OF HEATER TUBE THICKNESS IN
PETROLEUM REFINERIES”.
 ASME B31.3 2016 Edition “PROCESS PIPING”.
 2-12-7 (19 March 2015) “FIRED HEATER” – UOP Specification.
 ASME II 2017 Edition (Part A, C, D).
 ASME V 2017 Edition “NONDESTRUCTIVE EXAMINATION”.
 ASME VIII Div. 1 2017 Edition “RULES FOR CONSTRUCTION OF PRESSSURE VESSELS”.
 ASME IX 2017 Edition “QUALIFICATION STANDARD FOR WELDING, BRAZING AND
FUSING PROCEDURES; WELDERS; BRAZERS; AND WELDING, BRAZING AND FUSING
OPERATORS”.
 EN 10204 2004 Edition “METALLIC PRODUCTS-TYPES OF INSPECTION DOCUMENTS”.
 B034-0MN-80-45-SP-0002 Rev. 0 “JOB SPECIFICATION FOR FIRED HEATER
PACKAGE”.
 B034-0MN-80-45-SP-0003 Rev.0 “SPECIFICATION FOR PROCUREMENT OF PRESSURE
PARTS”.
 B034-9-1842-1001-R1 “INSPECTION METHODOLOGY FOR PACKAGE ITEMS”.
 6-17-0001 Rev. 5 “STANDARD SPECIFICATION FOR EXECUTION OF FIRED HEATERS
AND APH SYSTEMS”.
 6-17-0003 Rev. 4 “STANDARD SPECIFICATION OF COIL WORK FOR FIRED HEATERS”.
 6-17-0017 Rev. 0 “STANDARD SPECIFICATION FOR QUALITY CHECKS FOR
FABRICATION ERECTION AND EXECUTION OF FIRED HEATERS”.
 6-44-0051 Rev. 6 “TECHNICAL NOTES FOR PIPES”.
 6-44-0053 Rev. 6 “TECHNICAL NOTES FOR FLANGES, SPECTACLE BLINDS AND DRIP
RINGS”.

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 NHT CHARGE HEATER PRESSURE PARTS FABRICATION
SHEET 3 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

 6-44-0054 Rev. 6 “TECHNICAL NOTES FOR BUTT WELDED, SOCKET WELDED AND
SCREWED FITTINGS”.
 6-78-0003 Rev. 1 “SPECIFICATION FOR DOCUMENTATION REQUIREMENTS FROM
SUPPLIERS”.
 6-82-0002 Rev. 3 “STANDARD SPECIFICATION FOR POSITIVE MATERIAL
IDENTIFICATION AT CONSTRUCTION SITES”.
 API 578 3rd Edition 2018 “MATERIAL VERIFICATION FOR NEW AND EXISTING ALLOY
PIPING SYSTEMS”.
 6-82-0004 Rev. 1 “STANDARD SPECIFICATION FOR PIPING & HEATER (FIRED) COIL
MATERIAL TRACEABILITY AT CONSTRUCTION SITES”.
 6-82-1010 Rev. 1 “INSPECTION AND TEST PLAN (ITP) FOR INCOMING MATERIAL
CHECKING FOR CONTRACTOR’S SUPPLIED MATERIALS”.
 6-82-5000 Rev. 0 “INSPECTION & TEST PLAN FOR HEATER PACKAGES”.
 B034-000-80-45-4404 Rev. 0 “GENERAL ARRANGEMENT DRAWINGS NOTES”.
 B0340MN804501301 Rev. 0 “GENERAL ARRANGEMENT CROSS & LONG SECTION
NHT CHARGE HEATER (MN-H-01)”.
 B0340MN804501302 Rev. 0 “GENERAL ARRANGEMENT PLANS-1”.
 B0340MN804501303 Rev. 0 “GENERAL ARRANGEMENT PLANS-2”.

1.2. GENERAL WELDING REQUIREMENTS:

- No production welding shall be performed until the welding dossier (weld map with all
weld joints clearly marked, WPS and PQR) has been reviewed and returned to Vendor
either with minor comments or without comments.
- Welder performance qualifications as per clause 3.3 of 6-17-0003 Rev. 4. All Welders
and welding operators shall be qualified in accordance with ASME IX with the procedure,
materials and wall thickness range which are used for coils. Inspector shall witness the
test and certify the qualification of each welder. Only welders approved by the Inspector
shall be employed.

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 NHT CHARGE HEATER PRESSURE PARTS FABRICATION
SHEET 4 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

- All PQR’s must be qualified in accordance with the requirements of ASME B31.3 2017
Edition, ASME IX 2017 Edition, API 560 5th Edition and applicable Project Specifications
6-17-0003 Rev. 4, 2-12-7 and B034-000-80-45-4404 Rev. 0.
- Welding consumables shall be selected in accordance with Appendix I & II of Project
Specification 6-17-0003 Rev. 4, Note 16 Section B of B034-000-80-45-4404 Rev. 0 and
Section 11.m of UOP Project Specification 2-12-7:
 Material certificates (welding consumables) shall be certified as indicated in
section 3.4.3 of 6-17-0003:
a) Material certificate shall be EN 10204 3.1 in chemical and EN 10204 3.1 in
mechanical properties in accordance with the corresponding SFA of ASME II
Part C 2017 Edition.
 Brand of welding consumables shall be is subjected to the approval of EIC, as
required in Section 3.7.7 of Project Specification 6-17-0003 Rev. 4.
 In case of dissimilar metals to be welded together the composition of welding
consumables shall be at least similar to that of higher alloyed material, as per
Note 16 Section B of B034-000-80-45-4404 Rev. 0 and section 11.m of UOP
Project Specification 2-12-7.
 Rutile type electrodes (E-3XX-17 or E-3XX-16) are strictly forbidden for any
kind of welding operation for stabilized stainless steel (347H material).
 For Stainless steel material, ferrite value shall be reported in the corresponding
welding consumable certificate. Acceptance criteria shall be minimum 5 FN and
maximum 10 FN for type 347 weld deposit. For other weld deposit minimum FN
shall be 3 and maximum 10 FN.
- Permitted welding processes as per API 560 5th Edition (2016), applicable Code ASME
B31.3 2016 Edition and Section 3.7 of Project Specification 6-17-0003 Rev. 4.
GTAW process shall be used for root passes and GTAW or SMAW process for fill and
cap passes (See appendix II of 6-17-0003 Rev. 4).
As required in section 3.7.2 of 6-17-0003 Rev. 4, purging inside the tubes for GTAW
welding shall be done with Argon 99.98% purity. Shielding gas shall be Argon 99.99%
purity.

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 NHT CHARGE HEATER PRESSURE PARTS FABRICATION
SHEET 5 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

- Backing strips or consumable inserts shall not be used (section 3.7.4 of 6-17-0003 Rev.
4 and section 11.n of UOP Project Specification 2-12-7).
- Installation and welds of thermocouples on furnace tubes shall be carried out in
accordance with Appendix V of Project Specification 6-17-0003 Rev. 4 and also in
accordance with the applicable Codes.
- Preheating shall be as per section 3.8 and Appendix III of 6-17-0003 Rev. 4 and Section
330 of ASME B31.3 2016 Edition.
The preheat zone shall be at or above the specified minimum temperature in all
directions from the point of welding for a distance of the larger or 75 mm or 1.5 times
the greater nominal thickness.
Preheating shall be made using electrical resistances as required in section 7.4.5 of
B034-0MN-80-45-SP-0002 Rev. 0.
For welding in the case of dissimilar alloy combinations, the preheat temperature shall
be according to the alloy requiring the higher temperature.
Temperature measurement for preheating may be by thermocouple or temperature
sensitive crayons.
Minimum preheat temperature shall be in accordance with the requirements of the
specific Codes and applicable Project Specifications, the most stringent:
 Welds between stainless steel material (ASME Number P8): 10ºC.
- Maximum interpass temperature shall be monitored by means of thermosticks or
thermocouples.
Maximum interpass temperature shall be in accordance with the requirements of the
specific Codes and applicable Project Specifications, the most stringent:
 Welds between stainless steel material (ASME Number P8): 175ºC.
- Specific test of PQR’s:
 PQR’s for stainless steel material (347H) shall be qualified with stabilization heat
treatment 900 ± 4 ºC during 4 hours rapidly cooled down by air, macrographic
test, chemical analysis, intergranular corrosion test, ferrite test (to be carried
out before stabilizing heat treatment) and the specific test required by ASME IX
2017 Edition.

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 NHT CHARGE HEATER PRESSURE PARTS FABRICATION
SHEET 6 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

- No welding repairs shall be carried out without the approval of Client and Owner
inspector.

1.3. GENERAL REQUIREMENTS FOR FABRICATION & INSPECTION:

- All vendor documents (material certificates, NDT and fabrication procedures, QC
reports, …) shall be in English Language.
- Material certificates (base metal) shall be in accordance with EN 10204 3.2.
- Non Destructive Test procedures shall be in accordance with the applicable Articles of
ASME V 2017 Edition, considering the specific requirements of the following of 6-17-
0003 Project Specification for Radiographic test.
Inspection Methodology shall be as per Project Specification B034-9-1842-1001-R1.
- All fabrication work shall be subject to inspection by EIL/Owner and/or their nominated
inspecting authority.
Inspection of all Indigenous/Domestic items shall be by TPIA (Third Party Inspection
Agency). All Foreign items shall be inspected by foreign based TPIA.
Suggested Third Party Inspection Agencies are (as per section 6.2 of Project Specification
B034-9-1842-1001-R1:
 Certification Engineers International Ltd. (CEIL).
 Lloyd’s Register of Industrial Services (LRIS).
 Dt Norske Veritas (DNV).
 Bureau Veritas (BV).
 TUV.
Involvement of the appointed TPIA shall be reflected in the corresponding Inspection
and Test Plan.
Third party inspection charge is under Vendor Scope.
As required by Section 10.4 & Section 11 of B034-9-1842-1001-R1, TPIA shall issue an
Inspection Certificate (IC) and Inspection Release Note (IN) after satisfactory completion
of all Inspection stages of the approved ITP and after ensuring compliance to specified
requirements of all relevant applicable documents. IC and IRN shall include as a
minimum the information required in Section 11 of B034-9-1842-1001-R1 and shall be

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 NHT CHARGE HEATER PRESSURE PARTS FABRICATION
SHEET 7 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

accompanied by the applicable documents referred in the section previously

mentioned.
Material shall be accepted by EIL site based on the Release Note to be signed by TPIA.
- As per ITP 5011 Rev. 0 (Fired Heaters), included in document 6-82-5000 Rev. 0,
Inspection Category of Coils is Category A. Matrix of Inspection and Certification
Responsibility for Category A shall be as indicated in Annexure to Standard Inspection
Methodology for Package Items B034-9-1842-1001.
- Vendor shall provide sufficient advance notice for the upcoming inspections.
In case of Indigenously procured equipment, Vendor shall notify to TR in writing, at least
15 working days in advance of the date and the place at which the items will be ready
for witnessing of inspection/testing. In case any postponement becomes necessary,
Vendor shall provide written notification at least 72 hours prior to the original scheduled
date.
In case of imported equipment, Vendor shall notify to TR in writing, at least 6 weeks (30
working days) in advance.
- Vendor shall guarantee that all items shall conform to the stated requirements in all
aspects. Any item found defective at any stage of project execution or during guarantee
period shall be replaced by the supplier at his own cost and without any delay.
- If there is any contradiction between specifications requirements manufacturer shall
bring it to the attention of TR.

2. NHT CHARGE HEATER MN-H-01, PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
CROSSOVERS, H2 SERVICE, MATERIAL 347H - ASME B31.3 2016 Ed.- MDMT = 15ºC:

- Required documentation:

 Inspection and test plan in accordance with ITP 5011 Rev. 0 included in Project
Specification 6-82-5000 Rev. 0 and considering the requirements indicated in
these fabrication requirements. At least, 4 columns shall be included in each ITP:
MANUFACTURER, TECNICAS REUNIDAS, TPIA & EIL.

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 NHT CHARGE HEATER PRESSURE PARTS FABRICATION
SHEET 8 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

 Welding dossier (Weld map marking clearly all weld joints, WPS, PQR) in
accordance with the specific Codes, Project Specifications and requirements of
section 1.2 of this document. Fabrication shall not commence until all the
involved documents have been reviewed and returned to Vendor either with
minor comments or without comments.
 Welders Qualifications in accordance in accordance with the specific Codes,
Project Specifications and requirements of section 1.2 of this document.
 Weld control sheets. Information there included shall be, at least, the following:
Heater number, Coil reference, Weld number/identification, Base Material
Specifications and base material heat number, WPS reference, Welding
Consumable specification and heat number, Welding date, Welder
identification, NDTs report number and date of test, PMI report number and
date of test, PWHT report number and date, Hardness report number and
date…. See an example in Annex I of this document.
 Welding Repair Procedure (in accordance with the requirements of ASME B31.3
2016 Edition and Sections 3.6.7 & 5 of 6-17-0003 Rev. 4). Only two repairs per
joint are permitted. No welding repairs shall be carried out without the approval
of Client and TR inspector.
 Material Certificates of welding consumables in accordance with EN 10204 3.1
(for chemical and mechanical properties).
 Procedure for material inspection at reception and material traceability
procedure in accordance with ASME Code and Project Specifications 6-17-0003
Rev. 4 , 6-82-0004 Rev. 1 and ITP 6-82-1010 Rev. 1 “Inspection and test plan for
incoming material (checking for contractor’s supplied materials)”.
 Positive Material Identification Procedure (PMI), quantitative and recordable
measure method in accordance with Project Specification 6-82-0002 Rev. 3, API
578 3rd Edition (2018) and API 560 5th Edition (2016). Acceptable PMI
instruments shall be “Optical Emission” type for the detection of Carbon
content.
Elements to be analyzed for 347H and 310H shall be:

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 NHT CHARGE HEATER PRESSURE PARTS FABRICATION
SHEET 9 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

 347H: C, Cr, Ni, Columbium & Tantalum.

 310H; C, Cr, Ni.
Acceptance criteria shall be:
 Base metal: within 10% of the range specified in the applicable material
standard.
 Deposited weld metal: within 12.5% of the range specified in the
applicable welding consumable specification.
 Visual Examination Procedure (VT) in accordance with ASME B31.3 2016 Edition
and ASME V 2017 Edition (Article 9). Acceptance criteria shall be as per table
341.3.2 of ASME B31.3 2016 Edition (normal fluid service) and section 3.6.3 &
3.6.4 of 6-17-0003.
VT procedure shall be prepared by a person qualified to ASNT Level III in visual
testing.
 Radiographic Test Procedure (RT) in accordance with Article 2 & Article 22 of
ASME V 2017 Edition, ASME B31.3 2016 Edition and Section 4.3 of Project
Specification 6-17-003 Rev. 4.
RT procedure shall be got approved from the Owner’s Inspector before
proceeding.
RT procedure shall be prepared by a person qualified to ASNT Level III in
radiographic testing.
Type of RT sources and films shall be as indicated in section 4.3.2 and Appendix
VI of 6-17-0003 Rev. 4.
Acceptance criteria shall be in accordance with section UW-51 of ASME VIII Div.
1 2017 Edition and table 341.3.2 of ASME B31.3 2016 Edition (normal fluid
service), the most stringent.
 Ultrasonic Test Procedure (UT) in accordance with Article 4 of ASME V 2017
Edition. Acceptance criteria shall be in accordance with Section 344.6.2 (a) of
ASME B31.3 2016 Edition.
UT procedure shall be prepared by a person qualified to ASNT Level III in
Ultrasonic testing.

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 NHT CHARGE HEATER PRESSURE PARTS FABRICATION
SHEET 10 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

 Liquid Penetrant Test Procedure (MT) in accordance with Article 6 of ASME V

2017 Edition. Acceptance criteria shall be in accordance with section 344.3.2 of
ASME B31.3 2016 Edition.
PT procedure shall be prepared by a person qualified to ASNT Level III in Liquid
Penetrant testing.
 Non destructive personnel qualifications (at least level II) in accordance with
SNT-TC-1A as required in Section 9 of Project Specification B034-9-1842-1001-
R1.
 Ferrite examination procedure in accordance with section 1.17.4 of Project
Specification 6-44-0051 Rev. 6 and section 1.23.d of Project Specification 6-44-
0054 Rev. 6. Acceptance criteria shall be minimum 5 FN and maximum 10 FN for
type 347 weld deposit. For other weld deposit minimum FN shall be 3 and
maximum 10 FN.
 Stabilizing Heat Treatment Procedure at 900 ± 4 ºC during 4 hours with rapid air
cooling, as per section 2.14.d of Project Specification B034-0MN-80-45-SP-0003
Rev. 0 and section 11.h of Licensor Specification 2-12-7.
 Dimensional Control Procedure (tolerances for fabrication shall be as per
applicable Codes, Section 7.4.1 of Project Specification B034-0MN-80-45-SP-
0002 Rev. 0, Section 2.3 of Project Specification 6-17-0003 Rev. 4. Dimensional
requirements of welds (weld reinforcement & undercuts) shall be in accordance
with Section 3.6.2 of 6-17-0003 Rev. 4 or table 341.3.2 of ASME B31.3 2017
Edition, the most stringent.
General dimensions shall be verified in accordance with the corresponding
checklist (Heater quality check reporting formats) included in Annex II of Project
Specification 6-17-0017 Rev. 0.
 Hydrostatic test procedure including cleaning and drying (all segments of coil
shall be thoroughly drained immediately after the test and flushing of coil after
hydrostatic test with compressed air shall be performed), as required in section
4.13.vii of B034-0MN-80-45-SP-0002 Rev. 0, section 4.2 of 6-17-0003 Rev. 4, API
560 2016 Edition and section 345 of ASME B31.3 2016 Edition. Water used for

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 NHT CHARGE HEATER PRESSURE PARTS FABRICATION
SHEET 11 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

hydrostatic testing shall be potable with maximum chloride content of 25 ppm

(section 4.2 of 6-17-0003). In case of non-drainable heaters or where the total
evacuation of the water cannot be ensured, coil shall be hydro tested with De-
Mineralized water having preservative chemicals.
 Pickling and passivation procedure.
 Nitrogen blanketing procedure as required in section 7.18.6 of B034-0MN-80-
45-SP-0002 Rev. 0.
 Packing, marking, shipping procedure and preservation specification in
accordance with Section 8 of Project Specification 6-17-0001 Rev. 5 and Section
7 of Project Specification 6-17-0003 Rev 4. All assemblies and joints shall be
marked as indicated in section 7.2 of 6-17-0003 Rev. 4. According to section 8 of
Project specification 6-17-0001 Rev. 5 and section 7.3 of Project Specification 6-
17-0003 Rev. 4, all material shall be supplied with proper wrapping and packing
so that they will be preserved in as new condition during transportation,
handling and under the rainy/corrosive outdoor condition of storage at site.
Packing shall be suitable for rail or road transport and also seaworthy if
transported by sea. Open ends shall be capped to prevent entrance of foreign
matter.
 Quality dossier index.
 Packing list.
 As-built drawings.
 Final Quality Dossier. It shall be available for review during intermediate
inspections and final inspection. Equipment shall not be released for shipment
until the Final Quality Dossier are in TR possession.
- Pre-inspection meeting (PIM).
- Material reception:
 100% visual inspection, check of marks and dimensional control (including
thickness control of materials) of base materials and welding consumables.
Inspection shall be performed in accordance with ITP 6-82-1010 Rev. 1. Material

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SHEET 12 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

inspection records as per Project Specification 6-82-1010 Rev. 1 and traceability

records as per Project Specification 6-82-0004 Rev. 1 shall be maintained.
 Review of welding consumables certificates.
- Fabrication/Tests:
 Cutting of materials and marking transfer (when needed). Welding ends
preparation (when applicable).
Beveling (when needed or when required) shall be carried out by the coil
manufacturer by grinding/machining and shall be in accordance with the
corresponding figure of ASME B16.25 as per table 1.7 of Project Specification 6-
44-0051, table 1.4 of Project Specification 6-44-0053 and table 1.6 of Project
Specification 6-44-0054.
 100% visual inspection and dimensional control of welding edges. As per section
12.4 (a) & section 12.3.(c) of UOP Project Specification 2-12-7, fillet welds to
pressure retaining components shall be ground to a smooth concave contour.
 Dressed bevels shall be examined by Liquid Penetrant Test, as per Section 3.2 of
Project Specification B034-0MN-80-45-SP-0003 Rev.0 in order to confirm that
the bevels are free from linear indications 1,6 mm or longer. Liquid Penetrant
test on material bevel ends is mandatory when coil manufacturer bevels some
material or makes any additional work on existing bevels.
 Joint preparation, fit-up and tack welding.
 Removal of temporary tack welds by grinding or chipping and ground smooth of
the area without reduction of wall thickness. Liquid penetrant test (PT)
inspection to verify the absence of linear indications.
 Root pass welding (with GTAW process).
 100% visual examination and dimensional control of root pass welds.
 100% liquid penetrant examination of 100% root passes of austenitic welds.
 Welding (fill & cover passes).
 100% visual examination and dimensional control of cover passes.
 10% liquid penetrant test of cover passes (per welder and shift) of branch welds,
including fillet welds before Stabilizing Heat treatment. Branch welds shall

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 NHT CHARGE HEATER PRESSURE PARTS FABRICATION
SHEET 13 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

consist of the welds between the pipe & reinforcement element (weldolet),
welds between weldolets and running pipes, welds between nozzle and flanges.
 10% Radiographic test (RT) per welder and shift of butt-welds and branch
connections (welds between weldolets and pipes, welds between pipes and
flanges) before Stabilizing Heat treatment.
 10% Ultrasonic examination per welder and shift, before PWHT, may be applied
instead of radiography when the configuration makes radiographic examination
difficult to interpret or impossible to perform (welds between weldolets and
manifolds, fillet welds). When ultrasonic examination is impractical, liquid
penetrant test may be permitted (see section 4.3.7 of 6-17-0003 Rev. 4).
 100% ferrite test of welds before stabilizing heat treatment with ferritoscope.
 100% PMI of base metal and welds before Stabilizing Heat Treatment in
accordance with Project Specification 6-82-0002.
 Stabilizing heat treatment of welds at 900 ± 4 ºC during 4 hours rapidly cooled
down by air. Monitoring of Heat Treatment cycle and review of Heat treatment
graph and report.
 100% visual examination after Stabilizing Heat Treatment.
 100% liquid penetrant test of cover passes of branch welds (vent & drains,
including fillet welds), after Stabilizing Heat Treatment. Branch welds shall
consist of the welds between the pipe & reinforcement element (weldolet),
welds between weldolets and running pipes, welds between nozzle and flanges.
 100% Radiographic test (RT) of all butt welds and branch connections (welds
between weldolet and pipes, welds between pipes and flanges) after Stabilizing
Heat Treatment in accordance with section 4.3.1 of 6-17-0003 Rev. 4, section
11.q, 11.r & 12.3.d of 2-12-7.
 100% Ultrasonic examination after Stabilizing Heat Treatment may be applied
instead of radiography when the configuration makes radiographic examination
difficult to interpret or impossible to perform (welds between weldolets and
manifolds, fillet welds), see section 4.3.7 of 6-17-0003 Rev. 4, 12.3.d of 2-12-7

13
 NHT CHARGE HEATER PRESSURE PARTS FABRICATION
SHEET 14 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

and 17.2.2.f of API 560. When ultrasonic examination is impractical, liquid

penetrant test may be permitted (see section 4.3.7 of 6-17-0003 Rev. 4).
 Hydrostatic test of coils to be performed after written clearance has been
obtained from the EIC (see section 4.2 of 6-17-0003 Rev. 4). Test pressure shall
be maintained for a minimum period of 1 hour.
 Purged and filled of coil with nitrogen and blanked off (see section 7.18.6 of
B034-0MN-80-45-SP-0002 Rev. 0).
 100% Dimensional control.
 Pickling and passivation.
 Final inspection.
 Protection of all fabricated assemblies (including flange faces and other
machined faces) with easily removable rust preventive. Coil ends beveled for
welding shall be coated with heavy grease (see section 6 of Project Specification
6-17-0003 Rev. 4).
 Packing, marking and preparation for shipping.
 Nameplate review.
 Review of Final Quality Dossier.

14
 NHT CHARGE HEATER PRESSURE PARTS FABRICATION
SHEET 15 OF 16
REQUIREMENTS
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY
EQUIPMENT: NHT CHARGE HEATER MN-H-01 EIL PROJECT Nº: B034
TRSA PROJECT Nº:
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND
33117
CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A

ANNEX I: WELD CONTROL SHEETS

15
NHT CHARGE HEATER PRESSURE PARTS FABRICATION REQUIREMENTS SHEET 16 OF 16

PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY

EIL PROJECT Nº: B034
EQUIPMENT: NHT CHARGE HEATER MN-H-01
TRSA PROJECT Nº: 33117
PROCESS RADIANT COIL, PROCESS CONVECTION COIL AND CROSSOVERS

DOCUMENT CODE: 33117-IQC-006 REV.: A