33117-Iqc-0005 Rev. B

CCR PRESSURE PARTS FABRICATION REQUIREMENTS SHEET 1 OF 46
PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY

EQUIPMENT: CCR HEATER
CHARGE HEATER (MR-H-01), Nº 1 INTERHEATER HTR (MR-H-02), Nº 2 EIL PROJECT Nº: B034
INTERHEATER HTR (MR-H-03), Nº 3 INTERHEATER HTR (MR-H-04), HOT OIL TRSA PROJECT Nº:
CONVECTION SECTION, STEAM SUPERHEATER CONVECTION SECTION, 33117
STEAM GENERATION CONVECTION SECTION & BFW ECONOMIZER
CONVECTION SECTION
DOCUMENT CODE: 33117-IQC-005 REV.:B
CCR PRESSURE PARTS

FABRICATION REQUIREMENTS
CHANGES OF P22 PWHT

TEMPERATURE CCR RADIANT
B 27‐APRIL‐2018 SGI SAR AP
COIL/HYDROSTATIC TEST OF
CCR RADIANT COIL
A 09‐APRIL‐2018 FIRST ISSUE SGI SAR AP
REV. ISSUE DATE REASON FOR ISSUE PREPARED BY CHECKED BY APPRVEDO BY
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CONVECTION SECTION
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” (Applicable to Radiant Coils Charge Heater MR‐H‐01, Nº 1
Interheater HTR MR‐H‐02, Nº 2 Interheater HTR MR‐H‐03, Nº 3 Interheater HTR MR‐
H‐04 and Hot Oil Convection Coil).
 ASME I 2017 Edition “RULES OF CONSTRUCTION OF POWER BOILERS” (Applicable to
Steam Superheater Convection Coil, Steam Generation Convection Coil and BFW
Economizer Convection Coil).
 INDIAN BOILER REGULATIONS IBR (Applicable to Steam Superheater Convection
Coil, Steam Generation Convection Coil, BFW Economizer Convection Coil).
 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 B31.3 2016 Edition “PROCESS PIPING” (Applicable to Radiant Coils Charge
Heater MR‐H‐01, Nº 1 Interheater HTR MR‐H‐02, Nº 2 Interheater HTR MR‐H‐03, Nº
3 Interheater HTR MR‐H‐04 and Hot Oil Convection Coil).
 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”.
 2‐12‐7 (19 March 2015) “FIRED HEATER” – UOP Specification.
 B034‐0MN‐80‐45‐SP‐0003 Rev.0 “SPECIFICATION FOR PROCUREMENT OF PRESSURE
PARTS”.
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CONVECTION SECTION
 B034‐000‐79‐41‐PLS‐01 Rev. 0 “SPECIFICATION FOR SURFACE PREPARATION AND

PROTECTIVE COATING”.
 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”.
 6‐44‐0054 Rev. 6 “TECHNICAL NOTES OR 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”.
 7‐17‐0607 Rev. 5 “INTERMEDIATE WELD FOR FINNED/STUDDED TUBES” (Applicable
to Hot Oil Convection Coil, Steam Superheater Convection Coil, Steam Generation
Convection Coil and BFW Economizer Convection Coil).
 6‐82‐5000 Rev. 0 “INSPECTION & TEST PLAN FOR HEATER PACKAGES”.
 B034‐000‐80‐45‐4404 Rev. 0 “GENERAL ARRANGEMENT DRAWINGS NOTES”.
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CONVECTION SECTION
 B0340MR80450101 Rev. 0 “GENERAL ARRANGEMENT CROSS & LONG SECTION (MR‐

H‐01/02/03/04)”.
 B0340MR80451104 Rev. 0 “GENERAL ARRANGEMENT PLANS‐3”.
 B0340MR80451106 Rev. 0 “GENERAL ARRANGEMENT PLANS‐5”.
 B0340MR80451107 Rev. 0 “GENERAL ARRAGEMENT PLANS‐6”.
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 and in accordance with IBR
where applicable. Inspector shall witness the test and certify the qualification of each
welder. Only welders approved by the Inspector shall be employed.
‐ All PQR’s must be qualified in accordance with the requirements of ASME B31.3 2016
Edition (for Charge Heater MR‐H‐01, Nº 1 Interheater HTR MR‐H‐02, Nº 2 Interheater
HTR MR‐H‐03, Nº 3 Interheater HTR MR‐H‐04 and hot oil convection coil), ASME I 2017
Edition & IBR (for Steam Superheater Convection Coil, Steam Generation Convection
Coil and BFW Economizer Convection Coil), 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:
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CONVECTION SECTION
a) For carbon steel material (P1) welding consumable shall be delivered with
material certificate 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.
b) For alloy material (grades P11, P9 and P22) welding consumable shall be
delivered with material certificate EN 10204 3.1 in chemical and EN 10204
3.1 in mechanical properties according to 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.
 For alloy material use of low hydrogen welding consumables is highly
recommended (supplemental diffusible‐hydrogen designator of H4 or lower).
 As per section 12.3.g. (2) of 2‐12‐7, product analysis content of tin and
phosphorous for welding consumables P11 material, when used, shall be less
than 0.015% and 0.012% respectively. The percentage limits are weight percent.
 Weld metal for P22 base metals shall have a carbon content > 0,05% (as per
ASME II Part D requirements). It is highly recommended the use of only one
welding consumable heat number in order to reduce the number of PQR
qualifications.
Additionally, welding consumables of P22 material shall comply with the
following requirements of section 12.4.c.(3) of 2‐12‐7:
 Mn and Si levels shall be maintained at the lowest possible levels
consistent with good weldability.
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CONVECTION SECTION
 Each batch or heat of welding consumable and covered electrodes,

including the wire flux combinations used in fabrication, shall be
analyzed for P, Sn, Sb and As. Analysis shall be performed on deposited
weld metal. The Temper Embrittlement Factor, X‐bar, shall be as
follows:
X‐bar = (10P + 4 Sn + 5 Sb + As)/100 ≤ 15 ppm (element concentration
are in parts per million).
‐ Permitted welding processes as per API 560 5th Edition (2016), applicable Code (ASME
B31.3 for Charge Heater MR‐H‐01, Nº 1 Interheater HTR MR‐H‐02, Nº 2 Interheater HTR
MR‐H‐03, Nº 3 Interheater HTR MR‐H‐04 and hot oil convection coil and ASME I/IBR
Steam Superheater Convection Coil, Steam Generation Convection Coil and BFW
Economizer Convection Coil) and Section 3.7 of Project Specification 6‐17‐0003 Rev. 4.
GTAW process shall be used for root passes and SMAW process for fill and cap passes.
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.
‐ 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, Section 330
of ASME B31.3 2016 Edition (for Charge Heater MR‐H‐01, Nº 1 Interheater HTR MR‐H‐
02, Nº 2 Interheater HTR MR‐H‐03, Nº 3 Interheater HTR MR‐H‐04 and hot oil convection
coil), Section PW‐38 & A‐100 of ASME I 2017 Edition & IBR (Steam Superheater
Convection Coil, Steam Generation Convection Coil and BFW Economizer Convection
Coil).
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CONVECTION SECTION
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.
Preheat temperature shall be maintained without interruption until any required PWHT,
except when all of the following conditions are satisfied: sections 3.8.3 & 3.8.4 of 7‐17‐
003 and section 330.2 of ASME B31.3 2016 Edition, the most stringent.
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 P9‐P9 material (ASME Number P5B): 205ºC.
 Welds between P9‐P11 material (ASME Number P5B‐P4): 205ºC.
 Welds between P11‐P22 material (ASME Number P4‐ P5A): 205ºC.
 Welds between P22‐P22 material (ASME Number P5A‐P5A): 205ºC.
 Welds between CS‐CS material (ASME Number P1‐P1): 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 P9‐P9 material (ASME Number P5B): 315ºC maximum.
 Welds between P9‐P11 material (ASME Number P5B‐P4): 315ºC maximum.
 Welds between P11‐P22 material (ASME Number P4‐ P5A): 315ºC maximum.
 Welds between P22‐P22 material (ASME Number P5A‐P5A): 315ºC maximum.
 Welds between CS‐CS material (ASME Number P1‐P1): 315ºC maximum.
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CONVECTION SECTION
‐ Specific test of PQR’s:

 PQR’s for carbon steel material shall be qualified in accordance with ASME IX
2017 Edition, Project Specification 6‐17‐0003 Rev. 4, B034‐000‐80‐45‐4404 Rev.
0, UOP 2‐12‐7, ASME B31.3 2016 Edition (for Hot oil convection coil) and ASME
1 2017 Edition and IBR (for Steam Generation and BFW Convection Coils).
 PQR’s for P9 material (9Cr‐1Mo) and PQR’S for dissimilar joints between P9
pipes and P11 weldolets, supporting WPS’s for CCR radiant coil, shall be
qualified in accordance with the requirements of ASME IX 2017 Edition, 6‐17‐
0003 Rev. 4, B034‐000‐80‐45‐4404 Rev. 0 and UOP 2‐12‐7, as follows:
Postheating at 300ºC minimum during 30 minutes (after postheating welds shall
be allowed to cool to room temperature in a slow and uniform manner under
the cover of mineral wool); 3 cycles of PWHT at 730±10ºC during 2 hours/per
cycle (above 315ºC heating rate shall be 150ºC/h and cooling rate to 315ºC shall
be 60ºC/h) – mechanical test and hardness test shall be reported after one cycle
of PWHT and after 3 cycles of PWHT; chemical analysis, macrography, hardness
test [(maximum acceptance value shall be 2225 HB or the equivalent value in
HV10 ].
 PQR’s for joints between P22 material (2 ¼ Cr‐1Mo & 2 ¼ Cr‐1Mo) and PQR’s for
dissimilar joints between P22 material (2 ¼ Cr‐1Mo) & P11 (1 ¼ Cr ‐ ½ Mo) (welds
between manifolds and flanges & manifolds and weldolets) supporting WPS’s
for welding of CCR Radiant coil, shall be qualified in accordance with the
requirements of ASME IX 2017 Edition, 6‐17‐0003 Rev. 4, B034‐000‐80‐45‐4404
Rev. 0, UOP 2‐12‐7, ASME B31.3 2016 Edition (for Radiant Coil), as follows:
welds shall be cooled slowly under the cover of mineral wool from the
recommended preheat temperature to room temperature; PQR’s shall be
qualified with 3 cycles of PWHT at 690 ± 10ºC during 2 hours/per cycle (above
315ºC heating rate shall be 150ºC/h and cooling rate to 315ºC shall be 60ºC/h)‐
mechanical test, impact test and hardness test shall be reported after one cycle
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CONVECTION SECTION
of PWHT and after 3 cycles of PWHT; chemical analysis; macrography; hardness

test (maximum acceptance value shall be 225 HB or the equivalent value in
HV10); all weld metal tensile test at room temperature [(maximum tensile
strength shall be 7030 kg/cm2 (689 MPa = 100 Ksi) or the maximum value
specified in the standard of the welding consumable, the most stringent];
impact test at ‐29ºC as per ASME B31.3 (see section 12.4.c (4) of UOP Project
Specification 2‐12‐7, average impact values of three specimen shall not be less
than 55 Joules with no single value below 47 Joules); step cooling test
representing each batch or heat of welding consumable, covered electrodes and
wire flux combinations for each welding process used in production:
 Plot of transition temperature curves (impact energy versus
temperature) of each batch or heat of welding consumable at 690 ±
10ºC during 2 hours, before step cooling: a minimum of 8 sets of three
impact test shall be prepared and obtained as specified in ASME VIII Div.
1 2017 Edition. The 8 sets shall be performed at different temperatures
including ‐29ºC. The remaining test temperatures shall be selected so
that the generated transition curve shall clearly define the transition
zone and upper shelf. The maximum test temperature shall be on upper
shelf energy level (defined as 100% shear fracture) and the minimum
test temperature shall be on the lower shelf energy level (defined as
zero percent shear fracture). The upper and lower shelves shall be
defined by at least two set points, with at least four additional defining
the transition curve.
 Step Cooling test on a sample representing each batch or heat of
welding consumable, covered electrodes and wire flux combinations for
each welding process used in production, at 690 ± 10ºC during 2 hours,
as follows:
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CONVECTION SECTION
a) Step cooling shall be in accordance with the following temperatures,

holding times and cooling rates to the next lowest temperature:
b) Impact test of each Step cool test sample shall be performed and
transition curves developed per the requirements of point 1 of this
section.
c) Acceptance criteria shall be in accordance with the following:
 PQR’s for joints between P22 material (2 ¼ Cr‐1Mo & 2 ¼ Cr‐1Mo) supporting
WPS’s for welding of Steam Superheater Convection Coil, shall be qualified in
accordance with the requirements of ASME IX 2017 Edition, 6‐17‐0003 Rev. 4,
B034‐000‐80‐45‐4404 Rev. 0, UOP 2‐12‐7, ASME I 2017 Edition and IBR, as
follows: welds shall be cooled slowly under the cover of mineral wool from the
recommended preheat temperature to room temperature; PQR’s shall be
qualified with 3 cycles of PWHT at 730 ± 10ºC during 2 hours/per cycle (above
315ºC heating rate shall be 150ºC/h and cooling rate to 315ºC shall be 60ºC/h)‐
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CONVECTION SECTION
mechanical test and hardness test shall be reported after one cycle of PWHT
and after 3 cycles of PWHT; chemical analysis; macrography; hardness test
(maximum acceptance value shall be 241 HB or the equivalent value in HV10);
‐ No welding repairs shall be carried out without the approval of Client and Owner
inspector.
1.3. GENERAL REQUIREMENTS FOR FABRICATION & INSPECTION:

‐ Vendor shall provide IBR form where applicable.
‐ 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.
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CONVECTION SECTION
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
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.
‐ All items covered by IBR (Steam Superheater Convection Coil, Steam Generation
Convection Coil and BFW Economizer Convection Coil), shall be inspected at the
manufacturer’s works and duly certified by competent authority. In addition to IBR
authority, TPIS shall witness all IBR items. (See section 10.6 of B034‐9‐1842‐1001‐R1).
‐ 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.
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CONVECTION SECTION
‐ If there is any contradiction between specifications requirements manufacturer shall

bring it to the attention of TR.
2. RADIANT COIL OF CCR HEATER (CHARGE HEATER MR‐H‐01, Nº 1 INTERHEATER HTR MR‐H‐
02, Nº 2 INTERHEATER HTR MR‐H‐03 & Nº 3 INTERHEATER HTR MR‐H‐04)‐ H2 SERVICE,‐P9,
P11 & P22 MATERIAL‐ 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.
 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
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CONVECTION SECTION
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 either “Portable X‐Ray fluorescence” or “Optical Emission”
type.
Elements to be analyzed for P11, P22, and P9 shall be Cr and Mo. 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.
 Cold bending Procedure (including information about bending procedure, visual
inspection & dimensional control after bending), in accordance with Section 332
of ASME B31.3 2016 Edition, Section 2.5 of Project Specification 6‐17‐0003 Rev.
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CONVECTION SECTION
4 and PFI Standard ES‐24. Tolerances for thinning, flattening and wrinkling of
bends shall be in accordance ASME B31.3 2016 Edition PFI Standard ES‐24, the
most stringent. (Finished surface shall be free of cracks and substantially free
from buckling. Thickness after bending of forming shall b not less than that
required by the design. Flattening of a bend: the difference between maximum
and minimum diameters at any cross section shall not exceed 8% of nominal
outside diameter).
 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.
 Magnetic Particle Test Procedure (MT) in accordance with Article 7 of ASME V
2017 Edition and Section 7.4.6 of B034‐0MN‐80‐45‐SP‐0002 Rev. 0. Acceptance
criteria shall be in accordance with section 344.3.2 of ASME B31.3 2016 Edition.
15
CONVECTION SECTION
MT procedure shall be prepared by a person qualified to ASNT Level III in

magnetic particle 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.
 Post Weld Heat Treatment Procedure at 690 ± 10ºC during 2 hours for welds
between P22 material, welds between P22 reducer‐P11 flanges & welds
between P22 manifolds and P11 weldolets. (Above 315ºC, heating rate shall
be 150ºC/h and cooling down to 315ºC shall be done with a rate of 60ºC/h).
Post Weld Heat Treatment Procedure at 730±10ºC during 2 hours for welds
between P9 material (pipe‐pipe) and welds between P9 material and P11
(pipe‐weldolets). (Above 315ºC, heating rate shall be 150ºC/h and cooling rate
to 315ºC shall be 60ºC/h).
Post weld heat treatment shall be carried out using electrical resistance coil
method (see section 7.4.5 of B034‐0MN‐80‐45‐SP‐0002 Rev. 0) and shall comply
with section 3.9 of 6‐17‐0003 Rev. 4 and ASME B31.3 2016 Edition.
 Hardness test procedure in accordance with sections 3.9.2 & 4.4 of 6‐17‐0003
Rev. 4. Equipment to be used in production shall be a portable Vickers digital
harness tester (Poldi hardness testers are not permitted). Acceptance criteria
shall be maximum value of 225 HB, as per section 1.17.3 of 6‐44‐0051 Rev. 6
and section 1.23.c of 6‐44‐0054 Rev. 6.
 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.
16
CONVECTION SECTION
General dimensions shall be verified in accordance with the corresponding

checklist (Heater quality check reporting formats) included in Annex II of Project
 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
hydrostatic testing shall be potable. 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.
 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.
17
CONVECTION SECTION
 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
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 Magnetic Particle Test in accordance with
Guide ASTM E709 to confirm that the bevels are free from linear indications 1,6
mm or longer, as per Section 3.2 of Project Specification B034‐0MN‐80‐45‐SP‐
0003 Rev.0. Magnetic particle test on material bevel ends is mandatory when
coil manufacturer bevels some material or makes any additional work on
existing bevels.
18
CONVECTION SECTION
 Cold bending of P9 pipes in accordance with Section 332 of ASME B31.3 2016
Edition.
Inspection of bends: 100% Visual (no cracks or linear indications shall be
present) and dimensional inspection of bends. (Finished surface shall be free of
cracks and substantially free from buckling. Thickness after bending of forming
shall b not less than that required by the design. Flattening of a bend: the
difference between maximum and minimum diameters at any cross section
shall not exceed 8% of nominal outside diameter).
Heat Treatment of bends is not required as per section 332.4 of ASME B31.3
2016 Edition.
 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. Magnetic particle test (MT)
inspection to verify the absence of linear indications.
 Root pass welding (with GTAW process).
 100% visual examination and dimensional control of root pass welds.
 Welding (fill & cover passes).
 Post heating of welds of between P9‐P9 material or welds between P9‐P11
materials shall be carried out, immediately after welding (prior to dropping the
preheat and before PWHT), as required in section 3.9.1 of Project Specification
6‐17‐0003 Rev. 4: at 300ºC minimum during 30 minutes. Welds shall be allowed
to cool to room temperature in a slow and uniform manner under the cover of
mineral wool.
Other Cr‐Mo steels (P22‐P22, P11‐P22) shall be cooled under the cover of
mineral wool from the recommended preheat temperature.
 100% visual examination and dimensional control of cover passes.
 10% magnetic particle test of cover passes (per welder and shift) of branch
welds, including fillet welds before Post Weld Heat treatment. Branch welds
19
CONVECTION SECTION
shall 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 Post Weld 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, magnetic
particle examination may be permitted (see section 4.3.7 of 6‐17‐0003 Rev. 4).
 100% PMI of base metal and welds before Post Weld Heat Treatment in
accordance with Project Specification 6‐82‐0002.
 Post Weld Heat Treatment of welds between P9 material (pipe‐pipe) and
welds between P9 material and P11 (pipe‐weldolets) at 730 ± 10 ºC during 2
hours (above 315ºC heating rate shall be 150ºC/h and cooling down to 315ºC
shall be done with a rate of 60ºC/h).
Post Weld Heat Treatment of welds between P22 material (manifold‐
manifold, manifold‐reducer) and between P22 material and P11 material
(reducer‐flange, manifold‐weldolet) at 690 ± 10ºC during 2 hours. (Above
315ºC, heating rate shall be 150ºC/h and cooling down to 315ºC shall be done
with a rate of 60ºC/h).
Monitoring of PWHT cycle and review of PWHT graph and report.
 100% visual examination after Postweld Heat Treatment.
 100% Hardness test after Post Weld Heat Treatment (maximum acceptance
value shall be 225 HB). Harness test shall be performed in base material, heat
affected zone and weld.
20
CONVECTION SECTION
 100% magnetic particle test of cover passes of branch welds (vent & drains,
including fillet welds), after PWHT, in accordance with section 7.4.6 of Project
Specification B034‐0MN‐80‐45‐SP‐0002 Rev. 0. 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 Post Weld
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 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),
see section 4.3.7 of 6‐17‐0003 Rev. 4, 12.3.d of 2‐12‐7 and 17.2.2.f of API 560.
When ultrasonic examination is impractical, magnetic particle examination may
be permitted (see section 4.3.7 of 6‐17‐0003 Rev. 4).
 Hydrostatic test of coils shall not be performed at workshop. It shall be
performed on site.
 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.
 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.
21
CONVECTION SECTION
3. HOT OIL CONVECTION COIL OF CCR HEATER – CARBON STEEL MATERIAL, ASME B31.3 2016
EDITION, MDMT = 15ºC:
MANUFACTURER, TECNICAS REUNIDAS, TPIA & EIL.
section 1.2 of this document. Fabrication shall not commence until all involved
documents have been reviewed and returned to Vendor either with minor
comments or without comments.
 Welding Repair Procedure (in accordance with applicable Code 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.
22
CONVECTION SECTION

(for chemical properties) and EN 10204 3.1 (for mechanical properties).
Rev. 4, 6‐82‐0004 Rev. 1 and ITP 6‐82‐1010 Rev. 1 “Inspection and test plan for
 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.
testing.
ASME V 2017 Edition, ASME B31.3 2016 Edition and Section 4.3 of Project
proceeding.
VI of 6‐17‐0003 Rev. 4.
1 2017 Edition and table 341.3.2 of ASME B31.3 2016 Edition (normal fluid
service), the most stringent.
Edition. Acceptance criteria shall be in accordance with Section 344.6.2 (a) of
ASME B31.3 2016 Edition.
23
CONVECTION SECTION

ultrasonic testing.
R1.
2017 Edition and Section 7.4.6 of B034‐0MN‐80‐45‐SP‐0002 Rev. 0. Acceptance
criteria shall be in accordance with section 344.3.2 of ASME B31.3 2016 Edition.
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.
Specification 6.17‐0017 Rev. 0.
560 2016 Edition and section 345 of ASME B31.3 2016 Edition. Water used for
hydrostatic testing shall be potable. 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.
24
CONVECTION SECTION

45‐SP‐0002 Rev. 0.
matter.
 Packing list.
25
CONVECTION SECTION
 100% visual inspection and dimensional control of welding edges.
existing bevels.
the area without reduction of wall thickness. Magnetic Particle Test (MT)
including fillet welds) in accordance with section 7.4.6 of Project Specification
B034‐0MN‐80‐45‐SP‐0002 Rev. 0. (Branch welds shall consist of the welds
between the pipe & reinforcement element (weldolet), welds between
weldolets and running pipes, welds between nozzle and flanges).
26
CONVECTION SECTION
between weldolet and pipes, welds between pipes and flanges), in accordance
with section 4.3.1 of 6‐17‐0003 Rev. 4, sections 11.p & 11.q of UOP Specification
2‐12‐7.
 100% Ultrasonic examination may be applied instead of radiography when the
configuration makes radiographic examination difficult to interpret or
impossible to perform (welds between weldolets and running pipe, fillet welds),
see section 4.3.7 of ‐17‐0003 Rev. 4 and 17.2.2.f of API 560. When ultrasonic
examination is impractical, magnetic particle examination may be permitted
(see section 4.3.7 of 6‐17‐0003 Rev. 4).
 Intermediate welds of finned tubes shall be performed in accordance with the
requirements of section 2.19 of B034‐0MN‐80‐45‐SP‐0003 Rev. 0, section 3.7.6
of 6‐17‐0003 Rev. 4, section 3.13 of 6‐17‐0001 Rev. 5, EIL Standard 7‐17‐0607
Rev. 5:
 Complete the tube weld joint following the corresponding WPS.
 RT of the Intermediate welds shall be done before welding of bridging
pieces.
 Welding of bridging pieces (which shall be spaced as close as possible,
depending upon the tube diameter), according to EIL Standard 7‐17‐
0607 Rev 5 and section 3.7.6 of 6‐17‐0003. Weld continuously with only
one run using stringer bead technique with a thin electrode (less than
2.0 mm diameter) with the size of weld restricted to 2 or 3 mm.
 Hydrostatic test of each convection finned tubes at ground after welding
of bridging pieces and before assembly of finned tubes in convection
section.
 After hydrotest tubes shall be cut to final length as per drawing (see
section 7.18.6 of B034‐0MN‐80‐45‐SP‐0002 Rev. 0) in case of end pipes
are not beveled. Beveling (when needed) shall be made in in accordance
27
CONVECTION SECTION
with Section 1.7 of Project Specification 6‐44‐0051 Rev. 6 by mechanical

means (grinding/machining).
 If beveling activities are needed, Magnetic Particle Test in accordance
with Guide ASTM E709 shall be performed to confirm that the bevels
are free from linear indications 1,6 mm or longer, as per Section 3.2 of
Project Specification B034‐0MN‐80‐45‐SP‐0003 Rev.0.
Pipes shall be purged by compressed air/hot air to remove water and
moisture.
 Hydrostatic test of Hot oil convection section 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.
Coil shall be purged by compressed air/hot air to remove water and moisture
(see section 7.18.6 of B034‐0MN‐80‐45‐SP‐0002 Rev. 0).
B034‐0MN‐80‐45‐SP‐0002 Rev. 0).
6‐17‐0003 Rev. 4).
 Review of Final Quality Dossier.
4. STEAM SUPERHEATER CONVECTION COIL OF CCR – P22 MATERIAL, ASME I 2017 EDITION,
IBR, MDMT = 15ºC:
28
CONVECTION SECTION
these fabrication requirements. At least, five columns shall be included in each
ITP: MANUFACTURER, TECNICAS REUNIDAS, TPIA, EIL & IBR.
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.
Project Specifications and requirements of section 1.2 of this document. IBR.
 Welding Repair Procedure (in accordance with the requirement of applicable
Codes ASME I & IBR and Section 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.
(for chemical properties and mechanical properties).
29
CONVECTION SECTION
 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 either “Portable X‐Ray fluorescence” or “Optical Emission”
type.
Elements to be analyzed for P22 shall be Cr and Mo. 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 I 2017 Edition, IBR,
and ASME V 2017 Edition (Article 9). Acceptance criteria shall be as per ASME I
2017 Edition and section 3.6.3 & 3.6.4 of 6‐17‐0003.
testing.
 Radiographic Test Procedure (RT) in accordance with Article 2 ASME V 2017
Edition, ASME I 2017 Edition, IBR and Section 4.3 of Project Specifications 6‐17‐
003 Rev. 4.
RT procedure shall be got approved form the Owner’s Inspector before
proceeding.
VI of 6‐17‐0003 Rev. 4.
1 2017 Edition and Section PW‐51 of ASME I 2017 Edition, the most stringent.
30
CONVECTION SECTION
 Ultrasonic Test Procedure (UT), in accordance with Article 4 of ASME V 2017,

ASME I 2017 Edition and IBR. Acceptance criteria shall be in accordance with
section PW‐52 of ASME I 2017 Edition.
ultrasonic testing.
2017 Edition, ASME I 2017 Edition, IBR and Section 7.4.6 of B034‐0MN‐80‐45‐
SP‐0002 Rev. 0. Acceptance criteria in accordance with ASME I 2017 Edition.
SNT‐TC‐1A as required in section 9 of Project Specification B034‐9‐1842‐1001‐
R1.
 Post Weld Heat Treatment Procedure 730 ± 10 ºC during 2 hours (above 315ºC
heating rate shall be 150ºC/h and cooling down to 315ºC shall be done with a
rate of 60ºC/h). Post weld heat treatment shall be carried out using electrical
resistance coil method (see section 7.4.5 of B034‐0MN‐80‐45‐SP‐0002 Rev. 0)
and shall comply with section 3.9 of 6‐17‐0003 Rev. 4, ASME I 2017 Edition and
IBR.
 Hardness test procedure in accordance with sections 3.9.2 & 4.4 of 6‐17‐0003
Rev. 4. Equipment to be used in production shall be a portable Vickers digital
harness tester (Poldi hardness testers are not permitted). Acceptance criteria
shall be maximum value of 241 HB.
31
CONVECTION SECTION
with Section 3.6.2 of 6‐17‐0003 Rev. 4 or Section PW‐35 of ASME I 2017 Edition,
the most stringent.
4.13.vii of B034‐0MN‐80‐45‐SP‐0002 Rev. 0, section 4.2 of 6‐17‐0003 Rev. 4,
Section PG‐99 of ASME I 2017 Edition, API 560 2016 Edition and IBR
requirements. Water used for hydrostatic testing shall be potable. 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.
45‐SP‐0002 Rev. 0.
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,
matter.
32
CONVECTION SECTION
 Packing list.
 All statutory approvals from IBR are in Vendor’s scope including the necessary
co‐ordination and liaison work in this respect. Any change/addition required to
be made to meet the requirements and full satisfaction of statutory authority
shall be carried out by Vendor with the approval of Contractor and part of his
scope without any time and cost implications to the owner.
Beveling (when needed or required) shall be carried out by the coil
33
CONVECTION SECTION

Guide ASTM E709 to confirm that the bevels are free form linear indications 1,6
0003 Rev. 0. Magnetic particle test on material bevel ends is mandatory when
existing bevels.
 Welding (fill and cover passes). As required in section 3.9.1 of Project
Specification 6‐17‐0003 Rev. 4 welds shall be cooled under the cover of mineral
wool from the recommended preheat temperature to room temperature.
 10% magnetic particle test of cover passes (per welder and shift) of branch
welds, including fillet welds before Post Weld Heat treatment. Branch welds
shall consist of the welds between the pipe & reinforcement element
(weldolet), welds between weldolets and manifolds/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 Post Weld 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, magnetic
34
CONVECTION SECTION
particle examination may be permitted (see section 4.3.7 of 6‐17‐0003 Rev. 4

and 17.2.2.f of API 560).
 100% PMI of base metal and welds before Post Weld Heat Treatment in
accordance with Project Specification. 6‐82‐0002.
 Post Weld Heat Treatment of welds 730±10ºC during 2 hours (above 315ºC
heating rate shall be 150ºC/h and cooling down to 315ºC shall be done with a
rate of 60ºC/h). Monitoring of PWHT cycle and review of PWHT graph and
report.
 100% visual examination after Postweld Heat Treatment.
 100% Hardness test after Post Weld Heat Treatment (maximum acceptance
value shall be 241 HB). Hardness test shall be performed in base material, heat
affected zone and weld.
including fillet welds), after PWHT, in accordance with section 7.4.6 of Project
Specification B034‐0MN‐80‐45‐SP‐0002 Rev. 0. Branch welds shall consist of the
welds between the pipe & reinforcement element (weldolet), welds between
weldolets and running pipes, welds between nozzle and flanges.
between weldolet and pipes, welds between pipes and flanges) after Post Weld
Heat treatment in accordance with section 4.3.1 of 6‐17‐0003 Rev. 4, section
11.q & 11.r of 2‐12‐7.
 100% Ultrasonic examination after 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),
see section 4.3.7 of 6‐17‐0003 Rev. 4. When ultrasonic examination is
impractical, magnetic particle examination may be permitted (see section 4.3.7
of 6‐17‐0003 Rev. 4).
35
CONVECTION SECTION

Rev. 5:
 Complete the tube weld joint following the corresponding WPS (with
the corresponding preheat).
 Perform the applicable PWHT.
 Hardness test and RT of the Intermediate welds shall be done after the
corresponding PWHT and before welding of bridging pieces.
0607 Rev 5 and section 3.7.6 of 6‐17‐0003. Tube shall be preheated
around bridging pieces locations to approximately 25ºC higher than the
preheating temperature indicated in section 1.2 of this document.
Bridging pieces shall be welded using weaving technique with a thin
electrode. The completed joint shall be wrapped with insulating blanket
and allowed gradual cooling. PWHT, hardness test and RT are not
needed after bridging welding.
 Hydrostatic test of each convection finned tubes at ground after welding
of bridging pieces and before assembly of finned tubes in convection
section.
36
CONVECTION SECTION
moisture.
 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.
B034‐0MN‐80‐45‐SP‐0002 Rev. 0).
6‐17‐0003 Rev. 4).
 Review of Final Quality Dossier, including the corresponding IBR form.
 Vendor shall comply with all IBR regulations for this convection coil. Vendor
shall arrange for inspection of coils and all necessary IBR documentation and
approvals.
5. STEAM GENERATION AND BFW CONVECTION COILS OF CCR HEATER – CARBON STEEL
MATERIAL, ASME I 2017 EDITION, IBR, MDMT = 15ºC:
37
CONVECTION SECTION

MANUFACTURER, TECNICAS REUNIDAS, TPIA, EIL & IBR.
section 1.2 of this document. Fabrication shall not commence until all involved
documents have been reviewed and returned to Vendor either with minor
comments or without comments.
 Welding Repair Procedure (in accordance with applicable Code Requirements
of ASME I 2017 Edition, IBR 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.
(for chemical and mechanical properties).
38
CONVECTION SECTION
 Visual Examination Procedure (VT) in accordance with ASME I 2017 Edition, IBR
and ASME V 2017 Edition (Article 9). Acceptance criteria shall be as ASME I 2017
Edition and section 3.6.3 & 3.6.4 of 6‐17‐0003.
testing.
ASME V 2017 Edition, ASME I 2017 Edition, IBR and Section 4.3 of Project
proceeding.
VI of 6‐17‐0003 Rev. 4.
1 2017 Edition and Section PW‐51 of ASME I 2017 Edition, the most stringent.

Edition, ASME I 2017 Edition and IBR. Acceptance criteria shall be in accordance
with Section PW‐52 of ASME I 2017 Edition.
ultrasonic testing.
2017 Edition, ASME I 2017 Edition, IBR and Section 7.4.6 of B034‐0MN‐80‐45‐
SP‐0002 Rev. 0. Acceptance criteria shall be in accordance with ASME I 2017
Edition.
39
CONVECTION SECTION

R1.
with Section 3.6.2 of 6‐17‐0003 Rev. 4 or Section PW‐35 of ASME I 2017 Edition,
the most stringent.
Specification 6.17‐0017 Rev. 0.
560 2016 Edition and section PG‐99 of ASME I 2107 Edition and IBR
Requirements. Water used for hydrostatic testing shall be potable. 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.
45‐SP‐0002 Rev. 0.
40
CONVECTION SECTION

matter.
 Packing list.
 All statutory approvals from IBR are in Vendor’s scope including the necessary
co‐ordination and liaison work in this respect. Any change/addition required to
be made to meet the requirements and full satisfaction of statutory authority
shall be carried out by Vendor with the approval of Contractor and part of his
scope without any time and cost implications to the owner.
41
CONVECTION SECTION

existing bevels.
including fillet welds) in accordance with section 7.4.6 of Project Specification
B034‐0MN‐80‐45‐SP‐0002 Rev. 0. (Branch welds shall consist of the welds
between the pipe & reinforcement element (weldolet), welds between
weldolets and running pipes, welds between nozzle and flanges).
42
CONVECTION SECTION
between weldolet and pipes, welds between pipes and flanges), in accordance
with section 4.3.1 of 6‐17‐0003 Rev. 4, sections 11.p & 11.q of UOP Specification
2‐12‐7.
 100% Ultrasonic examination may be applied instead of radiography when the
configuration makes radiographic examination difficult to interpret or
impossible to perform (welds between weldolets and running pipe, fillet welds),
see section 4.3.7 of ‐17‐0003 Rev. 4 and 17.2.2.f of API 560. When ultrasonic
examination is impractical, magnetic particle examination may be permitted
(see section 4.3.7 of 6‐17‐0003 Rev. 4).
Rev. 5:
 Complete the tube weld joint following the corresponding WPS.
 RT of the Intermediate welds shall be done before welding of bridging
pieces.
0607 Rev 5 and section 3.7.6 of 6‐17‐0003. Weld continuously with only
one run using stringer bead technique with a thin electrode (less than
2.0 mm diameter with the size of weld restricted to 2 or 3 mm.
 Hydrostatic test of each convection finned tubes at ground after
welding of bridging pieces and before assembly of finned tubes in
convection section.
43
CONVECTION SECTION

moisture.
 Hydrostatic test of convection section 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.
Coil shall be purged by compressed air/hot air to remove water and moisture
(see section 7.18.6 of B034‐0MN‐80‐45‐SP‐0002 Rev. 0).
B034‐0MN‐80‐45‐SP‐0002 Rev. 0).
6‐17‐0003 Rev. 4).
 Review of Final Quality Dossier, including the corresponding IBR form.
 Vendor shall comply with all IBR regulations for these convection coils. Vendor
shall arrange for inspection of coils and all necessary IBR documentation and
approvals.
44
CONVECTION SECTION
ANNEX I: WELD CONTROL SHEETS
45
EIL PROJECT Nº: B034
CHARGE HEATER (MR-H-01), Nº 1 INTERHEATER HTR (MR-H-02), Nº 2 INTERHEATER HTR (MR-H-03), Nº 3
TRSA PROJECT Nº: 33117
INTERHEATER HTR (MR-H-04), HOT OIL CONVECTION SECTION, STEAM SUPERHEATER CONVECTION SECTION,
STEAM GENERATION CONVECTION SECTION & BFW ECONOMIZER CONVECTION SECTION
DOCUMENT CODE: 33117-IQC-005 REV.: B

33117-Iqc-0005 Rev. B

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CCR PRESSURE PARTS FABRICATION REQUIREMENTS SHEET 1 OF 46

PROJECT: BS-VI MS BLOCK PROJECT KOCHI REFINERY

DOCUMENT CODE: 33117-IQC-005 REV.:B

CCR PRESSURE PARTS

CHANGES OF P22 PWHT

A 09‐APRIL‐2018 FIRST ISSUE SGI SAR AP

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

DOCUMENT CODE: 33117-IQC-005 REV.:B

1.1. APPLICABLE CODES, STANDARDS AND PROJECT SPECIFICATIONS:

DOCUMENT CODE: 33117-IQC-005 REV.:B

 B034‐000‐79‐41‐PLS‐01 Rev. 0 “SPECIFICATION FOR SURFACE PREPARATION AND

DOCUMENT CODE: 33117-IQC-005 REV.:B

 B0340MR80450101 Rev. 0 “GENERAL ARRANGEMENT CROSS & LONG SECTION (MR‐

1.2. GENERAL WELDING REQUIREMENTS:

DOCUMENT CODE: 33117-IQC-005 REV.:B

DOCUMENT CODE: 33117-IQC-005 REV.:B

 Each batch or heat of welding consumable and covered electrodes,

DOCUMENT CODE: 33117-IQC-005 REV.:B

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‐ Specific test of PQR’s:

DOCUMENT CODE: 33117-IQC-005 REV.:B

of PWHT and after 3 cycles of PWHT; chemical analysis; macrography; hardness

DOCUMENT CODE: 33117-IQC-005 REV.:B

a) Step cooling shall be in accordance with the following temperatures,

DOCUMENT CODE: 33117-IQC-005 REV.:B

1.3. GENERAL REQUIREMENTS FOR FABRICATION & INSPECTION:

DOCUMENT CODE: 33117-IQC-005 REV.:B

Third party inspection charge is under Vendor Scope.

DOCUMENT CODE: 33117-IQC-005 REV.:B

‐ If there is any contradiction between specifications requirements manufacturer shall

DOCUMENT CODE: 33117-IQC-005 REV.:B

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MT procedure shall be prepared by a person qualified to ASNT Level III in

DOCUMENT CODE: 33117-IQC-005 REV.:B

General dimensions shall be verified in accordance with the corresponding

DOCUMENT CODE: 33117-IQC-005 REV.:B

 Final Quality Dossier. It shall be available for review during intermediate

DOCUMENT CODE: 33117-IQC-005 REV.:B

DOCUMENT CODE: 33117-IQC-005 REV.:B

DOCUMENT CODE: 33117-IQC-005 REV.:B

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 Material Certificates of welding consumables in accordance with EN 10204 3.1

DOCUMENT CODE: 33117-IQC-005 REV.:B

UT procedure shall be prepared by a person qualified to ASNT Level III in

DOCUMENT CODE: 33117-IQC-005 REV.:B

 Nitrogen blanketing procedure as required in section 7.18.6 of B034‐0MN‐80‐

DOCUMENT CODE: 33117-IQC-005 REV.:B

DOCUMENT CODE: 33117-IQC-005 REV.:B

DOCUMENT CODE: 33117-IQC-005 REV.:B

with Section 1.7 of Project Specification 6‐44‐0051 Rev. 6 by mechanical

DOCUMENT CODE: 33117-IQC-005 REV.:B

DOCUMENT CODE: 33117-IQC-005 REV.:B

 Positive Material Identification Procedure (PMI), quantitative and recordable

DOCUMENT CODE: 33117-IQC-005 REV.:B

 Ultrasonic Test Procedure (UT), in accordance with Article 4 of ASME V 2017,

DOCUMENT CODE: 33117-IQC-005 REV.:B

DOCUMENT CODE: 33117-IQC-005 REV.:B

DOCUMENT CODE: 33117-IQC-005 REV.:B

 Dressed bevels shall be examined by Magnetic Particle Test in accordance with

DOCUMENT CODE: 33117-IQC-005 REV.:B

particle examination may be permitted (see section 4.3.7 of 6‐17‐0003 Rev. 4