C1230D Intercooler Specifications

C1230D Intercooler Specifications
C1230D/ C1230E Interstage cooler current operating parameters are as follows:
 Water flow: 9.3 m3/hr

 Air Flow: 3143 m3/hr
 Inlet Water temperature: 35 Degrees C
 Inlet Air temperature: 156 Degrees C
 Outlet air temperature: 45 Degrees C
Vendor to consider following MOC for the intercooler:
 Tube plate (ST) : C.S. SA 516 Gr. 70 epoxy coating

 Tube Plate (FT): C.S. SA 516 Gr. 70 epoxy coating
 Tube: CuNi 90:10
 Fin: Aluminium with metsol coating
 Seal: Silicon Rubber.
Notes:
1. Vendor to design new intercooler (type as per attached drawing i.e., tube with Aluminium fins)
by reverse engineering to achieve current operating parameters.
2. The drawing attached is for reference only, indicating the dimensions of the existing cooler, to
provide a general idea to the vendor for submission of bid.
3. Vendor can check the existing intercooler available at HPCL Mumbai refinery to quote for this
tender.
4. After placement of the PO, the Vendor is to visit HPCL Mumbai Refinery to check the existing
cooler and measure its dimensions, size, and existing design. The Intercooler shall exactly fit into
the existing setup. Any deviation after the placement of the PO shall not be acceptable.
5. Vendor to cross-check all the dimensions of the existing intercooler (e.g., tube diameters,
length, number of tubes, fins per inch, etc.) before taking up manufacturing. Vendor to cross-
check these dimensions and check through reverse engineering, if the operating parameters are
being achieved. Vendor to contact HPCL and inform them about their findings and modifications
to be done to achieve the desired performance of the intercooler.
6. Acceptance criteria: - The intercooler supplied shall perform as per the above-mentioned
operating parameters.
7. The Bidder or its OEM {themselves or through re-seller(s)} should have supplied the same or
similar Category Products, in at last seven years before tender date to any Central / State Govt
Organization / PSU / Public Listed Company. Copies of contracts/work orders and documentary
evidence of successful execution/completion in support of Past Experience of Similar Services
along with names, addresses, and contact details of clients shall be uploaded with the bid for
verification by the Buyer.
8. The definition of "same or similar" is as follows. "Bidder shall have successfully designed,
manufactured, and supplied at least one air fin cooler having carbon steel/Alloy steel/ Stainless
steel/ Aluminium metallurgy in Petroleum Refinery/Petrochemical /Fertilizer/Chemical/ Gas
Plant in India / Abroad as applicable."
9. The scope of work includes preparation of fabrication drawings, procurement of materials and
bought-out components, fabrication, inspection, testing, NDT, surface preparation, packing &
and delivery of the complete exchanger assembly, which is being procured as a replacement for
the existing exchanger, as per attached datasheets, drawings, specifications, standards and
other codes referred herewith. Submission of documents as per “Documentation” and “As-Built
Drawing” referred to below shall also form part of the vendor’s scope.
10. APPLICABLE CODES AND STANDARDS: - The intercooler shall be designed as per applicable
ASME codes and standards. Vendor to inform HPCL about the applicable codes and standards
for the intercooler in their latest editions. The same shall be verified by out inspection team and
comments shall be shared with the vendor.
11. MATERIAL SUPPLY: - All materials required as per attached drawings, specifications, codes, etc.,
required for fabrication, testing, and inspection of the tube bundle shall be supplied by the
vendor. No material shall be supplied as "FREE ISSUE" by HPCL-MR.
12. QAP, inspection, and testing: - Vendor shall prepare and submit a customized QAP by combining
attached HPCL-approved QAPs and submit to HPCL for approval. The approved QAP shall form
the basis of the inspection and testing of the intercooler. The inspection and testing of the
intercoolers shall be carried out by HPCL-approved Third-party inspection agencies only. A list of
HPCL-approved TPI agencies is attached with the tender.
a. QAP 31: - FINNED TUBES (STAINLESS STEEL, DUPLEX STAINLESS STEEL & ALLOY STEEL)
FOR AIR FIN COOLERS PROCURED FROM VENDOR
b. QAP 43: - CARBON STEEL EXCHANGER COMPONENTS (SHELL, SHELL COVER, CHANNEL,
CHANNEL COVER & FTS COVER)
c. QAP 46: - PROCUREMENT OF COPPER & COPPER ALLOY TUBES FOR CONDENSER AND
HEAT EXCHANGER FROM MANUFACTURE DIRECTLY
d. QAP 93: - TUBE BUNDLE WITH NON-FERROUS TUBES
e. QAP 0138: - STAINLESS STEEL EXCHANGER COMPONENTS (SHELL, SHELL COVER,
CHANNEL, CHANNEL COVER & FTS COVER)
मुंबई रिफाइनिी / MUMBAI REFINERY QAP No. : INSP / QAP 093
तकनीकी सेवा ववभाग / TECHNICAL SERVICES DEPARTMENT Rev. :0
QAP Date : 18 / 11 / 2013
वनिीक्षण प्रभाग / INSPECTION DIVISION
Page : 1 of 5
TECHNICAL ADVISORY
STANDARD QUALITY ASSURANCE PLAN
EQUIPMENT OR COMPONENT TUBE BUNDLE WITH NON-FERROUS TUBES
Stage Type of check Quantity Specification / Records / Vendor TPI HPCL Remark QAP
Reference / Documents Compliance
Acceptance norms Check
1.0 Raw Materials: Review of 100% As per applicable Mill test & R R - - -
(Tubes, forgings, Manufacturer’s ASTM standard / NDT reports,
Plates, fittings certificates: PO dimensional
etc.) – Material test requirements check report,
certificates (chemical HT chart
and mechanical)
- NDT reports
- Heat treatment reports
- Hydrotest reports
- Identification &
correlation / transfer of
markings.
2.0 Testing / NDE:
2.1 Tubes A. Chemical testing: Min. 1 As per applicable Test report P&W R - -
Chemical Analysis per each ASTM standard /
heat PO
/ Approved Dwg
B. Mechanical Properties:
- Tensile test -do- -do- -do- P&W R - -
- Hardness test -do- -do- -do- P&W R - -
- Flaring test -do- -do- -do- P&W R - For seamless tubes
- Flange test -do- -do- -do- P&W R - For welded tubes
C. PMI -do- -do- PMI report P&W RW - -
D. NDE
- Visual Inspection 100% -do- Report P&W W - -
- Dimensional check 20% -do- Inspection P&W W - -
report
- ECT of tubes 100% -do- ECT report P&W RW - -
QAP Date : 18 / 11 / 2013
Page : 2 of 5
TECHNICAL ADVISORY
2.2 Plates / Forging A. Chemical: Min. 1 As per applicable Test Report P&W R -
(Baffles, Tie- rods Chemical Analysis per each ASTM
& Tube sheet) heat
- Tensile test -do- -do- -do- P&W R - -
- Hardness test -do- -do- -do- P&W R - -
- % Elongation -do- -do- -do- P&W R - -
C. PMI 100% PO / Approved PMI report P&W W - -
drawings
D. Heat Treatment as 100% -do- HT Report P&W R - -
applicable
E. NDE: UFDT & 100% As per PO / approved Test report P&W R - -
DPT of tubesheet drawing
3.0 Inspection of Machined components:
3.1 Tube sheet - Visual Inspection 100% Approved drawing Report P&W W -
Machining - Flatness/Face out 100% -do- -do- P&W W -
- Dimensional 100% -do- -do- P&W W -
check like, thickness / holes,
ligaments etc.
3.2 Baffle Machining -do- 100% -do- -do- P&W RW -
3.3 Tube bundle cage Dimensional verification & 100% -do- -do- P&W RW -
and tube insertion visual check
3.4 Qualification of Visual inspection of tube 100% Approved Drawing Report P&W RW -
mock up procedure bundle with tubes inserted &
prior to rolling of tubes
3.5 Tube ID check after Dimensional verification & 100% -do- Report P&W RW -
expansion visual check
QAP Date : 18 / 11 / 2013
Page : 3 of 5
TECHNICAL ADVISORY
3.6 & tube end projection
4.0 Final Inspection
4.1 Visual & Overall dimensional check 100% Approved Drawing Dimensional P&W W -
Dimensional Check - Completeness of report
assembly & workmanship
etc.
4.2 Hydrotest HT to check the tube leak, 100% -do- Test report P&W W -
roll leak etc.
4.3 Cleaning & drying Drying by air blowing, 100% As per standard - P&W R
of tube bundle and N2 cleanliness, Nitrogen filling practice / PO
filling & proper preservation.
4.4 Final stamping of Stamping details Release 100% Approved Drawings - P&W R
heat exchanger & note
issue of release note
5.0 Documentation Verification for 100% PO / QAP Final Report P&W R
Completeness, Compilation
of inspection & test record
of TPI certified documents
for submission to HPCL.
LEGENDS - P : PERFORM W : WITNESS R : REVIEW H : HOLD RW : RANDOM WITNESS
NOTES:
1.0 Vendor:
1.1. Vendor shall forward the HPCL QAP to the TPI. TPI signature shall be taken on each page of HPCL QAP prior to commencement of order
execution confirming TPI acknowledgement of all QAP requirements. A copy of such acknowledgement shall be sent to HPCL for record
QAP Date : 18 / 11 / 2013
Page : 4 of 5
TECHNICAL ADVISORY

immediately.
1.2. The following are to be followed & ensured by Vendor:
a. All physical, chemical testing and microscopic examinations are to be carried out at NABL / HPCL approved laboratory. If the Lab is not
approved by HPCL then HPCL concurrence shall be taken prior to testing at the Lab.
b. The NDT reports shall be certified and approved by minimum ASNT/ISNT Level II qualified personnel. The microscopic examination shall
be carried out and certified by suitable qualified personnel.
c. All the reports reviewed/certified by TPI shall be submitted to HPCL in original.
1.3. A summary sheet stating fulfillment of all QAP items and requirements shall be prepared and sent to HPCL along with all relevant testing
certificates and documents and clearance to be taken from HPCL prior to dispatch of material. Also, the vendor shall fill up the last column of QAP
with “Done” or “Not Done” prior to dispatch of material and send the QAP copy to HPCL at the time of submission of all documents.
2.0 TPI
2.1. Each item shall be clearly marked with TPI stamping in addition to the other information as per standards/specification.
2.2. Stage wise clearance by TPI shall be obtained at the end of every stage as specified before proceeding to the next stage. Without TPI or HPCL
clearance, no hot job or repair is permitted on the finished material. (In case of repair, as permitted by ASTM standard, the procedure and extent
shall be duly approved/ witnessed by TPI and accepted with necessary NDTs).
2.3. In case the materials are manufactured exclusively for HPCL, only HPCL approved TPI Agencies shall be engaged. In other cases, TPI by
HPCL approved agencies shall be done additionally. HPCL shall be informed in writing the name of the approved TPI agency engaged for the job
along with the TPI inspector’s name, telephone number, e-mail ID etc. prior to proceeding with the inspection jobs.
2.4. Any deviations/ specific observations recorded by TPI in their report shall be reported to HPCL soon after TPI inspection.
2.5. The following are to be ensured by the TPI involved by the vendor:
QAP Date : 18 / 11 / 2013
Page : 5 of 5
TECHNICAL ADVISORY

a. All MTCs and other testing documents shall be signed as required clearly specifying whether satisfying and acceptable or not. Simple
comments like “Reviewed”, “Noted”, “Witnessed”, etc. are not acceptable.
b. Any deviations/ specific observations shall be recorded in their report and the same shall be reported to HPCL.
3.0 General
3.1. The material supplied if found to be not complying with any of the QAP items or “Note” requirements will be liable for rejection.
3.2. HPCL reserves the right to carry out inspection/ witness at any stage of QAP including after receipt and if the material found not conforming
with the required specification, it is liable for rejection.
3.3. Random Witness (RW) indicates 10% Witness, subject to minimum 1 no. each heat/lot
0 18/11/2013
Rev. Date Prepared by : Reviewed by : Approved by :

QAP Date : 09 / 02 / 2018
Page : 1 of 6
TECHNICAL ADVISORY
PROCUREMENT OF COPPER & COPPER ALLOY TUBES FOR CONDENSER AND HEAT EXCHANGER
EQUIPMENT OR COMPONENT
FROM MANUFACTURE DIRECTLY
1.0 Raw material (metallic parts) inspection:
1.1 Review of Review of 100% As per applicable Mill test & R R -
manufacturer’s certificates ASTM standard / PO NDT reports,
certificates - Material test requirements Dimensional
certificates check report,
(chemical and HT chart -
mechanical)
- heat treatment
details
- Hydro test details
- NDT Details
- Identification &
correlation /
transfer of making
2.0 Finished Tubes Chemical Testing: Sampling as per As per applicable ASTM Test report P& W R Sample to be
Chemical analysis applicable standard /PO stamped by TPI
ASTM std. (min requirements
l no. per lot)
Mechanical Properties:
A. Tensile Testing -do- As per applicable ASTM Test Reports P& W W -do-
standard / PO requirements
B. Hardness test (if -do- -do- -do- P& W RW -do-
applicable)
C. Flattening -do- -do- -do- P& W W -do-
QAP Date : 09 / 02 / 2018
Page : 2 of 6
TECHNICAL ADVISORY
D. Expansion -do- -do- -do- P& W W -do-
E. Microscopic -do- -do- -do- P& W W

Examination
F. Mercurous Nitrate -do- As per applicable ASTM Test Reports P& W -do-
test (If applicable) standard /PO
requirements
G. PMI Check 100% -do- PMI Report P& W W/20% -do-
H. Heat treatment of 100% -do- HT Report P& W R If applicable
the tubes after (review of HT
forming as chart)
applicable
2.1 NDT NDE:
A. Visual Inspection 100% As per applicable ASTM Inspection P& W RW
standard / PO requirements reports
B. Dimensional check. 100% -do- Dimensional P& W RW
reports
C. DPT of U section 100% -do- -do- P& W RW If applicable
of tubes (in case of
U tubes
D. ECT 100% -do- NDT Report P& W W
3.0 Hydrostatic test Hydro test 100% -do- Test P&W W
Certificate
4.0 Drying and Drying by air blowing 100% As per standard practice - P&W W Refer Note 1.6
preservation cleanliness & proper
preservation
QAP Date : 09 / 02 / 2018
Page : 3 of 6
TECHNICAL ADVISORY
5.0 Documentation Verification for 100% PO / QAP Final report P&W W Refer Note 1.3
completeness,
compilation of
inspection test records
of TPI certified
documents for
submission to
customer
NOTES:
1.0 Vendor
1.1 Vendor shall forward the HPCL QAP to the TPI. TPI signature shall be taken on each page of HPCL QAP prior to commencement of order execution
confirming TPI acknowledgement of all QAP requirements. A copy of such acknowledgement shall be sent to HPCL for record immediately.
1.2 The following are to be followed & ensured by Vendor:
a. All physical, chemical testing and microscopic examinations are to be carried out at NABL approved laboratory only.
b. The NDT reports shall be certified and approved by minimum ASNT/ISNT Level II qualified personnel. The microscopic examination shall be carried out
and certified by suitable qualified personnel.

QAP Date : 09 / 02 / 2018
Page : 4 of 6
TECHNICAL ADVISORY
1.3 After TPI clearance, vendor shall take dispatch clearance from HPCL concern before dispatch of material.
1.4 At every stage of QAP vendor shall forward relevant certificates or documents in support of the satisfactory completion of inspection activity at that stage as
per QAP and shall take clearance from HPCL in writing prior to proceeding further.
If TPI is involved in the inspection / review, vendor shall take stage wise clearances in writing from TPI with their signature and stamp and shall send the
TPI clearance documents for each stage as and when completed to HPCL for their information / record I clearance before proceeding to the next stage of
job.
1.5 A summary sheet stating fulfillment of all QAP items and requirements shall be prepared and sent to HPCL along with all relevant testing certificates and
documents and clearance to be taken from HPCL prior to dispatch of material. Also, the vendor shall fill up the last column of QAP with "Done" or "Not
done" prior to dispatch of material and send the QAP copy to HPCL at the time of submission of all documents.
1.6 The following are to be followed & ensured by vendor:
a. After completion of all testing and inspection, the inside of all tubes shall be thoroughly drained and dried out
b. Tube bundle shall be completely dried by passing hot air for sufficient time until no further increase in relative humidity of outgoing air is observed.
c. After drying all tube ends shall be suitably protected.
2.0 TPI
2.1 Each item shall be clearly marked with TPI stamping in addition to the other information as per standards/specification.
2.2 Stage wise clearance by TP1 shall be obtained at the end of every stage as specified before proceeding to the next stage. Without TPI or HPCL clearance, no
hot job or repair is permitted on the finished material. (In case of repair, as permitted by ASTM standard, the procedure and extent shall he duly approved/
witnessed by TP1 and accepted with necessary NDTs).
QAP Date : 09 / 02 / 2018
Page : 5 of 6
TECHNICAL ADVISORY
2.3 In case the materials are manufactured exclusively for HPCL, only HPCL approved TPI Agencies shall be engaged. In other cases, TPI by HPCL approved
agencies shall be done additionally. HPCL shall be informed in writing the name of the approved TPI agency engaged for the job along with the TPI
inspector's name, telephone number, e-mail ID etc. prior to proceeding with the inspection jobs.
2.4 Any deviations/ specific observations recorded by TPI in their report shall be reported to HPCL soon after TPI inspection.
2.5 The following are to be ensured by the TPI involved by the vendor:
a. All MTCs and other testing documents shall be signed as required clearly specifying whether satisfying and acceptable or not. Simple comments like
"Reviewed", "Noted", "Witnessed", etc. are not acceptable.
3.0 General
3.1 The material supplied if found to be not complying with any of the QAP items or "Note" requirements will be liable for rejection.
3.2 HPCL reserves the right to carry out inspection/ witness at any stage of QAP including after receipt and if the material found not conforming to the
required specification, it is liable for rejection.
3.3 Random Witness (RW) indicates 10% Witness, subject to minimum I no. each heat/lot, unless otherwise specified.
QAP Date : 09 / 02 / 2018
Page : 6 of 6
TECHNICAL ADVISORY
0 09/02/2018

तकनीकी सेवा ववभाग / TECHNICAL SERVICES DEPARTMENT Rev. : 01
QAP Date : 24 / 01 / 2014
Page : 1 of 5
TECHNICAL ADVISORY
CARBON STEEL EXCHANGER COMPONENTS (SHELL, SHELL COVER, CHANNEL, CHANNEL COVER
& FTS COVER)
1.0 Raw Materials: Review of Manufacturer’s 100% As per applicable Mill test & R R - - -
(Plates, Pipes, certificates: ASTM standard / NDT reports,
forgings, - Material test certificates PO requirements dimensional
Fasteners etc.) (chemicaland check report,
mechanical) HT chart
- NDT reports
- Heat treatment reports
- Hydrotest reports
- Identification &
markings.
2.0 Testing / NDE A. Chemical testing: Min. Oneper heat As per applicable Lab testReport P & W R - - -
Plates / Pipes & - Chemical Analysis ASTM standard /
forging PO requirements
B. MechanicalProperties:
- Tensile test Min. Oneper As per applicable Test Report P&W R - - -
- Hardness test heat ASTM standard /
- % Elongation PO requirements
C. NDE
- UFDT of plates /forging 100% -do- Inspection P&W W - - -
report
- Visual & dimensional 100% -do- -do- P&W W - - -
Inspection
3.0 Inspection of - Visual & Dimensional 100% As per PO / Inspection P&W W -
formed Inspection including the Approved Report
components shell plate after rolling & Drawing
QAP Date : 24 / 01 / 2014
Page : 2 of 5
TECHNICAL ADVISORY
& FTS COVER)
bending .
- Heat Treatment (as 100% Applicable std HT Chart P&W R - - -
applicable)
- DPT of knuckle (I/S & 100% As per approved Inspection P&W W - - -
O/S) surface and weld Drawings Report
edge.
4.0 Welding Qualification &Inspection (As applicable)
4.1 WPS / PQR Review for conformityto 100% As per applicable WPS / PQR / P&W R - - -
/WPQ requirement ASME standard / WPQ
Approved Dwg
4.2 Welding Welding consumablesvisual Min. 2 nos. from -do- Approved P&W RW - - -
inspection inspection (HPCL each lot. certificates
approved)
5.0 Fabrication
5.1 Fit-ups of Visual & Dimensionalcheck 100% As per applicable Inspection P&W W - - -
Pressure parts ASME std / PO checklist
(incl. alignment requirements
of L/S, Sections
& Nozzle
settings)
5.2 Root DPT Visual and DPT afterroot 100% As per approved Inspection &W RW - - -
of welds pass welding. drawing Checklist
5.3 Inspection - Visual Inspection 100% As per approved -do- P& W W - - -
of drawing / ASME
completed Sec VIII-1
welds - UFDT of Shell tonozzle 100% As per ASTM / PO UFDT Report P& W R - - -
QAP Date : 24 / 01 / 2014
Page : 3 of 5
TECHNICAL ADVISORY
& FTS COVER)
welds
- DPT/MPT of weldsof 100% -do- Reports P& W RW - - -
lugs with pressure part
- RT of butt welds 100% -do- RT Reports P& W R - - -
(films)
- RF pas air test 100% No leaks Inspection P& W W - - -
report
6.0 Visual Overall dimensional check, 100% Approved Drawing Report P&W W -
&Dimensional completeness ofassembly & / PO
check workmanship etc
7.1 General Visual Inspection of 100% Inspection Std. Report P&W R -
Inspection workmanship, DFT of
external painting.
7.2 Final Stamping & Stamping details &release 100% Approved Drawing Name plate / P&W -
issue of release note / PO Rub-off
note
8.0 Documentation Verification for 100% PO / QAP Final Report P&W R -
Completeness,
Compilation of
inspection & test record
of TPI certified
documents for
submission to HPCL.

QAP Date : 24 / 01 / 2014
Page : 4 of 5
TECHNICAL ADVISORY
& FTS COVER)
NOTES:
1.0 Vendor:
1.1. Vendor shall forward the HPCL QAP to the TPI. TPI signature shall be taken on each page of HPCL QAP prior to commencement of order execution confirming TPI
acknowledgement of all QAP requirements. A copy of such acknowledgement shall be sent to HPCL for record immediately.
a. The NDT reports shall be certified and approved by minimum ASNT/ISNT Level II qualified personnel. The microscopic examination shall be carried out and certified
by suitable qualified personnel.
b. All the reports reviewed/certified by TPI shall be submitted to HPCL in original.
1.3. A summary sheet stating fulfillment of all QAP items and requirements shall be prepared and sent to HPCL along with all relevant testing certificates and documents and
clearance to be taken from HPCL prior to dispatch of material. Also, the vendor shall fill up the last column of QAP with “Done” or “Not Done” prior to dispatch of
material and send the QAP copy to HPCL at the time of submission of all documents.
2.0 TPI
2.2. Stage wise clearance by TPI shall be obtained at the end of every stage as specified before proceeding to the next stage. Without TPI or HPCL clearance, no hot job or
repair is permitted on the finished material. (In case of repair, as permitted by ASTM standard, the procedure and extent shall be duly approved/ witnessed by TPI and
accepted with necessary NDTs).
2.3. In case the materials are manufactured exclusively for HPCL, only HPCL approved TPI Agencies shall be engaged. In other cases, TPI by HPCL approved agencies
shall be done additionally. HPCL shall be informed in writing the name of the approved TPI agency engaged for the job along with the TPI inspector’s name,
telephone number, e-mail ID etc. prior to proceeding with the inspection jobs.
QAP Date : 24 / 01 / 2014
Page : 5 of 5
TECHNICAL ADVISORY
& FTS COVER)
a. All MTCs and other testing documents shall be signed as required clearly specifying whether satisfying and acceptable or not. Simple comments like “Reviewed”,
“Noted”, “Witnessed”, etc. are not acceptable.
3.0 General
3.2. HPCL reserves the right to carry out inspection/ witness at any stage of QAP including after receipt and if the material found not conforming with the required
specification, it is liable for rejection.
1 24/01/2014
0 25/06/2012
QAP Date : 05 / 03 / 2012
Page : 1 of 6
TECHNICAL ADVISORY
FINNED TUBES (STAINLESS STEEL, DUPLEX STAINLESS STEEL & ALLOY STEEL) FOR AIR FIN
COOLERS PROCURED FROM VENDOR
Acceptance Check
norms
1.0 Raw Material (metallic parts) inspection:
1.1 Review of Review of certificates 100% As per applicable Mill test & R R - - -
Manufacturer’s – Material test certificates ASTM standard / NDT reports,
certificates (chemical and mechanical) PO requirements dimensional
- NDT reports check report,
- Heat treatment reports HT chart
- Hydrotest reports
- Identification & correlation
/ transfer of markings.
2.0 Finished Tubes Chemical Testing: Sampling as per As per applicable Test report P&W R - - -
Chemical analysis appl ASTM std ASTM standard /
(min 1 no. per lot) PO requirements
Mechanical Properties:
A. Tensile Test -do- -do- Test reports P&W R -
B. Hardness test -do- -do- -do- P&W RW -

C. Flattening -do- -do- -do- P&W R -
D. Flaring -do- -do- -do- P&W R -
E. Microscopic examination -do- -do- -do- P&W R - Review of
(grain size) microstructure for
AS & DSS tubes
F. Sulphide Stress Cracking Sampling as per As per EIL std 6- Test reports P&W R - For DSS tube only
(SSC) test EIL std no. 6-79- 79-0015 Rev. 0
0015 Rev 0 (min 1
no. per heat)
QAP Date : 05 / 03 / 2012
Page : 2 of 6
TECHNICAL ADVISORY
Acceptance Check
norms
G. Chloride Stress Cracking -do- -do- -do- P&W R - -do-
(CSC) test
H. Pitting Corrosion Test -do- -do- -do- P&W R - -do-
I. Crevice Corrosion test -do- -do- -do- P&W R - -do-
J. PMI Check 100% As per applicable PMI Reports P&W RW -
ASTM standard /
PO requirements
K. Heat treatment 100% -do- HT Chart P&W R - Review of HT charts
(Annealing) as applicable
2.1 NDT NDE:
A. Visual Inspection & 100% -do- Inspection P&W RW -
dimensional check. Report
B. IRIS / RFET of tubes 100% -do- IRIS / RFET P&W RW -
reports
3.0 Welding of studs Review for conformity of 100% ASME Sec IX / Inspection P&W RW - -
Qualification WPS qualification requirement Drawing Report
/ PQR / WPQ
4.0 Fins Chemical Testing: Sampling as per As per applicable Test P&W R - -
(i) Chemical Analysis appl ASTM std ASTM standard / Certificate
(Min 1 No. per PO requirements
each heat)
(ii) PMI check 100% -do- PMI Report P&W RW - -
5.0 Final NDT of Visual Inspection & 100% As per applicable Inspection P&W W - -
finned tubes dimensional check ASTM standard / report
PO requirements
QAP Date : 05 / 03 / 2012
Page : 3 of 6
TECHNICAL ADVISORY
Acceptance Check
norms
6.0 Hydrostatic test Hydrotest 100% -do- Test P&W W - Refer Note 3.3
certificate
7.0 Drying and Drying by air blowing 100% As per standard - P&W RW R Refer Note 1.6
preservation cleanliness & proper practice
preservation
8.0 Documentation Verification for 100% PO / QAP Final report P&W R -
completeness, compilation of
inspection test records of TPI
certified documents for
submission to customer

NOTES:
1.0 Vendor:
1.1. Vendor shall forward the HPCL QAP to the TPI. TPI signature shall be taken on each page of HPCL QAP prior to commencement of order execution confirming TPI
acknowledgement of all QAP requirements. A copy of such acknowledgement shall be sent to HPCL for record immediately.
a. All physical, chemical testing and microscopic examinations are to be carried out at NABL approved laboratory only.
b. The NDT reports shall be certified and approved by minimum ASNT/ISNT Level II qualified personnel. The microscopic examination shall be carried out and certified
by suitable qualified personnel.
QAP Date : 05 / 03 / 2012
Page : 4 of 6
TECHNICAL ADVISORY
1.3. Vendor shall certify that gaskets meet compressibility and seal ability test requirement as per relevant codes.
1.4. At every stage of QAP vendor shall forward relevant certificates or documents in support of the satisfactory completion of inspection activity at that stage as per QAP
and shall take clearance from HPCL in writing prior to proceeding further.
If TPI is involved in the inspection / review, vendor shall take stage wise clearances in writing from TPI with their signature and stamp and shall send the TPI clearance
documents for each stage as and when completed to HPCL for their information / record / clearance before proceeding to the next stage of job.
1.5. A summary sheet stating fulfillment of all QAP items and requirements shall be prepared and sent to HPCL along with all relevant testing certificates and documents and
clearance to be taken from HPCL prior to dispatch of material. Also, the vendor shall fill up the last column of QAP with “Done” or “Not Done” prior to dispatch of
material and send the QAP copy to HPCL at the time of submission of all documents.
1.6 The following are to be followed & ensured by vendor:
a. After completion of all testing and inspection, the inside of all tubes shall be thoroughly drained and dried out
b. Tubes shall be completely dried by passing hot air for sufficient time until no further increase in relative humidity of outgoing air is observed.
c. After drying all tube ends shall be suitably protected.
2.0 TPI
QAP Date : 05 / 03 / 2012
Page : 5 of 6
TECHNICAL ADVISORY
2.2. Stage wise clearance by TPI shall be obtained at the end of every stage as specified before proceeding to the next stage. Without TPI or HPCL clearance, no hot job or
repair is permitted on the finished material. (In case of repair, as permitted by ASTM standard, the procedure and extent shall be duly approved/ witnessed by TPI and
accepted with necessary NDTs).
2.3. In case the materials are manufactured exclusively for HPCL, only HPCL approved TPI Agencies shall be engaged. In other cases, TPI by HPCL approved agencies
shall be done additionally. HPCL shall be informed in writing the name of the approved TPI agency engaged for the job along with the TPI inspector’s name,
telephone number, e-mail ID etc. prior to proceeding with the inspection jobs.
a. All MTCs and other testing documents shall be signed as required clearly specifying whether satisfying and acceptable or not. Simple comments like “Reviewed”,
“Noted”, “Witnessed”, etc. are not acceptable.
3.0 General
3.2. HPCL reserves the right to carry out inspection/ witness at any stage of QAP including after receipt and if the material found not conforming with the required
specification, it is liable for rejection.
QAP Date : 05 / 03 / 2012
Page : 6 of 6
TECHNICAL ADVISORY
0 05/03/2012

QAP Date : 05 / 08 / 2015
Page : 1 of 5
TECHNICAL ADVISORY
STAINLESS STEEL EXCHANGER COMPONENTS (SHELL, SHELL COVER, CHANNEL, CHANNEL

COVER & FTS COVER)
Acceptance Check
norms
1.0 Raw Review of 100% As per Mill test & R R - - -
Materials: Manufacturer's applicable NDT reports,
(Plates, Pipes, certificates: ASTM standard / dimensional
forgings, -Material test PO requirements check report,
Fasteners etc.) certificates (chemical and HT chart
mechanical)
- NDT reports
- Heat treatment reports -
Hydrotest reports
- Identification &
markings.
-PMI of all material
2.0 Testing / NDE A. Chemical testing:
Plates / Pipes & - Chemical Analysis Min. One per heat As per Test Report P&W R - - -
Forging applicable
Standard/ PO
-IGC Test -do- As per A262 Test Report P&W R - - -
Practice E
- Tensile test Min. One As per Test Report P&W R - - -
- Hardness test per heat applicable
- % Elongation Standard/ PO
Requirement
C. NDE
QAP Date : 05 / 08 / 2015
Page : 2 of 5
TECHNICAL ADVISORY

COVER & FTS COVER)
Acceptance Check
norms
- UFDT of plates / forging 100% -do- Inspection P&W W - - -
Report
- Visual & dimensional 100% -do- Inspection P&W W - - -
Inspection Report
3.0 Inspection of -Visual & Dimensional 100% As per PO / Inspection P&W W - - -
Formed Inspection including the shell Approved
components plate after rolling & bending Drawing
Applicable std.
- Heat Treatment (as 100% As per approved HT Chart P&W R - - -
applicable)
-DPT of knuckle 100% Drawings Inspection P&W W - - -
(I/S & 0/S) surface and weld Report
edge.
4.0 Welding Qualification & Inspection (As applicable)
4.1 WPS / PQR / Review for conformity to 100% As per WPS / P&W R - - -
WPQ requirement applicable PQR/WPQ
ASME standard
4.2 Welding -Welding consumables 100% -do- Approved P&W R - - -
inspection visual inspection certificates
(HPCL approved)
5.0 Fabrication
5.1 Fit-ups of Visual & Dimensional 100% As per Inspection P&W W - - -
Pressure parts Check applicable checklist
(incl. ASME std / PO
alignment of Requirements
QAP Date : 05 / 08 / 2015
Page : 3 of 5
TECHNICAL ADVISORY

COVER & FTS COVER)
Acceptance Check
norms
L/S, Sections &
Nozzle settings)
5.2 Root DPT of Visual and DPT after 100% As per approved Inspection P&W R - - -
Welds root pass welding. dwg Checklist
5.3 Inspection of -Visual Inspection 100% As per approved Inspection P&W W - - -
completed Dwg. / ASME Checklist
welds Sec VIII-1
- UFDT of Shell to nozzle welds 100% As per ASTM / UFDT P&W W - - -
PO Report
- DPT/MPT of welds 100% -do- Reports P&W R - - -
of lugs with pressure part
- RT of butt welds 100% -do- RT Reports P&W R - - -
(films)
- RF pad air test 100% No leaks P&W W - - -
6.0 Visual & Overall dimensional check,. 100% Approved Report P&W W - - -
Dimensional completeness of assembly & Drawing / PO
Check workmanship etc
6.1 Dummy Bundle passing through shell 100% -do- Inspection P&W W - - -
passing for as per Report
Shell the specification
7.1 Final Stamping details & 100% Approved Name plate P&W R - - -
Stamping & release note Drawing,/PO /Rub-off
issue of release
note
QAP Date : 05 / 08 / 2015
Page : 4 of 5
TECHNICAL ADVISORY

COVER & FTS COVER)
Acceptance Check
norms
8.0 Documentation Verification for 100% PO / QAP Final Report P&W R - - -
Completeness, Compilation
of inspection & test record of
TPI certified documents for
submission to HPCL.
NOTES:
1. Important Notes
a. The above QAP is general in nature.
b. Specific requirement to any particular equipment would be separately advised
2. Note to Vendor/TPI
a. Vendor shall forward HPCL QAP to TPI. TPI signature shall be taken on each page of HPCL QAP prior to commencement of order ex ecution.
b. All test as applicable, are to be carried out at NABL approved laboratory only
c. TPI shall fill up the last column of QAP with 'Done' or 'Not Done' and shall sent along with the dossier.
QAP Date : 05 / 08 / 2015
Page : 5 of 5
TECHNICAL ADVISORY

COVER & FTS COVER)
d. Random witness (RW) indicates 10% witness, subject to minimum 1 no. each heat/lot.
e. Inspection by HPCL or HPCL nominated agency.
0 05/08/2015

C1230D Intercooler Specifications

Uploaded by

Copyright:

Available Formats

You might also like

C1230D Intercooler Specifications

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

C1230D Intercooler Specifications

Uploaded by

Copyright:

Available Formats

C1230D Intercooler Specifications

C1230D/ C1230E Interstage cooler current operating parameters are as follows:

 Water flow: 9.3 m3/hr

Vendor to consider following MOC for the intercooler:

 Tube plate (ST) : C.S. SA 516 Gr. 70 epoxy coating

EQUIPMENT OR COMPONENT TUBE BUNDLE WITH NON-FERROUS TUBES

EQUIPMENT OR COMPONENT TUBE BUNDLE WITH NON-FERROUS TUBES

EQUIPMENT OR COMPONENT TUBE BUNDLE WITH NON-FERROUS TUBES

LEGENDS - P : PERFORM W : WITNESS R : REVIEW H : HOLD RW : RANDOM WITNESS

EQUIPMENT OR COMPONENT TUBE BUNDLE WITH NON-FERROUS TUBES

1.2. The following are to be followed & ensured by Vendor:

c. All the reports reviewed/certified by TPI shall be submitted to HPCL in original.

EQUIPMENT OR COMPONENT TUBE BUNDLE WITH NON-FERROUS TUBES

Rev. Date Prepared by : Reviewed by : Approved by :

E. Microscopic -do- -do- -do- P& W W

LEGENDS - P : PERFORM W : WITNESS R : REVIEW H : HOLD RW : RANDOM WITNESS

1.2 The following are to be followed & ensured by Vendor:

c. All the reports reviewed/certified by TPI shall be submitted to HPCL in original.

1.6 The following are to be followed & ensured by vendor:

c. After drying all tube ends shall be suitably protected.

Rev. Date Prepared by : Reviewed by : Approved by :

LEGENDS - P : PERFORM W : WITNESS R : REVIEW H : HOLD RW : RANDOM WITNESS

1.2. The following are to be followed & ensured by Vendor:

b. All the reports reviewed/certified by TPI shall be submitted to HPCL in original.

B. Hardness test -do- -do- -do- P&W RW -

LEGENDS - P : PERFORM W : WITNESS R : REVIEW H : HOLD RW : RANDOM WITNESS

1.2. The following are to be followed & ensured by Vendor:

c. All the reports reviewed/certified by TPI shall be submitted to HPCL in original.

1.6 The following are to be followed & ensured by vendor:

c. After drying all tube ends shall be suitably protected.

Rev. Date Prepared by : Reviewed by : Approved by :

STAINLESS STEEL EXCHANGER COMPONENTS (SHELL, SHELL COVER, CHANNEL, CHANNEL

STAINLESS STEEL EXCHANGER COMPONENTS (SHELL, SHELL COVER, CHANNEL, CHANNEL

STAINLESS STEEL EXCHANGER COMPONENTS (SHELL, SHELL COVER, CHANNEL, CHANNEL

STAINLESS STEEL EXCHANGER COMPONENTS (SHELL, SHELL COVER, CHANNEL, CHANNEL

LEGENDS - P : PERFORM W : WITNESS R : REVIEW H : HOLD RW : RANDOM WITNESS

a. The above QAP is general in nature.

b. Specific requirement to any particular equipment would be separately advised

STAINLESS STEEL EXCHANGER COMPONENTS (SHELL, SHELL COVER, CHANNEL, CHANNEL

e. Inspection by HPCL or HPCL nominated agency.

Rev. Date Prepared by : Reviewed by : Approved by :

You might also like