sec 1.i_typical quality assurance & inspection plan

7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan

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UF13006_ACRON_H201 rev02

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8, COURSLOUIS LUMIERE

94306 VINCENNES CEDEX

FRANCE

SPECIFICATIONOF

QUALITY CONTROL & INSPECTION PLAN

FOR

TUBULAR REFORMER

JSC “ACRON” – AMMONIA PLANT 4DDP Ancor Jobsite - VELIKY NOVGOROD

RUSSIA

Item:

H-201

02 Jun. 13 Adding convection section, air ducts

and flue gas ductsKB GGU MP

01 Oct. 13 Adding Piping and DeNOx unit KB GGU MP Customer : ACRON

Process Licensor : HALDOR TOPSOE 00 Sept. 13 First Issue KB GGU MP

REV. DATE DESCRIPTION

BY/PAR VISA BY/PAR VISA BY/PAR VISA

HPC Ref: UF 13006 ISSUED ETABLI

CHECKED VERIFIE

APPROVED APPROUVE

This document contains proprietary information belonging to HEURTEY PETROCHEM, its parent and/or affiliated companies and shall be used only for the purpose for which it was supplied. It shall not becopied, reproduced or otherwise used, nor shall such information be furnished in whole or in part to others, except in accordance with the terms of any agreement under which it was supplied or with theprior written consent of HEURTEY PETROCHEM and shall be returned upon request.Ce document contenant des informations confidentielles est la propriété de HEURTEY PETROCHEM, ses filiales et compagnies associées. Il ne peut être copié, reproduit, divulgué ou utilisé de quelque façonque ce soit, aussi bien dans sa totalité que partiellement, excepté en accord avec l es termes d’un engagement préétabli ou d’ autorisation formelle de HEURTEY PETROCHEM (retour à première demande).

CONTENTS LIST UF 13006

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CHAPTER DESIGNATION Note

I n s p e c t i o n

l e v e l

Revision

0 1 2 3 4

GENERAL NOTE “SCOPE OF INSPECTION” X

1 Inlet distributors 4 X

2 Combustion air preheater – E205 4 X

3 Steam fired combustion air preheater – E220 4 X

4 Burners 4 X

5 Air Blowers – K 201 & K 202 4 X

6 Hairpin tube in gas inlet and braces 4 X

7 Hairpin tube in gas outlet 4 X

8 Loose parts for catalyst tubes 4 X

9 Cold outlet collector 4 X

10 Hot Collectors 4 X

11 Radiant casing with grating, ladders and platforms 4 X

12 Convection casing with grating, ladders and platforms 4 X

13 Prefabrication of piping 4 X X

14 DeNOx D251 4 X X

15 Convection section 4 X

16 Flue gas ducts casing and air ducts casing 4 X

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SCOPE of INSPECTIONFor

Tubular Reformer

GENERAL

1. PurposeThe Purpose of this Specification is to describe the Scope of inspection activities of HEURTEY PETROCHEM'sand of this customer ACRON for the AMMONIA PLANT 4, in DDP Ancor Jobsite VELIKY NOVGOROD, RUSSIANFederation.

2. VENDOR’s Responsibility

2.1 Vendor will remain fully responsible for the compliance of the fabrication processes, quality control processes,etc., with the applicable Laws, Regulations, Codes and all Project Specifications.

HEURTEY PETROCHEM and/or “ ACRON” inspection activities will never release the Vendor from the above

responsibilities.

2.2 As required in the Purchase Order and HPC Requisition "Documentation to be furnished by Vendor" which isindicated to the Specification, the Vendor (HPC Supplier) shall supply an Inspection and Test Plan (ITP)with detailed description of every Q-C/Inspection step required by the Laws, Regulations Codes,Project specifications, requisition, etc....

The Vendor's ITP will be reviewed and approved by HEURTEY PETROCHEM. HEURTEY PETROCHEMwill confirm its own scope of inspection and/or Client scope upon first submittal of the ITP by Vendor.

The ITP will be always submitted to HEURTEY PETROCHEM at least four (4) weeks prior to holding thePre-Production Meeting and/or Pre-Inspection Meeting.

3. Applicable PROCEDURES, SPECIFICATION…

3.1 Client Specifications:

3.1.1 Main documents for Tubular ReformerREF51001-Rev.0-H 201-List of documents for reformer radiant & convection sectionREF51002-Rev.0-H 201-Primary reformer_radiant section General arrangementREF51004-Rev.1-H 201-List of main componentsREF51005-Rev.0-H 201-Primary reformer_radiant section General arrangement of gas inletREF51006-Rev.0-H 201-Primary reformer_radiant section General arrangement of gas outletREF51007-Rev.1-H 201-Primary reformer_radiant section Inlet distributorREF51009-Rev.0-H 201-Primary reformer specification for low alloy inlet distributorREF51011-Rev.1-H 201-Primary reformer_radiant section Hairpin tube in gas inlet

REF51013-Rev.0-H 201-Primary reformer specification for hairpin tubes in gas inletREF51015-Rev.1-H 201-Primary reformer_radiant section Catalyst tube support_ flange_ two-part ring and gridREF51018-Rev.1-H 201-Primary reformer_radiant section Hairpin tube in gas outletREF51019-Rev.0-H 201-Primary reformer specification for hairpin tubes in gas outletREF51020-Rev.1-H 201-Primary reformer_radiant section Hot collectorREF51021-Rev.0-H 201-Primary reformer specification for hot collectorREF51024-Rev.0-H 201-Primary reformer_radiant section Cold outlet collectorREF51026-Rev.0-H 201-Primary reformer specification for refractory lining in cold collectorREF51027-Rev.0-H 201-Tubular reformer_radiant section Instrument connection for cold collectorREF51030-Rev.0-H 201-Primary reformer specification for field welding of inlet hairpin tubesREF51032-Rev.0-H 201-Primary reformer specification for field welding of outlet hairpin tubesREF51041-Rev.0-H 201-Primary reformer_radiant section General arrangement of steel structure. part IREF51042-Rev.0-H 201-Primary reformer_radiant section General arrangement of steel structure_ part II

REF51043-Rev.0-H 201-Primary reformer_radiant section Typical details of steel structure and casing

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REF51044-Rev.0-H 201-Primary reformer specification for radiant and convection section steel structure and casingREF51045-Rev.0-H 201-Primary reformer_radiant section Reformer roofREF51048-Rev.0-H 201-Primary reformer_radiant section arrangement of platforms_ ladders and stairwaysREF51050-Rev.0-H 201-Tubular reformer_radiant section Braces for hairpin tubes in gas inletREF51051-Rev.0-H 201-Primary reformer_radiant section Guide ring for catalyst tubeREF51052-Rev.0-H 201-Tubular reformer_radiant section Access doorREF51053-Rev.0-H 201-Tubular reformer_radiant section Spring support for hairpin tube in gas inletREF51054-Rev.0-H 201-Primary reformer_radiant section Spring support for hairpin tube in gas outletREF51055-Rev.0-H 201-Primary reformer_radiant section Counterweight for hot collectorREF51056-Rev.0-H 201-Tubular reformer_radiant section Burner plate and refractory block

REF51059-Rev.0-H 201-Tubular reformer_radiant section General arrangement of refractory liningREF51060-Rev.0-H 201-Tubular reformer Typical refractory lining detailsREF51061-Rev.0-H-201-Tubular reformer radiant and convection section specification for refractory liningREF51065-Rev.0-H 201-Primary reformer_radiant section Insulation for hot partsREF51066-Rev.0-H 201-Tubular reformer_radiant section Arrangement of combustion air ductingREF51068-Rev.0-H 201-Primary reformer radiant and convection section specification for erectionREF51071-Rev.0-H 201-General arrangement Sketch of convection sectionREF51072-Rev.0-H 201-Tubular reformer specification for convection sectionREF51074-Rev. 0-H 201-Tubular reformer_radiant section Plinth layout (preliminary)

3.1.2 Other Specifications for Tubular Reformer:J61024-Rev.0-Typical Hook-up Drawings for Instrumentation in Petrochemical PlantsJ61025-Rev.0-General specification for instrument erection materials (piping & tubing)

J63203-1-Rev.0-Detailed specification for thermocouples in flue gas ductsJ63203-2-Rev.0-Detailed specification for thermocouples in primary reformer hot collectorJ63203-3-Rev.0-Detailed specification for thermocouples in primary reformer cold collectorP41001-Rev.0-MSD1-Reforming w_FD L2-Desulphurization and Reforming[1]P41401-Rev.1-C4 PFD1-Reforming-Desulphurization and ReformingP42103-Rev.0-P03-Natural gas preheatP42104-Rev.0-P04-Process air preheatP42105-Rev.0-P05-Hp steam superheatP42106-Rev.0-P06-Feed_steam mixingP42107-Rev.0-P07-Reformer convection sectionP42108-A-Rev.0-P08A-Flue gas blowerP42108-B-Rev.0-P08B-Combustion air blowerP42109-Rev.0-P09-Primary reformer fuel control

P42110-Rev.0-P10-Primary reformerP51201-H-002-Rev.0-Primary reformer gas burnersP51201-H-005-Rev.0-WHS-Convection Section CoilsP51201-H-Rev.0-H 201-Primary ReformerP51205-E-Rev.1-E 205 _ E 220-Combustion air preheatersP54251-V-Rev.0-V 251-Ammonia water storage tankP56201-K-Rev.0-K 201-Flue gas blowerP56202-K-Rev.0-K 202-Combustion air blowerP56251-K-Rev.0-K 251-Ammonia mixing blowerP59201-X-Rev.0-X 201-Flue gas stackP59251-J-Rev.0-Specification for J 251 DeNOx inlet sample ejectorP59252-J-Rev.0-Specification for J 252 DeNOx outlet sample ejector

3.2 HPC Documents :

3.2.1 Data Sheets (FJ)

3.2.2 Technical Specification (FS)

3.2.3 Drawings (FD)

3.2.4 Calculation Notes (FC)

3.2.5 General Specification (SG)

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4. Specific and/or Important Requirements

4.1 Inspection Levels for Materials and Equipments

The inspection Levels for materials and/or equipments are as follow:

Level 0: No Inspection required; No Inspection Certificate required

Level 1: Documentation review only; Inspection Release Note (IRN) required

Level 2: Only final inspection required prior to Shipment; Inspection Release Note (IRN) required

Level 3: Inspection of all Witness and Hold points required by approved Supplier ITP and Scope ofinspection; Inspection Release Note (IRN) required

Level 4: Include Pre-Inspection Meeting (PIM), Inspection of all Witness and Hold points required by approvedSupplier ITP and Scope of inspection; Inspection Release Note (IRN) required

Level 5: Level 4 + Monitoring/expediting visits on regular basis (Weekly, Bi-weekly, Monthly…). Thefrequency visits shall be decided by HPC Project manager

Level 6: Level 4 + a full time resident inspector continuously, monitoring the fabrication (progress and quality); thecommencement of the resident status shall be decided by HPC Project manager.

4.2 Material test Certificates

For pressure retaining parts and all elements welded to the pressure retaining parts:

Vendor shall provide Mill certificates ASME (SA) / ASTM / EN-10204, 3.1 or 3.2 types which will give atleast the following data for each heat and/or heat treatment batch:

Material specification references

Heat number

Material description (plate thickness, tube diameter, thickness, etc...)

Material specification minimum requirements,

Actual chemical analysis, mechanical tests results,

Heat treatment conditions of the material (if required), with records/charts

Heat treatment conditions of the mechanical test samples,

Non-destructive tests (if required) fully documented results

MDMT: Minimum Design Metal Temperature

For Non-pressure parts:HEURTEY PETROCHEM recommends the Vendor to provide Material Certificates as above describedbut is ready to accept certificates of compliance for these parts unless required otherwise by the Laws,Regulations on Codes

Note: HEURTEY PETROCHEM reserves the right to reject all material Test Certificates altered by reproduction(photocopy) and/or illegible and/or not signed and dated by the Mill QC Responsible or not in compliance withthe latest edition of Material Specification in accordance with its requirements.

IMPACT Test: Vendor will refer to MDMT (Minimum Design Metal Temperature) stated in the applicable datasheet to HEURTEY PETROCHEM equipment data, to get the execution temperature of impact test.

4.3 Welding Consumables

For pressure retaining parts:For welding consumables used for execution of pressure retaining welds, the Vendor shall provide Millcertificate as described in applicable code, standard, according to ASME or EN-10204 (Certificate 3.1 or3.2 type).

A welding consumables used shall have a chemical composition which shall be within the range of thatspecified for the vessel shell and mechanical properties that are within range of that specified in theheat-treated condition.

When required by the contract, the conformity to the MDMT (as required hereafter in thisspecification) shall be indicated on the certificates

For Non-pressure parts:HEURTEY PETROCHEM recommends the Vendor to provide Material Certificates as above described

but is ready to accept certificates of compliance for these parts unless required otherwise by the Laws,Regulations on Codes

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4.4 Refractory Bricks and Shapes

Use/Classification, Design, Supply, Installation and Maintenance of all REFRACTORY Materials shallcomply and in according with ISO 13705 (API560) section 11, as well as the following ISO Norms and/or ASTM Specification:

Fireclay brick: ISO 1109, ISO/DIS 10081, ASTM C27

Insulating Firebrick: ISO 2245, ASTM C155

Castable Refractory: ISO 1927, ASTM C401 (class N, O, P, Q or R)

Insulating Block (Mineral Slag wool, Neutral pH): ASTM C612 Cl5

4.5 Steel Structures

The steel Structure shall be in accordance with ISO 13705 (API560) Section 12The design and Engineering of building shall comply with all codes, norms and others regulations applicableThe effects of fatigue shall be verified in compliance with ANSI/AWS D1.1.

5. Manufacturer’s Record Book “MRB”

The details of the content and format of the manufacturer's file shall be discussed during Pre-Fabrication and/orPre-inspection Meeting (PIM), if any.This PIM wil l be held b efore commencement o f fabr icat ion and af ter f i rs t review, comments, approval of

manufacturer’s documents and drawings The Vendor will compile the Manufacturer's File progressively during the fabrication and will keep it up to date andwill make it available to HEURTEY PETROCHEM inspector during each visit.

6. Reminder

We remind the Vendor that the documents listed here below must be sent by fax and/or mailed to the followingaddresses:

Please contact Mrs. Elmira ZAKIROVA Tel: +7 (812) 448 76 80Email: [email protected]

Adresse: HEURTEY PETROCHEM SAService Gestion Documentation Technique 8, Cours Louis Lumière94306 VINCENNES Cedex - FRANCE

Detailed Inspection Test Plan (ITP) defining Main elements to be testedList of control & test operations carried out by the Vendor under his responsibility. Sub-contractorinspection & test plan, more detailed shall be issued.

Welding Book including Weld map, WPS and PQR NDE Procedures (RT, PT, MT, US “if required”…) PWHT Procedure (When applicable) Hardness test Procedure

PMI Procedure (if any) Notification for Inspection Form Non-Conformance reports Form Preservation, Packing Procedure Name plate (When required) Etc…

7. Main REQUIREMENTS

The Purchaser, Client reserves the right to witness or audit the Supplier's Quality Control at the Vendor'sfacilities when deemed necessary.

When code requirements are more stringent they shall prevail over the requisition, specification and

standards; should any doubt arise regarding the rules, the SELLER shall submit to the BUYER, all request ofdeviations and/or clarifications and obtain a written approval before proceeding.

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Inspection authorities or people attending the controls & test

Controls and/or tests carried out by the VENDOR i.e. Subcontractor / Manufacturer are indicated by a cross(X) in the relevant column.

7.1 Pre-Award Meeting/Kick-off Meeting (KOM) and Pre-Inspection Meeting (PIM)

For certain Purchase Order, a Pre-Award meeting/Kick-off meeting could be scheduled. This meeting could becarried out in the HPC offices or in the supplier workshop.

Before commencement of Fabrication and minimum after first review/approval of manufacturer’s quality

documents, drawings and others documents, a PIM shall be obligatory performed on all main Purchase Order.This point will be indicated in the Scope of Inspection.

During the PIM, the following minimum requirement above, concerning the fabrication, the inspection and thetests shall be discussed to be in accordance to PO requirement:

- Review of technical requirements, covering codes, governing codes and/or standards- Final review of vendor’s detailed ITP - Review of fabrication & control/tests procedures submitted or to be submitted- Review of schedule of document’s submission - Review of sub. P.O. & their requirements- Review of fabrication schedule- Review finalization of Sub-Supplier inspection and test plan. (if any)- Welding and Heat treatment

- Material test report, Traceability… - Non-conformances- Supplier personnel qualification & training- Supplier documentation schedule timing for submission- Proposed Sub-suppliers review of suborders requirements- Records, reports and documentation data book- Workshop tour

7.2 Detail of INSPECTION POINTS

The interventions carried out by HEURTEY PETROCHEM (HPC), his CLIENT and/or the OFFICIAL INSPECTION AUTHORITY is indicated in the relevant column according to the type of intervention:

DOCUMENT APPROVAL: AThe vendor submits the documents for approval at least 10 calendar days before the relevant actiontakes place. The action shall not start before the approved (A) or for information (E) status has beengranted to the document.

DOCUMENT REVIEW: R (Only Documents)The Vendor performs the contractual controls & tests & sends to HPC, within 48 h, copy of the relevantcertificates & reports.

WITNESS POINT: W (hold 100%) SW (hold 10%)The Vendor notifies HPC 10 calendar days in advance by Email, or fax. If HPC does not attend, the Vendorcarries out the contractual controls & tests, sends the relevant certificates & report to HPC, and continuousthe manufacturing insofar as the results of the controls & test are acceptable.

HOLD POINT: HThe Vendor notifies HPC 10 calendar days in advance by Email or Fax. He is not allowed to carry out

controls & test without the presence of HPC, unless HPC has given its written agreement. If any case,HPC reserves the right to request the Vendor, who accept to defer tests & controls by a maximum of 5days working days from the initial purposed date. If HPC cannot be present within the 5 working daysfollowing the initial date, the Vendor carries out the control & tests according to the instructions given in §“Witness point”.

MONITORING/SURVEILLANCE: MNotifications to witness are advised informally – Activities proceed as planned

NOTA: Same requirement have to be applied by the Vendor to his sub-suppliers. All documents relevant tocontrol & tests operations or to non-conformity are regrouped by the vendor in the Quality Dossier whichis at the disposal of HPC’s Client’s inspectors at any time

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Same requirements have to be applied by the MANUFACTURER/SUPPLIER to his Sub-Suppliers.

All documents relevant to control and tests operations or to non-conformity are regrouped by the

MANUFACTURER/SUPPLIER in quality Dossier which is at the disposal of CONTRACTOR or Client's

Inspector at any time.

7.3 Abbreviation:

Ceq : Carbon Equivalent SCR : Stress Relaxation Cracking

PQR : Procedure Qualification Record HT : Heat Treatment

WPS : Welding Procedure Specification PWHT : Post Welding Heat Treatment

WPQR : Welder's Performance Qualification Record IPWHT :Intermediate Post Welding Heat Treatment

NDE : Non-Destructive Examination DHT : Dehydrogenation Heat Treatment

RT : Radiographic Test PMI : Positive Metal Identification

UT : Ultrasonic Test SS : Stainless Steel

MT : Magnetic Particle Test CS : Carbon Steel

PT : Liquid Penetrate Test Thk : Thickness

TPIA : Third Party Inspection Authority’s HAZ : Heat Affected Zone

NoBo : Notify Nobody HPC : HEURTEY PETROCHEM

MDR : Manufacturer Data Record (Data Book) P/O : Purchase OrderIOMM : Installation Operation Maintenance Manual

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1. Category: INLET DISTRIBUTORSSCOPE of INSPECTION

R e v

Supplier: Inspection Level: 4 0

No Inspection Item / Step

By

S u p p

l i e r ’ s R e c o r d

C e r t i f i c a t e R e p o r t

RemarksAcceptance Criteria

S U P

P L I E R

H

P C

H

T A S

A C

R O N

O T

H E R S

1.1. DATA / ENGINEERING

1.1.1 Design Temperature (°C): -27°C/560°C

Design Pressure (kg/cm²g): 41

X

1.1.2 Code : ISO 13705 (API560)

: API530: ASME B31.3

: RUSSIAN STANDARDS

X

1.1.3 HTAS Process Specifications

REF51009 : Specification for Low Alloyinlet distributor

REF51030 : Specification for fieldwelding of inlet hairpin tubes

X See point 3

1.1.4 HTAS Drawings

REF51005 : General arrangement of

gas inlet

REF51007 : Inlet distributor

X See point 3

1.1.5 HPC Documents

H201-FS-403 : Material requisition for

inlet distributors

X See point 3

1.2. Pre-award meeting or Kick-off meeting X W Report See point 7.1

1.3. PRE-INSPECTION MEETING (PIM) X H Report See point 7.1

1.4. DOCUMENTS TO SUBMIT PRIOR PIM

1.4.1 Schedule Fabrication X A Shall be revised (when required) and

confirmed each end of month.

1.4.2 Detailed Inspection Test Plan X A To be approved by HTAS before start ofmanufacture.

1.4.3 Arrangement Drawing X A

1.4.4 Details Drawing X A

1.4.5 WELDING Book including: X A To be approved by HTAS before start ofmanufacture.

Root passes to be made by TIG Process

1.4.5.1 Welding Map X A

1.4.5.2 WPS X A

1.4.5.3 PQR X A ASME IX

1.4.5.4 Filler metal certificate X A EN 10204 type 3.1

1.4.5.5 Welders Qualifications X A ASME IX or equivalent

1.4.6 NDT Procedures including: X A

1.4.6.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)

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1.4.6.2 Dye Penetrant procedure X A

ASME V + ASME VIII Div.1 App 8

REF51009

- Ends bevelled for welding: 100% - No

indication is allowed in bevel and within

10 mm of it

- 100% root and final capping passes – No

indication is allowed

1.4.6.3 Radiographic procedure (on butt welds): X A

ASME V + ASME VIII Div. 1 §UW-51

REF51009 100%

1.4.6.4 Analysis for weld metal deposited (P.M.I.)procedure X A ISO 13705 §17.5.4.310% of welds and materials

1.4.6.5 Hardness test procedure X AHardness to be checked by Brinell testingin HAZ.

1.4.6.6 Hydrostatic test procedure X A

REF51009

Complete assembly at 218 kg/cm2g

during 30 minutes mini.Water< 20 ppm Cl-

1.4.6.7 Leak test procedure X AREF51009

Test at 5 barg with oil free air.

1.5 MATERIAL IDENTIFICATION

1.5.1 Main pipe : ASTM A335 P22 X R Report EN10204 – 3.1

1.5.2 Cap : ASTM A234 WP22 Cl.3 X R Report EN10204 – 3.1

1.5.3 Weldolet : ASTM A182 F321H X R Report

Grain size to be in the range ASTM E112N°7 to N°4

EN10204 – 3.1

1.5.4 Support saddle : ASTM A387 Gr.22 X R Report EN10204 – 3.1

1.5.5 Guide plate : ASTM A36 or equivalent X R Report EN10204 – 3.1

1.6 WELDING EXAMINATION

1.6.1 Beveled ends examination X SW Report

100% PT on bevels

No indication allowed on the bevel or

within 10 mm of it.

1.6.2 Welding of main pipes

1.6.2.1 Visual examination of welds X SW Report 100%

1.6.2.2 Dye penetrant examination X SW Report100% of root pass and complete welds –

No indication is allowed

1.6.2.3 Radiographic examination X SW Report 100% RT on butt welds

1.6.3Welding of support saddles on main

pipe

1.6.3.1 Visual examination of welds X SW

Report 100%

1.6.3.2 Dye penetrant examination X SW Report100% of root pass and complete welds – No indication is allowed

1.6.4 Welding of weldolets on main pipe


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1.6.4.2 Dye penetrant examination X SW Report100% of root pass and complete welds – No indication is allowed

1.7 FINAL EXAMINATION

1.7.1 Visual and Dimensional examination X H Report Drawing

1.7.2 PMI examination X W Report 10% of welds and materials

1.7.3 Hydrostatic test examination X H Report218 bars during 30 minutes minimum

No leak or deformation allowed

1.7.4Leak test

X WReport Test at 5 bargNo leak or deformation allowed

1.7.5 Cleaning X W

REF51009 §9

All scale, resulting from welding shall beremoved from internal surface

All traces of welding slag, grease, dye

shall be removed

1.7.6 Drying X W

REF51009 §9.4

Drying with clean, dry air to remove dust,swarf…

1.7.7 Marking X W

REF51009 §10

Use of indelible ink not harmful to the

alloy

1.7.8 Packing X W REF51009 §12

1.7.9Manufacturer Data Book including RTN

passport X H Approved HPC summary

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2. Category: COMBUSTION AIR PREHEATER

– E205 SCOPE of INSPECTION R e v



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2.1 DATA / ENGINEERING

2.1.1 MDMT: -27°C X

2.1.2

Code : ISO 13705 (API560)

: API530: AWS D1.1

: RUSSIAN STANDARDS

X

2.1.3 HTAS Specifications

P51205-E: Process specification for

E205/E220 Combustion Air preheaters

X See point 3

2.1.4

HPC Documents

H201-FS-741 : Material requisition

for air preheater

H201-FJ-741 : HPC Datasheet

X See point 3

2.2 Pre-award meeting or Kick-offmeeting

X WReport See point 7.1

2.3 PRE-INSPECTION MEETING (PIM) X H Report See point 7.1

2.4 DOCUMENTS TO SUBMIT PRIOR PIM



2.4.2 Detailed Inspection Test Plan X A To be approved by HTAS before start ofmanufacture.



2.4.5 WELDING Book including:


2.4.5.2 WPS X A ASME IX


2.4.5.5 Filler metal certificate X A EN 10204-3.1 ASME II Part C


2.4.6 Painting procedure X A




ASME V Art. 6 + AWS D1.1

10% examination of main structural welds

2.4.7.3 Leak test procedure X A Supplier's procedure


2.5.1 Plates X R EN10204-3.1 By supplier

Suitable for -27°C

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2. Category: COMBUSTION AIR PREHEATER

– E205 SCOPE of INSPECTION R e v



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2.5.2 Profiles X R

EN10204-3.1By supplier

Suitable for -27°C

2.5.3 Consumables X R EN10204-3.1 ASME II Part C


2.6.1 Beveled ends examination X SW Report Approved procedure

2.6.2 Dye penetrant examination X SW ReportAWS D1.1 Section 6 Part C §6.10

10% of main structural welds

2.7 LEAK TEST X H ReportApproved procedure

No leak and distortion


2.8.1 Visual and Dimensional examination X H ReportDrawings

100%

2.8.2 Painting X H Report Approved procedure

2.8.3 Marking X W

Approved procedureUse of indelible ink not harmful to the

alloy

2.8.4 Packing X W Approved procedure


passport

X H Approved HPC summary

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3.Category: STEAM FIRED COMBUSTION AIRPREHEATER – E220

SCOPE of INSPECTION R e v



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S U P P L I E R

H P

C

H T A

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A C R O N

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3.1.1 MDMT: -45°C X

3.1.2 Code : ISO 13705 (API560)

: ASME VIII Div. 1: RUSSIAN STANDARDS

X

3.1.3

HTAS Specifications

P40001-BED R1: Design Basis

P51205-E: Process specification for

E205/E220 Combustion Air preheaters

X

See point 3

3.1.4

HPC Documents


Steam air preheater

H201-FJ-742 : HPC Datasheet

X

See point 3

3.2 Pre-award meeting or Kick-off

meeting

X W Report See point 7.1



3.4.1 Detailed Inspection Test Plan X ATo be approved by HTAS before start ofmanufacture.



3.4.4 Schedule Fabrication X AShall be revised (when required) andconfirmed each end of month.







3.4.6 Painting procedure X A



3.4.7.2 Dye Penetrant procedure X A ASME V ART. 6 + ASME VIII Div.1 APP. 8

3.4.7.3 Radiographic procedure X A ASME V ART. 2 + AWS VIII Div.1 §UW-51

3.4.7.4 Hydrostatic test procedure X A Supplier's procedure


3.5.1 LP steam side

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3.Category: STEAM FIRED COMBUSTION AIRPREHEATER – E220




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A C

R O N

O T H E R S

3.5.1.1 Tube / Manifold / Bends X R EN10204-3.1By supplier

Suitable for -45°C

3.5.1.2 Flanges X R EN10204-3.1By supplier

Suitable for -45°C

3.5.2 Air side

3.5.2.1 Structural steel X R EN10204-3.1By supplier

Suitable for -45°C

3.5.2.2 Casing X R EN10204-3.1By supplier

Suitable for -45°C

3.5.2.3 Consumables X R EN10204-3.1By supplier - ASME II Part C

Suitable for -45°C


3.6.1 Beveled ends examination X SW Report Approved procedure

3.6.2 Dye penetrant examination X SW ReportASME VIII Div. 1 App.8

10% when RT is not possible

3.6.3 Radiographic test X SW ReportASME VIII Div. 1 §UW-51

10% on buttwelds

3.7 HYDROSTATIC TEST X H Report

Approved procedure

No leak



100%

3.8.2 Painting X H Report Approved procedure

3.8.3 Marking X W

Approved procedure


alloy


3.8.5Manufacturer Data Book including RTNpassport


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4.Category: BURNERS SCOPE of INSPECTION

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P C

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T A S

A C

R O N

O T H E R S


4.1.1

Type of burner: Forced draught

radiant wall type

Quantity: 432

- 360 size 1

- 72 size 2

X

4.1.2 Code : ISO 13705 (API560): RUSSIAN STANDARDS

X

4.1.3

HTAS SpecificationsP51201 R0: Primary reformer gasburners

REF51056: Tubular reformer_ radiantsection Burner plate and refractory

block

X

See point 3

4.1.4

HPC Documents

H201-FS-201: Material requisition forburners

X

See point 3


meeting




4.4.1 Detailed Inspection Test Plan X ATo be approved by HTAS before start of

manufacture.



4.4.4 Schedule Fabrication X AShall be revised (when required) and








4.4.6 NDT Procedures including:


4.4.6.2 Dye Penetrant procedure X AASME V Art. 6 + ASME B31.3 Table

341.3.2 (Normal Fluid Service)

4.4.6.3 P.M.I. procedure X A Supplier’s procedure

4.4.7 Performance test procedure X A P51201 R0 §11

4.4.8 Preservation and packing procedure X A Supplier’s procedure

4.5 MATERIAL EXAMINATION

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O T H E R S

4.5.1 Plate / tube / flange & bolting X R EN 10204-3.1 Carbon Steel suitable for low temperature(-45°C)

4.5.2 Gas riser X R EN 10204-3.1 Stainless Steel

4.5.3 Gas tip X R EN 10204-3.1 Cast 25 Cr 20 Ni

4.5.4 Burner block X R EN 10204-2.2 High density refractory

4.5.5 Consumables X R EN 10204-3.1 ASME II Part C

4.6 PERFORMANCE TEST

4.6.1 Flame stability testing X W Report P51201 R0 §11One test for each size of burner

4.6.2 Ignition test X W ReportP51201 R0 §11.4

One test for each size of burner

4.7 MECHANICAL EXAMINATION

4.7.1 Welding X SW Report Approved welding book

4.7.2 Penetrant test examination X SW Report100% on fuel gas welds and 10% on

casing welds

4.7.3 PMI examination X SW Report 100% on gas tips, nozzles and risers

4.7.4 Chemical cleaning of welds X SW Report 100% of welds


4.8.1 Visual and Dimensional examination X H Report

4.8.2 Air flow test X W ReportP51201 R0 §11.85% of burners of both sizes & mini. 3 of

each size

18.8.2 Marking X H

Approved procedure


alloy

4.8.3 Packing X H Approved procedure


X H Approved HPC summary E x a m

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5.Category: AIR BLOWERS–K 201 & K 202 SCOPE of INSPECTION

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S U P P L I E R

H

P C

H

T A S

A C

R O N

O T H E R S


5.1.1

MDMT

K-201: -27°C

K-202: -45°C

5.1.2


: API 673

: RUSSIAN STANDARDS

X

5.1.3

HTAS Specifications

P56202 R0: Process specification for K202 Combustion Air Blower

P56201 R0: Process specification for K201 Flue Gas Fan

P55202-TK: Process specification forTK-202

P55201-TK: Process specification forTK-201

P40001: Design basis

REF5107: GA Convection section

J61021 R2: General specification for

instrumentation

4-1246 E R7: Painting

X

See point 3

5.1.4

HPC Documents

H201-FS-721 : Material requisition forforced draft fan (Air fan)

H201-FS-899A : Fan damper actuatorspecification

H201-FS-850 : ID-FD fan motordatasheet

H201-FJ-721 : Data sheet Heavy dutycentrifugal Fan (Air fan)

H201-FJ-722 : Data sheet Heavy dutycentrifugal Fan (Flue gas fan)

X

See point 3


meeting











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P C

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R O N

O T H E R S







5.4.6.2 Dye Penetrant procedure X A ASME V Art. 6 + AWS D1.1 Section 6 Part

C §6.10

5.4.6.3 Ultrasonic test procedure X AASME V Art. 2 + AWS D1.1 Section 6 PartC §6.13

5.4.7 Balancing test procedure X A API 673

5.4.8 Performance test procedure X A API 673

5.4.9 Running test procedure X A API 673

5.4.10 Preservation and packing procedure X A Supplier's procedure

5.4.11 Painting procedure X A 4-1246 E R7


5.5.1 Plate / steel profile X R EN 10204-3.1 Carbon Steel suitable for low temperature(-27°C for K201 and -45°C for K202)

5.5.2 Shaft X R EN 10204-3.1 Carbon Steel suitable for low temperature(-27°C for K201 and -45°C for K202)

5.5.3 Impeller X R EN 10204-3.1 Carbon Steel suitable for low temperature

(-27°C for K201 and -45°C for K202)

5.5.4 Blade material X R EN 10204-3.1 Carbon Steel suitable for low temperature

(-27°C for K201 and -45°C for K202)

5.5.5 Bolting X R EN 10204-2.2 Supplier's drawing

Standard

5.6 FANS INSPECTION

5.6.1 Balancing test X SW Report Compliance with approved procedure

5.6.2 Performance test X H Report Compliance with approved procedure

5.6.3 Running test X H Report Compliance with approved procedure

5.7 MOTORS

5.7.1 Low voltage directive X R

Certificate 73/23/EC

Compliance with directive

5.7.2 Machine directive X R

Certificate98/37/EC


5.7.3 Electromagnetic compatibility directive X R

Certificate2004/108/EC


5.7.4 Atex directive X R

Certificate94/9/EC


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H

P C

H

T A S

A C

R O N

O T H E R S

5.8 MECHANICAL EXAMINATION

5.8.1 Welding X SW Approved welding book

5.8.2 Penetrant test examination X SW ReportISO 13705 §E.4.2.2

100% on impeller welds after running test

5.8.3 Ultrasonic examination of shaft X SW ReportApproved procedure

100% of the shaft

5.8.4 Painting

5.8.4.1 Surface preparation X SW Report Approved procedure

5.8.4.2 Thickness examination X SW Report Approved procedure



100%

5.9.2 Marking X H Report

Approved procedure

Use of indelible ink not harmful to thealloy




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6. Category: HAIRPIN TUBE IN GAS INLETAND BRACES




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S u p p l i e r ’ s R e c o r d

C e r t i f i c a

t e

R e p o r t

Remarks

Acceptance Criteria

S U P P L

I E R

H P C

H T A

S

A C R O N

O T H E

R S


6.1.1Design Temperature (°C): -27°C/560°C


X

6.1.2



: RUSSIAN STANDARDS

X


REF51013 : Primary reformer

Specification for hairpin tubes in gas inlet

X See point 3

6.1.4

HTAS drawings

REF51005 : General arrangement of gas

inlet

REF51011 : Hairpin tubes in gas inlet

REF51050 : Braces for hairpin tubes in

gas inlet

REF51053 : Spring support for hairpin

tube in gas inlet

REF51065 : Radiant section insulation

for hot parts

X See point 3

6.1.5HPC Documents


inlet hairpins

X See point 3

6.2 Pre-award meeting or Kick-off meeting X W Report See point 7.1





6.4.2 Detailed Inspection Test Plan X A To be approved by HTAS before start of

manufacture.



6.4.5 Bending procedure X A REF51013 §6Cold forming

6.4.6 WELDING Book including:6.4.6.

1 Welding Map X A

6.4.6.

2 WPS X A ASME IX

6.4.6.

3 PQR X A ASME IX


6.4.6.

5 Welders Qualifications X A ASME IX or equivalent


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ASME V Art. 6 + ASME VIII Div.1 App. 8

REF51013 §6.4

Bend arc surfaces and 150 mm surfacesadjacent to bends shall be free of

indications – 100% examination

REF51013 §7.7

Root passes and capping passes shall be100% dye penetrant tested

6.4.7.4 Radiography procedure X A REF51013 §7.8

100% of welds

6.4.7.3 UT Wall thickness measurement procedure X A REF51013 §6.5 and 8.2

Extent: 10% of pigtails

6.4.7.4Analysis for weld metal deposited (P.M.I.)

procedure X A 10% of tubes/flanges/weldolets


6.5.1 Tube: ASTM A312 TP321H X R Report

Cold drawn, solution annealed and pickled

Grain size to be in the range ASTM E112

N°7 to N°4

EN10204 – 3.1

1


6.6.1 PMI examination X SW Report 10% of tubes/flanges/weldolets

6.6.2 Grain size determination X R Report

REF51013 §5.4

Grain size in the range ASTM E112 N°7 to

N°4

6.6.3 Visual examination X W Report

REF51013 §8.1

Bend arc surfaces free of cracks and

buckles

6.6.4 Dye penetrant examination X W Report

REF51013 §6.4



REF51013 §7.7Root passes and capping passes shall be

100% dye penetrant tested

6.6.4 Radiographic examination X W ReportREF51013 §7.8Welds shall be 100% radiographed

6.6.5 Dimensional examination X H Report

REF51013 §6.5 and 8.2

Bending tolerances: to be within ±3mm

Flattening of bend: Less than 8% -

Extent: 10% of the hairpins tubes

UT Wall thickness measurement: Wall

thinning < 10% -


Ovality: to be checked on 10% of the

hairpins or minimum 20 pieces.

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6.7.1

Visual and Dimensional examination

including flattening of bend and wallthickness measurement

X H Drawings

6.7.2 Cleaning X W

REF51013 §9

All scale, resulting from welding shall beremoved from internal surface


shall be removed

6.7.3 Marking X W

REF51013 §11


alloy




7. Category: HAIRPIN TUBE IN GAS OUTLET SCOPE of INSPECTION R e

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7.1.1Design Temperature (°C): -27°C/829°C


X

7.1.2


: API530

: ASME B31.3: RUSSIAN STANDARDS

X

7.1.3

HTAS Process Specifications

REF51019 : Primary reformer

Specification for hairpin tubes in gas

outlet

X See point 3

7.1.4

HTAS drawings

REF51006 : General arrangement of gasoutlet

REF51018 : Hairpin tubes in gas outlet

REF51065 : Radiant section insulation

for hot parts

X See point 3

7.1.5

HPC Documents

H201-FS-402 : Material requisition forgas outlet hairpins

X See point 3

7.2 Pre-award meeting or Kick-off meeting X W Report See point 7.1





7.4.2 Detailed Inspection Test Plan X A To be approved by HTAS before start of

manufacture.



7.4.5 Bending procedure X A REF51019 §6

Cold forming


7.4.6.1NDT Operator certifications X A

EN 473 (Level II) or SNT TC 1A (ASNT)



REF51019 §6.7



7.4.7.3 UT Wall thickness measurement procedure X A REF51019 §6.5 and 7.2


7.4.7.4Analysis for weld metal deposited (P.M.I.)procedure

X A 10% of tubes


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7.5.1 Tube: ASTM B407 X R Report

Cold drawn, solution annealed and pickled


N°5 to N°3

EN10204 – 3.1


7.6.1 PMI examination X SW Report 10% of tubes

7.6.2 Grain size determination X R Report

REF51019 §5.3


N°5 to N°3

7.6.3 Visual examination X W Report

REF51019 §7.1

Bend arc surfaces free of cracks andbuckles

7.6.4 Dye penetrant examination X W Report

REF51019 §6.7Bend arc surfaces and 150 mm surfaces

adjacent to bends shall be free ofindications – 100% examination

7.6.5 Dimensional examination X H Report

REF51019 §6.4 and 7.2

Bending tolerances: to be within ±3mm

Flattening of bend: Less than 8% -

Extent: 10% of the hairpins tubes

UT Wall thickness measurement: Wall

thinning < 10% -Extent: 10% of pigtails

Ovality: to be checked on 10% of thehairpins or minimum 20 pieces.


7.7.1

Visual and Dimensional examination

including flattening of bend and wallthickness measurement

X H Drawings

7.7.2 Cleaning X W

REF51019 §8

All scale, resulting from welding shall be

removed from internal surface


shall be removed

7.7.3 Marking X W

REF51019 §10


alloy




8. Category: LOOSE PARTS FOR CATALYST

TUBES SCOPE of INSPECTION R e v


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8.1.1 Design Temperature : Inlet 560°C

Main tube 901°C

Outlet 829°C 901°C

Design Pressure : Inlet 41 kg/cm²g

Main tube 41 kg/cm²g

Outlet 41 kg/cm²g

X

8.1.2 Code : ISO 13705 (API560)


: RUSSIAN STANDARDS

X

8.1.3 HTAS Drawings

REF51011 : Radiant section Hairpin

tube in gas inlet REF51015 : Radiant section Catalysttube support, flange, two-part ring and

grid

X See point 3

8.1.4 HPC Documents


catalyst tubes element

X See point 3

8.2. Pre-award meeting or Kick-offmeeting

X WReport See point 7.1



8.4.1 Schedule Fabrication X A

Shall be revised (when required) andconfirmed each end of month.

8.4.2 Detailed Inspection Test Plan X A

To be approved by HTAS before start ofmanufacture.







Tube support, Cast grid to be 100% dye

penetrant tested

Weld of weldolet/inlet flange to be 100%dye penetrant tested

Welding between inlet flange and

weldolet to be 100% dye penetranttested

8.4.5.3 Radiographic test procedure X A

ASME VIII Div. 1 §UW-51 & ASME V Art.

2

Welding between inlet flange and

weldolet to be 100% radiographed.

8.4.5.4Analysis for weld metal deposited(P.M.I.) procedure X A

10% of inlet flanges and weldolet, welding

between inlet flange and weldolet, looseinlet flange, two-part rings

8.5. MATERIALIDENTIFICATION/INSPECTION

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8.5.1Catalyst tube grid

Static cast ASTM A351 Gr.HK40 X R

REF51015

EN 10204 – 3.1

8.5.1.1 Visual examination X R Report REF51015

8.5.1.2 Dimensional examination X R ReportREF51015

100%

8.5.1.3 Dye penetrant examination X R ReportASME V Art. 6 + ASME VIII Div.1 App. 8

100% examination

8.5.2 Inlet flanges and weldolets

ASTM A312 TP321H X R

REF51011

EN 10204 – 3.1

8.5.2.1 P.M.I. X R ReportREF51011

10% of each heat n°

8.5.2.2 Grain size determination X R Report

REF51011

Grain size to be in the range ASTM E112N°7 or coarser.

8.5.3 Loose flanges

ASTM A312 TP321H X R

REF51015

EN 10204 – 3.1

8.5.3.1 P.M.I. X R ReportISO 13705 §17.5.4.3


8.5.3.2 Grain size determination X R ReportREF51011Grain size to be in the range ASTM E112

N°7 or coarser.

8.5.4 Two-part ring

AISI 304 X R

REF51015

EN 10204 – 3.1

8.5.4.1 P.M.I. X R ReportISO 13705 §17.5.4.3


8.5.5 Spiral wound metal gasket

AISI 304 X R

REF51015

EN 10204 – 3.1

8.5.6 Stud bolts and nuts

ASTM A193 Gr.B16 et ASTM A194 Gr.4

X RREF51015

EN 10204 – 3.1

8.5.7Catalyst tube bottom support

ASTM A297 HH X R

REF51015

EN 10204 – 3.1


100% tested

8.5.8 Welding flat weldolet / Flange X R

8.5.8.1 Approved welding book X R

8.5.8.2 P.M.I. X R ReportISO 13705 §17.5.4.3



100% – No indication is allowed

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8.5.8.4 Radiographic examination X W Report

ASME V Art. 2 + ASME VIII Div.1 §UW-51

100%

8.6. FINAL EXAMINATION OF COMPLETEASSEMBLY

8.6.1 Visual & Dimensional examinationincluding PMI and flange assembly

X H

Drawings

10% mini. to be checked during final

inspection

8.6.2 Marking X H

H201-FS-101 Part.6


alloy

8.6.3 Packing X H H201-FS-101 Part.7

8.6.4 Manufacturer Data Book including RTNpassport


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S U P P L I E R

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A C

R O N

O T H E R S


9.1.1 Design Temperature (shell): -27/400°C Design Pressure: 39 kg/cm²g

Operating Temperature : 804°COperating Pressure : 32 kg/cm²g

X

9.1.2 Code : ISO 13705 (API560)


: RUSSIAN STANDARDS

X


REF51024 : Radiant section cold outletin Cold Outlet Collector

REF51026 : Refractory lining in cold

Collector

S-02949 B30004: HTAS vendor list for

refractory lining vendors

4-1246 E R7 : Painting

X See point 3

9.1.4 HTAS Drawings

REF51027 : Instrument connection ofcold Collector

REF51020 : For information details ofhot collector

REF51002 : Radiant section GAD forinformation details of radiant layout

X See point 3

9.1.5 ACRON documentation

YK-A-1441_pril : Connection to

secondary reformer

33753-OT-1 : Site condition, general

requirements for complete plants

X See point 3

9.1.6 HPC Documents

H310-FS-406 : Requisition package forCold Collector

SG1505 : Refractory and insulationconcrete application

X See point 3






9.4.2 Detailed Inspection Test Plan X ATo be approved by HTAS prior the start of

manufacture

9.4.3 Arrangement/detail Drawings (If any) X A




9.4.4.3 PQR X A

ASME IX

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9.4.4.4 Filler metal certificate X AASME II Part C

EN 10204 type 3.1




9.4.5.2

Radiographic procedure (on butt welds) X A

ASME VIII Div. 1 §UW-51

& ASME V Art.2

100%

9.4.5.3

Ultrasonic test procedure (on nozzles) X A

ASME VIII Div. 1 §UW-53 & App.12

& ASME V art.4

100%

9.4.5.4

Magnetic particle inspection procedure X A

ASME VIII Div. 1 App.6

& ASME V art.7

100%

9.4.5.5

Penetrant test examination procedure X A


& ASME V art.6

100%

9.4.6 PMI procedure X A 10% of welds and material

9.4.7 Heat treatment procedure X APreheating: min. 150°C

PWHT: 2h at 705-730°C

9.4.8 Hardness test procedure X AHardness to be checked by Brinell testing

in weld, HAZ & base metal

9.4.9 Hydrostatic test procedure X AH201-FS-406

66 bars during min. 30 minutes

9.4.10 Refractory lining procedure X A REF51026

9.4.11 Painting procedure X A 4-1246/E R7


9.5. MATERIAL

IDENTIFICATION/INSPECTION

9.5.1 Shell & head : ASTM A387 Gr. 11 Cl.2 X R Report EN10204 – 3.1

9.5.2 Pipe : ASTM A335 P11 X R Report EN10204 – 3.1

9.5.3 Flange : ASTM A182 F11 X R Report EN10204 – 3.1

9.5.4 Stud bolts / nuts : A193 Gr. B7 / A194 Gr. 3 X R Report EN10204 – 3.1

9.5.5Support saddle & foundation plates : ASTMA283 Gr. A or equivalent

X R Report EN10204 – 3.1

9.5.6 Spiral Wound Gaskets : SS 18/8 graphite X R Report EN10204 – 3.1

9.5.7Insulating Castable Refractory : JM 2300 VL1or equal


9.5.8Castable refractory 94% Al2O3 : JM Firecrete95 or equal


9.5.9Ceramic fibre blanket compressed : 1260°C /

128 kg/m3 X R Report EN10204 – 2.2

9.6. WELDING EXAMINATION

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9.6.1 Beveled ends examination X SW Report 100% PT or MT on bevels

9.6.2 Welding of shell / head


9.6.2.2Dye penetrant examination or Magnetic

particle inspection on root passes X SW Report 100%


particle inspection after PWHT X SW Report 100%

9.6.2.3 Radiographic examination after PWHT X R Report 100%

9.6.3 Welding of nozzles / shell






9.6.3.3 Ultrasonic examination after PWHT X SW Report 100%

9.6.4 Welding of internal plates


9.6.2.2

Dye penetrant examination or Magnetic




9.7. POST WELD HEAT TREATMENT X SW Chart

9.8. HARDNESS EXAMINATION X SW Report 225 HB max

9.9. PMI EXAMINATION X SW Report 10% of welds and material

9.10. HYDROSTATIC TEST X W Report 66 bars during min. 30 minutes

9.11. FINAL INSPECTION BEFORE LINING X H Report Approved procedure

9.12. REFRACTORY APPLICATION REF51026 §9

9.12.1 Preparation of surface X SW Report

9.12.2 Welding of SS anchors X SW Report Soundness of the weld to be hammertested

9.12.3 Mixing of refractory X SW Report Water analysis

9.12.4 Installation of refractory X SW Report REF51026 §9

9.12.5

Refractory material testing :

- Compressive strength,

- Permanent linear change,

- Density,

- Chemical composition,

- Tensile strength for ceramic fiber blankets

X SW Report

R REF51026 §7 & §9

One test piece shall be taken daily with

material type and date marking.

First and last cube to be tested for each

material

9.12.6 Curing X SW Approved procedure

9.12.7 Dry-out X W Chart Approved procedure

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9.13. BUTTWELDING OF FINAL SECTIONS

9.13.1 Sections alignment & welding X SW Approved welding book

9.13.2 Local PWHT X SW Chart Approved procedure

9.13.3 Hardness examination X SW ReportApproved procedure

225HB max

9.13.4 Ultrasonic examination of closing welds X SW Report 100%

9.13.5 Dye penetrant examination or Magneticparticle inspection of closing welds

X SW Report 100%

9.14. FINAL EXAMINATION BEFORE

PAINTING X W Report Approved procedure

9.15. PAINTING

9.15.1 Surface preparation X SW Report Approved procedure

9.15.2 Thickness examination X SW Report Approved procedure

9.16. TRIAL ASSEMBLY WITH TRANSFERPIECE

X H Report

9.17. FINAL EXAMINATION

9.17.1 Visual and dimensional examination X H Report Drawing

9.17.1 Marking X H

REF51026 §13



9.17.1 Manufacturer Data Book including RTN


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10. Category:HOT COLLECTORS SCOPE of INSPECTION

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10.1.1 Design Temperature (shell): -27/829°C

Design Pressure: 39 kg/cm²g Operating Temperature : 804°C

Operating Pressure : 32 kg/cm²g

X

10.1.2 Code : ISO 13705 (API560): API530

: ASME B31.3: RUSSIAN STANDARDS

X


REF51021 : Specification for hot

Collector

REF51024 : Radiant section cold outlet

in Cold Outlet Collector

X See point 3

10.1.4 HTAS Drawings

REF51020 : Hot collector drawing

REF51002 : Radiant section GAD for

information details of radiant layout

REF51006 : General arrangement of gas

outlet for information about connections

X See point 3

10.1.5 ACRON documentation

33753-OT-1 : Site condition, general

requirements for complete plants

X See point 3

10.1.6 HPC Documents

H310-FS-405 : Requisition package for

Hot Collector

X See point 3






10.4.2 Detailed Inspection Test Plan X ATo be approved by HTAS prior the start of

manufacture

10.4.3 Arrangement/detail Drawings (If any) X A





10.4.4.4 Filler metal certificate X AASME II Part C

EN 10204 type 3.1



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10.4.5.2

Radiographic procedure (on butt welds) X A

ASME VIII Div. 1 §UW-51

& ASME V Art.2

100% of static and centrifugally cast

100% of butt welds

10.4.5.3

Penetrant test examination procedure X A


& ASME V art.6

100% of machined surfaces

100% of beveled ends within 25mmThe first three root passes made by each

welder

10.4.6Boroscope X A

Root pass of main tube shall be checkedfor full penetration


10.4.8 Leak test procedure X AREF51021

5 bars during min. 10 min

10.4.9 Hydrostatic test procedure X A

REF51021

77 bars during min. 30 minutes

20ppm Cl.

10.4.10 Eddy current test procedure X AREF51021

100% of bored tubes10.4.11 Preservation and packing procedure X A Supplier's procedure

10.5. MATERIAL

IDENTIFICATION/INSPECTION

10.5.1 Main tube : 20Cr 32Ni Nb X R Report EN10204 – 3.1

10.5.2 Cone : 20Cr 32Ni Nb X R Report EN10204 – 3.1

10.5.3 End cap : 20Cr 32Ni Nb X R Report EN10204 – 3.1

10.5.4Nozzle for Hairpin tubes: ASTM B564 ALLOYUNS NO8811

X R Report EN10204 – 3.1 Grain size ASTM n°5 to 3.

10.5.5 Sleeve : ASTM B409 ALLOY UNS NO8811 X R Report EN10204 – 3.1 Grain size ASTM n°5 to 3.

10.5.6½” nozzle for thermowell: ASTM B564 ALLOYUNS NO8811


10.5.7 ½” Pipe nom. SCH160: ASTM B407 ALLOYUNS NO8811


10.5.8Flange 18” Nom class 600 ANSI B16.25 : ASTM

A182 F11 X R Report EN10204 – 3.1

10.5.9 Tee : 20Cr 32Ni Nb X R Report EN10204 – 3.1

10.5.10 End cap : ASTM B564 ALLOY UNS NO8811 X R Report EN10204 – 3.1 Grain size ASTM n°5 to 3.

10.6. WELDING EXAMINATION

10.6.1 Beveled ends examination X SW Report 100% PT or MT on bevels

10.6.2 Welding of main tube / tube ends


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10.6.2.2

Dye penetrant examination or Magneticparticle inspection on 3 first root passes

made by each welder X SW Report

10.6.2.3Boroscope check on root passes for fullpenetration

X SW Report 100%


particle inspection on final root passes X SW Report 100%

10.6.2.5 Radiographic examination X R Report 100%

10.6.3 Welding of nozzles / main tube


10.6.2.2

Dye penetrant examination or Magnetic

particle inspection on 3 first root passes

made by each welder

X SW Report

10.6.3.3Dye penetrant examination or Magneticparticle inspection on final root passes

X SW Report 100%

10.6.4 Welding of end cap / ½” nozzle




10.6.4.3 Dye penetrant examination or Magneticparticle inspection on final passes

X SW Report 100%

10.6.4.4 Radiographic examination X R Report 100%

10.7. PMI EXAMINATION X SW Report 10% of welds and material

10.8. LEAK TEST X W Report 5 bars during min. 10 min

10.9. HYDROSTATIC TEST X W Report 77 bars during min. 1 hour - 20ppm Cl. 1

10.10. FINAL EXAMINATION

10.10.1 Visual and dimensional examination X H Report Drawing

10.10.2 Marking X H

REF51026 §13


alloy10.10.3 Packing X H Approved procedure

10.10.4 Manufacturer Data Book including RTN


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11.1.1

Design casing temperature: +55°C

Ambient temperature for design: -38°C

MDMT : -45°C

X

11.1.2 Code : ISO 13705 (API560)

: AWS D1.1

: RUSSIAN STANDARDS

X

11.1.3

HTAS Specifications


P40001 : Project design basis

REF51041 : Specification for steel

structure, part 1

REF51042 : Specification for steel

structure, part 2

REF 51002: General arrangement of

Radiant section

REF 51044: Primary reformer

specification for radiant and convection

section steel structure and casing

REF 51043: Typical details of steel

structure and casing

REF 51048: Arrangement of Platforms,Ladders and Stairways

REF 51047: Peep door

REF 51045: Reformer roof

REF 51050: Brace for hairpin tubes ingas inlet

REF 51051: Guide ring for catalysttube

REF 51055: Counterweight for hotcollector

REF 51052: Access door

REF 51053: Spring support for hairpin

tube in gas inlet

REF 51054: Spring support for hairpintube in gas outlet

REF 51056: Burner plate and

refractory block


refractory

REF 51066: Arrangement ofcombustion air ducting

REF 51074: Radiant section plinthlayout

REF 51060: Typical lining details.


gas inlet


See point 3

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gas outlet

REF 51066: Arrangement of

combustion air ducting

11.1.4

HPC Documents


radiant panels and penthouse

DG031 rev 1 Base plate details

H211 FE 501 Rev 05 Lining anchor

details (for information only from

example project)

DG 3303 Rectangular platform details

DG 3304 Handrail details

DG 3307 Stairway

DG 3308 Ladder

DG 3309 Ladder with cage protection

H201-FD-001 Foundation layout

H201-FD-002 Foundation base plate –

details

H201-FD-010 Radiant section generalassembly – general data

H201-FD-020 Radiant section generalassembly – Elevation

H201-FD-030 Radiant section generalassembly – Plan view I

H201-FD-031 Radiant section general

assembly – Plan view

X

See point 3












11.4.5.2 WPS X A AWS D1.1

11.4.5.3 PQR X A AWS D1.1


11.4.5.5 Welders Qualifications X A AWS D1.1 or equivalent



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11.4.6.2 Dye Penetrant procedure X AASME V Art. 6 + AWS D1.1 Section 6 PartC §6.10

11.4.6.3 Radiographic procedure (if applicable) X AASME V Art. 2 + AWS D1.1 Section 6 Part

C §6.12


11.4.7 Lining procedure X A REF51061 R0

11.4.8 Painting procedure X A 4-1246 E R7 Table 9.2 Item 11


11.5.1 Material for structural steel X R EN 10204-3.1 Carbon Steel suitable for low ambienttemperature (-45°C)

11.5.2 Grating X R EN 10204–2.2 Hot dip galvanized acc. to ASTM A123

11.5.3 Structural bolts X R EN 10204-3.1 Suitable for low ambient temperature

(-45°C)

11.5.4 Ladders and handrails X R EN 10204–2.2Carbon Steel suitable for low ambient

temperature (-45°C)

11.5.5 Lining materials X R

11.5.5.1 Bricks for side walls and floors X R EN 10204–2.2

REF51061 R0 §5.1

Al2O3 + TiO2: 35-45%

SiO2: 40-55%

Fe2O3: max. 1%

11.5.5.2 Bricks for furnace hot face X R EN 10204–2.2

REF51061 R0 §5.2

Al2O3 + TiO2: 55-65%

SiO2: 35-40%

Fe2O3: max. 0.8%

11.5.5.3 Firebricks for radiant floor top layer X R EN 10204–2.2

REF51061 R0 §5.3

Al2O3 + TiO2: 38-42%

ASTM C27 High Duty

11.5.5.4 Ceramic fibre lining for furnace side and endwalls, arch and flue gas duct

X R EN 10204–2.2

REF51061 R0 §5.4

For 1260°C grade modules: Al2O3 + ZrO2:

min. 45%

For 1425°C grade modules: 35% Al2O3 +

15% ZrO2

11.5.5.5 Peephole blocks (precast refractory castable) X R EN 10204–2.2

REF51061 R0 §5.5

Al2O3 + TiO2: min. 38%

SiO2: max. 38%

11.5.5.6 Block insulation X R EN 10204–2.2 REF51061 R0 §5.6

11.5.5.7 Air setting mortar for bricks X R EN 10204–2.2

REF51061 R0 §5.7

Cold curing time acc. to ASTM C 199Medium Duty

11.5.5.8 Loose fibre filling for catalyst tube bottoms X R

EN 10204–2.2

REF51061 R0 §5.8

45% Al2O3

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11.5.5.9Ceramic fibre blanket for covering of loosefibre

X R EN 10204–2.2

REF51061 R0 §5.9

For 1260°C grade modules: Al2O3 + ZrO2:

min. 45%


15% ZrO2

11.5.6 Consumables X R EN 10204–2.2ASME II Part C

NAKS certificates for onsite welds

11.6 WELDING EXAMINATION X SW REF51044 R.A §7 & AWS D1.1

11.7 NDT EXAMINATION REF51044 R.A §7 & AWS D1.1

11.7.1 Dye penetrant examination X SW Report

AWS D1.1 Section 6 Part C §6.10

100% on lifting lugs welds. Free of cracks,

undercutting, linear indications over 2 mmand rounded indications over 4 mm

11.7.2 Radiographic examination X SW Report


100% on full penetration BW for

reconstituted beams

11.7.3 Ultrasonic test X SW Report


100% on area where lifting lugs arewelded

11.8 TRIAL ASSEMBLY X W Report Approved drawings

11.9 LINING APPLICATION

11.9.1 Preparation of surface X SW

11.9.2 Welding of anchors X SW

11.9.3 Mixing of refractory X SW Report Water Analysis

11.9.4 Application of refractory X SW ReportPre-qualification of refractory material &

installers

11.9.5 Visual and dimensional examination X SW ReportApproved drawings & procedure

After drying of castable

11.9.6 Production samples X SW Report

Approved procedure :

Compressive strength

Permanent linear changeDensity

Chemical compositionTensile strength (ceramic fiber blankets)

11.9.7 Anchors bending & hammer testing X SW Report Approved procedure

11.10 PAINTING EXAMINATION X W

4-1246 E R7

Surface preparation, climatic conditions,Wet film thickness and DFT



100%

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11.11.2 Marking X W

Approved procedure


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12.1.1

Design casing temperature: +55°C

Ambient temperature for design: -38°C

MDMT : -45°C

X

12.1.2 Code : ISO 13705 (API560)

: AWS D1.1

: RUSSIAN STANDARDS

X

12.1.3

HTAS Specifications


P40001 : Project design basis

REF 51071: General arrangement,

sketch of Convection section

REF 51044: Primary reformer

specification for radiant and convectionsection steel structure and casing

REF 51043: Typical details of steel


REF 51048: Arrangement of Platforms,

Ladders and Stairways

REF 51074: Radiant section plinth

layout

See point 3

12.1.4

HPC Documents

H201-FS-303 : Material requisition forconvection fabrication

H201-FD-402 Convection coil E-201

H201-FD-403 Convection coil E-202A


H201-FD-405 Convection coil E-203B

H201-FD-406 Convection coil E-206




H201-FD-081 Convection section

general assembly – Plan views II


general assembly – Plan views I


general assembly – Elevation


general assembly – General data

H201-FD-002 Foundation base plate –

details

X

See point 3





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12.4.5.2 WPS X A AWS D1.1

12.4.5.3 PQR X A AWS D1.1





12.4.6.2 Dye Penetrant procedure X AASME V Art. 6 + AWS D1.1 Section 6 Part

C §6.10

12.4.6.3 Radiographic procedure (if applicable) X AASME V Art. 2 + AWS D1.1 Section 6 Part

C §6.12





12.5.1 Material for structural steel X R EN 10204-3.1 Carbon Steel suitable for low ambient


12.5.2 Grating X R EN 10204–2.2 Hot dip galvanized acc. to ASTM A123

12.5.3 Structural bolts X R EN 10204-3.1 Suitable for low ambient temperature

(-45°C)

12.5.4 Ladders and handrails X R EN 10204–2.2Carbon Steel suitable for low ambienttemperature (-45°C)

12.5.5 Lining materials X R

12.5.5.1Castable for upper part of convection section

and furnace floor X R EN 10204–2.2

REF51061 R0 §5.1

Al2O3 + TiO2: min 38%

SiO2: max 38%

12.5.5.2 Castable for lower part of convection section X R EN 10204–2.2

REF51061 R0 §5.2

Al2O3 + TiO2: min 31%

SiO2: max 36%

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12.5.6 Consumables X R EN 10204–2.2ASME II Part C

NAKS certificates for onsite welds

12.6 WELDING EXAMINATION X SW REF51044 R.A §7 & AWS D1.1

12.7 NDT EXAMINATION REF51044 R.A §7 & AWS D1.1



100% on lifting lugs welds. Free of cracks,undercutting, linear indications over 2 mm

and rounded indications over 4 mm

12.7.2 Radiographic examination X SW ReportAWS D1.1 Section 6 Part C §6.12

100% on full penetration BW forreconstituted beams

12.7.3 Ultrasonic test X SW Report


100% on area where lifting lugs are

welded


12.9 LINING APPLICATION





installers





Compressive strengthPermanent linear change

DensityChemical composition

Tensile strength (ceramic fiber blankets)


12.10 PAINTING EXAMINATION X W

4-1246 E R7

Surface preparation, climatic conditions,

Wet film thickness and DFT



100%

12.11.2 Marking X W

Approved procedure


alloy



passport


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13.1.1Code : ASME B31.1

: ASME B31.3 X

13.1.2 HTAS Specifications

4-1246 E R7: Painting X

See point 3


meeting





manufacture.












13.4.6.2 Radiographic procedure X A

ASME V Art. 2 + ASME B31.1 §136.4.5

ASME B31.3 Table 341.3.2 Normal Fluid

Service


ASME V Art. 6 + ASME B31.1 §136.4.4

ASME B31.3 Table 341.3.2 Normal Fluid

Service

13.4.7 Heat treatment procedure X A Supplier's procedure

13.4.8 Hardness test procedure X A Supplier's procedure

13.4.9 Hydrostatic test procedure X A

ASME B31.1 §137

ASME B31.3



13.5.1 Pipe X R EN 10204-3.1 As per iso

13.5.2 Elbow X R EN 10204-3.1 As per iso

13.5.3 Flange X R EN 10204-3.1 As per iso

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A C

R O N

O T H E R S


13.6.1 Beveled ends examination X SW Report 100% PT on bevels

13.6.2 Welding X SW Report

100% visual

10% PT on socket and branch welds

10% RT on buttwelds

13.7POST WELDING HEAT TREATMENT(IF APPLICABLE)

X SWChart Approved procedure

13.7.1 Hardness test examination X SW Report Approved procedure

13.8 HYDROSTATIC TEST X SW Chart Approved procedure

13.9 PAINTING EXAMINATION

4-1246 E R7


Wet film thickness and DFT





100%

13.10.2 Marking X W

Approved procedure


alloy




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14.Category: DeNOx – D251 SCOPE of INSPECTION

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14.1.1

Design Temperature :

R251: -27°C / 380°C

X251: -27°C / 380°C

X252: -27°C / 380°C

V251: -45°C / 70°C

P252 A/B: -45°C / 50°C

MP252 A/B: -45°C / 50°C

K251: -45°C / 380°C

MK251: -45°C / 380°C

J251: -27°C / 510°C

J252: -27°C / 380°C

J253: -27°C / 510°C

J254: -27°C / 510°C

J255: -27°C / 380°C

X

14.1.2

Code : ISO 13705 (API560): ASME VIII Div. 1

: ASME IX: AWS D1.1: ASME B16.25

: ASME 16.20: ASME B31.3

: API 675

: OSHA (Noise level)

: ASME V: EN 10204

: RUSSIAN STANDARDS

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14.1.3

HTAS Specifications

P52251-R R1: Process specification for

R251 DeNOx reactor

P54251-V R1: Process specification for

V251 Ammonia water storage tank

P56251-K R0: Process specification for

K251 motor driven centrifugal blower

P56252-P R0: Process specification forP252 A/B Ammonia water dosing pump

P59251-J R0: Specification for J251DeNOx inlet sample ejector

P59252-J R0: Specification for J252DeNOx outlet sample ejector

P59251-X R0: Specification for X251Ammonia water injector

P59252-X R0: Specification for X252

Ammonia/flue gas mixer

P59253-J R0: Specification for J253

Ammonia/flue injection grid


inlet sample grid


outlet sample grid


P40001-BED R1: Design Basis

M80001 R1: General piping

specification

REF51071-R0: General arrangement

of convection section

J61021-Rev. 2: General specification

for instrument

J61025-Rev. 0: General specification

for instrument erection materials(piping & tubing)

J61024-Rev. 0: Typical hook-updrawings for instrumentation in

petrochemical plantsJ61021-1-Rev. 1: Selection list for

instrumentation and control peripherals

X

See point 3

14.1.4

HPC Documents

H201-FS-723 R0 : Material

requisition for DeNOx system package

H201-FD-806 R0 : PID for DeNOx unit

H201-FD-801 R0 : PID for Reformerconvection section

X

See point 3


meeting




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14.4.6.2 Dye Penetrant procedure X AASME V Art. 6 + ASME VIII Div.1 App 8

14.4.6.3 Radiographic procedure X AASME V Art. 2 + ASME VIII Div.1 §UW-51& UW-52

14.4.6.4 Ultrasonic test procedure X A

ASME V Art. 5 + AWS D1.1 Section 6 Part

C §6.13

14.4.7 Hydrostatic test procedure X A 1 hour mini.

14.4.8 Running test procedure X A

14.4.9 Balancing test procedure

14.4.10 Functional and performance procedure X A Noise level must not exceed 80dBA at 1m


14.4.12 Painting procedure X A 4-1246 E R7



14.5.1 Shell & head X R EN10204-3.1 Material as per drawing / requisition

14.5.2 Flange X R EN10204-3.1 Material as per drawing / requisition

14.5.3 Piping X R EN10204-3.1 Material as per drawing / requisition

14.5.4 Gaskets X R EN10204-3.1 Material as per drawing / requisition

14.5.5 Bolts/nuts X R EN10204-3.1 Material as per drawing / requisition

14.5.6 Motors X R EN10204-3.1 Material as per drawing / requisition

14.5.7 Pumps X R EN10204-3.1 Material as per drawing / requisition

14.6 MATERIAL/WELDING EXAMINATION

14.6.1 Beveled ends examination X SW Report 100% PT

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14.6.2 Tank V251 X SWReport

Chart

100% visual

100% PT

100% RT after PWHT

Hardness 197 HB max. for CS after PWHTon weld, HAZ and material.

Pressure test during min. 1 hour20ppm Cl.

14.6.3 Ammonia mixing blower and motor K251 X SW Report

Running test for motors

Balancing test

Functional and performance test

Running test

100% PT on impeller welds after runningtest

14.6.4 Ammonia water dosing pump P252A/B X SW Report

Running test for motors

Functional and performance test

Running test

Hydrostatic test

14.6.5 DeNOx inlet sample ejector J251 X R Report Functional and performance test

14.6.6 DeNOx outlet sample ejector J252 X R Report Functional and performance test

14.6.7 Ammonia water injector X251 X R

Certificate of

conformance As per supplier standard

14.6.8 Ammonia/Flue gas mixer X252 X R Report 100% PT

14.6.9 Ammonia/Flue gas injection grid J253 X R Report 100% PT

100% of welds and material

14.6.10 Inlet sample grid J254 X SW Report 100% PT

100% PMI of welds and material

14.6.11 Outlet sample grid J255 X R Report 100% PT

14.6.12 Piping X SW Report100% PT on welds

100% RT on welds

14.6.13 Steel structure for DeNOx unit X R Report

100% PT on lifting lugs welds

10% PT on welds100% UT on lifting lugs welds

14.7 HYDROSTATIC TEST X H ReportApproved procedure

1 hour mini., No leak

14.8 PAINTING As per H201-FS-723 part.12





100%

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14.9.2 Marking X H

Approved procedure


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15.Category: Cross flow heat exchanger – Convection Section Coils


Supplier: HPM Inspection Level: 4 2


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15.1.1 Minimum Design Temperature : -27°C X

15.1.2

Code : API530

: ASME B31.3 (process gas coils

: ASME I (steam coils)

: RUSSIAN STANDARDS

X

15.1.3

HTAS Specifications

REF51072 R0: Specification for

convection sectionP51201-H-005 R0: Process

specification for Waste Heat Section

convection section coils

REF51061 R0: Radiant and convection

section specification for refractory lining

REF51071 R0: General arrangement

sketch of convection section

X

See point 3

15.1.4

HPC Documents

SG 1431 Rev5: Fin Welding on

Furnaces & Boilers Tubes

H201-FS-303: Material requisition for

Convection fabrication

H201-FD-402: Convection coil E-201

H201-FD-403: Convection coil E-202A


H201-FD-405: Convection coil E-203B

H201-FD-406: Convection coil E-206




H201-FD-901: Lifting diagrams &

lifting lugs

X

See point 3


meeting





manufacture.






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15.4.5.2WPS

X AASME IX

Root pass by TIG process






15.4.6.2 Dye Penetrant procedure X A ASME V Art. 6 + ASME I §A-270

15.4.6.3 Radiographic procedure X AASME V Art. 2 + ASME I PW-51

15.4.6.4 Hydrostatic test procedure X AASME I PW-541 hour mini



15.5.1 Tube X R EN10204-3.1

ASTM A312 Gr.TP304H

ASTM A312 Gr.TP304H + Helical fins

SS304HASTM A106 Gr. B + Helical fins CS

ASTM A335 Gr.P11 + Helical fins 11Cr

15.5.2 Inlet Manifold X R EN10204-3.1

ASTM A335 Gr.P11

ASTM A335 Gr.P22

ASTM A106 GR. B

15.5.3 Outlet Manifold X R EN10204-3.1

ASTM A335 Gr.P22

ASTM A312 Gr.TP321H

ASTM A106 GR. B

ASTM A335 Gr.P11


15.6.1

Beveled ends examination X SW ReportApproved procedure

100% PT on bevels

15.6.2 Welding of tube to inlet/outlet manifold X SW Report

Approved welding book

100% visual

Approved procedure

100% RT on buttwelds

Approved procedure

100% PT when RT is not possible

15.7 HYDROSTATIC TEST X H Report

Approved procedure

One hour minimum

No leak



100%

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15.8.2 Marking X H

Approved procedure


alloy


15.8.4 Manufacturer Data Book X H Approved HPC summary

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16.Category: FLUE GAS DUCTS CASING ANDAIR DUCT CASING




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16.1.1

Design furnace temperature: 1150°C

Design casing temperature: 55°C

above ambient

Ambient temperature for design: 27°C

MDMT for structural parts : -27°C

X

16.1.2 Code : ISO 13705 (API560)

: AWS D1.1

: RUSSIAN STANDARDS

X

16.1.3

HTAS Specifications


REF51061 R0 : Specification for

refractory lining

REF51040 R0 : Specification for steel


X

See point 3

16.1.4

HPC Documents

H201-FS-302: Material requisition forPenthouse fabrication

H201-FS-304: Material requisition forFlue gas fabrication

X

See point 3






manufacture.




16.4.5WELDING Book including:


16.4.5.2 WPS X A AWS D1.1

16.4.5.3 PQR X A AWS D1.1





16.4.6.2 Dye Penetrant procedure X AASME V Art. 6 + AWS D1.1 Section 6 Part

C §6.10

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16.4.6.3 Radiographic procedure (if applicable) X AASME V Art. 2 + AWS D1.1 Section 6 PartC §6.12

16.4.6.4 Ultrasonic test procedure X AASME V Art. 5 + AWS D1.1 Section 6 Part

C §6.13




16.5.1 Material for structural steel X R EN 10204-3.1

Carbon Steel suitable for low ambient


16.5.2 Structural bolts X R EN 10204-3.1 Suitable for low ambient temperature(-43°C)

16.5.3 Lining materials

16.5.3.1 Ceramic fibre lining for flue gas duct X R EN 10204–2.2

REF51061 R0 §5.4

For 1260°C grade modules: Al2O3 + ZrO2:min. 45%


15% ZrO2

16.5.4 Consumables X R EN 10204–2.2 ASME II Part C

16.6 WELDING EXAMINATION X SW REF51040 R0 §7 & AWS D1.1

16.7 NDT EXAMINATION REF51040 R0 §7 & AWS D1.1



100% on lifting lugs welds. Free of cracks,

undercutting, linear indications over 2 mm

and rounded indications over 4 mm

16.7.2 Radiographic examination X SW Report


100% on full penetration BW forreconstituted beams

16.7.3 Ultrasonic test X SW ReportAWS D1.1 Section 6 Part C §6.13

100% on area where lifting lugs are

welded


16.9 LINING APPLICATION FOR FLUE GASDUCT





installers



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Compressive strength

Permanent linear changeDensity

Chemical compositionTensile strength (ceramic fiber blankets)


16.10 PAINTING EXAMINATION X W Report

4-1246 E R7


Wet film thickness and DFT examination

16.11 FINAL EXAMINATION X H Report


100%

16.11.2 Marking X W

Approved procedure



16.11.4 Manufacturer Data Book X H Approved HPC summary

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