BHEL Quality Assurance Department

Tiruchirappalli 620014
CONTRACT INSPECTION PROCEDURE

DOC No : CIP: 394 Rev : 00

EFFECTIVE DATE : 17.12.2010
Page 1 of 2

Procedure for
1. Replacement of damaged tubes of SH horizontal spaced upper coil
2. Hot correction for the bent tubes of SH horizontal spaced upper coil
3. Welding repair in the stubs of SH vertical platen header of MALWA (Customer number: 1602)
SCOPE:
This procedure is applicable for
1. Replacement of damaged tubes of SH horizontal spaced upper coil
2. Hot correction for the bent tubes of SH horizontal spaced upper coil
3. Replacement of the damaged stubs of SH vertical platen header of MALWA (Customer number: 1602)
PRESENT STATUS:
It was reported from Site through email via commercial/FB dated. 15.12.2010 that during transit some of the
tubes are observed with dents, some tubes got bent in SH horizontal spaced upper coil and few stubs of SH
platen header got damaged. It was decided to replace the dent tubes by inserting the required length spool
pieces, the bent tubes to be hot corrected and the damaged stubs of the header to be replaced.
MATERIAL SPECIFICATION, SIZE & LOCATION:
SH horizontal spaced upper coil:
Tube Material: SA213 T11

Tube Size: D 51 x 6.6 mm

SH Platen header:
Pipe: SA 335 P12 Dia 406.4x60
Tube: SA 213 GrT22

REFERENCE DOCUMENTS:
IBR & ASME Section I
Drg Nos : 2-11-036- 11041 for SH horizontal spaced upper coil
0-10-178-01004/01 for SH vertical platen header.
PROCEDURE for replacement of damaged tubes:
1. Prior approval from Statutory Authorities, as required, shall be obtained for repair.
2. Identify and mark the damaged tubes.
3. Deploy IBR qualified welders and use approved welding consumables.
4. Remove the damaged portion of the tube (Minimum 150mm by length) by cutting.
5. Edge prepare the cut out portions of the tube on the coils and spool pieces by grinding as per the
drawing.
6. Carry out LPI on the EPs to confirm defect free areas.
7. Insert the required spool pieces at the appropriate places in the coil assy.
8. Carry out welding using GTAW&SMAW process using ER 80S-G wire of 2.5 mm dia for the root
layer and E 8018-B2 of 3.15 mm dia for the subsequent layers.During welding the maximum
interpass temperature shall not exceed 300 deg C.
9. Clean the welds and carry out RT for butt joints.
10. Carry out PWHT @ 655+/- 15 deg C with a minimum soaking time of 30 minutes. ROH and ROC
above 400 deg C shall be a maximum of 220 deg C per hour.
11. Clean the welds and carry out MPI to ensure defect free welds.

BHEL Quality Assurance Department

Tiruchirappalli 620014
CONTRACT INSPECTION PROCEDURE

DOC No : CIP: 394 Rev : 00

EFFECTIVE DATE : 17.12.2010
Page 2 of 2

Procedure for Hot correction of the bent tubes:

1.
2.
3.
4.

Prior approval from Statutory Authorities, as required, shall be obtained for the hot correction.
Identify and mark the bent tubes.
Use C clamp properly where exactly the bent has to be hot corrected.
Heat the tube and apply mechanical force simultaneously till the shape of bent tube comes to a
better shape.
5. The hot correction temperature shall not exceed 720 deg C. If it exceeds, then carry out PFHT @
655+/-15 deg C with a minimum soaking time of 30 minutes by maintaining ROH and ROC
maximum of 220 deg C per hour above 400 deg C.
Procedure for SH Vertical Platen header:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Prior approval from Statutory Authorities, as required, shall be obtained for the repair.
Identify and mark the damaged tubes.
Deploy IBR qualified welders and use approved welding consumables.
Remove the damaged stubs by grinding till the root and clean the area properly.
Carry out LPI on the ground areas to ensure defect free areas.
Edge prepare the areas of header hole and the tube (if not received with EP) as per the drawing.
Fit the new stubs as per the drawing.
Preheat the area to 150 deg C and ensure using thermal chalk.
Weld the groove by SMAW process using E8018-B2 electrode of 2.5mm dia for the first layer and
3.15 mm dia for the subsequent layers. Ensure that during welding the maximum inter pass
temperature is 300 deg C.
10. Dress the welds and carry out MPI to ensure defect free welds.
11. Carry out PWHT @ 695+/15 deg C with a minimum soaking time of 150 minutes. The ROH and
ROC above 400 deg C shall be a maximum of 75 deg per hour.
12. Clean the welds and carry out MPI to ensure defect free welds.

Documentation:
Record the details regarding the repair carried out on the header, coils in correlation with the
welder, NDE test reports, heat treatment etc.

Prepared

V.Sampath Kumar

Reviewed and Approved

S.Selvarajan