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TECHNICAL SPECIFICATION

FOR

FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR


HEATER B101
NOCL CUDDALORE, INDIA
EF 10013

B101-FS-301

Onshore or Offshore Fabrication

PREFABRICATION OF B101
ATMOSPHERIC SERVICE HEATER
CONVECTION MODULE

20/07/2011

TECHNICAL SPECIFICATION

LAHTI

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1/12

TECHNICAL SPECIFICATION
FOR

FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR


HEATER B101
NOCL CUDDALORE, INDIA
EF 10013

B101-FS-301

TABLE OF CONTENT
Page
1

INTRODUCTION....................................................................................................................................... 3

DESIGNATION.......................................................................................................................................... 3

CONTRACTUAL DOCUMENTS ............................................................................................................. 3


3.1GENERAL ...................................................................................................................................................... 3

SCOPE OF SUPPLY .................................................................................................................................. 4


4.1GENERAL ...................................................................................................................................................... 4
4.2DESCRIPTION OF WORKS ............................................................................................................................... 5
4.2.2 Convection modules (for Heater B-101) Fabricators Responsibilities: ................................................ 5
4.3.1 Structure & Plate Steel: (Fabricaot Supply) ........................................................................................... 6
4.3.2 Bolts: (Fabricator Supply + 10% spare) ................................................................................................. 6
4.3.3 External painting: Heurtey Supply) ........................................................................................................ 6
4.3WEIGHTS & QUANTITIES: PER HEURTEY DRAWINGS & DATA SHEETS ......................................................... 6
4.5.1 Marking .................................................................................................................................................. 7
4.5.2 Trial assembly ........................................................................................................................................ 7
4.5.3 General ................................................................................................................................................... 7
4.6. Pressure parts ........................................................................................................................................... 7

MISCELLANEOUS ................................................................................................................................... 8
5.1.
5.2.
5.3.

PLANNING ............................................................................................................................................ 8
RESPONSIBILITY OF HPC ..................................................................................................................... 9
GUARANTEE......................................................................................................................................... 9

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TECHNICAL SPECIFICATION
FOR

FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR


HEATER B101
NOCL CUDDALORE, INDIA
EF 10013
1

B101-FS-301

INTRODUCTION
This specification defines the minimum requirements to
prefabricate one Convection Section to be installed at the NOCL
Refinery in Cuddalore, India. The works include all structural and
plate fabrication and any required shop detailed drawings.
Anchor, mastic and castable refractory installation, coil
installation and welding, hydro-testing, blastcleaning, painting
and transport preparation.
Any concerns or comments shall be addressed to Heurtey
Project Manager, Mr. Antoine Fauqembergue.

DESIGNATION
Client: NOCL (OWNER)
Engineering: HEURTEY PETROCHEM
Heater manufacturer: PER FURNACE

CONTRACTUAL DOCUMENTS

3.1

General

Fabrication Contractor shall comply with project specifications.


Contractor shall assure the edition of all drawings or documents
in his hands shall be in their latest edition.
In case of conflict, the following list of precedence shall be
applied:
CODES:
ASME B16.5: Pipe Flanges and Flanged Fittings NPS
through NPS 24 metric/inch Standard.
ASME B31.3 Process Piping.
ASME Section II: Material Specifications
ASME Section IX: Welding and Brazing Qualifications.
ASME B1.20.1 Pipe Threads, General Purpose.
STANDARS/RECOMMENDED PRACTICES:
API STD 530 / ISO 13704: Calculation of Heater Tube
Thickness in Petroleum Plants.
API RP 531M: Measurement of noise from Fired Process
Heaters.
API STD 560: Fired Heaters for General Refinery Service

3/12

TECHNICAL SPECIFICATION
FOR

FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR


HEATER B101
NOCL CUDDALORE, INDIA
EF 10013

B101-FS-301

REFERENCE SPECIFICATIONS:
: Basis for Steel Stack-Fired Equipment (doc no: CC-000-ME40-0010).
: Civil/Structural Design (doc no: CC-000-CI-40-0001).
: Surface Preparation and Painting (doc no: CC-000-ME-420004).
: Nozzle Loadings for Equipment (doc no: CC-000-ME-420005).
: Welding of Pressure Vessel Equipment (doc no: CC-000-PR42-0005).
ANSI/AWS D1.1 Structural Welding Code
Shop fabrication drawings shall be submitted to Heurtey for
review per PO reference. Fabricator shall be responsible for the
accuracy of all shop drawings. Heurtey shall review for
conformance to design intent only. Heurtey review of drawings
shall not be held responsible for fabricators schedule. However,
should Heurtey discover discepancies, the fabricator must correct
these discrepancies in a timely manner.
Vendor shall provide (an itemized) Master Shipping Bill of
materials for the entire scope of fabrication works.
The following minimum information shall be provided for field
erection drawings:
Piece Marks for all assemblies to be erected.
Field bolting requirements for all connections including
all nuts and washers, plus 10% spare.
Field weld requirements
The bill of material
4

SCOPE OF SUPPLY

4.1

General

Goods shall conform to the documents listed in the present


specification.
Contractor shall provide all additional drawings (in English to be
submitted to HPC) necessary for the manufacture, including the
checking (with calculation notes submitted to HPC) of the annex
equipments (lifting lugs, crossbar, temporary stiffeners, cradle
meant to the lifting operations of the heavy and large elements.

4/12

TECHNICAL SPECIFICATION
FOR

FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR


HEATER B101
NOCL CUDDALORE, INDIA
EF 10013
4.2

B101-FS-301

Description of works

The goods to be delivered to site by road transportation according


to this contract are as follow:
The newly fabricated convection section for heaters B-101
including:
Shop fabrication drawings
Lined panels and roof;
Convection coils;
Jumpovers & crossovers;
4.2.2 Convection modules (for Heater B-101)
Fabricators Responsibilities:
Supply of detailed fabrication drawings for review by Heurtey
prior to start of works
Supply for structural steel & plate for the prefabrication of
module (including header boxes, end tube sheets) with welded
stiffeners;
Supply of lined end tube sheets;
Supply & installation of access / inspection doors, connections
for instruments;
Installation of end tube sheets;
Installation of refractory anchors (Heurtey supply)
Installation of mastic paint material (Heurtey supply)
Installation of castable refractory (Heurtey supply)
Installation and welding of coil tubes and fittings;
Drilling of convection beams & columns for the installation of
platforms (by others);
Drilling of Connection Boltholes for Field Installation
Supply of all connection bolts plus 10% spare
Protection of tube ends with plastic caps/ blind wood for
flange faces;
NDT of structural and tube coils
Hydrotest of coils (including necessary material for carrying
out + water) shall be in accordance with ANSI B31.3, Section
337.4.1.
Application of painting system per Heurtey painting
requirements (Heurtey supply)
Blastcleaning & final painting.
Supply and assembly of lifting lugs or trunions (with
calculations)
Transport to site

5/12

TECHNICAL SPECIFICATION
FOR

FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR


HEATER B101
NOCL CUDDALORE, INDIA
EF 10013

B101-FS-301

4.3.1 Structure & Plate Steel: (Fabricaot Supply)


Main beams / columns: (doc no: CC-000-CI-40-0001)
Secondary beams / casing: (doc no: 000-CI-40-0001)
4.3.2 Bolts: (Fabricator Supply + 10% spare)
For Mains assemblies: Grade 8.8
For secondary assemblies: Grade 4.6
4.3.3 External painting: Heurtey Supply)
According to CBI/NOCL Document: CC-000-ME-42-004 Rev 2.
Surface preparation: SA 2.5 (ISO 8501-1) / SSPC SP10
Painting system C (attachment 2.1) on heater and structural
steel:
Primer: Zinc rich epoxy 75 microns
Intermediate: High build MIO epoxy 125 microns
Finish: Polyurethane 40 microns (finish coat not
required where fireproofing is applicable)
Color:
Furnace including steel structures, stack and ducts:
Grey Aluminum RAL 7038.
Platform frame and brackets, stairs: Grey
Aluminium RAL 7038.
Safety cages, ladders, handrails of stairs and
platforms: RAL 1004.
Internal coating to be Carboline Bitumastic 1248,
with a tolerance thickness of 16 mils after receiving
a surface preparation of SSPC SP6.
All TEMPORARY steel bracing shall be painted
RAL 1012 Lemon Yellow.

4.3

Weights & quantities: Per Heurtey Drawings &


Data Sheets
4.4.1 Steel structure estimated weights
Convection section
4.4.2 Insulation
Convection section:

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TECHNICAL SPECIFICATION
FOR

FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR


HEATER B101
NOCL CUDDALORE, INDIA
EF 10013

B101-FS-301

4.4.3 Welds
Convection Structural Steel & Process Coil
4.5.1 Marking
Marking of all prefabricated elements in order to make erection
easier:
Marking shall contain: heater assembly reference, letter of
sub-assembly, part reference;
Bolts shall be packaged by: quality, diameter, and length (with
these indications on each label).
4.5.2 Trial assembly
The B101 convection box sections are to be fabricated in such a
manner that each module shall be prefit in the workshop prior to
acceptance as per HPC specifications.
4.5.3 General
Reception, verification, unloading, storage and protection of
all material supplied by HPC;
Segregation between stainless steel and carbon steel works;
Protection against winterizing during concrete application
phases;
Suitable packing;
Marking piece drawings for site erection activities;
Electricity, water & other facilities for lining activities;
Supply + installation of scaffolding, lagging;
Temporary beams and other structures for storage (including
shims) and transportation;
Material for handling (crane, sling, hoist, crossbar, etc.);
Suitable reinforcement of all insulated materials during
transport & handling;
The well and careful adjustments of all elements lined by
concrete (precautions must be done to avoid any shocks,
deformation. Addition of temporary stiffeners for transport
shall be mandatory.
4.6. Pressure parts
Pressure parts shall be free of any foreign body and blowing
shall be provided after hydrotests;

7/12

TECHNICAL SPECIFICATION
FOR

FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR


HEATER B101
NOCL CUDDALORE, INDIA
EF 10013

B101-FS-301

Welding and NDE shall be in accordance with the following


requirements:
a) Applicable National / International / Indian Codes &
Directives
ASME B16.5: Pipie Flanges and Flanged Fittings NPS
through NPS 24 metric/standard
ASME B31.3: Process Piping
ASME Section II: Material Specifications
ASME Section IX: Welding and Brazing Qualifications
Applicable code and specifications
Heurtey Technical description Inspection and Test
Plan for Heater B-101, document no: B-101-FQ-001.
CB&I & NOCL specification no: CC-000-PR -42-005
for Welding of Pressure Vessel Equipment
API Standard 560 last edition
AWS D1.1
5

MISCELLANEOUS

5.1. Planning
Fabricator shall provide a global planning project form based on
the main HPC targets and must be sufficient detailed to follow
the progress. It will be regularly updated.
Fabricator shall assure the work is conscientiously executed in
order to permit its completion within the required time, or within
the shortest normal delay compatible with a standard execution.
Fabricator shall not take advantages of constraints due to normal
exploitation of public or private ownership and public services to
evade its commitment or not to address any complain.
Fabricator shall not take advantages of constraints due to other
contracts performed simultaneously on shop for which HPC has
given its agreement.
Fabricator shall inform HPC in writing and within 48 hours
maximum of any major circumstances which may occurred to
delay the work on shop.
Normal bad weather for the season will not be considered as a
major circumstance. If the work is stopped due to bad weather,

8/12

TECHNICAL SPECIFICATION
FOR

FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR


HEATER B101
NOCL CUDDALORE, INDIA
EF 10013

B101-FS-301

Fabricator shall present reports showing stop and restart work


periods which will be signed by the HPC representative.
If at any time during the execution of contract, Fabricator finds
necessary to modify the program, he shall inform immediately
HPC and submit him the modified schedule for approval.
All delays on jobs, which are under Fabricators responsibility,
must be made up during the due date with no repercussion on this
date.

5.2. Responsibility of HPC


Drawing and other documentation issued by HPC are under his
responsibility.

5.3. Guarantee
Fabricator guarantees that all the equipments and materials
forming the subject of the present order are:
Designed, dimensioned, selected, installed and inspected so
that they will correctly execute their function throughout the
normal period of use, and satisfy the contract and production
requirements as to quantity and quality for the planned
operating conditions.
Free from all design, manufacture and assembly faults as well
as all defects due to the use of inferior materials from those in
the specifications.
During the guarantee period, the contractor undertakes to replace
any faulty equipment at his own cost, including equipment,
accommodation, transport costs, etc.

9/12

TECHNICAL SPECIFICATION
FOR

FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR


HEATER B101
NOCL CUDDALORE, INDIA
EF 10013

B101-FS-301

ANNEXE B TECHNICAL DATA BOOK


Documents shall be in English (issued with Autocad, Excel,
Word, Project softwares) and sent to our DCC (as per PO) as
follow;
- For approval / information :
1 electronic file
- For Final data book :
1 hard copy + 1 CDrom
Mailing date (weeks)
with proposal

10/12

For approval

For info.

TECHNICAL SPECIFICATION
FOR

FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR


HEATER B101
NOCL CUDDALORE, INDIA
EF 10013
-

B101-FS-301

As built drawings.
Welding procedures of structural
Welding procedure of coils
Heat treatment procedure
NDT procedures (PMI, Hydrotest, Heat Treatment)
Welding book
Map with weld location

J+4
J+4
J+4
J+4
Typ.

J: Date of initial letter of intend or order


R: Date of the final acceptance in the work shop

ANNEXE C MANUFACTURING DATA BOOK


Documents shall be in English (issued with Autocad, Excel,
Word, Project softwares) and sent to our DCC (as per PO) as
follow;
- For Final data book :
1 hard copy + 1 CDrom
As per summary data book issued by HPC:
Requested

STRUCTURAL STEEL WORKS


-

Certificate of compliance for material (plates, beams, shapes,

11/12

Observation

R
R

TECHNICAL SPECIFICATION
FOR

FABRICATION & ASSEMBLY OF CONVECTION MODULE FOR


HEATER B101
NOCL CUDDALORE, INDIA
EF 10013
-

B101-FS-301

bolting, other structure)


Inspection certificates as per specification and/or additional
requirements for material (tubes & fittings)
Inspection certificate of filler material
Welding procedure qualification record
Welders and/or operators performance qualification
Welds inspection and radiographic examination records
Map of radios

X
X
X
X
X
X

COILS
-

Certificate of compliance for material without pressure and/or


welding (plates, beams, shapes)
Inspection certificates as per specification and/or additional
requirements for material (tubes & fittings)
Inspection certificate of filler material
Welding procedure qualification record
Welders and/or operators performance qualification
Welds inspection and radiographic examination records
Map of radios
Heat treatment curve of welds
Hydrotest report

12/12

X
X
X
X
X
X
X
X
X