Specification for Fabrication Ofthermalstoragetank

ANNEXURE-1

SPECIFICATION FOR FABRICATION OFTHERMALSTORAGETANK

Part-I

Scope of the work

The scope of this work includes fabrication, supply and testing of components, machining, edge preparation for butt weld joints, full radiography of butt weld joints, fabrication, inspection, assembly, hydrostatic testing at room temperature and safe deliveryof THERMAL STORAGE TANK as per the details given in Drawing No. 1

Part-II

TECHNICAL SPECIFICATION

1.0 INTRODUCTION.

The thermal storage tank is made of DN 1050 sch 40 pipe made by Electric Resistance Welding (ERW). The tank will be used to store fluid at high temperature.The temperature of the tank will vary from room temperature to 550 oC during operation. The all parts of the tank including the supports will be made of SS 316. For the fabrication, Drawing number 1 should be strictly followed.The design temperature and pressure of the loop is 600 0C and 5 bar respectively.

2.0 APPLICABLE DOCUMENTS

The raw material, inspection and testing of the tank shall comply with the requirement of the latest edition of codes and standards specified hereunder, the specification and theapplicable drawings.

In the event of any conflict between the requirements of this specification and the documents listed bellow, the more stringent requirements shall apply.

3.0APPLICABLE SPECIFICATIONS

3.1 American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Codes.

1. Section II, PART-B Ferrous Material Specification.

2. Section II, PART-C Specification for welding rods, electrodes and filler metals.

3. Section II, PART-D Material Properties.

4. Section V Nondestructive examination.

5. Section VIII, Div. 1 Rules of construction of pressure vessels.

6. Section IX Welding and brazing qualification.

3.2American Society for Testing of Materials (ASTM)

1)ASTM-E- 94Recommended practice for radiographic testing

2)ASTM-E-142Methods for controlling quality of radiographic testing.

3)ASTM-E-165Liquid penetrant inspection method.

3.3 ASME B16.5 Pipe flanges and flange fittings

3.4ASME B16.2 Metallic gaskets for pipe flanges

4.0RAW MATERIALS

4.1 No free issue material will be supplied by the purchaser.

4.2 All the materials used in fabrication ofthe tank should be SS 316conforming to material specification no.: SA-312 and alloy designation/UNS no.: S31600 as per the section-II of ASME Boiler and Pressure Vessel Code. Chemical composition in percentage is given below:

SS 316 / C / Mn / Si / P / S / Cr / Mo / Ni / N / Fe
Min. / - / - / - / 0 / - / 16.0 / 2.00 / 10.0 / - / -
Max / 0.08 / 2.0 / 0.75 / 0.045 / 0.03 / 18.0 / 3.00 / 14.0 / 0.1 / Bal.

4.2The materials to be used shall be of tested quality. The material test certificates clearly indicating chemical composition & mechanical properties shall be submitted to the Purchaser for approvalbefore initiating fabrication.

4.3The materials of construction as indicated in this specification are the minimum acceptable.The vendor may offer equivalent or better materials provided the purchaser approve the material.

4.4All the material shall conform to relevant ASTM specification suitable for the service mentioned in this specification & shall meet all the requirements stated there in.

4.5The purchaser will witness ultrasonic test of material used & a test report of the same shall be submitted for purchaser’s approval.

4.6All the materials used for manufacturing shall be properly stamped/marked & the identification on each part goes in to assembly that shall be easily assessable for verification. The identification marking shall not be punched or scribed on the internal surface of the test section.

4.7WELDING MATERIALS

4.7.1Welding Materials shall be from reputed manufacturers & tested as required by ASME section II, part –C.

4.7.2 Proper identification & inventory control of all accepted/approved welding material shall be maintained throughout the process of fabrication of the tank.

5.0 Welding Procedure

It is the responsibility of the supplier to develop the best welding procedure to meet the end requirement. All welding procedures & performance test required for this job are to be established as per ASME section IX and other applicable codes like ASME section V.

5.1The welding is to be performed by GTAW process with an inert gas backing. The Welding Procedure shall be such as to assure substantially full root penetration & through fusion in the lands of the root & in the entire weld preparation.

5.2Each layer of weld metal in a multi-layer welding shall be cleaned before applying the next.

5.3Dye penetration & radiographic inspection shall be carried out on all the butt welds. All the butt-welded joints shall be fully radiographed with at least ten percent overlap & radiography films shall be submitted for approval during inspection.

5.4All welds shall be checked by dye penetration after root pass as well as final pass.

5.5The welding procedure & performance shall be qualified as per ASME code section IX.

5.6The methods used to prepare the base metal shall leave the weld preparation with reasonable smooth surfaces. The surfaces for welding shall be free of cracks, deep indentations, scale, rust, oil, grease & other deleterious material. The work shall be protected from deleterious contamination, from rain & wind during welding. The welding shall not be performed on wet surfaces.

5.7The specification of electrodes, voltages, welding speed, current & polarity should be as specified in approved welding procedure. Any deviation from the welding procedure will be treated as objectionable & may disqualify the procedure & the welder or welding operator.

5.8The inspector/ purchaser’s representative has the authority to reject any unsatisfactory process or operation or workmanship at any stage of fabrication.

6.0 Fabrication Drawings:

6.1 The parts shall be fabricated as per the drawings supplied by the purchaser. However, fabricator can make minor changes in the drawings with the prior approval of purchaser for the ease of fabrication. In such cases, Fabrication drawings giving complete information necessary for the fabrication of the components viz. Procedure for machining/fabrication, inspection tools planned along with accuracy, weld details, quality assurance plan & methods for achieving/measuring critical tolerances shall be prepared before starting the actual fabrication. Three sets of these drawings shall be submitted for approval & the manufacturer shall get them approved within three weeks of placement of the purchase order.

6.2Drawings submitted by vendor for approval will be checked / reviewed by purchaser and comments, if any, on the same will be conveyed to vendor. It is the responsibility of vendor to incorporate correctly all the comments conveyed by purchaser on vendor’s drawings. The drawings, which are approved with comments, are resubmitted to purchaser for purpose of records. Such drawings will not be checked/ reviewed by purchaser to verify whether vendor has incorporated all the comments. If the vendor is unable to incorporate certain comments in his drawings, he shall clearly state in his forwarding letter such non-compliance along with valid reasons. He shall proceed for the job only after receiving written approval of purchaser for non-compliance.

6.3Any work performed or material ordered by vendor prior to receipt of drawings stamped or “approved” or “approved with comments as noted” by purchaser shall at the risk of vendor. After a print drawing has been returned “approved” vendor may release all parts covered by drawing for the production.

6.4The purchaser’s approval of the contractor’s drawings does not relive the contractor for any responsibility with respect to the fabrication of the tanks in accordance with the code requirements.

6.5Fabrication:The fabrication of the parts shall conform to the requirement of ASME section VIII, Division I.

PART-III

GENERAL REQUIREMENTS

1.0Fabrication of components: The contractor has the freedom to decide the sequence of machining & welding to achieve the final machined dimensions given in the drawing. However, a procedure including shop drawings shall be submitted and got approved by the bidder or his representative before proceeding with the work. The procedure shall include sequence of fabrication/machining, welding, inspection & testing.

2.0Inspection Facility:Most of the important dimensions such as inside diameter, outside diameter, length, orientation & relative locations of the features of the components shall be inspected by the calibrated gauges. Supplier shall provide all necessary tools, facilities & services for the inspection & related jobs. Inspection shall be carried out in a manner satisfactory to & shall be subject to approval by the purchaser. Purchaser shall have access to the premises of the fabricator for carrying out or witnessing the inspection of the job. The supplier shall provide all the equipment & consumable required for carrying out inspection.

3.0All non-destructive examination, dye penetrant, radiography, ultrasonic testing for flaw detection and thickness measurementshall be in accordance with ASME SE-213, hydro test & helium leak testing shall be done in accordance with a detailed written procedure.Products with defects that produce indications in excess of the indications produced by the standard defects in the reference specimen are unacceptable. The depth of the notch for ultrasonic testing shall not exceed 5% of the specified wall thickness.

4.0Inspection of parts shall be carried out in the following stages.

a) Preliminary Inspection

A preliminary inspection will be made prior to fabrication of the tank, to check materials, welding procedures, welding qualifications & testing of materials.

b) Intermediate Inspection

Intermediate stage inspection will be made to check inside diameter, outside diameter, straightness, ovality, concentricity, alignment, attachment details deemed necessary by the inspector to insure that the Manufacturer work meets the requirements of the contract.

c) Final inspection

After fabrication is complete, a final inspection will be made to insure completeness of Fabrication & assembly. For this purpose, the supplier will have to assemble all the components. The gaskets, studs & nuts required for assembly are a part of supply. This inspection will include radiographs, stress relieving charts, hydrostatic & other specified non-destructive tests, checking as built dimensions, orientation of nozzles, etc. for the above checking.

5.0Inspection plan:- The supplier shall prepare detailed inspection plan for the job & get approved before the commencement of the work.

6.0Inspection Report:- Two copies of the inspection report, covering all inspections duly signed by the manufacturer, shall be submitted to the purchaser at the time of delivering the item.

7.0Testing of final assembly

7.1Hydrostatic Testing

a)The completed test section constructed under this specification shall be hydrostatically tested in the presence of the purchaser’s inspector as per the requirement of UG-99 of ASME section VIII, division 1 & the approved procedure.

b)The manufacture shall close all the openings by using blind flanges/plugs for hydro test.

c)All mechanical & welded joints shall be left exposed for examination during the test.

d)The test medium shall be demineralised water.

e)The tank with its all components shall be hydrotested at 12kgf/cm².

f)The hydrostatic test pressure shall be maintained for a minimum of 10 minutes prior to conducting the examination for the leakage.

g)There should not be any leakage from the assembly;the hydro test procedure shall conform to the ANSI B31.1 or ASME section VIII division 1.

h)Examination for leakage shall be made at all joints, connections & of all regions of high stress such as regions around openings & thickness transition section.

7.2In the event of the test section or any part thereof fails to meet the examination or test requirements specified herein, the vendor shall notify the purchaser. The vendor shall obtain written permission from purchaser before repair & subsequent use of any part. If the repairs are likely to affect the results of examination & test or work previously completed, appropriate re-examination, re-inspection & re-testing shall be conducted.

7.3If the fabrication, examination, inspection & testing is not in conformance to the requirements of this specification, the test section will be rejected.

7.4The completely assembled parts shall be examined to determine its conformance with respect to material dimension, workmanship, cleanliness & test requirements. In case of nonconformance to this specification, the whole tender will be rejected.

8.0Packing & Shipment:

The finished goods shall be packed in a road worthy packing to avoid any damage to the finished product. The purchaser will not be responsible for any kind of damage during transport or unloading.

9.0 The fabricator shall submit quality assurance plan with in two weeks of the

receipt of purchase order.

10.0The supplier must accept quality surveillance by the purchaser or his representative. The decision of the purchaser in this regard would be final. This however does not relieve the manufacturer from his responsibility to supply the tank as per approved drawings & to have his own inspection to maintain the quality.

PART IV

NOTES TO BIDDERS

1.0Drawings: All the drawings shall be returned to the purchaser along with the quotation.

2.0Rawmaterialtesting: All the raw materials required for the item will be tested before starting the fabrication. Supplier shall start the fabrication only after the qualification of the raw materials.

3.0Sub-Contracting: No part of the job shall be contracted to any other party without the consent and prior written permission from the purchaser. In the event of sub-contracting the sub-contractor shall provide the inspection facilities and shall agree to the quality surveillance by the purchaser as mentioned above.

4.0Shipping Release: The finished material shall not be dispatched before getting the written shipping release from the purchaser.

5.0Minor changes: The purchaser reserves the right to make minor changes in the shape dimensions of the finished product, which may not seriously affect the fabrication requirements. Such changes shall be intimated to the bidder at the time of placement of purchaser order or before starting fabrication. However, such changes shall not lead to increase in the quoted amount.

6.0Facilities: The bidders having adequate experience and facilities to execute the work only need to quote. The bidder shall submit along with quotation, details of machining,fabrication, testing and inspection facilities available with him and/or the sub-contractor for executing the work. The bidder shall arrange to show and explain these facilities to the purchaser or his representative before placing the purchase order to establish the capability to execute the job. The manufacturer shall have in-house facility for radiography and helium leak testing.

7.0Proof of Ability: The bidder shall submit along with their quotation a list of similar jobs, executed in the past as a proof of their ability.

Annexure- A

Questionnaire

Sr. No. / Comment / Response from supplier
Yes / No
1 / Whether supplier is a original manufacturer
If NO, whether certificate of dealership from the principle is provided
2 / Whether manufacturer has manufactured tank of similar size and construction material.
If Yes, whether list of client with contact detail attached with the offer.
3 / Whether calculations for thermal storage tankdesign in accordance with the standard code is provided with the offer
4 / Whether Weld Procedure Specification (WPS), Procedure Qualification Record (PQR) and Welder Performance Qualification (WPQ) are provided.
5 / Whether Supplier has provided details of material of construction of the all the parts of the tank including support.
6 / Whether surface finish of the item indicated in the offer
7 / Whether details of gasket material of the tank is provided
8 / Whether five spare gasket of the main tankwill be provided
9 / Whether the compliance statements given in Annexure A and B are responded point by point along with offer
10 / Whether the supplier shall test the tankat his premises to its full operating conditions.
11 / Whether quotation is in INR only.

Annexure-B

Compliance Statement

Sl no / Important Specification As per Tender / Specifications offered by manufacturer
1. / Tank
Size / The sizes and geometries of all the components shall be as per Drawing No 1.
Material / All the components including supports are made of SS316 (non-magnetic).
2. / Design Conditions
Pressure / 5bar
Temperature / 500 oC
3. / Applicable codes for materials / American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Codes.

Section II, PART-B:

Ferrous Material Specification.

Section II, PART-C: Specification for welding rods, electrodes and filler metals.

Section II, PART-D: Material

Properties.
4. Section V: Nondestructive
Examination.
5. Section VIII, Div. 1: Rules of construction of pressure vessels.
6. Section IX: Welding and brazing
qualification
4. / Applicable codes for testing / American Society for Testing of Materials (ASTM)
1) ASTM-E- 94: Recommended practice for radiographic testing.
2)ASTM-E-142:Methods for controlling quality of radiographic testing.
3)ASTM-E-165: Liquid penetrant inspection method.
5. / Applicable Codes for Piping / ASME B16.5 Pipe flanges and flange fittings.
ASME B16.2 Metallic gaskets for pipe flanges.
6. / Raw Materials / All the materials used in fabrication ofthe tank should be SS 316 conforming to material specification no.: SA-312 and alloy designation/UNS no.: S31600 as per the section-II of ASME Boiler and Pressure Vessel Code.Chemical composition in percentage is given in section 4.2.
7. / Welding Materials /

Welding Materials shall be from reputed manufacturers & tested as required by ASME section II, part –C.

Proper identification & inventory control of all accepted/approved welding material shall be maintained throughout the process of fabrication of the tank.

8. / Welding / All welding procedures & performance test required for this job are to be established as per ASME section IX and other applicable codes like ASME section V.
9. / Fabrication Drawings /

Fabrication drawings giving complete information necessary for the fabrication of the components viz. Procedure for machining/fabrication, inspection tools planned along with accuracy, weld details, quality assurance plan & methods for achieving/measuring critical tolerances shall be prepared before starting the actual fabrication. Three sets of these drawings shall be submitted for approval & the manufacturer shall get them approved within three weeks of placement of the purchase order.

Drawings submitted by vendor for approval will be checked / reviewed by purchaser and comments, if any, on the same will be conveyed to vendor. It is the responsibility of vendor to incorporate correctly all the comments conveyed by purchaser on vendor’s drawings. The drawings, which are approved with comments, are resubmitted to purchaser for purpose of records. Such drawings will not be checked/ reviewed by purchaser to verify whether vendor has incorporated all the comments. If the vendor is unable to incorporate certain comments in his drawings, he shall clearly state in his forwarding letter such non-compliance along with valid reasons. He shall proceed for the job only after receiving written approval of purchaser for non-compliance.

Any work performed or material ordered by vendor prior to receipt of drawings stamped or “approved” or “approved with comments as noted” by purchaser shall at the risk of vendor. After a print drawing has been returned “approved” vendor may release all parts covered by drawing for the production

The purchaser’s approval of the contractor’s drawings does not relive the contractor for any responsibility with respect to the fabrication of the tanks in accordance with the code requirements.

10. / Fabrication / The fabrication of the parts shall conform to the requirement of ASME section VIII, Division I.
11. / Inspection Facility / Most of the important dimensions such as inside diameter, outside diameter, length, orientation & relative locations of the features of the components shall be inspected by the calibrated gauges. Supplier shall provide all necessary tools, facilities & services for the inspection & related jobs. Inspection shall be carried out in a manner satisfactory to & shall be subject to approval by the purchaser. Purchaser shall have access to the premises of the fabricator for carrying out or witnessing the inspection of the job. The supplier shall provide all the equipment & consumable required for carrying out inspection.
12. / Preliminary Inspection / A preliminary inspection will be made prior to fabrication of the tank, to check materials, welding procedures, welding qualifications & testing of materials.
13. / Intermediate Inspection / Intermediate stage inspection will be made to check inside diameter, outside diameter, straightness, ovality, concentricity, alignment, attachment details deemed necessary by the inspector to insure that the Manufacturer work meets the requirements of the contract.
14. / Final inspection / After fabrication is complete, a final inspection will be made to insure completeness of Fabrication & assembly. For this purpose, the supplier will have to assemble all the components. The gaskets, studs & nuts required for assembly are a part of supply. This inspection will include radiographs, stress relieving charts, hydrostatic & other specified non-destructive tests, checking as built dimensions, orientation of nozzles, etc. for the above checking.
15. / Inspection plan / The supplier shall prepare detailed inspection plan for the job & get approved before the commencement of the work.
16. / Inspection Report / Two copies of the inspection report, covering all inspections duly signed by the manufacturer, shall be submitted to the purchaser at the time of delivering the item.
17. / Hydrostatic Testing / a)The completed test section constructed under this specification shall be hydrostatically tested in the presence of the purchaser’s inspector as per the requirement of UG-99 of ASME section VIII, division 1 & the approved procedure.
b)The manufacture shall close all the openings by using blind flanges/plugs for hydro test.
c)All mechanical & welded joints shall be left exposed for examination during the test.
d)The test medium shall be demineralised water.
e)The storage tank with its all components shall be hydrotested at 12 kgf/cm².
f)The hydrostatic test pressure shall be maintained for a minimum of 10 minutes prior to conducting the examination for the leakage.
g)There should not be any leakage from the assembly; the hydro test procedure shall conform to the ANSI B31.1 or ASME section VIII division 1.
h)Examination for leakage shall be made at all joints, connections & of all regions of high stress such as regions around openings & thickness transition section.
18. / Failure of tests / In the event of the test section or any part thereof fails to meet the examination or test requirements specified herein, the vendor shall notify the purchaser. The vendor shall obtain written permission from purchaser before repair & subsequent use of any part. If the repairs are likely to affect the results of examination & test or work previously completed, appropriate re-examination, re-inspection & re-testing shall be conducted.
19. / Rejection / If the fabrication, examination, inspection & testing is not in conformance to the requirements of this specification, the test section will be rejected.
20 / Workmanship / The completely assembled parts shall be examined to determine its conformance with respect to material dimension, workmanship, cleanliness & test requirements. In case of nonconformance to this specification, the whole tender will be rejected.
21. / Packing & Shipment
/ The finished goods shall be packed in a road worthy packing to avoid any damage to the finished product. The purchaser will not be responsible for any kind of damage during transport or unloading.
22. / Quality Assurance Plan / The fabricator shall submit quality assurance plan within two weeks of the receipt of purchase order.
23. / Quality Surveillance / The supplier must accept quality surveillance by the purchaser or his representative. The decision of the purchaser in this regard would be final. This however does not relieve the manufacturer from his responsibility to supply the tanks as per approved drawings & to have his own inspection to maintain the quality.