Projekt / Project: PKZ / PC

Termoelectrica del Sur BO1000

Termoelectrica de Warnes BO1001
Termoelectrica Entre Rios BO1002

Inhaltskennzeichen / Contents Code

Dept
DCC Doc. Class. Code.

Lieferant / Supplier

Index/ Rev Version

Siemens Dokumentennummer / Siemens Document Number:
0 -

Seitenanzahl Format
Originator Document Number
Page Number

21054-409-10 1 of 26
33 A4
21055-409-10
21056-409-10
Dokumententitel / Document Title: Unid

Project specification for fabrication and supply of piping

IKZ09 409-10 rev. 3, amendment, 32 pages
Handhabung / Handling
restricted
AL: ECCN:
Export Control Classification N N

Änderungen / Changes:

Jun 13, 2016

0 09-Jun-16 EH OO
Jun 09, 2016 LFER PSME First issue
Reviewed Approved
Rev. Date Prepared by Remarks
by by
 Amendment to NEM standard specification for
fabrication and supply of Piping (IKZ 09 409-10)

Project

1 Scope
ASME I ed. 2015
 

ASME B31.1 ed. 2012

2 Engineering
(not amended)

3 Qualifications and certification

 Fabricator shall perform chemical analysis and mechanical testing on each material heat from Chinese suppliers to verify
compliance with CMTR. Comentado [u1]: 3 Cualificaciones y certificación
• El fabricante realizará análisis químicos y pruebas
4 Fabrication mecánicas en cada material de calor de los proveedores
(not amended) chinos para verificar el cumplimiento con el CMTR.

5 Testing and inspection



Spot examination is 10%.

6 Preservation, packing and preparation for transport

(not amended)

7 Documentation
(not amended)

8 Relevant documents


Following documents are relevant and included in this specification unless indicated otherwise:
IKZ09 309-01, Standard specification for Tolerances.
IKZ09 713-10, Standard specification for marking, packing and notification (not included in this specification).
IKZ09 784-01, Buyers project specification for painting and corrosion prevention (not included in this specification).
IKZ09 900-20, Instruction document numbering (not included in this specification).
IKZ09 909-00, Glossary of terminology used in standard specifications. Comentado [u2]: 8 documentos relevantes
IKZ09 909-10, Instruction for compilation of manufacturing data records. Los siguientes documentos son relevantes e incluidos en esta
especificación a menos que se indique lo contrario:
IKZ09 909-12, Instruction for heat treatment of ferritic steels.
IKZ09 309-01, especificación estándar para tolerancias.
IKZ09 909-16, Instruction for cleanliness and preservation. IKZ09 713-10, especificación estándar para marcado,
IKZ09 909-20, Requirements for ASME Boiler/pressure parts manufacturing. embalaje y notificación (no incluida en esta especificación).
IKZ09 784-01, especificaciones del proyecto de compradores


Following documents are not relevant for this project: para pintura y prevención de la corrosión (no incluidas en esta
IKZ09 909-11, Instruction for hardness testing. especificación).
IKZ09 909-14, Instruction for fabrication and supply of 9Cr-1Mo modified materials. IKZ09 900-20, numeración de documentos de instrucciones
(no incluida en esta especificación).
IKZ09 909-15, Instruction for fabrication and supply of 15NiCuMo materials.
IKZ09 909-00, Glosario de terminología utilizado en las
IKZ09 909-17, Instruction for fabrication and supply of 2¼Cr-1Mo modified materials. especificaciones estándar.
IKZ09 909-21, Instruction for EN 12952 requirements. IKZ09 909-10, Instrucción para la compilación de registros
IKZ09 909-22, Instruction for PED requirements. de datos de fabricación.
IKZ09 909-23, Instruction for AS requirements. IKZ09 909-12, Instrucciones para el tratamiento térmico de
IKZ09 909-27, Instruction for fabrication and supply of 9Cr-2W materials. aceros ferríticos.
IKZ09 909-16, Instrucciones de limpieza y conservación.
IKZ09 909-20, Requisitos para la fabricación de calderas /
End piezas de presión ASME.
Comentado [u3]: Los siguientes documentos no son
relevantes para este proyecto:
IKZ09 909-11, Instrucción para pruebas de dureza.
IKZ09 909-14, Instrucciones para la fabricación y suministro
de materiales modificados con 9Cr-1Mo.
IKZ09 909-15, Instrucción para la fabricación y suministro de
materiales 15NiCuMo.
IKZ09 909-17, Instrucción para la fabricación y el suministro
de materiales modificados 2¼Cr-1Mo. IKZ09 909-21,
Prep'd:
Instrucción para los requisitos EN 12952.
IKZ09 909-22, Instrucción para requisitos de PED.
Printdate: 14-6-2016 Page 1 of 1
IKZ09 909-23, Instrucción para requisitos de AS.
IKZ09 909-27, Instrucciones para la fabricación y suministro
de materiales 9Cr-2W.
Book IKZ09
Number 409-10
Rev. 3
Page 1/4
Piping

Comentado [u4]: ESPECIFICACIÓN ESTÁNDAR PARA

STANDARD SPECIFICATION LA FABRICACIÓN Y SUMINISTRO DE TUBERÍAS

FOR

FABRICATION AND SUPPLY

OF

PIPING
1 SCOPE
1.1 This specification covers the Buyer standard re-
quirements for the engineering, fabrication and supply of pip-
ing. For project specific requirements, this standard specifica-
tion shall be read in conjunction with the overruling amend-
ment applicable to the project.
1.2 The amendment to this specification will also iden-
tify code and other (detail) specifications and instructions
which are applicable to the scope.
1.3 All work executed under this specification shall be of
first class, made of new materials and be of good workman-
ship. Vendor shall further ensure that execution does not
jeopardize local law and regulations at the construction site.
Vendor is to adhere to all relevant codes, procedures and
practices, expressed or implied, to ascertain conformity to the
intent of this specification.
1.4 A clarification of the terminology used in this speci-
fication can be found in instruction 909-00.
2 ENGINEERING
2.1 Fabricator is to submit the documents as per VDRS;
the following documents are required as a minimum:
a) WPS/PQR and test procedures.
b) Weld matrix, showing WPS’s planned to be used
for the project
c) Other documents as per applicable VDRS
2.2 A manufacturing, welding or NDE activity may not
be started before the related documentation as per VDRS has
been reviewed by Buyer.
2.3 Buyer generated drawings and free-issue material
certificates will be issued by buyer with a transmittal. Unless
specifically identified as being for information, vendor shall
consider these documents as being “approved for construc-
tion”.
2.4 A (master) traveller (including sample LISL) shall be
prepared by fabricator as a sequential plan, including the in-
tervention points (e.g. hold, witness and random inspection
points) according to buyer’s ITP. All applicable codes, stan-
dards, tolerances and acceptance criteria shall be included.
Once returned by buyer without comments, this document
will supersede the buyer ITP, as issued earlier.
2.4.1 Fabrication steps of each isometric shall be re-
corded on a traveller specific for that component.
2.4.2 In case a master traveller is used to obtain buyer’s
approval, then the specific travellers shall be based on the
master traveller entries only. The specific travellers do not
need to be submitted for buyer’s approval when based on an
accepted master.
2.5 Fabricator shall uniquely identify each joint. This
will be referenced on the LISL and filled out on the As-
Built version of the drawing.
2.6 Welding typicals shall be prepared to facilitate the
review of welding documents by Buyer. The welding typical
will address all joint configurations applicable to the project
with cross reference to the selected WPS.
2.7 Preparation of WPS/PQR:
a) WPS must be submitted for every weld configu-
ration and each material type.
b) Each WPS shall be supported by a PQR.
c) WPS shall identify actual brand and type of
filler metal.
d) Thermocouple welding require WPS to be sub-
mitted.
3 QUALIFICATIONS AND CERTIFICATION
CERTIFICATION OF MATERIALS
3.1 The material certification shall comply with EN
10204-3.1 as a minimum for pressure containing parts and
other parts permanently joined to it.
PERSONNEL
3.2 Welder’s Qualifications shall be made available.
For special materials (e.g. P91), critical welding positions
(e.g. poor accessibility) or questionable results during fabri-
cation Buyer may request additional qualifications.
Comentado [u5]: 1 ALCANCE
1.1 Esta especificación cubre los requisitos estándar del
Comprador para la ingeniería, fabricación y suministro de
tuberías. Para los requisitos específicos del proyecto, esta
especificación estándar debe leerse junto con la modificación
de anulación aplicable al proyecto.
1.2 La modificación a esta especificación también identificará
el código y otras especificaciones (detalladas) e instrucciones
que son aplicables al alcance.
1.3 Todo el trabajo ejecutado bajo esta especificación debe
ser de primera clase, hecho de nuevos materiales y ser de
buena mano de obra. El proveedor deberá garantizar además
que la ejecución no ponga en peligro las leyes y regulaciones
locales en el sitio de construcción. El proveedor debe
adherirse a todos los códigos, procedimientos y prácticas
relevantes, expresas o implícitas, para determinar la
conformidad con el propósito de esta especificación.
1.4 Una aclaración de la terminología utilizada en esta
especificación se puede encontrar en la instrucción 909-00.
Comentado [u6]: 2.2 Una actividad de fabricación,
soldadura o ECM no puede iniciarse antes de que el
Comprador haya revisado la documentación relacionada
según VDRS.
Comentado [u8]: 3.1 La certificación del material debe
cumplir con EN 10204-3.1 como mínimo para partes que
contienen presión y otras partes unidas permanentemente a la
misma.
Comentado [u7]: 2.3 Los planos generados por el
comprador y los certificados de material de emisión libre
serán emitidos por el comprador con una transmisión. A
menos que se identifique específicamente como de
información, el vendedor considerará estos documentos como
"aprobados para la construcción".
Comentado [u9]: 3.2 Las calificaciones del soldador
estarán disponibles. Para materiales especiales (por ejemplo,
P91), posiciones de soldadura críticas (por ejemplo,
accesibilidad deficiente) o resultados dudosos durante la
fabricación, el Comprador puede solicitar calificaciones
adicionales.
Book IKZ09
Number 409-10
Rev. 3
Page 2/4
Piping

3.3 NDE personnel shall be qualified according stan- 4.15 All welds and surrounding areas shall be chipped,
dards acceptable to the code. ground, or wire brushed to remove all flux, scale and spat-
ter.

4 FABRICATION 4.16 Attachments welded temporary to the item shall be

PREPARATION
4.1 Control of incoming materials:
a) Materials shall be stored as per paragraph 6.1 in
a suitable, covered area clearly identifying Buy-
ers PO reference.
b) Materials may be used only after receipt of the
relevant certificates and upon successful verifica-
tion of heat and marking by fabricator. Observe
paragraph 5.3.
c) Tolerances shall be in accordance with 4.17.
4.2 Instruction 909-14 (grade 91), 909-15 (15NiCuMo),
etcetera are governing for fabrication, joining and forming of
material grades described therein. Instructions are also appli-
cable for dissimilar joints where the subject grades are one of
the components.
4.3 Field weld end preparation shall be in accordance
with figures indicated on Buyers drawing.
4.4 Welding consumables shall be used within the limi-
tations of use as specified by the filler metal supplier, i.e.
storage and handling conditions and typical welding parame-
ters.
4.5 All flame cut or plasma cut edges shall be ground to
sound metal and visually inspected.
4.6 All machined edge preparations and drilled holes
shall be deburred.
4.7 Cleanliness requirements are outlined in 909-16.
4.7.1 Pressure parts (pipe, fittings) shall be cleaned before
processing in accordance with paragraph 8.12.
4.8 GTAW, SMAW and SAW are accepted welding
processes. FCAW on pipe may be acceptable for outer diame-
ters of DN 80 and over.
4.9 Single side, full penetration root passes shall be
made with GTAW.
of a compatible chemical composition as the permanent ma-
terial. Removal of the attachment shall not result in damage
of the item. Affected area shall be inspected according para-
graph 5.6.1g). Comentado [u14]: 4.16 Los accesorios soldadas
4.17 Tolerances shall be in accordance with Buyer’s temporalmente al elemento deberán ser de una composición
drawing and applicable code or standard. Tolerances not química compatible como el material permanente. La
eliminación del accesorio no debe dañar el artículo. El área
specified shall be derived from the tolerance standard as per
afectada se inspeccionará de acuerdo con el párrafo 5.6.1g).
paragraph 8.2. Note also drawing series 410-05 which is
providing additional information.
HEAT TREATMENT
4.18 Heat treatment as per code, observe:
a) Preheat and interpass temperature to be
checked according EN ISO 13916.
b) Instructions for heat treatment as specified in
Buyers instruction 909-12.
c) Specific instructions for enhanced materials as
called for in paragraph 8. Comentado [u15]: 4.18 Tratamiento térmico según el
código, observar:
REPAIRS
a) Temperatura de precalentamiento e interpaso a controlar
4.19 In case repairs are required paragraph 7.2 shall be según EN ISO 13916.
observed. Welds can be repaired twice. When repair is un- b) Instrucciones para el tratamiento térmico tal como se
successful, all weld metal of the joint shall be cut-out and especifica en la instrucción de los Compradores 909-12.
renewed. c) Instrucciones específicas para materiales mejorados como
se pide en el párrafo 8.
Comentado [u16]: 4.19 En caso de que se requieran
5 TESTING AND INSPECTION reparaciones, se observará el párrafo 7.2. Las soldaduras se
5.1 Invitations for inspection shall take into account a pueden reparar dos veces. Cuando la reparación no tenga
notification period for buyer attendance of 15 working days éxito, se cortará y renovará todo el metal de soldadura de la
before inspection can take place. junta.
5.2 Receipt of free-issued materials from Buyer.
Fabricator will verify delivery against the buyer provided
unpriced copies of Purchase Order for the shipment. Supply
shall be checked against Packing List. Reference is made to
paragraph 8.2.
Comentado [u10]: 4.8 GTAW, SMAW y SAW son
5.3 Fabricator shall check all delivered goods on quan- procesos de soldadura aceptados. FCAW en tubería puede ser
tity, dimension, damage, documents and heat number. aceptable para diámetros exteriores de DN 80 y superiores.

WELDING
4.10 Single pass welding in pressure retaining joints is
prohibited.
NDE GENERAL
4.11 Socket connections shall have a gap of 2mm between
pipe end and bottom of the socket.
4.12 Use of low carbon filler metal (C%<0.05) for weld-
ing creep resistant CrMo-steel is prohibited.
4.13 Dissimilar joints between ferritic and austenitic steel
shall be welded using E(R)309 filler metal for service tem-
peratures below 300°C. For service or PWHT temperatures
above 300°C filler metals ERNiCr-3 or ENiCrFe-2, ENiCrFe-
3 shall be selected.
4.14 Weave width of deposited beads shall be limited to
10mm for GTAW, 15mm for FCAW and 3 times electrode
diameter for SMAW.
5.4 Welder performance qualifications and LISL’s shall
be available at Fabricator’s premises for review on Buyer
request.
5.5 Non destructive examination (NDE) shall be car-
ried out after the procedures have been reviewed by Buyer.
5.5.1 Where -ray RT is applied, only Ir192 shall be se-
lected as source unless specifically accepted otherwise by
Buyer.
5.5.2 Where surface defect detection (i.e. MT, PT) shall
be performed, this need to be done after PWHT (in case this
treatment is required).
5.5.3 Repairs shall be examined by the same technique
that revealed the initial defect.
Comentado [u11]: 4.9 Las pasadas de raíz de penetración
completa de un solo lado deben hacerse con GTAW.
Comentado [u17]: 5.5.1 Cuando se aplica RT de rayos,,
solo se seleccionará Ir 192 como fuente a menos que el
Comprador acepte lo contrario.
Comentado [u18]: 5.5.2 Donde deba realizarse la
detección de defecto de superficie (es decir, MT, PT), esto
debe hacerse después de PWHT (en caso de que se requiera
este tratamiento).
Comentado [u12]: 4.13 Las uniones desiguales entre el
acero ferrítico y austenítico se deben soldar con metal de
aporte E (R) 309 para temperaturas de servicio inferiores a
300 ° C. Para temperaturas de servicio o PWHT superiores a
300 ° C, se deben seleccionar los metales de relleno ERNiCr-
3 o ENiCrFe-2, ENiCrFe-3.
Comentado [u13]: 4.14 El ancho de tejido de las perlas
depositadas se limitará a 10 mm para GTAW, 15 mm para
FCAW y 3 veces el diámetro del electrodo para SMAW.
Book IKZ09
Number 409-10
Rev. 3
Page 3/4
Piping
SPOT EXAMINATION
5.5.4 Where random spot examination (like an extent of
10%) is indicated, the recorded examination shall cover the
performance of each welder and/or each joint configuration as
a minimum. Examinations shall be timed evenly over the
production period. The extent of spot examination is defined
in the amendment or detailed specification/instruction, but
will be 10% minimum.
5.5.5 If during initial spot examination (e.g. 10%) any
welds are rejected, double amount of tests (e.g. 20%) of day
production shall be made in addition. If this reveals an addi-
tional defect then the remainder of the (welder's) day-
production shall be 100% examined. First subsequent
(welder’s) batch shall be examined at the rate where the de-
fect of the previous day was found.
EXTENT OF NDE
5.6 NDE shall be in accordance with the applicable code.
5.6.1 The applicable code requirements and the following
examinations shall be performed as minimum:
a) 100% VT on all welds.
b) Spot RT or UT on butt joints.
c) Spot MT or PT on other welds than butt joints.
d) 100% MT or PT on lifting and hanging lugs.
e) Specific instructions for enhanced materials as
called for in paragraph 8.
f) Hardness testing on P91 welds in accordance
with instruction 909-11.
g) 100% MT or PT on surfaces after removal of
temporary welded attachments.
h) Spot RT on socket connections to verify presence
of gap.
5.6.2 Dimensional verification to be performed with cali-
brated equipment and results shall be recorded. Deviations to
specified values (see paragraph 4.17) shall be reported.
REPORTING OF TEST RESULTS
5.7 Vendor is responsible for comprehensive inspection
reporting.
a) Vendor’s QC shall sign off the travellers imme-
diately after a fabrication stage has passed in-
spection or examination.
b) Inspection reports and records which are refer-
renced in the LISL or traveler shall remain avail-
able at fabrication location.
5.8 Final documentation (see also paragraph 7.1) shall
be available for review during the final/release inspection.
5.9 Only when all stages of fabrication and engineering
have passed inspection satisfactory, a buyer Release Note will
be issued. Transport will only be allowed when this release
(or a written waiver to the final inspection) has been obtained
and all (transport) documentation is accepted by buyer.
6 PRESERVATION, PACKING AND
PREPARATION FOR TRANSPORT
6.1 Goods shall be stored under cover, free from the
ground. Piping etc. shall be stored on a slope.
6.2 Finished and released spools are to be mounted in
racks, also when transport will be per container. Notwith-
standing the mode of packing, due care shall be taken to
avoid damage or distortion of any kind while in transit.
6.3 Markings shall remain legible after (heat-) treat-
ments and placed in a visually accessible location.
Comentado [u19]: 5.5.4 Cuando se indique un examen al
7 DOCUMENTATION azar (como una extensión del 10%), el examen registrado
deberá cubrir el rendimiento de cada soldador y / o cada
7.1 Certificates of vendor-supplied material shall bear configuración de unión como mínimo. Los exámenes se
proof of approval by vendor’s QC. Copy of certificates of programarán de manera uniforme durante el período de
vendor-supplied material shall be presented buyer for re- producción. El alcance del examen puntual se define en la
view. enmienda o especificación / instrucción detallada, pero tendrá
un mínimo del 10%.
7.2 When non-conformances occur, found either by
vendor or buyer, an NCR shall be drafted by vendor and is-
sued to buyer. NCR’s shall be issued per fabricated part.
The non-conform part shall be clearly labelled and segre-
gated from production pending resolution by buyer. It is
vendor’s responsibility to ensure timely resolution in order
to safeguard production schedule.
7.3 Final documentation package shall include As-Built
versions of the isometrics. The As-Built data shall cover, as
a minimum: relocations of welds, changes to material, loca-
tion of NDE, cross reference to LISL and changes to spool
geometry.
8 RELEVANT DOCUMENTS
8.1 This specification is the body for the production of
captioned items. The following documents form an integral
part of the complete specification package. The latest issue
of mentioned documents shall be used unless stated other- Comentado [u20]: 5.6.1 Los requisitos del código
wise. aplicable y los siguientes exámenes se realizarán como
mínimo:
8.2 IKZ09 309-01, Tolerance standard, general toler- a) 100% VT en todas las soldaduras.
ances. b) Spot RT o UT en juntas a tope.
c) Spot MT o PT en otras soldaduras que las juntas a tope.
8.3 IKZ09 713-10, Buyer’s project specification d) 100% MT o PT en orejetas de elevación y colgantes.
“Marking, packing, notification and logistic documenta- e) Instrucciones específicas para materiales mejorados como
tion”. se solicita en el párrafo 8.
f) Prueba de dureza en soldaduras P91 de acuerdo con la
8.4 Project specification 784-01, Buyer’s project speci-
instrucción 909-11.
fication “Painting and corrosion prevention”.
g) 100% MT o PT en las superficies después de la
8.5 IKZ09 900-20, Buyer’s specification for “Docu- eliminación de los accesorios soldados temporales.
ment numbering” h) Spot RT en las conexiones de socket para verificar la
presencia de brecha.
8.6 IKZ09 909-00 “Definition of Terms” specifying
definitions of terms used throughout NEM specifications
and instructions.
8.7 IKZ09 909-10, Buyer’s instruction “Compilation of
manufacturing data records”
8.8 IKZ09 909-11, Buyer’s “Instruction for hardness
testing”, specifying technique, extent and reporting on hard-
ness testing.
8.9 IKZ09 909-12, Buyer’s instruction “Instruction for
heat treatment of ferritic steel”, indicating requirements and
guidelines for heat treatment.
8.10 IKZ09 909-14, Buyer’s instruction “Fabrication of
9Cr-1Mo modified materials”.
Book IKZ09
Number 409-10
Rev. 3
Page 4/4
Piping

8.11 IKZ09 909-15, Buyer’s instruction “Fabrication of

15NiCuMo”.
8.12 IKZ09 909-16 “Instruction for cleanliness and pres-
ervation” specifying instructions for cleanliness and preserva-
tion during manufacturing and supply.
8.13 IKZ09 909-20, Buyer’s instruction for ”ASME re-
quirements”.
8.14 IKZ09 909-21, Buyer’s instruction for ”EN 12952
requirements”.
8.15 IKZ09 909-22, Buyer’s instruction for ”PED re-
quirements”
8.16 IKZ09 909-23, Buyer’s instruction for “Australian
Standard requirements”.
Book IKZ09
Number 309-01
Rev. 0
Page 1/2
Tolerances

STANDARD SPECIFICATION

FOR

TOLERANCES
Book IKZ09
Number 309-01
Rev. 0
Page 2/2
Tolerances
Book IKZ09
Number 909-00
Rev. 4
Page 1/5
Definition of terminology
GLOSSARY
OF
TERMINOLOGY USED
IN
STANDARD SPECIFICATIONS
1 DEFINITIONS
1.1 Abrasive blasting is the method to clean steel
surface using particle impact energy. Particles shall be
inert to the subsequent processes, e.g. grit or steel shot of
compatible metal or Garnet (Almandite) with less than
1% free Silica (SiO2). Sand is prohibited for abrasive
blasting on water/steam side and should in general be
avoided for health considerations and silica contamina-
tion of boiler parts.
1.2 AI(A) or Authorised Inspector (Authorised In-
spection Agency), Inspection authority for ASME code
design and manufacturing.
1.3 Alloy steel, in the context of this specification, is
a steel composition where elements are added on purpose
to improve steel properties. In high alloyed steels the sum
of alloying elements is greater than 5%.
1.4 And/Or may be used to indicate the applicability
of a case to one or more conditions. Those conditions are
not necessarily exclusive. The term –although gramati-
cally and logically unsound– is used to avoid the logically
correct use of “or” as this is often incorrectly interpreted
as a mutually exclusive condition.
1.5 Basic arrangement drawing contains lay out, ma-
terials, beam sizes, tolerances and applicable calculations
and design specifications.
1.6 BM means base metal, i.e. the two main bodies
forming a joint, fused by WM (weld metal).
1.7 Bundle is a set of tubes in between two or more
manifolds. Tubes are generally connected with elbows to
form multiple pass in the gasflow. Typically, the tubes
are supported by tubesheets. This assembly is the heat
exchanging element for a boiler with a vertical exhaust
gas flow. In smaller configurations, vertically arranged
bundles can be applied in a horizontal gasflow.
1.8 Butt joint is a joint between two members
aligned approximately in the same plane. Weld between
header and forged flat cover shall be considered to be a
“butt joint”
1.9 Buyer shall mean any company belonging to the
NEM group issuing a purchase order or a party enforcing
a buyer (group) frame agreement.
1.10 Client shall mean Buyer’s customer.
1.11 CMTR, or Certified Material Test Record. Test
results as demanded by the material specification shall be
certified by a quality department of the material producer
that is independent from the production department.
Scope and responsibilities is identical to an EN10204-3.1
type certification.
1.12 CoBo, or Competent Body, is an entity estab-
lished in the European community. For PED projects a
CoBo is commonly involved in auditing (production)
quality systems for material manufacturers.
1.13 Code shall mean fabrication, testing and/or de-
sign regulation or standard.
1.14 Cold forming is defined as a deformation process
that takes place at a temperature below the maximum al-
lowable PWHT temperature specified for the material
grade concerned. See also hot forming.
1.15 Cruciform joints are three members joined by a
(groove and-) fillet weld. Two members are not necessar-
ily perpendicular to the third, but are aligned with each
other, usually forming a cross when viewed in cross-
section.
1.16 CVN stands for Charpy-V Notch impact test. Test
results are expressed in absorbed energy at a predefined
test temperature, e.g. 27J @ 21°C
1.17 Default is a value used when none has been
given. Often used attributively, e.g. default value.
1.18 Demand Critical Welds are welds that are a part
of seismic load resistance system that are deemed to be
critical, since they are designed to transfer important
earthquake loads.
1.19 Dimensions in this specification are in millime-
tres unless noted otherwise. (Where indicated, inches may
be used).
1.20 DFT means Dry Film Thickness.
Book IKZ09
Number 909-00
Rev. 4
Page 2/5
Definition of terminology
1.21 Drawings and specifications will be referred to
by their 5 digits in a xxx-xx format.
1.22 Engineering shall comprise all vendor actions in
the fabrication stadium necessary as preparation or sup-
port the actual production. Reference to documents previ-
ously approved by Buyer might suffice if appropriate to
the scope.
1.23 Enhanced materials are those material grades
where properties are improved by modification of the
chemistry in combination with a specific thermal treat-
ment. Often these materials require extra attention during
manufacture, fabrication and heat treatment. Examples
are: P23, P91, 15NiCuMo.
1.24 ESR, or Essential Safety Requirement, is a set of
requirements that need to be fulfilled for PED projects.
The ESR’s can be found in 97/23/EC (PED), annex I.
1.25 Fabricator shall mean the party responsible for
the physical execution of the contract. In those cases
where the fabricator received the purchase order from
buyer directly, vendor and fabricator shall be considered
one entity.
1.26 FAT shall mean Factory Acceptance Test
1.27 FCAW is Flux Cored Arc Welding.
1.28 Fogging is the method to introduce a corrosion
preservative powder into a volume by blowing low-
pressure air or nitrogen, carrying the powder through the
item to preserve.
1.29 Furnace load is the amount of raw materials,
components or structure that is subjected to one planned
heat treatment batch.
1.30 Furnace survey shall mean a furnace test de-
signed to determine temperature variation within the
working zones of furnaces and to determine the correla-
tion of working zone time with temperature set point,
heating and cooling rate.
1.31 Grit blasting, see 1.1.
1.32 GTAW is Gas Tungsten Arc Welding.
1.33 Hardcopy is a printed version of data. Where re-
quired a hardcopy shall bear proof of being a true copy of
the original. This proof, usually in the form of a stamp,
shall be original for each hardcopy.
1.34 Harp is a set of tubes in between two manifolds,
headers, forming one heat exchanging element for a
boiler with horizontal exhaust gas flow. Multiple passes
can be established by inserting partition plates in the
headers. A harp is supported by lugs at the top header.
1.35 HB stands for hardness Brinell.
1.36 Heat is a unique batch of base metal for which
ladle analysis and mechanical testing has been certified
on material certification.
1.37 Hot forming defined as a deformation process
that takes place at a temperature above the maximum al-
lowable PWHT temperature specified for the material
grade concerned. See also cold forming.
1.38 HRSG stands for Heat Recovery Steam Genera-
tor.
1.39 Instructions, IKZ09 909 series, define require-
ments on a specific topic to complement the main specifi-
cation. Instructions may refer to other instructions.
1.40 ITP stands for Inspection and Test Plan. Issued
by buyer, it indicates the inspections and tests required
together with the intervention points for parties concerned
as known at time of issue.
1.41 Joint is the generic term for a welded connection
of any type (butt-, fillet-, seal-, etc.).
1.42 K-Area, applicable to rolled profiles in seismic
loaded structures (SLRS), designate the volume of a web
where it meets the radiused transition with the flanges,
see picture.
40mm
K-Area
1.43 LISL stands for Line Inspection Summary List.
These lists are the basic registration tool for piping fabri-
cation, linking the isometric to used material heat no’s,
WPS’s, welder and passed NDE intervention points.
1.44 LMP is Larson Miller parameter also referred to
as Temper Parameter.
1.45 Main steel are pressure part supporting structures
such as goal posts and associated parts.
1.46 Measurement used in the context of this specifi-
cation refers to portable hardness testing and is the aver-
age result of three readings in one material type (BM or
WM).
1.47 Module is a preassembled package of a number
of individual heat exchanging elements, harps or bundles,
to facilitate assembly of the boiler. Where required, the
harps will have interconnecting piping installed.
1.48 NCR stands for Non Conformity Report
1.49 NDE stands for Non Destructive Examination.
1.50 NoBo, or Notified Body, is an entity established
in the European community. For PED projects this organi-
sation is responsible for the conformity assessments dur-
ing design and fabrication.
1.51 NPSH stands for Nominal Pump Suction Head.
Book IKZ09
Number 909-00
Rev. 4
Page 3/5
Definition of terminology

1.52 N+T stands for normalizing and tempering heat 1.69 Review will result in a document status. See in-
treatment. struction 900-20 for description of status indicators.
1.53 Outlet duct is a transition duct between boiler 1.70 Ronnie is a solution to a problem that did not ex-
casing and stack. ist before, often leading to problems that cannot be solved
anymore. Named after a facilities manager, in apprecia-
1.54 Out-of-roundness (%) of pipe or tube bends shall tion.
be calculated using the following relation:
dmax - dmin 1.71 RTPO or Recognised Third Party Organisation is
Out-of-roundness (%) = an entity established in the European community. For
X X 100
2 dmax + dmin PED projects, a RTPO can perform the procedure and
personnel qualifications (PQR, WPQ and NDE).
with: dmin = minimum diameter
dmax = maximum diameter
and dmin  dmax 1.72 SAT shall mean Site Acceptance Test.
1.55 Ovality see out-of roundness 1.73 SAW is Submerged Arc Welding.
1.56 P23 is a generic term for all 2¼Cr-1Mo modified 1.74 Secondary steel covers railing, platforms, lad-
materials, e.g. grade T23, grade F23, grade 23, ders, stairs, kick plates, grating, silencer supports and
7CrWVMoNb91, etc. bracings.
1.57 P91 is a generic term for all 9Cr-1Mo modified 1.75 SLRS is Seismic Load Resistance System.
materials, e.g. grade T91, grade F91, grade 91, WP91,
X10CrMoVNb91, C12A, etc. 1.76 SMAW is Shielded Metal Arc Welding.

1.58 PBHT is Post Bend Heat treatment.
1.59 PED is the Pressure Equipment Directive,
97/23/EC, of the European community.
1.60 Pipe is used, as distinguished from tube, to apply
to tubular products of dimensions commonly used for (in-
terconnecting) piping systems. Pipe dimensions of sizes
12” and smaller have outside diameters numerically lar-
ger than their corresponding size denominator.
1.61 PMA stands for Particular Material Appraisal.
This is a material grade and type specific inventory of
(additional) requirements to adhere to in order to have
non EN harmonized material comply with PED essential
safety requirements.
1.62 PMI stands for Positive Material Identification.
A method to detect alloying elements in metal to ascer-
tain use of correct metals. Usually a portable device
based on X-ray fluorescence.
1.63 PQR is a (welding) Procedure Qualification Re-
cord.
1.64 Protected zone is a designation to areas in struc-
tural members used in the AISC seismic design (SLRS)
where specific (and restrictive) fabrication requirements
apply.
1.65 PWHT is Post Weld Heat Treatment.
1.77 Softcopy is a digital representation of the re-
quired data. This is usually in the form of a scan that is
saved as Adobe’s Portable Document Format (PDF) file.
Note that specific requirements to the scan quality may
apply.
1.78 Specifications define requirements on specific
products. Specifications refer extensively to obligatory
supporting instructions.
1.79 Spot examination defines the extent of examina-
tion. The amount of tests required (i.e. the value of the
variable “spot”) is defined on the amendment and can dif-
fer per project.
1.80 Stack is a self supporting structure, designed for
the vertical transport of forced or natural draft fluegases.
It excludes the outlet duct.
1.81 Strain (%) in outer fiber (extrados) on bending
plate, tube or pipe, shall be calculated using the following
relation:
D
bending strain (%)= X 100
2R
with: D = outer diameter of tube/pipe bending, or
D = thickness of plate bending
R = bending radius along neutral axis
1.82 T-Crossing is where butt joints in a plate field
join at an angle in the same plane.

1.66 Raw materials are construction materials, e.g. 1.83 T-Joint is two members joined by a (groove and-)
bare tube, pipe, fittings, rods, forgings, wrought, rolled fillet weld. The members are not necessarily perpendicu-
and cast products, which are meant for fabricator’s action lar to each other.
under this specification. Bends made out of straight pipe
1.84 TC is abbreviation used for Thermocouple.
or tubes are not considered being raw material.
1.85 Temperature controller is an instrument control-
1.67 Reading is the result of one hardness test inden-
ling the heat source to achieve temperature set point, rate
tation.
of heating and rate of cooling.
1.68 Release Note is issued at the fabrication locations
1.86 TOFD stands for Time Of Flight Diffraction.
indicated in the ITP once the buyer representative is satis-
fied the quality and quantity as called for are met.
Book IKZ09
Number 909-00
Rev. 4
Page 4/5
Definition of terminology
1.87 Transmittal will be used to indicate the docu-
ments sent to and from vendor. A copy of the transmittal
will be signed and returned to sender as proof of receipt
of the underlying documentation.
1.88 Transverse stressed fillet weld. A weld that is
loaded perpendicularly to its length.
1.89 The Traveller is a document that translates the
buyer ITP into the production sequence with respect to
the intervention points of fabricator, buyer, its client, au-
thority representatives and other third parties as defined
in the contract.
1.90 Tube in the context of this specification is used
for heat transfer applications. The outside diameters of
tubes are numerically identical to their corresponding size
denominator.
1.91 VDRS is a generic name for Vendor Document
Requirement Sheet and identifies the type of document,
the quantity and timing of submittal buyer expects Fabri-
cator to provide.
1.92 VHN stands for Vickers Hardness Number, e.g.
Hv5 or Hv10.
1.93 Vendor shall mean the party awarded with the
contract for supply of services under the specification.
1.94 VpCI stands for Vapour Phase Corrosion Inhibi-
tor. Also referred to as VPI or VCI.
1.95 VT, RT, UT, MT and PT stand for Visual-, Ra-
diographic-, Ultrasonic-, Magnetic- and Liquid Penetrant
Testing respectively. PT and MT are considered methods
to detect surface defects.
1.96 Weld end is a (bent) tube welded onto the header
to establish a butt joint to the (finned) tubes.
1.97 Welding record lists all welding and test re-
quirements and is later appended with actual test data.
The welding record is used for non-presure part manufac-
turing and erection and is comparable with a LISL for
piping.
1.98 Weld matrix, see welding typical.
1.99 Weld map see welding typical.
1.100 Weld overlay is a corrosion, heat and/or wear re-
sistant surface layer applied by welding.
1.101 Welding typical is a document showing a tabula-
tion of all joint configurations used, identifying its critical
weld parameters (e.g. materials joined, groove configura-
tion, WPS/PQR). The weld typical is issued for review,
together with the WPS/PQR’s. This document can also be
called a weld matrix or weld map.
1.102 WM is Weld metal. i.e. the part of a joint where
filler metal is deposited.
1.103 WPQ stands for Welder’s Performance Qualifica-
tion.
1.104 WPS is a Welding Procedure Specification.
2 COMMENTARY
2.1 (1.71) Invoking a RTPO in stead of a NoBo can
be beneficial to production as the NoBo might have a pro-
ject specific involvement only, like in the case of module
G, where the NoBo might only review the applicability of
the qualifications. Refer to 97/23/EC article 13.
2.2 (1.12, 1.60) Attention is drawn to the distinction
between EN 10204:1991 and EN 10204:2004. The former
identifies inspection certificate types 3.1B, 3.1C and in-
spection report type 3.2, whereas the latter recognises in-
spection certificate types 3.1 and 3.2. Only the EN
10204:2004 version is in conformity with 97/23/EC, rele-
vant for PED projects.
2.3 (1.41, 1.46) For portable hardness tests the num-
ber of required indentations can be calculated as follows:
a joint will have measurements made on its adjacent base
metals and weld metal, i.e. BM/WM/BM. Hence, one
joint will comprise of three measurements, each of three
readings. This totals 9 readings per joint. Note that HAZ
will not be measured. See also IKZ09 909-11.
2.4 (1.86) Time Of Flight Diffraction is a computer-
ised, sensitive UT method. Measuring the amplitude of
reflected signal, as with common UT methods, is a rela-
tively unreliable method of sizing defects because the am-
plitude strongly depends on the orientation of the indica-
tion. Instead of amplitude, TOFD uses the time of flight
of an ultrasonic pulse to determine the position of a re-
flector and is thus able to size indications more accu-
rately. For ASME projects, TOFD will require Buyer’s
approval of Code Case 2235 before use of TOFD is con-
sidered.
2.5 (1.79) The spot examination method is used to
monitor the production process, rather than assessing the
test subjects itself (as is the case with full examination).
For this tool to be effective, it is imperative that the test
subjects are evenly distributed and cover the relevant
process parameters. The chance that a defect remains hid-
den is inversely proportional to the sampling size. So
when a defect is found, the pool shall be investigated to
establish whether the defect is incidental.
When defects are found in the sample, an extended sam-
pling shall be taken from the same pool. Sample size shall
be twice the amount of the initial spot extent. The com-
plete pool shall be tested if the extended sampling reveals
defects too.
The sampling extent of next day’s production shall be
sized according to the sampling amount where defects
were found:
Book IKZ09
Number 909-00
Rev. 4
Page 5/5
Definition of terminology

Day Production Next day Y N

production OK?

Next day
production
Spot Examina- 2x Spot
tion

100%
Y N
OK?

Next day Y N
OK?
production
Book IKZ09
Number 909-10
Rev. 1
Page 1/2
Compilation of Manufacturing Data Record (MDR)
INSTRUCTION
FOR
COMPILATION
OF
MANUFACTURING DATA RECORDS
1 OBJECTIVE
1.1 This instruction covers the buyer standard mini-
mum requirements for the compilation of final manufactur-
ing data packages. These packages shall describe the
buyer-approved results of production steps for subcon-
tracted parts, bought-out items, engineered equipment and
erection.
1.2 The manufacturing data record shall be compiled
in accordance with this specification, and shall:
a) contain all the information as required per
vendor document requirement sheet and reflect
the fabrication history of the produced parts,
b) provide all information necessary for commu-
nication about the produced parts,
c) state the compliance with PO number, appli-
cable code and specification by certificate of
compliance, written in the contract language
and
d) be legible and suitable for reproduction.
1.3 Originals shall be provided where practicable.
1.4 Each manufacturing data record submitted by the
fabricator/vendor to buyer shall contain the contents as de-
scribed below. For chapters, which are not applicable, the
list of contents shall state “not applicable”.
1.5 The manufacturing data record shall be compiled
progressively during the fabrication. Proof of same will be
demonstrated to the satisfaction of buyer’s QC department.
1.6 One manufacturing data record shall be compiled
per purchase order.
a) All volumes shall be filed in secured bundles,
size: A4, four holes drilled in ‘888’ pattern.
Folders or binders are not required. Drawings,
reduced to A3 size, shall be folded to A4.
b) Each volume shall include a front sheet.
c) All documents/sheets shall be marked with
document number and buyer’s project number.
d) The documentation shall be divided into sec-
tions, sections into chapters and chapters into
paragraphs.
e) Each volume shall be marked with buyer’s pro-
ject number and volume number.
f) Each volume shall contain a main list of con-
tents with reference to part, volume number,
chapter and paragraphs, for all included docu-
mentation.
1.7 The vendor shall file all the relevant documents and
supporting records (e.g. RT films) in a conditioned area for a
period of 15 years. These documents/records shall be sub-
mitted to buyer upon request.
1.8 The manufacturing data record shall be reviewed
during the final inspection and stamped by buyer’s QC de-
partment. The original shall be sent to buyer.
1.9 Notes on the use of typical index:
a) These instructions do not replace any other re-
quirement for authority documentation; these
books shall be compiled and issued separately.
b) It is understood that control methods during
manufacturing can result in final documentation
compilation that differs from the Typical index.
This is acceptable provided the information as
prescribed in this specification is available and
traceable to the manufactured parts described.
c) The sequence as indicated below under Typical
index is preferred as it enables swift review.
Each topic, where applicable, shall start with a
new sub-number (e.g. RT test reports will ap-
pear in paragraph. 11.1).
d) Documents required as per contract, either for
review or to support requested information shall
be incorporated in manufacturing data record.
e) Italicised text is for reference and shall be de-
leted in case paragraph 2 is used as general in-
dex.
f) Pages shall be numbered sequentially starting
with each chapter.
g) Procedures and other documents that have been
submitted to and accepted by NEM shall bear
visible proof of such acceptance.
h) Data shall be provided as required by code or
regulation applicable to country/state of ultimate
operation.
Book IKZ09
Number 909-10
Rev. 1
Page 2/2
Compilation of Manufacturing Data Record (MDR)

2 TYPICAL INDEX
1. GENERAL TABLE OF CONTENTS
In addition to this, each volume shall have its own table of contents

2. RELEASE NOTES
Issued and signed by all parties concerned.

3. CERTIFICATE OF COMPLIANCE
See paragraph 1.2c).

4. MANUFACTURING DATA REPORT

Such as ASME, AD-Merkblätter, Stoomwezen, PED compliance certification, etc.

5. NON-CONFORMITY REPORTS, CONCESSION REQUESTS, REPAIR REPORTS

These documents shall reflect buyers consent.

6. INSPECTION PLAN
TRAVELLER
Signed off at relevant points by all parties identified.

7. PROCEDURES
Non-Destructive examination
RT, MT, PT, UT
Testing
Pneumatic, Hydraulic, Destructive, Hardness
Metallurgical
PMI, Ferrite, Chemical analysis, Etching, Replica
Fabrication
WPS/PQR, Repair, Lining, Welder performance qualifications summary list
Surface treatment
8. DRAWINGS (AS-BUILT)
Dimensioned outline drawings and weights
Cross sectional drawings, including parts list
Material take off
Isometrics

9. MATERIAL CERTIFICATES
Component certification (e.g. Nema, EexD etc.)
Also for welding material. An index, referring to the physical location of material is being used, shall be included in
this section. All material where certification is required as per VDRS shall be incorporated, documented according to
EN10204-2.2, 3.1 or 3.2.

10. WELD MAP

All welding documentation will be traceable to their location, materials used and respective tests conducted. Materials
certified to EN 10204-3.1 or 3.2 will be identified by heat number relevant to exact location.
Welding control sheets, Weldmatrix, LISL

11. TEST RESULTS

All documentation will be traceable to the location where the test is referring to.
Integrity tests: RT, MT, UT, PT, PMI, Ferrite, Visual, Hardness1, Dimensional, etc
Functional tests: Hydraulic, pneumatic, balancing, megger, etc.
Operational tests: Running, popping, relief, FAT, SAT, etc.

12. HEAT TREATMENT CHARTS

All charts will be traceable to the weld location.

13. SURFACE TREATMENT CERTIFICATES

Conservation records
DFT readings

14. NAMEPLATE RUBBING, PHOTOCOPY

1
Hardness test results shall be made available to NEM separate from the MDR by default. Only on specific request from NEM results of hard-
ness tests are to be incorporated in the MDR.
Book IKZ09
Number 909-12
Rev. 2
Page 1/7
Instruction for heat treatment of ferritic steel

INSTRUCTION

FOR

HEAT TREATMENT

OF

FERRITIC STEEL
1 SCOPE
1.1 To ascertain proper heat treatment this instruction
shall be observed for heat treatment of ferritic steel, i.e. car-
bon and (low) alloy steel, including enhanced materials. This
instruction provides proper selection and application of heat
treatment and furnace survey.
2 HEAT TREATMENT
2.1 Heat treatment shall be performed in accordance
with project related (and code) requirements. In case of any
conflict between instructions below and project specific re-
quirements, the most stringent is applicable.
2.2 Fabricator shall provide a written instruction to fur-
nace operator.
2.3 General
2.3.1 Post weld heat treatment is typically used to lower
internal stresses, i.e. stress relieving.
2.3.2 PWHT temperature holding time and gradients if not
detailed in paragraph 2.8 can be found in the applicable pro-
ject specifications and/or code.
2.3.3 PWHT temperature shall be controlled to the nomi-
nal temperature.
2.3.4 Normalizing and tempering is typically applied to
obtain the required properties of the raw material, e.g. for Cr-
Mo steels.
2.3.5 Normalizing and tempering can be used to restore
mechanical properties, after e.g. hot forming or wrong
PWHT. Note that this is only effective when the complete
object can be subjected to this heat treatment.
2.3.6 Normalizing without subsequent tempering is ap-
plied to improve or restore mechanical properties of unal-
loyed carbon base material, especially toughness.
2.4 Heat treatment shall not deteriorate materials prop-
erties.
2.5 PWHT shall not exceed the lower transformation
temperature (Ac1). Lower transformation temperature de-
pends on the chemical composition and may differ for weld
and base metal in which case the lowest is governing.
2.5.1 PWHT at a temperature higher than the tempering
temperature used during manufacturing of raw material may
result in decrease of tensile strength. Buyer shall be re-
quested for disposition in case PWHT temperature would ex-
ceed the tempering temperature recorded on CMTR.
2.5.2 PWHT temperature close to the lower end or around
the mid of the specified range prevents possible over-
tempering, i.e. a drop in tensile properties.
2.5.3 Total duration at specified PWHT temperature shall
be 10 hours maximum. This applies for each individual joint.
If more than one cycle is applied the total duration shall be
determined by summation of all individual holding times
from the separate PWHT cycles. Comentado [u22]: 2.5.3 La duración total a la temperatura
2.5.4 Normalizing of carbon and low-alloy weld metal de PWHT especificada será de 10 horas como máximo. Esto
may cause a drastic drop in tensile strength. However, P91 aplica para cada articulación individual. Si se aplica más de
weld metal properties will not be affected by N+T. un ciclo, la duración total se determinará sumando todos los
tiempos de espera individuales de los ciclos de PWHT
2.5.5 Holding time at normalization temperature shall be separados.
limited to prevent excessive grain growth.
2.5.6 During heating, holding and cooling, the furnace at-
Comentado [u21]: 2.3.2 El tiempo y los gradientes de
mosphere shall be controlled so as to avoid excessive oxida- mantenimiento de la temperatura del PWHT, si no se detalla
tion.
en el párrafo 2.8, pueden encontrarse en las especificaciones
2.5.7 During complete heat treatment cycle the compo- y / o códigos de proyecto aplicables.
nents shall be adequately supported to prevent distortion.
Comentado [u23]: 2.5.7 Durante el ciclo completo de
2.5.8 In case burners are used as heating source, the fuel tratamiento térmico, los componentes deberán soportar
shall not contain any detrimental elements. Furnace shall be adecuadamente para evitar la distorsión.
equipped to avoid flame impingement on the objects.
2.6 Furnace or local heat treatment
2.6.1 Piping spools, drums and individually heat treated
headers shall have PWHT in a batch type furnace, e.g. a top-
hat furnace.
2.6.2 For harp assembly, i.e. header joints, header to fin-
tube joints or weld-end to (fin)tube joints shall be heat
treated in one cycle in a clamshell furnace. Where the header
already received a PWHT than this cycle shall be taken into
account with respect to paragraph 2.5.3.
Book IKZ09
Number 909-12
Rev. 2
Page 2/7
Instruction for heat treatment of ferritic steel
2.6.3 Local PWHT of joints in piping shall be done by re-
sistance or induction heating in accordance with Figure 1 for
butt joints.
2.6.4 Local PWHT of piping branch connections may only
be done in accordance with Figure 3 after Buyers acceptance.
2.6.5 Local PWHT of joints to ‘olets, nozzles or stubs and
the like shall include provisions to avoid detrimental effects
on the run line, see also 2.7.4. Thermocouple shall be placed
at location “TC3” (see Figure 3), whereby:
0°C ≤ T weld − TC3 ≤ 250°C
with: Tweld = PWHT temperature at weld
TC3 = Temperature measured at TC3 location
2.6.6 In case of normalizing, the entire component (or
complete structure) shall be subjected to N+T cycle.
2.6.7 Furnace and heat treatment equipment used for P91
and 15NiCuMoNb5 shall be certified by furnace survey in
accordance with paragraph 3. Further, a furnace survey may
be required to check the performance of heat treatment
equipment used for other materials.
2.7 Heating pad placement
2.7.1 Equipment used for local PWHT shall be so ar-
ranged that the weld and the base materials on both sides are
heated in such a manner that uniform heating without distor-
tion can be achieved.
2.7.2 Due consideration for difference in thickness shall
be given when selecting heat input capacity.
2.7.3 Local overlapping of pads or mats (e.g. where pipe
diameter is smaller than pad length/width) is prohibited.
2.7.4 Heat treatment on joints as per 2.6.5 shall include a
provision to heat up run line. This to avoid local heat input
potentially leading to run line deformation. Also this will
avoid the run line to act as heat sink, thus enhancing the risk
of overheating at the heat input locations (i.e. weld and/or its
joining parts).
2.8 Heating and cooling rate
2.8.1 Heating and cooling rate shall be 220°C/hour maxi-
mum. P91 and 15NiCuMoNb5 heating and cooling rate shall
be 100°C/hour maximum.
2.8.2 The temperature of the furnace shall not exceed
300°C at the time the component is placed into or taken out
of the furnace.
2.8.3 After holding at normalizing temperature the com-
ponent shall be cooled in still air or oil as specified by the
raw material specification. For thicker parts accelerated cool-
ing may be necessary. Continuous cooling diagram can be
used for estimation of required cooling rate.
2.9 Temperature variation.
2.9.1 Maximum allowable temperature variation during
holding at heat treatment temperature is 30 °C. In case of
P91 the variation shall be 20°C maximum.
2.9.2 Minimum holding temperature shall be achieved for
the specified holding time as minimum.
2.9.3 Furnace shall be loaded in such a manner that the
(heat flow) situation is identical for all welds subjected to the
heat treatment cycle.
2.10 Thermocouples and recording equipment
2.10.1 Sufficient thermocouples shall be applied to the
work piece to obtain the highest and lowest material tem-
perature attained during the heat treatment.
2.10.2 Thermocouples shall be attached by capacitor dis-
charge welding.
2.10.3 Steering TC shall be attached at locations represen-
tative for complete furnace load and to a Temperature Con-
troller at the other end.
2.10.4 Steering TC shall be attached at the location where
the highest temperature input is expected.
2.10.5 Typically, steering TC and controller will not be
used to chart the heat treatment curve.
2.10.6 For local PWHT, each graph shall represent one
joint. One PWHT cycle on more than one joint may be com-
bined in one graph after buyer’s prior approval. TC set-up
and identification shall be included on the graph.
2.10.7 Thermocouples shall be attached at a location or in a
manner so that contact with heating element and incorrect
registration of temperature is avoided.
2.10.8 Temperature controllers and recorders shall be cali-
brated at a 6 month interval.
2.10.9 Recording thermocouples shall be attached at loca-
tions representative for complete furnace load to record the
complete heat treatment cycle.
a) Minimum 6 recording thermocouples shall be
applied for heat treatment in batch type furnace
on the component and/or the furnace itself.
b) For heat treatment of headers in a clamshell fur-
nace recording thermocouples shall be attached
at the header and weld ends as per Figure 4.
c) For heat treatment of stream drums the recording
thermocouples shall be attached in accordance
with Figure 5. For drums with a thickness over
50mm TC number 2 and TC number 5 shall be
attached at the inner side of the drum.
d) For heat treatment of piping spools and individu-
ally heat treated headers in batch type furnace
minimum of 6 recording thermocouples shall be
attached on the heat treated items at locations
nearest to bottom, top and outer sides of the fur-
nace.
Book IKZ09
Number 909-12
Rev. 2
Page 3/7
Instruction for heat treatment of ferritic steel

e) Local PWHT shall have recording thermocouples 3.2 Thermocouples to monitor time-temperature curve
attached according Figure 2 for piping butt joints shall be placed at locations in the working zone of the fur-
and according Figure 3 for branch welds in pip- nace, so that the highest anticipated temperature variation is
ing. recorded. The thermocouples shall be attached to the test
load and/or to the furnace itself.
2.11 Larson Miller Parameter
3.3 For furnace survey minimum of 12 thermocouples
2.11.1 Larson Miller Parameter can be used to express the
shall be used. A sketch shall clearly indicate the working
effect of PWHT temperature and time, using the following
zone of the furnace, the location of the test load and thermo-
relation
couple locations, identifying steering or as recording TC.
LMP= T (20+log t) 10-3
3.4 Heat treatment cycle for furnace survey shall be rep-
with: T = temperature in degrees Kelvin resentative for actual heat treatment during fabrication. In
t = holding time in hours
case of furnace survey for P91 the following heating cycle
applies.
2.11.2 LMP is only valid in the range of stress relieving
a) Heating rate up to 300°C not limited.
temperature, i.e. up to lower transformation temperature.
b) Heating from 300°C with 100°C/hour up to
2.11.3 Equal LMP for different PWHT temperatures and 760°C.
times are considered to have same effect.
c) Holding at 760°C for 2 hours.
For example, PWHT at 700°C for 1.5 hour results in a LMP
= 19.6. For a comparable PWHT at 680°C, a 4 hour holding d) Cooling from 760°C to 300°C with 100°C/hour.
time is required to have the same heat treatment effect. e) Cooling from 300°C in still air to ambient tem-
perature.
2.11.4 Ranges and temperatures as detailed in this specifi-
cation shall be adhered to. Deviation from the specified heat 3.5 Test results shall be submitted to buyer for review.
treatment range using LMP motivation may only be used on
buyer's prior consent.
2.11.5 PWHT temperatures shall be in accordance with
4 DOCUMENTATION
Table 1. Note that these temperatures apply for ASME I and 4.1 Fabricator’s heat treatment procedure shall have all
ASME B31.1 (values between brackets apply for EN pro- required information to guarantee proper heat treatment ac-
jects). For other codes or standards PWHT temperature cording contract requirements. The procedure shall be sub-
ranges may differ. mitted to buyer for review and at least address
For dissimilar joints involving P91-P22 and P23-P91, PWHT a) Item to be heat treated.
depends on the type of filler metal used. Refer to instruction
b) Type of heat treatment, i.e. furnace or local.
IKZ09 909-14 and 909-17 respectively.
c) Type of heating source, e.g. use of resistance or
Table 1 PWHT temperatures for material combinations induction heat, gas, etc.
Temperature range (ºC) d) Furnace type, with sketch of working zone.
Steel Grades CS 1¼Cr ½Mo 2¼Cr 1Mo 9Cr 1Mo V e) Number of thermocouples applied and their loca-
tions.
Carbon steel 615± 15 665± 15
[565±15] [note 1] 4.2 Actual heat treatment production data shall be com-
P11 665± 15 715± 15 piled into manufacturing data record (see buyer specification
[13CrMo4-5] [665±15] [670±10] IKZ 09 909-10). In case curve information is transferred,
proper reference to original shall be made.
P22 715± 15 735± 10
[10CrMo9-10] [695±15] [735±10]

P91 760± 10 5 REFERENCED DOCUMENTS

[X10CrMoVNb9-1] [760±10]
5.1 Croft, D.N., Heat treatment of welded steel struc-
Note 1. EN 12952: 615±15°C; EN 13480: 585±15°C; EN13445: 610±10°C.
tures, Abington publishing, 1996.
5.2 EN 12952 Part 5, European standard for water-tube
3 FURNACE SURVEY boilers and auxiliary installations.

3.1 Equipment for heat treatment shall be certified by a 5.3 Dirscherl, R., A simplified method for determining
furnace survey performed by the subcontractor and witnessed test specimen heat treatments, Metal Progress, May 1979,
by a buyers appointed engineer. Furnace certification shall be p84-87.
provided showing actual temperature on a representative ob-
ject. A furnace modification or repair requires a new survey.
Book IKZ09
Number 909-12
Rev. 2
Page 4/7
Instruction for heat treatment of ferritic steel

5.4 Spaeder, C.E. and Doty, W.D., ASME Post-Weld 5.5 Bailey, N., Weldability of ferritic steels, Abington
Heat treating practices: an interpretive report. WRC bulletin publishing, 1994.
407, p50-65.

Figure 1 Local PW HT of piping butt joints.

Min. heating band width
R= Internal Radius 5 Rt
t= Wall Thickness TC (see Figure 2)

Min. insulated band width

10 Rt

Figure 2 Location and quantity of recording thermocouples (TC) at piping butt joints

TC
TC TC

TC
TC
OD ≤ND50 ND50 < OD ≤ ND300 OD > ND300
Book IKZ09
Number 909-12
Rev. 2
Page 5/7
Instruction for heat treatment of ferritic steel
Figure 3 Local heat treatment of branch and nozzle connections with recording thermocouple location

Min. insulated band width:

2x heated band width

tb Rb
Min. Insulated
Min. Heated band width:
band width:
W TC 4* 5 R btb
TC 1
tr 2.5 Rbtb

≤ 2 tr
Rr TC 2

TC 3

Min. Heated band width:

Legend:
 Drums or vessels: The lesser of D + 2W + 2tr or D + 2W + 100mm
D = OD Branch  Piping: 5 R r tr
W = Weld width
tr = Thickness run pipe, vessel or drum
tb = Thickness branch ornozzle
Rr = Internal radius run pipe, vessel or drum
Rb = Internal radius branch or nozzle
TC # = Recording thermocople location (*TC4 only for branch D≤
ND100)
Book IKZ09
Number 909-12
Rev. 2
Page 6/7
Instruction for heat treatment of ferritic steel
Figure 4 Recording thermocouple location PW HT on headers and fintubes.

TC 3 TC 4

TC 5 & 6
TC 1 & 2

View A View B

TC 7, 8

TC 9, 10 TC 11, 12

TC 1, 2
TC 5, 6
Weld-end

TC 7, 9, 11
Bare end (fin) tube
20mm

TC 8, 10, 12
TC

View A
Butt welded cover View B
Plate cover
Book IKZ09
Number 909-12
Rev. 2
Page 7/7
Instruction for heat treatment of ferritic steel
Figure 5 Recording thermocouple location for heat treatment on steam drums.
Book IKZ09
Number 909-16
Rev. 3
Page 1/2
Instruction for cleanliness and preservation

INSTRUCTION
FOR
CLEANLINESS AND PRESERVATION
1 SCOPE
1.1 In addition to general requirements as defined in
the applicable project specifications, the instructions below
shall be observed. The intention is to arrive at a product
condition which will not have adverse effects on further
work or during operation.
1.2 This instruction applies to incoming raw material,
work during fabrication and on finalized parts ready for
transport.
1.3 Guidelines for extended storage of boiler pressure
part internals are included.
1.4 This instruction shall be read in conjunction with
fabrication and surface treatment specifications applicable
to the project.
2 STORAGE OF RAW MATERIALS
2.1 Raw materials for pressure parts shall be stored
under cover.
2.2 Materials shall be kept dry during storage.
2.3 Hollow sections, e.g. tubes, piping etcetera shall be
stored sloped to prevent the accumulation of water.
3 CLEANLINESS DURING FABRICATION
3.1 Pressure parts
3.1.1 All pressure parts (shell, pipe, fittings) with outer
diameter of DN 80 and over shall be blasted abrasively on
in- and outside surface.
a) For (fin-) tubes, grit blasting is not required.
However, tube surface condition shall not
cause bonding failures during finning.
b) Grit blasting shall be done before processing,
i.e. cutting and welding. Grit blasting cleanli-
ness shall be SA2 as minimum.
c) Fabricator shall include inspection steps to ver-
ify complete removal of blast media.
3.1.2 Inside surfaces shall be cleaned before welding.
3.1.3 Foreign matter shall be removed from tube bore by
sponge pigging each tube after machining and before fit-up.
3.1.4 Materials shall be kept dry and clean during manu-
facturing.
3.1.5 Drilled holes, welding faces and tubes shall be dry,
clean and free of dirt, grease or oxides.
3.1.6 Any oxidation near weld edge connections shall be
removed before welding.
3.1.7 Header and tube internal surface shall be cleaned
before welding (fin-) tubes.
3.1.8 After fabrication is completed, objects shall be
cleaned by means suitable for removing all scale, welding
slag and spatter or other foreign matter.
3.1.9 Hydrotested parts shall have remaining water ex-
pelled.
3.1.10 For objects with weld overlay:
a) Corrosion inhibitor shall be added to the cool-
ing water used during overlay welding to keep
the inner side of the tubes free of corrosion.
For recommended corrosion inhibitor see Table
1.
b) Contamination of high alloy weld overlay sur-
face, e.g. due to welding or grinding on carbon
and low alloy steels, shall be prevented.
3.2 Projected weld areas of structural parts shall be free
from rust, varnish or other foreign matter.
4 HYDROSTATIC TESTING OF PRESSURE
PARTS
4.1 General
4.1.1 All water that will be brought into contact with
large area’s of fabricated items, e.g. hydrostatic test, shall be
analyzed and comply with following requirements.
a) pH: >6.5, <8.0.
b) Chloride: <75ppm (mg/l).
c) Direct conductivity: <1000 S/cm (100 mS/m).
d) Suspended solids: <1ppm (mg/l).
e) Clear, odorless and colorless.
4.1.2 Vapour phase corrosion inhibiting preservative
shall be added to hydrostatic test water. Refer to Table 1 for
acceptable VpCI.
4.2 Objects shall be drained after hydrostatic test. Each
harp or bundle shall be placed on a rig under an angle to al-
low the hydrostatic test water to come out. After draining
the harp or bundle may be left damp.
4.3 The concentration of VpCI shall be tested and re-
ported monthly.
4.3.1 The VpCI shall be suitable for the test used.
4.3.2 Typical test method is a refractometer. A molybdate
testkit can be used in case Mo is present in VpCI product.
Book IKZ09
Number 909-16
Rev. 3
Page 2/2
Instruction for cleanliness and preservation

5 APPLICATION OF CORROSION INHIBITOR 6.1.2 All openings shall be closed with edge covering,
tight fitting and taped-off caps.
5.1 After drainage, VpCI shall be introduced into the
tubular objects within two weeks of hydrotest. The VpCI 6.2 Pressure parts without hydrostatic test at the shop
shall be suitable for fogging application as indicated in (e.g. drums, piping).
Table 1. 6.2.1 Inside surface shall be clean and dry.
5.1.1 To obtain the optimal distribution of VpCI powder 6.2.2 For drums preservation shall be in accordance to
through the harps or bundle, only two nozzles shall be left paragraph 5.2.
open. One nozzle shall serve as inlet. Another nozzle, di-
agonally across the inlet shall be left open to serve as outlet. 6.2.3 Piping shall be closed with edge covering, tight fit-
All other openings need to be capped. ting and taped caps.

5.1.2 The amount of VpCI powder to be blown through 6.3 Non-pressure parts.
the object shall be calculated on basis of object volume and 6.3.1 Exterior shall be painted with a primer, 75 m DFT
required amount of VpCI per cubic metre. See Table 1. (dry film thickness). Paint shall be so selected as to provide
5.1.3 The VpCI fogging need to continue until a “mist” for ample protection against handling and one year outside
of powder comes out of the outlet nozzle and calculated storage. Requirements of specification 784-01 will prevail.
amount of powder has been introduced into the object. If a
continuous “mist” comes out the object before the calcu-
lated amount of powder is fogged in, then reduce the veloc- 7 GUIDELINES FOR EXTENDED STORAGE
ity of fog entry and repeat operation. PERIOD
5.1.4 Openings shall be closed immediately after suc-
7.1 Fabricated parts shall be stored dry and under
cessful fogging with edge covering, tight fitting plastic
cover.
caps. Caps shall be securely taped to the protected object.
7.2 For extended storage, i.e. longer than one year after
5.2 The interior of a drum or vessel shall be provided completion.
with silica gel, the dosage is at least ½kg per m3. The inte-
rior shall be sealed from the atmosphere. The bags are to be 7.2.1 Sealing function of caps and tape shall be verified
securely fastened to the plastic caps. The amount of desic- regularly.
cant added shall be clearly indicated, detailing number of 7.2.2 Internal surface condition shall be checked periodi-
bags involved. A warning note to remove the given amount cally.
of silica gel bags before operating the unit shall be affixed
to each manhole cover. 7.2.3 Additional fogging shall be performed with VpCI
as recommended in Table 1.
7.2.4 Internal surface of drums, vessels, modules, harps,
6 PRESERVATION OF FABRICATED PARTS bundles and piping shall be checked each half-year and re-
6.1 For pressure parts hydrostatically tested at the sults reported.
shop. 7.3 Additional measures shall be taken on basis of pe-
6.1.1 Preservation shall be in accordance to paragraph 5. riodic inspections whenever necessary.

Table 1 Recommended type and application dosage of VpCI

VpCI application dosage1 protection2 remark

Cortec S-69 P Hydrotest 2 g/l Short Water soluble powder additive

Cortec M-370 Hydrotest 30-50 g/l Short Water based additive

Cortec 611 Hydrotest 5-10 g/l Short Corrosive for copper and soft yellow metals

Cortec 649L Hydrotest 2.5 g/l Moderate L=Liquid

Protecsol 649L Hydrotest 2.5 g/l Moderate L=Liquid

Protecsol 770P Fogging 300-500 g/m3 Long

Cortec 609 Fogging 300-500 g/m3 Long Corrosive for Cu and Ni-alloys; Silica Free

Cortec 309 SF Fogging 300-500 g/m3 Long SF = Silica Free; neutral for Cu or Ni

Note 1. 1 gram per liter [g/l] = 1000 gram per cubic metre [g/m3] ≈ 1000ppm = 0.1 percent [%].

Note 2. Protection period: short = 1 month, moderate = 6 months, long = over 1 year.

Note 3. VPCI selected for hydrostatic test water and subsequent fogging shall be of same brand.
Book IKZ09
Number 909-20
Rev. 0
Page 1/2
Requirements for boiler manufacturing under ASME

REQUIREMENTS
FOR
ASME
BOILER/PRESSURE PARTS MANUFACTURING
1 SCOPE
1.1 This instruction covers requirements for the engi-
neering, fabrication and supply of boilers parts under the
ASME Boiler and Pressure Vessel Code. This instruction is
intended to inform vendor about ASME requirements spe-
cifically where it relates to the scope of supply. It is not in-
tended to be an abstract, nor does it replace any section of
the applicable ASME code.
1.2 Items and equipment manufactured under this speci-
fication shall be code certified (ASME “stamped”)
2 ENGINEERING
4.2 Where indicated on buyer’s design documents, heat
treatment requirements as per ASME VIII div 1 shall be ob-
served and a separate procedure is to be submitted to buyer
for review.
5 TESTING AND INSPECTION
5.1 Boiler Proper (BP) and Boiler External Piping (BEP)
spools are subject to code authority inspection and certifica-
tion. Non Boiler External Piping (NBEP) shall be subject to
vendor’s quality system and vendor’s inspection, taking the
minimum requirements as per ASME B31.1 into account.
5.2 Drums are subject to code authority inspection.
Drum will receive ASME stamp upon completion.

2.1 The applicable edition of ASME section I, B31.1,
B16.25 and codes referenced herein shall be the codes by de-
fault, unless otherwise specified by an amendment to this
specification. Piping identified as boiler proper per PG-58
shall comply with ASME section I.
2.2 In case of ASME VIII div. 1 vessel(s), fabricator
shall ensure that Buyer’s design data is present at time of re-
view by fabricator’s authorized inspector in order to obtain
proper code authorization and stamp.
2.3 Design code jurisdiction is indicated on each iso-
metric drawing.
3 QUALIFICATIONS AND CERTIFICATION
3.1 Welding Procedure Qualifications: ASME IX.
3.2 Welder’s Qualifications: ASME IX.
3.3 NDE procedures: ASME V.
3.4 NDE personnel Qualifications: ASNT-TC 1A (edi-
tion/addendum as per ASME I A-360), minimum level II.
3.5 Welding consumables shall be provided in accor-
dance with ASME II - part C, SFA/AWS-A5.01, level of
testing schedule F. Alternatively, a test report conform
EN10204-2.2 can be supplied after Buyer prior consent.
4 FABRICATION
4.1 Bending and forming shall be in accordance with
ASME section B31.1.
5.3 For ASME VIII div. 1 compliant vessels observe
applicable joint efficiency (indicated on construction draw-
ing) and ASME VIII div. 1 UW-12 for extent of RT.
5.4 If RT per ASME PW-11 is applicable note that:
Economiser, Evaporator and Condensate preheat sections
have water service
Superheater and Reheater sections have steam service.
5.5 Volumetric examinations (e.g. RT, UT) shall be per-
formed before PWHT. Execution of surface defect detection
methods (e.g. PT, MT) shall be timed after PWHT.
5.6 For procedures and acceptance criteria for inspec-
tions as per NEM requirements (see relevant specification for
fabrication) but outside ASME code scope, the following
shall apply. The requirements set out below are minimum re-
quirements and are irrespective of fabrication scope.
5.6.1 Visual examination (VT)
a) Procedure to be based on ASME V, art. 9. De-
fault (assisted) direct visual examination.
b) Acceptance criteria according to ASME I, PW-
33 and PW-35 for alignment and reinforcement
tolerances respectively.
5.6.2 Magnetic particle examination (MT)
a) Procedure to be based on ASME V, art. 7. De-
fault colour contrast AC Yoke technique.
b) Acceptance criteria according to ASME VIII-1,
appendix 6.
5.6.3 Dye penetrant examination (PT)
a) Procedure to be based on ASME V, art. 6. De-
fault colour contrast technique.
Book IKZ09
Number 909-20
Rev. 0
Page 2/2
Requirements for boiler manufacturing under ASME

b) Acceptance criteria according to ASME VIII-1, 6 DOCUMENTATION

appendix 8.
5.6.4 Ultrasonic examination (UT)
a) Procedure to be based on ASME V, art. 4.
b) Acceptance criteria according to ASME VIII-1,
appendix 12.
c) Alternatively, acceptance criteria according to
ASME I, PW-52 may be used.
5.6.5 Ultrasonic lamination check
a) Procedure to be based on SA-435 with supple-
mentary requirement S1: 100% of allocated sur-
face to be checked.
b) Acceptance criteria according to SA-435.
5.6.6 Radiographic examination (RT)
a) Procedure to be based on ASME V, art. 2.
b) Acceptance criteria according to ASME VIII-1,
UW-51.
c) Alternatively, acceptance criteria according to
ASME I, PW-51 may be used.
d) Spot examination, not required by ASME VIII-
1, but demanded in the standard specification,
shall be based on UW-52, however, UW-51 ac-
ceptance criteria apply.
6.1 Upon completion of fabrication the pressure parts
shall be documented on the appropriate forms by unit
(HRSG), boiler system (pressure) and code jurisdiction
(ASME I, B31.1 and/or PED).
6.2 Parts do not need to be registered at the National
Board. The fabricator shall issue a “manufacturing serial
number” on the appropriate ASME forms and shall provide
for partial stamping. Buyer, as engineering-contractor, will
issue the National Board number and provide for its registra-
tion.
7 NOTES
7.1 Code stamping of pressure parts shall be carried out
as prescribed in the relevant code section.
7.2 Spools shall be die-stamped with data according PG-
106.8, or UG-116. The location shall be within 90mm from
upstream field connection (e.g. bevel or flange).