CE .122186-me. | TATA CONSULTING ENGINEERS LIMITED RE 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS V. PO PCBL (TN) LIMITED PROJECT: ENGINEERING CONSULTANCY SERVICES FOR GREEN FIELD PROJECT AT SIPCOT INDUSTRIAL PARK PURCHASE SPECIFICATION FOR REACTORS FILE NAME: TCE.12215B-ME-6070-PS-65021_PO 29-09-2021 PREPARED | CHECKED. BY BY ‘APPROVED. BY DATE CLEARED BY FILE NAME: TCE.122158-ME-6070-PS-65021_PO TCE FORM NO, 032 R4TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 6070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 2 of 30 REVISION STATUS REV. NO. DATE DESCRIPTION Po 29,09,2021 Inter Discipline Check FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3ce 122180-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 3 of 30 TABLE OF CONTENT SECTION DESCRIPTION race + | IDENTIFICATION 4 2 | SCOPE 4 3. | ABBREVATION 6 4 | TECHNICAL REQUIREMENTS 7 5 | SPARE PARTS 23 6 | EXCLUSIONS 23 7 | SITE AND ENVIRONMENTAL DATA 23 8 | SPACKING 24 9 | DOCUMENTATION 25 10 | MARKING 25 +1 | DEVIATION STATUS 26 12 QAP 28 13. | INSTALLATION LOCATION 26 14 | PAINTING 26 1s | CoLoUR 28 16 | INSPECTION AND TESTING 27 17 _| INSPECTION AND CERTIFICATION 27 18 | GUARANTEE 28 19 | ENGINEERING SCOPE OF SUPPLY 29 20 | LIST OF DOCUMENTS / DRAWING ATTACHED 29 ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12215B-ME- TATA CONSULTING ENGINEERS LIMITED REV. PO 6070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS, SHEET 4 of 30 4.0 IDENTIFICATON S.NO ITEM NUMBER QUANTITY DESCRIPTION 2101-R-01,2201-R- 0182301-R-01 3 Hard black reactor 2.0 SCOPE Tamilnadu, India selection of Reactor. CODES Is 2825: 1969 Is 4049: Part 1: 1988 Is 9683: 1980 Is 12145: 1987 Is 2002: 1992 Is 4353: 1995, 2.1 This specification covers the design, supply, construction, inspection & testing, ‘and commissioning of Reactor for Mis PCBL (TN) LIMITED, for their Carbon Black Project at SIPCOT Industrial Park, Thervoy Kandigai 2.2. The following codes and standards are applicable for the fabrication and material Tiruvallur District, DESCRIPTION Code for unfired pressure vessels Specification for Formed Ends for ‘Tanks and Pressure Vessels - Part 1 Based on Outside Diameter Carbon and low alloy steel forgings for fired and unfired pressure vessels ‘Quenched and tempered alloy steel forgings for pressure vessels Steel plates for pressure vessels for intermediate & high temperature service including boilers ‘Submerged Arc Welding of Mild Steel ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12215B-ME- TATA CONSULTING ENGINEERS LIMITED | REV. Po 6070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS, SHEET 5 of 30 ASME Sec, II Part-A ASME Sec. Il Part-D ASME Sec. V ASME Sec. Vill DIV.1-2015 Edition ASME Sec. IX ASME B16.5 ASME B 16.9 ASME B16.47 ASME B16.20 ASME 836,10M ASME 836.19M BS EN 10204 and Low Alloy Steels ~ Recommendations Boiler and Pressure Vessel Code: Ferrous Material Specifications Boiler and Pressure Vessel Code: Material Properties Boiler and Pressure Vessel Code: Non-Destructive Examination Design code for fabrication & inspection. Boiler and Pressure Vessel Code: Welding and Brazing Qualifications Pipe Flanges and Flanged Fittings NPS % through NPS 24 Factory-Made Wrought Steel Butt Welding Fittings Large Diameter Steel Flanges NPS 26 through NPS 60 Metallic Gaskets for Pipe Flanges - Ring Joint, Spiral Wound and Jacketed Welded and Seamless Wrought Steel Pipes Stainless Steel Pipes Metallic Products — Types of ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12215B-ME- TATA CONSULTING ENGINEERS LIMITED REV. PO 6070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS, SHEET 6 of 30 ISO 9001 ASME SA516-70 ASME SA106 ASME SA240 ASTM A182 F310 ASTM A193 ASTM A194 ASTM C892 - 19 1s 2062 SA 516 GR70 3.0 ABBREVATION inspection documents ‘Quality Management Systems — Requirements Medium carbon alloy ‘seamless carbon steel nominal wall pipe Stainless steel plate Forging material specification for 310 grade stainless steel Heat-treated chromium-molybdenum low-alloy stee! ‘standard material specification for high tensile nuts and other internally threaded fasteners Standard Specification for High- ‘Temperature Fiber Blanket Thermal Insulation ‘Supports for roller Lifting lug / stiffeners ‘Abbreviation Description ASME ‘American Society of Mechanical Engineers. AWS ‘American Welding Society CRA Corrosion Resistant Alloy cs Carbon Steel DP Design Pressure ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TATA CONSULTING ENGINEERS LIMITED | REV. Po PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 7 of 30 TCE.12215B-ME- 6070-PS-65021 MAW? Maximum Allowable Working Pressure Mm Millimeters NDE Nondestructive examination NOT. Non-Destructive Testing NPS) Nominal Pipe Size PWHT Post Weld Heat Treatment ams Quality Management System VORL Vendor Document Requirement List SI International System SPIR ‘Spare Parts and Interchangeabilily Record UNC Unified Coarse Thread OSHA ‘Occupational Safety and Health Administration WPQR ‘Weld Procedure Qualification Record 4.0 TECHNICAL REQUIREMENTS 4.1 Purchaser's design requirements are defined in this specification, other referenced specifications, codes, and standards. vendor shall be responsible for ensuring that all equipment and components provided are suitable for the design and operating conditions. 4.2. Equipment shall be designed and constructed in accordance with the design code specified in this specification and shall be code stamped accordingly Corresponding Code stamp and name plate are required on every vessel, unless agreed otherwise with the purchaser, 4.3. The vendor shall coordinate the complete design and supply of all the equipment and ensure satisfactory performance of equipmenticomponent supplied by sub- vendors. Where the vendor provides equipment that he has not manufactured, he shall ensure that the items are compatible with all other equipment supplied. The vendor shall be responsible for guaranteeing all equipmenticomponents including those supplied by sub-vendor if any. 4.4 In general, the SI unit system shall be used, However, pressure shall be in bar, ‘Where dimensions specified in inches, the nearest integer value in millimeters ISSUE FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12215B-ME- 6070-PS-65021 TATA CONSULTING ENGINEERS LIMITED | REV. Po 45 46 47 shall be used for SI unit system except for pipes dimensions up to 20 NPS and for tubes where dimensions remain in inches. Design / service life, reliability, and maintenance + The equipment and their components shall be designed and constructed for a service life of 25 years minimum. + Equipment components should be of a proven design for reliability and minimum maintenance. Corrosion allowance + The minimum internal corrosion allowance for carbon steel and low alloy stee! vessels shall be 3 mm, unless otherwise specified on drawings. The specified corrosion allowance shall be added to internal surfaces of pressure parts and exposed surfaces of non-removable intemals on both sides. + One half of the specified corrosion allowance shall be applied to each exposed surface of non-corrosion resistant removable internals. + Unless otherwise specified by the purchaser, corrosion allowance will not be applied on stainless steel and Nickel base materials. + When corrosion resistance is provided by a CRA lininglweld overlay, undiluted chemistry of 3 mm thickness of CRA shall be provided, unless otherwise specified + Vessel parts which are subjected to erosion e.g., due to impingement by the process stream, shall be protected with wear plates, or impingement baffles. Care shall be exercised to ensure that these components are not subjected to excessive vibration. Minimum thickness © Minimum wall thickness for vessels (shells and heads, after forming) shall be ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 8 of 30 TCE FORM NO. 120 R3TATA CONSULTING ENGINEERS LIMITED | REV. Po PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 9 of 30 TCE.12215B-ME- 6070-PS-65021 as given below: * For CS and low alloy steels 6 mm (including corrosion allowance up to 3mm), but not less than the following a. For diameter less than 2400 mm Wall thickness = Diameter + 1.5 + Corrosion allowance 1000 b. For diameter 2400 mm and above ‘Wall thickness = Diameter + 2.5 + Corrosion allowance 1000 c. For stainless steel! 5 mm but not less than the following Wall thickness = Diameter + 2.5 + Corrosion if any 1000 All dimensions are in mm. © Minimum wall thicknesses of carbon steel and low alloy nozzle necks, including corrosion allowance, shall be the greater of the code requirement and the following: a, 2 NPS and less — Sch 160 b. 3 NPS through 6 NPS - Sch 80 c. 8 NPS through 24 NPS - Sch 40 ‘+ Minimum wall thicknesses of stainless-steel nozzle necks shall be Sch 40S. 4.8 Design condition ‘= The design pressures recommended ‘1bar is acting at the top of the vessel. Pressure due to static head of liquid in vessels shall be added to the internal design pressure to calculate the thickness of respective shell sections/heads. * Vendor may consider the MAWP to be the same as the DP unless otherwise specified. ‘+The test pressure is the pressure measured at the highest point of the vessel ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12215B-ME- 6070-PS-65021 TATA CONSULTING ENGINEERS LIMITED | REV. Po ‘SHEET 10 of PURCHASE SPECIFICATION FOR REACTORS, 30 in its test position. The test pressure shall be established in accordance with the Code or as per local laws, wherever applicable. Higher of values shall be specified as test pressure The design temperature shall be as specified below, a. For vessels operating at and above 0°C, minimum design temperature shall be higher of operating temperature plus 15°C and 65°C. b. For vessels operating below 0°C, design temperature shall be equal to the lowest operating temperature, ¢. MDMT shall be lower of minimum ambient temperature and minimum operating temperature or any upset condition. Fatigue analysis shall be performed in accordance with ASME Section VIll, Division 2 or PD 5500, as applicable. Fatigue analysis shall consider all mechanical and thermal cycles anticipated in the service life of the vessel. Basis for fatigue analysis shall be as presented in ASME Section VIll, Division, 2 or PD 5500, as applicable In the fatigue analysis, peak stress determination shall be performed for all vessel discontinuity areas, including all nozzle/shell and nozzle/head intersections, support attachments, headishell intersection, weld contours, fillet welds and internal attachments, The following minimum stress analyses shall be provided as applicable (in addition to basic code calculation requirements) a. Complete detailed calculations for lug or ring type vessels supports, when used, These shall include the effects on the vessel shell local to the attachment. b. Complete design calculations/stress analysis for special, large diameter ISSUE Po nozzles, if any. FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 11 of ©. Stress analysis of shell and saddle at saddle support location 4, Stress analysis due to external loading on vessel nozzles and structural attachments + For buried equipment, external loads due to mound and buoyancy effects shall be included in the design, + Layered vessels are not acceptable unless specifically approved by purchaser on case-to-case basis, 4.8 Design load ‘= Pressure vessels shall be designed for combined loads applicable to the transportation, erection, operation, shutdown, and test conditions. These shall, as a minimum, include loads due to wind, seismic, erection, dead weight, static pressure, temperature gradients, forces and moments from piping and loads due to platforms and ladders etc. ‘© The design of the equipment, internals, attachments, anchor bolts, supports and saddles shall accommodate all the external loads in the following combinations: a. Erection: Empty Weight, Wind and Seismic loads at ambient temperature. Wind and Seismic should not be considered to act simultaneously. b. Hydraulic Test: Test weight, 30% of design wind load and test pressure at ambient temperature. ©. Normal Operation: Operating, Weight, Wind and Seismic loads, local mechanical loads, and local thermal loads (at design temperature and pressure), Wind and Seismic should not be considered to act simultaneously. ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 12 of d. Abnormal operation: Weight (allow for maximum liquid level), Wind and Seismic loads, local mechanical loads, and local thermal loads at design temperature and pressure, Wind and Seismic should not be considered to act simultaneously , Transportation/Dynamic loads; The vessel shall withstand acceleration forces of 1.0 g applied in horizontal transverse direction, 2.0 g in vertical direction and 1.5 g in longitudinal direction. * Any other conditions which would affect the safety of the vessel (e.g., cyclic loading). In addition to the above load combinations, horizontal vessels shall be designed to withstand the induced stresses in shells due to the location of, saddles. These stresses shall be calculated according to the analysis procedure of L.P Zick. 4.10 Allowable design stress ‘= The allowable tensile and compressive stresses for erection and operating conditions shall be in accordance with ASME Section VIII Division 1, 2 or 3 and ASME Section Il or PD 5500, as applicable. + Stress levels during hydro test shall not exceed limits on the specified minimum yield strength of the material at the test temperature as per code. 4.11 Wind loads The wind load shall be calculated as per “Civi, Structural and Architectural Design Basis’ for the project. 4.12 Seismic loads ‘The seismic load shall be calculated as per “Civil, Structural and Architectural ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3 Design Basis’ for the projectTCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 18 of 4.13. Shells and heads * Where shell courses differ in thickness the inside diameter of the vessel shall be constant. + Vessel heads shall be semi-ellipsoidal unless otherwise specified ‘= Tori spherical and hemispherical heads may be used provided all pertinent dimensions and information is submitted to the purchaser for approval before the heads are ordered, + Elipsoidal and tori spherical heads shall have a straight flange length of minimum three times of the thickness, but need not exceed 50 mm, + Allheads / knuckles which have been cold formed shall be normalized. All heads/knuckles, hot formed below normalizing temperature, shall be subsequently normalized. = Heads produced from more than one plate shall have the welds 100% radiographed after forming, = Any other pressure component (e.g,, shell, nozzles made from plate, etc.) having fiber elongation more than 5% shall be stress relieved in accordance with code. 4.14 Nozzle and manways * Unless otherwise stated, the minimum nozzle size shall be NPS 2. Flanges up to NPS 24 shall conform to ASME B16.5 "Pipe Flanges and Flanged Fittings". Flanges greater than NPS 24 shall conform to ASME B16.47 Series ALarge Diameter Stee! Flanges’ + Nozzle pipes up to NPS 12 shall be of seamless pipe construction only Nozzle sizes more than NPS 12 may be formed using plates. Longitudinal ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3 welds in such pipes shall be 100% radiographed,TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 14 of + Allnozzie connections shall be flanged. All fianges shall be forged. + Flanges shall be of Weld Neck type only + Unless otherwise specified, reinforcement for nozzles and manways shall be designed for the Test Pressure of the uncorroded vessel at test temperature and also for the Design Pressure of the corroded vessel at design temperature. ‘= The thickness of an integrally reinforced nozzle shall not be greater than two times the vessel wall thickness at the location of the altachment. ‘= All nozzles shall be flush with the inside of the vessel wall * All nozzles shall be ‘set-in’ type only except the nozzles located on blind flange which may be “set-on’ type, provided the attachment is a full penetration weld. = Where two or more openings are provided for installation of instrument, such as gauge glasses, level controls, etc. they shall be set with a jig to maintain their relative locations within specified tolerances, * Bolt holes in flanges of nozzles and manways located in heads of vessels shall straddle the principal centerlines of the vessel or lines parallel thereto. Bolt holes in flanges of nozzles and manways located in shells shall straddle the vertical centerline of the vessel. * When the horizontal centerline of the vessel slopes, the nozzles must be vertical and horizontal to the true horizontal line (and not perpendicular and parallel to the vessel centerline). + All internals shall be sized in order to facilitate their entry through the manholes. ‘= Calculation of local stresses due to external piping forces and moments, pipe supports, platform supports, etc., shall be carried out as per Welding ISSUE FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 15 of Research Council Bulletins Nos. 107 and 297. + Liner plate of high alloy shall not be used at the gasket contact face of a flange or blind flange. In all such cases gasket contact face shall be of weld overlayed, construction only. ‘+ Vessels up to 915 mm outside diameter without any removable internals may be provided with hand holes in lieu of manholes. Otherwise, shell top flange shall be provided. + Manholes shall be supplied with cover. Manhole covers shall be provided with davit or hinge support, as applicable * Shell top flange for vessels shall be provided with davit. = All nozzles up to NPS 2 shall be provided with 2 nos. stiffeners at 900 apart. 4.15. Nozzle projection * However, for top nozzles, projection may have to be increased to clear platform, if required. This shall be specified in nozzle orientation drawing * Allnozzles must extend clear of insulation with sufficient projection to afford easy removal of stud bolts through the back of the flange. 4.16 Vessel support * Horizontal pressure vessels shall be supported on two (2) saddles only. There shall be two 1/4" drilled tell-tale holes at outer extremities in each saddle pad. ‘Saddle pads shall have rounded corners. Saddles shall provide support for at least 120° arc at the circumference of vessel shell. Saddle wear plates shall be of the same material as the shell to which they are attached, Calculations shall be provided for the effect of support saddles on the vessel shell * Saddles shall be located within 0.5 x vessel radius from vessel tangent lines ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3 if nozzle positions permit.TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 16 of + All Vessels shall be designed to be self-supporting. 4.17 Lifting ‘Vessels shall be provided with all required lifting lugsitrunnions and tailing lug, to facilitate handling during transportation and erection at site. + Preferably, lifting attachments shall be positioned and orientated so that equipment can be lifted from a single point, without the aid of a spreader beam. Attachments shall be suitably positioned such that slings do not foul with any part of the vessel. * A vertical load impact factor of 2 shall be used when designing iting lugsttrunnions and tailing lug. Contingency factor of 1.1 shall also be included on the calculated weight ‘+ Where spreader beams are required, the vendor shall be responsible for their design, fabrication, supply, and certification. The lift weight shall be factored by 2.0 for design of spreader beams. Where spreader beams or frames are Used, they shall be proof tested. All liting equipment shall be proof tested (witnessed) by a recognized competent authority, + Vendor shall ensure that stresses generated in the vessel wall by the lifting lugsttrunnions are within the allowable limit. + Vendor shall submit liting sketches along with calculations during the lifting, transportation and erection phases. + Lifting lugs/trunnions and tailing lugs shall be subject to 100% NDE. 4.18 Earthing Each vessel shall be supplied with a minimum of two earthing lugs. The details of the Earthing lug shall be in accordance with the Standard Drawing for Typical Earthing Lug, ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 47 of 4.19 Tolerances and Dimensions All vessel connections, internals, etc. shall be located from the datum or reference line. 4.20 Material + Vendor shall review the materials specified and confirm its suitabilty for the specified design condition. * Materials other than those specified may be proposed as alternative with their advantages and past proven experience for the approval by the purchaser. + All materials used for fabrication shall be new. 4.21 Safety Requirements ‘The equipment shall comply with safety requirements as specified by OSHA, state and local regulations in effect where the equipment will operate. 4.22 Special Tools The Vendor shall provide any special tools that are required to correctly maintain their equipment. Special tools shall be clearly identified in the Vendor's Proposal, 4.23 Instrumentation and electrical All instruments and controls are according to Instrumentation design basis. 4.24 Composition and Heat Treatment * For carbon and carbon manganese steel the carbon content shall be 0.23% maximum for thicknesses up to 60 mm and 0.25% for thicknesses above 60 mm. The Carbon Equivalent (C.E) shall be 0.45 maximum, forall thicknesses, computed using the following formula: CE = C+ (Mni6) + (Cr+Mo#V)/5 + (Cu+Niyi15 * Carbon and carbon-manganese steel plates for Pressure parts shall be fully ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 18 of killed and shall be supplied in normalized condition. Additionally, the steet shall be of fine grain practice when the vessel requires impact testing = Carbon steel forgings shall be supplied in normalized or normalized and tempered or quenched and tempered conditions. Where quenched and tempered materials are offered, the tempering temperature shall be greater than 640°C, 4,25 Welding All welding shall be done with procedures and operators, which have been qualified in accordance with Section IX of the ASME Boller and Pressure Vessel Code or PD 5500 code. The vendor shall submit proposed qualified weld procedures and weld details for the purchaser's review and approval prior to commencing any production welding. Vessels shall be of welded construction, utilizing shielded metal arc, submerged-arc, and gas metal-arc or gas tungsten arc process. Submerged arc welding is preferred on all vessel seams. * When sound back welding is not feasible due to inaccessibillty, single-welded joints which utlize a gas tungsten arc welded or gas metal arc welded root pass, shall be used Vessels subject to cyclic loading shall have all full penetration butt welds ground smooth internally and externally and all other welds ground so as to blend smoothly into the parent material. * All vessel seams shall be located to clear all external and internal permanent attachments, The distance from the edge of the attachment weld to the edge of main weld shall be at least 50 mm. Where this is agreed by the purchaser to be impractical, seams shall be ground flush and 100% radiography or equivalent, shall be performed on the main seam where it will be covered plus ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 18 of 50 mm either side prior to the attachment weld. In addition, the attachment ‘weld shall cross the pressure weld completely by at least 50 mm or twice the wall thickness in order to avoid stress concentration, © When practical, circumferential welds shall be so located that visual inspection can be made with all internal equipment in place. Longitudinal seams for trayed vessels shall not be located behind down comers, Longitudinal seams for horizontal vessels preferably shall be located above the horizontal centerline. © Welding electrodes, automatic or manual, shall deposit a composition corresponding to the material being welded, Where applicable, electrodes shall meet AWS/ASME specifications. Welding electrodes and other welding materials may be of any recognized brand approved by the purchaser. + For materials with yield strength exceeding 330 Nimm2 andlor thickness exceeding 20 mm, consumables for manual metal arc welding shall be of the basic low hydrogen type. = Low hydrogen electrodes shall be dried or baked at the temperature level and times specified by the manufacturer and shall be used within 8 hours when stored in heated quivers. Electrodes stored in quivers, but not used within the specified times, shall be re baked in ovens prior to use. ‘= No electrodes shall be left ying about the site, or in workshops. Electrodes so left shall be scrapped. ‘= Submerged arc flux shall be stored in moisture-proof containers in a dry location, at a temperature above 20°C. = Submerged are consumables shall be withdrawn from store only when required for Immediate use. Used consumables shall be retumed to store on ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3 completion of the welding operation.TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 20 of ‘+ Submerged arc flux may be recycled but shall be free from fused flux, mill scale, dirt and other foreign matter. ‘+ The vendor shall provide proof to the satisfaction of the purchaser's Inspector that the welder has been using the process for which he is qualified within the previous 6 months. If not, then the welder shall be required to requalify. + Longitudinal and circumferential seams in shells and all seams in heads shall be full penetration single or double butt welds of the 'V or 'U type. Lap welds are not permitted, + All welding shall be subject to post weld heat treatment on (a) Materials and thickness requiring post weld heat treatment as per the design code, (b) all thicknesses of Vessels in caustic, MEA and H2S service, (c) all thicknesses of Chrome-moly alloy steels containing more than 2% Gr or more than 0.6% Mo. + When a vessel drawing contains the note "This Vessel Stress Relieved for Process Services’, absolutely no welding, hammering, processing or forming on the shells, heads, manholes, nozzles or other attachments, shall be performed after stress relieving, + No welding shall be allowed after vessel internal coating, if applicable. All attachments including ladder and platform clips must be welded before intemal coating, + Notwithstanding the requirements of the code, production test shall be conducted on longitudinal shell seams and head seams (if any) where run-off tabs shall be used. This shall apply to vessels with a design temperature below 0°C and thickness greater than 25 mm. One production test plate shall be provided per vessel for each weld procedure and shall be subject to full ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3 mechanical testing in accordance with the relevant welding code.TCE.12215B-ME- 6070-PS-65021 TATA CONSULTING ENGINEERS LIMITED | REV. Po PURCHASE SPECIFICATION FOR REACTORS, 30 4.26 427 4.28 ‘= Production control test plates shall be post-weld heat treated with the vessel where applicable. + Allfillet welds shall be continuous. © Backing strip type of weld joint is not allowed without prior approval of purchaser, Welding Repairs ‘+ All repairs welding shall be in accordance with procedures previously approved by the purchaser. ‘© The repaired weld shall be subjected, as a minimum requirement, to the same testing and inspection as the original weld, ‘+ The cost of all repairs and subsequent inspection shall be the responsibility of the vendor. ‘+ Weld repairs shall take place before hydro testing and care shall be taken to ensure that the wall thickness is not reduced below the specified minimum design thickness. + Surface defects, and areas of weld resulting from the removal of temporary attachments shall be ground smooth and the area subjected to 100% crack detection and wall thickness checking. Welding Procedure Qualification Record (WPQR) Each weld procedure specification shall be covered by a suitable procedure qualification tested in accordance with the requirements of the relevant welding code. Preheat Requirements The minimum preheat temperature to suit particular combined plate thickness, chemical composition, heat input, consumables and restraint shall be ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 ‘SHEET 21 of TCE FORM NO. 120 R3TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 22 of established before commencing welding and held until welding is complete Preheat temperatures shall be controlled by temperature indicating crayons or contact pyrometer. 4.29 Post Weld Heat Treatment Requirements + Vessels shall be post-weld heat treated when required by the design code, or when the process fluid dictates + Post-weld heat treatment shall also be considered for vessels subjected to large amounts of welding and where pressure parts have been formed from thick plate into tight radii (D/t ratios of less than 20:1). + When post weld heat treatment is required, this shall be done on the complete Unit of vessel in an enclosed furnace, and not in section. Any exceptions shall be clearly stated in the vendor's bid/drawing and shall require purchaser's, written approval + Field post-weld heat treatment procedures must be reviewed by the purchaser. + The vendor shall include in his material sub-order(s), the number of heat treatments envisaged during fabrication and repair, if any. The vendor shall ensure to obtain guarantee from the mill that the steel supplied shall meet the proposed no, of heat treatment cycles without detrimental effect on the minimum guaranteed mechanical properties. + The use of manually operated gas torches or gas rings shall not be permitted for PWHT. + During PWHT, a minimum of six thermocouples per furnace load shall be Used to ensure that uniform temperature is achieved throughout the heat treatment cycle. The thermocouples shall be used to record metal skin ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3 temperature.TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 6070-PS-65021 ‘SHEET 23 of PURCHASE SPECIFICATION FOR REACTORS, 30 + Ifwelded repairs are made to a vessel which has been heat treated, the vessel shall again be heat treated. This treatment shall form part of the repair procedure, + All heat treatments shall be recorded and documented by a calibrated temperature recording chart. + Flange facings and threaded connections shall be protected against oxidation during heat treatment 5.0 SPARE PARTS Vendor shall provide the itemized and priced recommended spare parts lists for: + Erection, Pre-commissioning, Commissioning, and inital Start-up (Shall be included in the base price). + 2Year's Normal Operation. ‘After award, the vendor shall complete and submit the SPIR form provided by the purchaser. 6.0 EXCLUSIONS ‘Any civil work but necessary load data shall be provided by Vendor. For Civil foundation loads: Wind Seismic whichever is governing 7.0. SITE AND ENVIRONMENTAL DATA Reactor are to be installed at the green field Carbon Black Project at SIPCOT Industrial Park, Thervoy Kandigai, Thiruvallur District, Tamilnadu. Location: SIPCOT Industrial Park, Thervoy Kandigai Thiruvallur District, Tamilnadu, India. ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 24 of 8.0 PACKING REQUIREMENTS 8.1 After the final hydrostatic test, the vessels shall be dried and cleaned thoroughly of all grease, loose scale, rust, flux and weld spatter, both internally and externally 82 All vessels shall be complete with necessary temporary support steelwork to enable safe transportation, lifting and installation, 8.3 Vessels undergoing ocean shipment shall be provided with corrosion inhibitors. Particular care shall be given to stainless steel vessels undergoing ocean shipping, 8.4 Flanged openings shall be protected with steel plate/wooden covers attached by proper bolting and sealed with a plastic compound, 85 All exposed machined and threaded surfaces shall be thoroughly coated with a suitable rust preventative compound and suitably protected for shipment. All female threaded connections shall be fitted with solid pipe plugs of the same material as the connection. All vent holes in reinforcing pads or lined nozzles shall be plugged with heavy grease, unless otherwise specified, 86 The vendor shalll be responsible for loading and anchoring vessels to prevent any damage during shipment. 8.7 All loose parts shall be adequately crated and given clear markings relating the parts to the vessel identification number, The Tags and wire used for markings shall be stainless steel 8.8 The vendor shall ensure that all items are protected with suitable preservation and packing ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12215B-ME- 6070-PS-65021 TATA CONSULTING ENGINEERS LIMITED | REV. Po PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 25 of 9.0 DOCUMENTATION 9.1 Vendor shall furnish the drawings & documents as per attached Vendor Data Requirement and Schedule. 9.2 Mechanical Design calculations. 9.3 Fabrication drawings 9.4 Installation and operating instructions. 9.5 Maintenance manuals with parts lst 9.6 Material Test Certificates & Inspection Report. 9.7 Vendor shall also supply (6) six sets of As Built drawings. 9.8 Soft copy of all the documents will also be submitted, 9.9 VDRS, 10.0 MARKING 10.1 A stainless-stee! nameplate showing, at least, the following information shall be attached to each piece of equipment a b, c 4 10.2 Each equipment shall be identified with a separate (in addition to the Manufacturer's standard) stainless steel nameplate listing the Purchaser's Manufacturer's Name Equipment Serial Number Equipment Size, Type and Model Number Design code Equipment Item Number, 10.3 All instruments shall be identified with a separate stainless-steel! nameplate showing the Instrument Item Number, 10.4 All nameplates shall be permanently attached to the item. FILE NAME: TCE.12215B-ME-6070-PS-85021 ISSUE Po TCE FORM NO. 120 R3TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 26 of 14.0 DEVIATION STATEMENT The vendor shall submit iter wise deviation statement seeking approval for marking deviation from the above drawings and specification. In case no relaxation is sought, ‘NIL’ statement shall be submitted. 12.0 QUALITY ASSURANCE PROGRAMME (QAP) 12.1 The vendor shall submit his internal quality assurance pian to PCBL (TN) / Purchaser. In the said QAP, infrastructure facilities (comprising of testing and manufacturing facilities), frequency of various checks, details of nature of work involved in the checks and record maintained regarding these checks should be indicated on demand by PCBL (TN) / purchaser or the Inspecting authority nominated by the purchaser, make the records of checks carried out during internal quality assurance available for scrutiny, 422. The vendor shall, on demand by PCBL (TN) / purchaser or the Inspecting authority nominated by the purchaser, make the records of checks carried out during internal quality assurance available for scrutiny 13.0 INSTALLATION LOCATION The reactor will be installed outdoor and shall be suitably protected against the local ‘extreme ambient conditions. 14.0 PAINTING 14.1 Lead based paint shall not be allowed. 14.2. All carbon steel components shall be coated according to the Manufacturer's standard, 15.0 COLOUR The reactor shall be supplied as per vendor colour scheme, Quality of paint shall be as ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 27 of per relevant |.S. publication, the details of which shall be indicated. 16.0 INSPECTION AND TESTING 18.1. Vendor to provide for stage wise or final inspection of the complete equipment with all accessories, depending on the requirements specified at the time of order placement, 16.2. The inspection shall be carried out by client or his authorized representative at the manufacturing facility, on getting advance notice from vendor 18.3 The Purchaser shall perform field tests during which all components shall be verified to perform satisfactorily at the design rate under design conditions. 18.4 Radiographic Inspection + Radiography shall be by X-ray unless agreed otherwise in writing by the purchaser. ‘+ Except where amplified in this specification the extent of radiography shall be in accordance with the design code ‘+ When 100% radiography is specified, all welds including flange butt welds and nozzle to shell connecting welds, shall be fully radiographed. Where radiography is considered to be impractical ultrasonic inspection may be substituted with prior approval of the purchaser. + For vessels requiring radiography where heat treatment is required, the radiography must be carried out after heat treatment. + The purchaser's appointed inspector shall view all radiographs and shall be advised of any defects found in any welds. 17.0 INSPECTION AND CERTIFICATION 17.1. The purchaser or his authorised representative shall always have free entry to the ‘Vendor's works and Vendor's work where and while the work is being performed. ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 28 of The inspectors shall have the rights to inspect all radiographed films as well as designs, calculations, material records and shop records. 17.2 Welding procedures, welding qualification tests, and welder's qualifications shall meet all requirements of ASME codes / IS standards 17.3 The vendor shall conduct tests and inspections as per Vendor's standard practice. Test certficates, wherever applicable shall be furnished by the vendor. 17.4 Vendor shall conduct tests at site as per the requirement of Statutory Board as required 417.5 The vendor shall furnish the procedure to be used for erection, cleaning, testing and commissioning of reactor. 17.8. Two-week trial run of the reactor after cleaning, at rated duty shall be performed under the supervision of the vendor. During this trial run the Vendor's representative shall train the operating personnel of the purchaser. 18.0 GUARANTEE 18.1 Equipment supplied shall be guaranteed against faulty design, defective or improper materials, poor workmanship, or failure from normal uses during the guarantee period. In the event of malfunctioning / mal performance of the equipment, or defects occurring in the equipment during alteration, repairs and replacement shall be free of charge. 18.2 Guarantee Period: 18 months from the date of commissioning or 24 months from the date of supply whichever is earlier for the proper workmanship, MOC of different parts and performance 18.3 The Vendor shall guarantee that the equipment and materials provided are suitable for the application specified in these documents. ISSUE Po FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12216B-me. | TATA CONSULTING ENGINEERS LIMITED | REV. Po 8070-PS-65021 PURCHASE SPECIFICATION FOR REACTORS. 30 19.0 ENGINEERING SCOPE OF SUPPLY 19.1 Vendor document register 19.2. Manufacturing schedule 19,3. Equipment Drawings and complete assembly drawings. 19.4 Overall foundation drawing including equipment and support, support structure foundations, and loading data (Static/Dynamic) — Only load details by Vendor: Total Load, Bending Moment, Shear for both Wind and Seismic, whichever is governing, 195 Instructions for receipt, storage, installation, and pre-commissioning & commissioning tests. 19,6 Design calculation report with native file, 19.7 Allowable Civil & Nozzle loads for all termination points, 19.8. Structural support steel G.A & fabrication drawings including drawing wise MTO. 19.9. Fabrication drawing for reactors in vendor's scope. 19.10 Unpriced copies of all sub-orders, 19.11 Statutory approvals. 19.12 List of Spares & consumables 19.13 QN/QC plan 20.0 LIST OF DOCUMENTS / DRAWING ATTACHED. ‘SHEET 29 of SL.NO DESCRIPTION DOCUMENT NO. 1 | SCOPE MATRIX ‘TCE,12215B-ME-6070-CM-65003 2 | PROJECT DESIGN BASIS TOE. 12215B-XX-XXXX-XX-XXAK 3. | PROCESS DESIGN BASIS. TCE.12215B-PR-2070-BS-25001 FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3TCE.12215B-ME- 6070-PS-65021 TATA CONSULTING ENGINEERS LIMITED | REV. Po PURCHASE SPECIFICATION FOR REACTORS —_| SHEET 30 of MECHANICAL DESIGN BASIS TCE.12215B-ME-6700-BS-85001 DESIGN CRITERIA (CIVIL AND STRUCTURAL) TCE, 12215A-CV-3000-DC-30004 INSTRUMENT DESIGN BASIS. TCE,12215B-IC-2070-BS-45001 ELECTRICAL DESIGN BASIS TCE,12215B-EL-4035-BS-55001 VENDOR DATA REQUIREMENT & ‘SCHEDULE TCE, 12215B-ME-XXXX-VD-XXXXX FILE NAME: TCE.12215B-ME-6070-PS-85021 TCE FORM NO. 120 R3