QUALITY DEPARTMENT Amendment to Quality Work Instructions meant for SQP for Tubular Air pre heater SQP APH 104 Rev 01 DT 2701 03 Amendment A1 DT 04 02 08 SQP for Tubular Air pre heater Clause Amended as Basis for Number and Amendment reference. Note Calculate percentage of tube thickness using the clause 4,9 | following formula: - Dh-d Based on feed % age of expansion K=1- 4-- X 100 _ | back from Qc Dh = Tube sheet hole ID in mm |. d= ID of the expanded tube in mm T= Thickness of tube in mm K = %age of tube thinning ye Wo Prepared by Reviewed & approved by( ( STANDARD QUALITY PLAN. Ha [gous rams Doc. No SGP APH TO M/S BHEL / BAP / RANIPET Tubular Air pre heater — | £ev.Ne. on Ronipet | TAMIL NADU-632 405 Date Boe ~ Page No ororos no | Component & | Characteristics Type Guaniom of] Reference Formal] Aganey ] Remar operation 3 oF Check | Documents of ° 0 Check 3 $ Records [ME 4 8 1.0 | MATERIAL * 1.1 | Plates, Sheets, Chemisiy, | Chemical Each | Respective Material Spec. tp |v Tubes, Tensile Tensile test Heat Properties 2.0 | In-process control 21 | wetcing Welders are to be qual 1&Procedures are pre qualified. 2.1.1 | Weld Quality wi 10% | ASPERASMESEC vinDIVI | NOT Repot |p |v 3.0 | Tube Sheet | Dimensional Measurement 100% Drawing/ Ref note 1.0, 2.0 Records |p | w | preparation check 3.1 | Tube Block Assy. | Dimensional | Measurement | 100% Drawing/ Ref note 3 Records |p | w | (skeleton) check 4.0 Tube Expansion | 4.1 | Mock up testfor | Soundness jammer test 100% Refer Nole 4.0 Records |p | w | |tube expansion | Expansion 8493 TEGENDS: Prepared by Axe Je ‘APPROVED BY M~ Manufacturer (BHEL Shop / Subcontractor, } | Reviewed b 8 = BHEL QC/ Authorised Inspection agency Reviewed by | GA! 3. Guminnuft Lif, . P ~ Perfomed By, V_- Verification Of Reporis/Records f+ W -Witness TC -Test Cerlificate R- repor ge BLpoe (Head/@a) Record of reviion Rev No Date Changes made 00 270108, The requirements of QCP A018 and PRA 415 are merged and this SGP is formed. MASTER COPY || STANDARD QUALITY PLAN ta aeree URER'SINAMER TTENA/SUB SYSTEM: Doe. No, SQPAPH 104 M/S BHEL / BAP / RANIPET Tubular Air pre heater — [Rev.Ne ot Roripet | TAMIL. NADU-632 406 Date Boros Page No ozor0s Jno | Component & | Charactenstes Tye Guanfom of | Reference ‘Accepiance | Formal | Agency | Reman 1 ‘operation 3 oF Check Documents Norms ° 9 10 2 Check 5 6 7 Records | |B 4 3 T 4.2. | Tube Expansion | Soundness of Hammer 100% Drawing /Ref Note 49.38.50 | Records | P| Ww In actual Expansion test 5.0 | Finol Inspection | Over Ai | Measurement | 100% Drawing/ Note 60 or je lw Dimension 51 | Painting and | Proper Visual 100% | Ref PRQAS=ORevOO BNoleso | - | Pw Preservation _| Preservation Note : For Notes referred in column 6 & 7 ,refer the page No 03 ,04, 05 of SQPaa 12 13 2.0 24 2.2 2.3 2.4 3.0 3a 3.2 33 34 35 Tube Plate preparation page no 03 of 05 Plates are to be sheared or gas cut . The gas cut edges shall be free from cutting notches and finish should be of 50 microns The tolerance on length and width shall be +1 mm. the diagonals shall be within 2 mm The square ness shall be maintained precisely. Minimum two perpendicular sides shall be taken for tube hole marking reference. ‘The stock preparation shall be as per the drawing subject to coaxial drilling of top, middle and bottom plate together for the same block with match marks. Match marking shall be carried out. Both top, middle and bottom plates have to be marked for Identification: Marking for dri Drilling shall be done ona batch of plates diagonal and it should be within 1 mm. Dri drilling, a stack. Mark the holes as per the drawing. Check the extreme holes for the the stack with proper support. Check the stack with water level of Imm before The tolerance for the holes shall be as per the drawing and finish shall be 12.5 microns. The pitch variations shall be within 1 mm subject to a cumulative variation of 2 mm maximum, Dismantle the stack. De burr the holes. Check the hole sizes using ‘Go’ and ‘No Go’ plug gauges which should be checked and approved by BHEL inspector. Tube Block Skeleton Assembly Layout the plates for bottom, middle (where applicable) and top assembly as per the drawing separately as given in the assembly drawing Identify the top, middle and end plates with proper match mark. Check the diagonals the variation shall not be more than 3 mm. Fit the tube plates and lifting eye pieces as per the drawing. For proper matching of the plate use eye piece by welding on to the plates at two or three places and using bolts and nuts for fastening. And Weld the lifting lug. Conduct root LPI and final MPI and then paint as per PRQA 590/LATEST. Do the skeleton assembly with the stay tubes and tack weld, Ensure the tube projection from tube plate as per drawing. Check water level & Plumb out with reference to the extreme row of hole & also at edge of the plate and Correct Within 1 mm Mark the water level reference & Plumb out with metal punch and bordered with paint.3.6 a7 38 3.9 4.0 4a 4.2 43 44 45 4.6 47 48 Page no 04 of 05 Check the top diagonals X1,X2 and front and back diagonals F1, F2 & B1, B2 respectively and side diagonals SD1, SD2, SD3 and SD4 . Record the diagonal dimensions on the history card .The tolerance on diagonal shall be 3 mm. Weld all stay tubes as per drawing. Dismantle the skeleton from trial assembly if weight of each block with all tubes inserted weights more than 25 MT. Inspect the tubes for defects such as rust, pitting, bends. The tubes shall be applied with rust preventive oil before inserting it into the holes. Insert the good ones in the tube holes and also ensure the tube length tolerance with in 2mm before tube Insertion. Mock Up test for tube Expansion The mock up for the tube expansion shall be carried out in the presence of QC personnel separately. Expand both ends of the tubes into the tube sheet using an Electronically torque controlled tube expander ensuring the projection of the tubes as per drawing. Prepare a tube plate cut bit of size approximately 300 x 300 mm and thickness equivalent to that of actual Tubular air pre heater. Drill holes of size covering the min and max _ limits of tolerance and in between size chosen suitably. The max number of holes drilled can be restricted to 8. Mark the holes as A,B,C, etc., as per the details of TAPH drawing. Also mark the corresponding tubes to be inserted as a,b,c etc., Measures the internal dia and pitch of these holes and record. Select a tube with max and min sizes (thickness) meant for the actual job and cut it to 8 pieces each measuring not less than 250 mm. Measure tube OD/ID and thickness and record. Set the electronic tube expander to minimum current for tube expansion. Insert tube in hole A, Expand the ID using electronic tube expander. Electronic tube expander should break on reaching the preset torque and should not break on preset timer. Note current setting and ID of tube after expansion. Perform Hammer test by giving a blow using a half pound hammer at free end of the expanded tube. There should not be any shake/displacement of tube. Perform kerosene leak test and confirm that it does not leak from one side to other side of tube plate through the area between tube plate hole and tube OD.Page no 05 of 05 4.9 Calculate percentage of tube thickness using the following formula: Dh-o % age of Expansion(k) = | ——— -1 | x100 2t ‘Tube sheet hole 1D in mm 10 of the expanded tube Thickness of tube in mm %age of tube thinning Aqa9 4.9.1 Repeat 4.5 to 4.9 for different current setting to ensure kerosene leak test and hammer test for tube holes 8 to H. 4.9.2 Record the values as follows:~ Hole Current | Tube sheet] Tube Tube Tube ID] Tube ID after | %age of No. setting Hole 1D oD | Thickness before expansion thinning Dh) (e) expansion id () 4.9.3 Choose the current setting, which gives a thinning Sage within 8% for the actual tube thickness, And In any case tube expansion beyond the tube sheet thickness Is not acceptable. 4.9.4 Complete the expansion of tubes in each split block and offer for inspection. 5.0 Hammer Test 5.1 Check the tube expansion at both free ends by y Hammer test. With half pound hammer, check for any shaking of tubes. If the joint fal to meet hammer test, repeat the expansion up until it passes hammer test. 5.2 After two or three expansions if still hammer test fai subject to a maximum of two percent of the tubes per 5.3 Weld the expansion piece and do kerosene leak test for the joint especially in the corners. 5.4 Fix the side walls and weld as given in the drawing 6.0 Final inspection Check overall dimension and water level & Plumb out with reference to the alread) 1 ly marked reference and record the readings 2 Ensure the match mark by punching and bordering with yellow paint.