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1
TECHNICAL SPECIFICATIONS
AUTOCLAVE DOOR WITH FLANGE AND SUSPENSION SYSTEM FOR
MARK II AUTOCLAVE
(Autoclave shell is not in the scope of supply. )
As per the enclosed drawings (Mark II-Door-000-001- 5 sheets)
1. SCOPE OF WORK :
The total job shall be handled by the supplier on a turnkey basis. Further, the job
shall be carried out under the supervision of NAL approved Third Party Inspection
Agecny..
Major tasks involved are as follows :
a) Preparation of manufacturing drawings, design calculations based on the NAL
supplied drawings and calculations.
b) Getting approval of drawings and design from Third Party.
c) Fabrication of torispherical dish door with lock ring flange
d) Inspection, testing, marking and supply of records as per IS-2825/ASME,
Sec.VIII, Div., 1 under the supervision of third party inspection agency and in
accordance with the “Factory acceptance tests ”
e) Transporting of Door to NAL, Bangalore
1. Integrating the fabricated door with the NAL supplied Crab and Autoclave shell
along with supporting structure.
2. Installation, integration and commissioning of the whole system at NAL.
3. Since Hydrostatic test cannot be carried out, a Pneumatic test has to be conducted
as per the code at NAL after commissioning. The required pressure and gauges
for the test will be provided by NAL.
3. MAJOR COMPONENTS OF AUTOCLAVE DOOR :
A) Torispherical dished door with lock ring flange.
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B) Door suspension system
4. BRIEF DESCRIPTION OF MAJOR COMPONENTS :
A. AUTOCLAVE DOOR:
Specifications:
a) Design code: The autoclave Door is designed, fabricated, tested and certified in
accordance with Indian standard code for unfired pressure vessel IS 2825.
1969/ ASME Sec VIII Div. I Edd 2004+ Add 2005 and will be certified by
third party inspection agency. The design and drawings will be provided by
NAL.
b) Working temperature : 250 º C
c) Working pressure : 7 barg approx. 7.14 kg/cm2 g
d) Design pressure : 7.854 kg/cm2 g
e) Design temperature : 250 º C
f) Internal dia. of the door : 2960 mm
g) Length of the cylindrical shell : 1500 mm
h) Thickness of the shell : 20 mm
i) Corrosion allowance : 1.5 mm (included in shell thickness)
j) Class of vessel : Class I
k) Material of shell & dishes : 5A 516 Gr.70
l) Pnuematic test pressure : 1.25 x design pressure
= 9. kgs/cm2 g
m) Internal volume : 17 m3 (approx.)
n) Empty weight : 6.5 tons (approx.)
Note: All the nozzles should be supplied with blind flanges duly fixed with necessary
gaskets and bolts.
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B. DOOR DISH :
It is deep dished and flanged (torispherical) dish with 16% knuckle radius as per IS 4049
Part (11) – 1979.
Specification:
Internal diameter: 2960 mm
Dish thickness: 25mm
Thinning allowance: 3 mm (included in dish thickness)
Corrosion allowance: 1.5mm (included in dish thickness)
Tolerance on out side circumference: ± 6mm (as per IS 4049 Port II – 1979 table 5)
Notes: i)The whole assembly has to be stress relieved..
ii) The difference between the maximum and minimum inside diameters of the
Straight flange shall not exceed one percent of the nominal diameter.
iii) Sharp grooves, lamination and other surface cracks shall be completely
removed by the grinding.
1) The flange shall be fabricated by cold / hot rolling or seamless forging.
The welded ring should be stress relieved before machining. It has to be
normalized subsequent to hot rolling or during the last process of hot
rolling. It is uniformly heated to temperature within the normalizing range.
Test coupons should be taken and tested for mechanical properties.
2. Minimum No. of weld joints should be used and in no case, the joints shall be
more than three.
3. The lock ring flange has to be machined precisely as per the drawing, as it has to
align with shell lock ring flange. Any variation in circularity, teeth dimensions
and teeth pitch will seriously affect the lock ring operation and it may not be
possible to lock the door at all.
4. The door lock ring has 24 teeth cut equally on the circumference of the lock ring.
This lock ring is stationary
iii) Door Suspension System: The door is suspended using fork screw supported
on thrust bearing with knuckle joint. This has to be integrated with crab and
supporting structure supplied by NAL.
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Note: The RF pad and Knuckle joint has to be welded on to the shell after checking
the alignment with the Autoclave shell at NAL.
J. DESIGN AND DRAWINGS :
NAL will provide the design calculations and drawings.
K. MATERIALS :
The material for all the pressure holding components of autoclave shall be SA 516, Gr.
70. The material for door flange is SA 105.
. Pipe / Nozzle necks shall be in general carbon steel confirming to 5A53/SA 106.
Forgings for flanges, etc. shall confirm to SA 105. Bolting material for pressure
connections such as blind flanges etc., shall be of SA 193. Gr. B7 bolt and SA 194 Gr.
2H for nut.
Note: All the materials used in the Autoclave shell, should have valid material test
certificate. No material should be used without the test certificate. All these test
certificates should be submitted to NAL.
L. FABRICATION :
The vessel fabricated under these specifications shall be fusion welded using the metallic
arc process. All the welding qualifications, manufacture and workmanship shall be
in accordance with the general requirements of section II - Fabrication and welding
of IS 2825-1969/ ASME Sec VIII Div. I Edd 2004+ Add 2005. All the inspection,
testing, marking and records should be carried out as per section III of IS 2825 –
1969 /ASME Sec VIII Div. I Edd 2004+ Add 2005.
The plate edges shall be scarfed by any method that will produce a reasonably smooth
surface suitable for welding. Drags, tears, accumulations of slag, excessive roughness
and dirt shall be removed. Vessel shall be designed using largest sheet courses consistent
with optimum economics based on amount of welding. The weld joints shall be so
located as to clear openings and shall be as per code. All attachments, nozzle pipes,
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nozzle flanges, reinforcing pads, gaskets, fasteners, accessories shall be as per the
requirement and shall be provided by the supplier. All the flange openings, threaded
nozzles should be supplied with suitable blank flanges and plugs with necessary gasket
and bolting.
Dimensions of nozzles flanges shall be as per ASME B 16.5 unless otherwise stated.
All temporary attachments made to the shell to facilitate erection shall be removed and
any noticeable projections of weld metal shall be chopped from plate. The plates must
not be gauged or storm in the process of removing the attachments. No hole shall be
made in the shell plate for erection purposes.
Post weld heat treatment shall be carried out as per the code requirement.
J. INSTALLATION , INTEGRATION AND COMMISSIONING :
. The required material handling equipment, tools, shackles, unloading from the trailer
and mounting in the pit is supplier’s responsibility. The supplier is responsible for any
damage during transportation, installation and commissioning.
K. INSPECTION AND TESTING :
The third party inspection agency shall be the prime inspection agency for the job. In
addition, NAL representatives will also carry out period inspection / review. All the
inspection and testing shall be carried out in accordance with code requirements.
The supplier shall prepare a “Quality plan” indicating the inspection stages and category
of inspection such as HP (Hold point – means no further work can proceed until
acceptance is given by inspection agency), WP (witness point – means notification to
Inspection Agency. Work can proceed to the next stage if inspection agency not present)
and RD (Review of Documents – means review of inspection related documents by
inspection Agency). The supplier shall prepare quality records for all the stages of
inspection. The quality plan shall be approved by inspection agency and NAL. Approval
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of the inspection agency shall not relieve the supplier of his responsibilities for
mechanical manufacturing, workman ship, guarantee and proper execution of work.
Welding procedure qualification and qualification of welders shall be carried out as per
IS 2825-1969 (Indian Standard Code for unfired pressure vessels) Section II. The
supplier shall make his own arrangements of such tests at his own cost in the presence of
clients / inspecting agency. No welding shall be permitted without approval of welding
procedure and welders qualification test by the inspecting agency.
Radiographic examination of welds and repairs of welds of required places shall be
carried out as per code and applicable appendix. Liquid penetrant test wherever required
shall be carried out as per code.
All welding and inspection should be accessible to inspector for examination. For this
purpose, the supplier shall agree with the inspector, the procedure and make available all
devices necessary for proper examination. The supplier shall supply all equipments,
blind flanges, fasteners and gaskets required for testing / hydro testing.
No cracks should be present on the autoclave shell or at the welding zones. An
examination for cracks will be performed by NAL before accepting the autoclave and the
autoclave supplier shall be responsible for all repairs during the warranty period.
L. PAINTING :
The painting of vessel shall be carried out after inspection, and examination for cracks.
All surfaces to be painted shall have surface preparation to clean out oil, grease, weld
sediments and rust. Thereafter, the interior of the shell, door should be sand blasted to a
white metal finish and painted with two coats of inorganic zinc chromate primer. This
shall be followed by two topcoats of high temperature aluminium paint of reputed make
(Suitable for 350 Deg C). Both paints shall be suitable for the elevated temperatures of
the shell. Application of paints shall be in accordance with the paint manufacturer’s
recommendations.
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The external surface of the vessel shall also be given same treatment. The exterior of the
shell and dishes should also be sand blasted to a white metal finish after cleaning out oil,
grease and rust. The prepared surface should be given with two coats of inorganic zinc
chromate primer of reputed make. No painting is required on the external surface of the
shell.
-o0o-
TERMS AND CONDITIONS
1) DOCUMENTS, MANUALS, DRAWINGS AND INSPECTION REPORTS
The supplier shall submit 3 copies each of fabrication drawings, test certificates of
materials, inspection reports, manufacturer’s test records certified by approved inspection
agency and 3 sets of “As built” drawings for the vessel and other accessories if any.
NAL is an ISO 9001- 2000 certified organisation and therefore it is mandatory that all
documents shall confirm to ISO standards.
2) WARRANTY
The equipment supplied by the supplier (including bought out items) must be guaranteed
for raw materials and workmanship for a period of 18 months after being put in
operation at NAL and accepted by NAL. The firm has to submit the 10% of the order
value as a performance Bank guarantee for the guarantee period.
During the warranty period, all the defective parts should be replaced by the contractor to
NAL’s satisfaction, free of cost.
3. DELIVERY
The delivery period is 4 months from the date of purchase order. The firm has to include
time schedule bar chart clearly indicating the various events such as.
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4) QUALITY & WORKMANSHIP
The quality and workmanship shall comply with the specifications in all respects and to
the satisfaction of NAL. The firm should get the autoclave shell certified by approved
inspection agency.
5) DESIGN MODIFICATIONS, IMPROVEMENTS
NAL reserves the right to change the design at any stage of fabrication of autoclave shell.
But these changes will not be on over all dimensions of the shell. Generally changes may
be of minor in nature and to meet any assembly problems if it occurs. The supplier
should not modify any approved drawing without written permission from NAL.
6) SECURITY OF TECHNICAL DATA
All the technical specifications, drawings supplied by NAL is proprietary drawings of
NAL should be kept confidential. These documents should not be distributed. No
copies or excerpts should be made without the prior written consent of NAL.
7) PACKING, SHIPPING AND OFF – LOADING AT SITE
The contractor shall at his own expenses arrange for the system to be crated suitably
depending on the mode of transport.
The system shall be carefully and securely packed so as best to avoid damage during
transit. All the cases should contain packing slips detailing the contents.
. The off loading of equipment at NAL, and positioning at the final place of
commissioning is the responsibility of the supplier.
8) INSURANCE
The supplier shall arrange the insurance for loading, transit, off-loading, storage, erection
and commissioning in respect of the equipment to cover all risks up to the commissioning
stage. In the event of any damage (or) loss of equipment or spares, the supplier shall take
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appropriate action to replace or repair such equipment / spares and lodge their claim on
the insurance company.
9) LIQUIDATED DAMAGES
Time is of essence of this contract and this work has to be executed on a turn-key basis
and completed in all respect including commissioning within a stipulated time. In the
even of delay in the scheduled commissioning date, the liquidated damages will be
recovered as per the rules in force.
BRIEF OUTLINE OF ACCEPTANCE TESTS
1) NAL approved third party inspection agency shall be the inspecting agency for
the job at the manufacturer’s works.
2) All the fabrication work carried out at manufacturer’s works shall be inspected by
the inspecting agency as per the approved quality plan to meet the requirements of
IS 2825/ASME, Sec VIII, Div.1 code for unfired pressure vessels
3) Pneumatic testing has to be conducted at NAL as hydro testing cannot be carried
out. .
4) Sand blasting and painting as per the specification.