5001/E-1/P-II/5.2.

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PROJECTS & DEVELOPMENT INDIA LTD DOCUMENT NO REV
SHEET 1 OF 61

PART II: TECHNICAL

SECTION – 5.2.1

DESIGN PHILOSOPHY – STATIC EQUIPMENT

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CONTENTS

SL.NO. DESCRIPTION SHEET NO.

1.0 General 3
2.0 Equipment Design Basis 17
3.0 Technical Requirements 25
4.0 Spare Parts 52
5.0 Documentation Schedule 52
6.0 Vendor List 53

LIST OF ATTACHMENTS

ATTACHMENT
DESCRIPTION NUMBER OF SHEETS
NUMBER
Guidelines For Dynamic Wind
Annexure - 1 1
Analysis
Annexure - 2 Inspection (Guidelines) 4

Painting Specification (Static

Annexure - 3 1
Equipment)

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1.0 GENERAL

1.1 SCOPE

1.1.1 This document defines the design philosophy to be applied to the design of various types of
static equipment i.e. Pressure Vessels, Heat Exchangers, Power and Waste heat Boilers,
Storage Tanks, and Vessel Internals e.t.c for Ammonia Urea Fertilizer Project for the M/s
Hindustan Urvarak and Rasayan Limited.

1.1.2 The complete design, material of construction/fabrication (shop/site as applicable),

inspection, testing, painting, supply, transportation and erection of equipment etc. at project
site shall conform to the specifications, drawings and internationally accepted codes /
standards duly accepted by the Owner. In addition, all statutory rules & regulations shall also
be complied with.

1.2 CODES AND STANDARDS

1.2.1 The equipment shall be designed & constructed as per the latest edition of the following
codes and standards:

Code** Description
ASME Section VIII Div 1 & 2 Rules for construction of Unfired Pressure Vessels
Standards of Tubular Exchangers Manufacturer's
TEMA ‘R’ / API 660
Association / For Shell & Tube Heat Exchanger
Heat Exchanger Institute standards for steam surface
HEI
condensers and steam jet ejectors
API 661 Air Cooled Heat Exchangers
API 662 Plate type Heat Exchangers
Rules for Construction of Power Boiler & Indian Boiler
ASME Section 1 & IBR
regulations
Design & Construction of Large, Welded, Low-pressure
API 620
Storage Tank
API 625 Tank Systems For Refrigerated Liquefied Gas Storage
API 650 Welded Steel Tanks for Oil Storage
API RP 2000 Venting Atmospheric and Low pressure storage Tanks
API 2550 Method for measurement and calibration of upright

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cylindrical Tanks
Steels for Hydrogen Service at Elevated Temperature &
API 941
Pressure
Metallic gaskets for raised face pipe flanges & flanged
API 605
Connections(Double jacketed corrugated & Spiral wound)
ASME Section II A&B/ ASTM Materials Specifications
ASME Section II PART C Specification for welding rod, electrode & filler metal
ASME SEC II PART D Properties
ASME Section V Non-destructive Examination
ASME Section IX Welding Qualification
PTC 4.1 ASME Power test code
EJMA * Standard of Expansion Joint Manufacturers Association
NACE National Association of Corrosion Engineers
ASME B 16.5 For flanges
ASME B 16.47 For large diameter flanges
ASME B 16.20 For gaskets
ANSI Pipes, Flanges, Fittings and Valves
IS: 875/SITE DATA For wind load consideration
IS: 1893 (Part 4):2005 / SITE For seismic design consideration
DATA
BSCP 3005 Insulation

BS 4994 Design & Construction of vessel & Tanks in Reinforced

Plastics
IS:4682 (Part-1) with Code of Practice for Rubber Lining of Vessels & Equipment
Amendment No. 3 for Chemical Process
Factory Act, 1948 BS CP Factory Act & State Govt factory rules Code of Practice on
3003 (Part 1) lining of Vessels and equipment for Chemical Process.

*- Except for heat exchangers, while for heat exchangers the expansion bellows shall be
designed as per TEMA standard.

NOTES:

1. LSTK Contractor may select DIN, BS or any other well known international materials as
substituted materials to ASTM/ASME ones, if they are equivalent or superior to ASTM /

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ASME ones. The chemical & mechanical properties of such equivalent or superior offered
materials preferably comparison w.r.t. ASTM materials shall be furnished along the bid.
LSTK Contractor shall also submit the references of past supplies of similar type of
equipment w.r.t. the proposed materials offered by them in their bid.

2. Process licensors guidelines / standards may be adopted complying minimum

requirements of this design philosophy of static equipment. Details of such selected
guidelines/standards along with the list shall be furnished in the bid.

3. Specifications of all critical equipments including those specified by the process licensor
shall be furnished in the technical bid.

**Any conflicts between documents, including regulations and codes, shall be brought to
the Purchaser’s attention for resolution.

1.3 REGULATIONS

Besides codes & standards, LSTK Contractor shall follow National Laws and Regulations
such as Indian Boiler Regulation and Department of Explosives, Nagpur, India together with
Local by Laws for the state including statutory requirements as applicable. Static and Mobile
Pressure Vessel (SMPV) rules as applicable shall also be complied with.

PUBLICATIONS:

NACE MR 0103 Materials Resistant to Sulfide Stress Cracking in Corrosive

Petroleum Refining Environments

NACE MR 0175 / ISO Petroleum and natural gas industries - Materials for use in H2S
15156 containing environments in oil and gas production

NACE RP 0296 Guidelines for Detection, Repair and Mitigation of Cracking of

Existing Petroleum Refinery Pressure Vessels in Wet H2S
Environment

NACE TM 0284 Evaluation of Pipeline and Pressure Vessel Steel for Resistance to
Hydrogen Induced Cracking

NACE TM 0177 Laboratory Testing of Metals for Resistance to Sulphide Stress

Cracking in Hydrogen Sulphide Environment

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WRC Bulletin # 107 Local Stresses in Spherical & Cylindrical Shells due to External
Loadings.

WRC Bulletin # 297 Local Stresses in Cylindrical Shells due to External Loadings on
Nozzles

1.4 SITE CONDITIONS

1.4.1 Climatic and other site conditions as defined elsewhere.

1.5 OPERATING DUTY

1.5.1 Service shall be twenty-four (24) hours per day, seven (7) days per week, and fifty-two (52)
weeks per year. The equipment design life shall be 25 years.

1.6 DESIGN DOCUMENTATION

1.6.1 Detailed design calculations considering different loadings shall be made as per
code/standards and the additional requirements as mentioned below:-

1.6.2 Design of equipment inside the Ammonia, Urea & offsite plant complex shall be in
accordance with the process licensor’s data sheets and specifications.

1.6.3 LSTK Contractor shall consider the interfaces with other engineering disciplines w.r.t.

- Piping Layout/Location Drawings

- Civil / Structural Drawings
- P & ID’s
- Materials
- 3D PDS Model for Piping and Equipment Layout
- Hazardous Area Classification

1.6.4 Design philosophy of other disciplines shall be observed and shall be relevant to the extent
applicable.

- Civil/Structural Design Criteria

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- Piping Design Criteria

- Process Design Criteria
- Electrical and Instrumentation Design Criteria

1.7 SAFETY

1.7.1 Safety standards and features which are inherent in the specific mechanical equipment
design codes, standards and regulations are applicable to this criterion. Job Hazard and
Operability [HAZOP] as per ISO-18001 & Factory Act shall be done during design stage the
equipment.

1.7.2 Safety features to be incorporated into the design include, but are not limited to, the following
features for equipment:

- Ladder cages
- Safety chain across platform access
- Step-off platforms with Hand Railing where necessary
- Platform grating with adequate thickness
- Toe plates

1.8 EQUIPMENT FABRICATION

1.8.1 Equipment design shall be based on maximizing shop fabrication and assembly where
deemed practical. Fabrication in open yard shall be avoided.

1.8.2 The LSTK Contractor shall comply in all respects with the provision of the applicable codes /
standards and specification during fabrication. For equipment fabricated in multi-wall /
multilayer construction, special fabrication requirements as per ASME Sec-VIII Div.2 Article
6.8 shall be complied with.

1.8.3 Impact test, when required as per code and specifications, shall be carried out on parent
metal, weld and HAZ.

1.8.4 Production Control coupons, when required as per code and specifications, shall be
subjected to all tests like impact, inter granular corrosion test etc., in addition to mechanical

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test as required. In case of heat treated equipment test coupons shall be given similar heat
treatment as for the equipment.

1.8.5 Due provisions must be kept for venting out entrapped gases during welding of pads, flanges
and liner plates etc.

1.8.6 In case of equipment involving site assembly/fabrication the entire site job including loading
& unloading at site, fabrication, radiography, heat treatment, Inspection & testing etc. shall be
included in the scope of supply.

1.8.7 All nozzle connections up to DN 10” size shall be made of seamless pipes. For sizes above
DN 10” nozzles connection may be rolled from plates with full radiography of welds.

1.8.8 No welding, hammering or deforming is permitted on the pressure retaining parts after post
weld heat treatment except as permitted by the codes or standards and when approved by
the purchaser.

1.8.9 Flange facing and thread connection shall be protected against oxidation during HT.

1.8.10 All welding shall be done by metal arc welding. For welding on thinner gauge sheets TIG
welding is preferred.

1.8.11 Gas or Carbon arc welding shall not be used.

1.8.12 Welding electrodes of composition similar to Internals material shall be used except austenitic
electrodes of higher chromium and nickel content such as AWS A5.4, ASME SFA 5.4 class
E309 and E310 may be used for 12-Cr stainless steel. For dissimilar material welding,
electrode composition shall be similar to nobler material being welded. Following electrodes
shall be used unless specified otherwise:

E 7018 for all CS materials

E 308 for all SS 304 to SS 304

E 308L for all SS 304L to SS 304L

E 309 MoL For SS 410S to SS 410S, SS to CS, SS 410S to SS 304, 304L,

316, 316L

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E 316 For all SS 316

E 316L For all SS 316L

E Ni – Cu7 For Monel to Monel and Monel to CS/SS

1.8.13 Welding wherever specified, is to be done by qualified and approved welders using the
suitable fillers and fluxes recommended for the materials in the fabrication drawings. For
welding the stud on tray decks and support beams, use of stud welding gun with suitable flux
is acceptable. In manually welding of studs, care should be taken to minimize the weld
spatter and the outside diameter of the weld so that it should not foul with tray deck or
washer. For stud welding, proper welding procedure shall be established. Torque required for
welding failure shall be higher than the torque required for failure of the stud.

1.8.14 A proposed Welding Procedure Specification (WPS) shall be submitted to approved

inspection agency for approval. On approval, a Procedure Qualification Test (PQT) shall be
conducted which shall be witnessed by approved inspection agency. On acceptance of all
tests as per ASME Section IX, a final WPS along with Procedure Qualification Record (PQR)
shall be submitted. Production welding shall start only after approval of final WPS/PQR and
qualification of welders as per ASME Section IX, approved inspection agency may accept
previously qualified WPS/PQR at his sole discretion.

1.8.15 Longitudinal and circumferential welded seams shall not interfere with nozzle openings,
reinforcement plates, saddle pads, and other attachments as far as possible.

1.8.16 MISCELLANEOUS

1.8.16.1 All parts fabricated shall be smooth, true, clean and free from burrs, grease and dents.
Openings for passage of workman must have exposed edges rounded.

1.8.16.2 All support rings, bolting bars, beams support brackets and other components which are
integral and therefore welded to the column shell inside, shall be supplied and installed by
column fabricator.

1.8.16.3 Total draw-off trays shall be designed for zero leakage construction and may be seal welded
(if required) at site to attain zero leakage.

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1.8.16.4 Seal welds shall have a throat thickness at least equal to the specified Corrosion allowance.

1.8.16.5 All stainless steel tray assemblies/internals and their components (e.g. Bubble caps, valves
etc.) shall be pickled and Passivated. Pickling and Passivation shall be as per ASTM 380.

1.8.16.6 All parts shall be fabricated in accordance with good shop practice and in uniformity so that
all corresponding parts will be inter-changeable.

1.9 CONSTRUCTION & ERECTION

1.9.1 LSTK Contractor shall follow standard established procedures for handling storage,
construction & erection. LSTK Contractor shall strictly follow Manufacturer’s/Principal’s
instructions, approved drawings and procedures for construction & erection and satisfy
Principal in all respects of storage, handling, construction & erection of Package. All erection
work shall conform to the working/erection drawings (to be prepared by LSTK Contractor) and
shall be in conformity with codes & standards as applicable. The LSTK Contractor shall
supply & arrange all necessary construction & erection tools and tackles, machinery,
scaffolding etc.

1.9.2 LSTK Contractor shall perform the following:

i) Before installing the equipment, the foundations shall be checked and wherever
necessary, chipping shall be done by the LSTK Contractor. All grouting materials,
packing plates/wedges required for the levelling and alignment of equipment,
structures & pipelines etc. shall be provided.

ii) Top of the foundations shall be thoroughly cleaned to the satisfaction of Principal /
LSTK Contractor before placing base plates.

iii) All equipment & structure etc. shall be checked and inspected for its proper levelling
and granting (grouting) shall be done with suitable grouting material as required.

iv) After tightening the foundation bolts, the final level / alignment shall be rechecked and
redone, if required.

v) Installation of all supports and hangers, including concreting or welding as necessary.

vi) To check correctness of the piping, instruments and other connecting points in the
equipment and piping installed.

vii) The welding joints shall be stress relieved wherever necessary as per applicable codes,
standards & specifications .

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1.9.3 The following shall be arranged and supplied by LSTK Contractor for completion of job. Any
other item whatsoever required shall also be included by LSTK Contractor in their scope.

i) All construction & erection materials, equipment & machinery, scaffolding, consumable,
and test equipment etc.
ii) Cranes/Hydra, temporary lifting beams and spreaders etc.
iii) Procedures for site assembly, construction & erection including lifting methodology for
Owner/Third party approval.

1.9.4 As a minimum contractor shall comply the requirements indicated below:

i) Fabricate, erect and align the equipment & internals as per applicable codes, standards
& specifications. All internals shall be inspected before and after installation.
ii) Carry out all NDT’s required. The Personnel performing NDT’s should have a
minimum qualification as “NDT LEVEL-II” in the relevant Technique, certified by
American Society for Non-destructive Testing.
iii) Perform non-operating field pressure tests and leak tests on field fabricated equipment
in accordance with the applicable codes, standards and specifications, ensuring
disposal of test media in accordance with instruction/recommendations.
iv) Notify Owner / Third party of the test schedules for witness the tests by concerned
inspector.

1.10 MATERIAL OF CONSTRUCTION

The minimum requirement of the materials shall be as per the plant equipment metallurgy
covered under specific process design guidelines. However superior materials as per the
recommendation of Process Licensor’s may be selected which shall be indicated in the Bid by
the LSTK Contractor.

1.10.1 All materials, whatsoever, required to complete the supplies shall be procured by LSTK
Contractor and all such materials shall be covered with due identifiable material test
certificate.

1.10.2 Materials used in low temperature service shall be impact tested (charpy V) if required as per
design code & specification. Impact test & energy value shall be in accordance with code
requirement, unless specified otherwise.

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1.10.3 For coarse grained & high tensile materials in carbon steels ( UTS>45 Kg/mm2) & low alloy
steel, guaranteed impact strength shall be ensured at a temperature 15 0C below envisaged
hydraulic test temperature as a precaution against brittle fracture during hydraulic test.

1.10.4 HEAT TREATMENT

Heat treatment of formed parts shall be carried out as per following:

For Carbon Steel:

a. Cold formed dished ends or knuckles upto 16 mm nominal thickness shall be stress relieved.
b. Cold formed dished ends or knuckles above 16 mm nominal thickness shall be normalised.
c. For Low alloy Steel: - Cold Formed Dish ends or Knuckles shall be stress relieved.
d. Hot formed dished ends or similar parts, which have not been uniformly heated in the
normalising range in the final stages of manufacture shall be normalised.
e. When the completed vessel involves post weld heat treatment, heat treatment
recommended in (a) above shall not be applicable.
f. Vessels in caustic service, Amine or Sour gas service shall be stress relieved.
g. All internal and external attachments, clips, insulation studs, name plate bracket, and the
like Shall be welded to the vessel before post weld heat treatment.

1.10.5 All CS & LAS materials including forging used for pressure parts shall be procured in fully
killed and normalized condition. CS & LAS materials above 50 mm thickness shall be vacuum
degassed except for plate ring flanges.

1.10.6 All SS plates shall be hot rolled & solution annealed and pickled as per SA 480.

1.10.7 All plates above 50 mm thickness shall be examined by UT as per ASTM-A435 at mills for
both at surface & edges.

1.10.8 Cladded plates shall be supplied as per ASTM A264 material specification. All clad plate shall
be UT examined at the steel works in accordance with ASTM A578 level S8.

1.10.9 The minimum thickness of weld overlay material shall be 1/8 inch (3 mm) except clad or weld
overlay tube sheets and gasket surfaces.

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1.10.10 Tube sheets shall have a nominal clad or weld overlay thickness of 3/8 inch (10 mm) but not
less than5/16 inches (8 mm) regardless of shell side or tube side face. The minimum
thickness of clad or weld overlay at a pass partition groove shall be 1/8 inch (3 mm) minimum.

1.10.11 Weld overlayed nozzle and girth flange gasket faces shall have a minimum thickness of 3/16
inch (4.8 mm) after machining.

1.10.12 All forgings except for flanges as per ANSI shall be UT tested as per ASTM A 388 for the
thickness greater than 100mm and shall be procured in normalized / annealed condition.
Acceptance standards shall be as per AM 203.2 of ASME Section VIII Div. 2. In case any
defect is found, no repair by welding shall be allowed.

1.10.13 All forgings including nozzle flanges shall be examined for surface defects by MP/PT testing
after machining as per ASTM A 275.

1.10.14 Tube sheet and Girth flanges must be made in one piece. Segmental butt-weld construction
shall not be accepted.

1.10.15 Unless more restrictive prescription given by material specification the max. Content for
carbon steel used for fabrication as shown by ladle analysis shall be 0.23% for plates, pipes
& tubes 0.25% for forging.

1.10.16 In order to minimise the effect of temper embrittlement for material to 2¼ Cr 1 Mo

specifications in the temperature range of 375-575oC, the embrittlement factors 'X' & 'J' shall
be limited to:

X = (10P + 5Sb + 4Sn + AS) / 100 ≤ 15

The elements above are expressed as ppm

J = (Si + Mn) (P + Sn) x 104 <160

The elements above are expressed as percentages

A stimulated PWHT followed by step cooling shall be performed on a sample of material.

Acceptable toughness shall be demonstrated by means of a Charpy V Impact Test.

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1.10.17 Unless otherwise specified Copper & Copper alloys shall not be used. Copper content up to
0.4% are acceptable in carbon steel & 0.6% in stainless steel.

1.10.18 Top portion of skirt (min. 500 mm height) welded to the bottom dished head shall be of same
material as that of shell /head for LAS & SS materials.

1.10.19 All directly welded external/internal attachments shall be of same materials as that of
equipment, unless specified otherwise.

1.10.20 Unless otherwise specified, all internal parts shall be removal type. Internal shall be designed
in units as large as can be installed through the nearest upper manhole or opening. The
weight of unit shall not generally exceed 40 Kg. except for support beams.

Trays, distributors, baffles and support beams shall be designed in such a way that
deformation of shell due to operating pressure and thermal expansion does not occur.
.
Bolts and nuts for fixing internals shall be 18/8 S.S and minimum size of bolts shall be M10.
All internal bolts shall be provided with locking nuts

1.10.21 External parts which are not strength welded to the shell, such as clips for insulation support
rings, may be of carbon steel, provided if SS 304 stainless steel pads are furnished between
shell & external parts.

1.10.22 PWHT of complete vessel shall be carried out in one go in a furnace. Local stress relieving of
weld joint in piece meal shall be avoided as far as possible.

1.10.23 For SS 316 & 316L , SS316L Mod (Urea Grade) materials and for other specialised urea grade
materials, the requirements of ferrite content and Intergrannular corrosion test, shall have to
be complied with in conformity with Process Licensor’s standard. The inter granular corrosion
test shall be carried on SS316 L mod (Urea Grade) materials for other specialised urea grade
materials , weld & HAZ as per ASTM A 262 practice C & While for SS316L material ASTM A
262 practice E shall be applicable. The corrosion rate shall be as per the recommendations of
Process Licensor.

1.10.24 For SS 316 & 316L material Ferrite content for plate, pipe, tubes and forging shall be max.
2%. However for SS 316L Urea grade and for other specialised urea grade materials, ferrite

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content shall be max. 0.6%.

1.10.25 In case of equipment fabricated of materials of SS316L for urea service, low ferrite filler
material shall be so selected that ferrite content in two subsequent pass in contact with
process fuel shall be max. 2% and for equipment fabricated of material SS316L urea grade,
the limitation of ferrite content shall be 1%. The welding not in contact with process fluid may
have ferrite content limited to 6%.

1.10.26 Steel for Hydrogen service at elevated Temperature & pressure shall be selected as per API
941 & API 934 .The following special requirements shall be met with for Hydrogen/Sour gas
as per NACE standard.

a) All pressure parts shall be post weld heat treated.

b) All pressure retaining welds shall be 100% radiographed. (Root run & Final
Weld radiography is must)
c) Hardness of base metals, weld and HAZ shall not exceed 22 HRC.

1.10.27 For high pressure equipments, in shell & heads, the impurity limit shall be Copper ≤ 0.20% &
Nickel ≤ 0.30% for Mo & Cr- Mo low alloy steels while Copper shall be ≤ 0.20% & Vanadium ≤
0.15% for carbon steels.

1.10.28 For equipment designed as per Power Boiler code ASME SECTION I, materials shall strictly
comply with the requirements of the code. All material must be procured from well known
recommended steel makers. All documents & Drawings shall be approved by IBR.

1.10.29 Girth flanges must be made in one piece. Segmental butt-weld construction shall not be
accepted.

1.10.30 a) Gaskets for all medium with flange rating ≤ 600 # shall be SS spiral wound type with
external & internal guide rings shall be used unless otherwise specified. CAF gaskets are
not acceptable.

b) Gaskets used for high pressure shall be of the following type:

- Ring Joint
- Double conical with graphite tape

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- Diaphragm gasket
- Lip seal Gasket

1.10.31 Unless otherwise stated gaskets used during testing shall be same as specified for operating
conditions. After testing, gaskets used during testing shall be replaced by new gaskets.

1.10.32 Inter granular corrosion test shall be carried out on all SS 316 L materials, weld & HAZ as
Per ASTM A 262 practice E (Strauss test) unless otherwise specified in specification

1.10.33 For equipment designed as per IBR, materials shall strictly comply with the requirement of
the IBR code.

1.10.34 Hydro testing of equipment shall be as per UG-99b. Design pressure for each nozzle shall be
sum of maximum allowable working pressure and static head of corresponding nozzles.

1.10.35 All directly welded external/internal attachments shall be of same materials as that
equipment, unless specified otherwise.

1.11 QUALITY ASSURANCE & CONTROL

1.11.1 The quality assurance shall be as per the approved procedures, test methods & facilities to
be developed by the LSTK Contractor to ensure that the supplied equipment shall be of
highest quality. The quality control shall mean that all the tests , measurements, checks &
calibration which are to be carried out may be compared with the actual specified
characteristics of the equipments/unit /system.

1.11.2 Quality Assurance (QA) shall mean the organizational set up, procedures as well as test
methods and facilities developed by LSTK Contractor in order to assure that Equipment
leaving LSTK Contractor’s shop are of the highest possible quality i.e. either equal to or better
than the requirement specified.

1.11.3 Quality Control (QC), shall mean all the tests, measurement, checks and calibration which are
to be carried out in LSTK Contractor’s shop in order to compare the actual characteristics of
the equipment/unit/system with the specified ones, along with furnishing of the relevant
documentation (certificates/records) containing the data or result of these activities.

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1.11.4 LSTK Contractor shall submit a comprehensive description (manual) of QA/QC measures
contemplated by him for implementation with regard to this specification. It is contractual
obligation of the LSTK Contractor to develop and implement adequate QA/QC systems.

1.11.5 QA/QC system shall cover all products and services required for the equipment as per scope
of work including job sub contracted by the LSTK Contractor.

2.0 EQUIPMENT DESIGN BASIS

2.1 GENERAL

2.1.1 Design conditions for all equipment shall be in accordance with the Process Licensor’s data
sheets/specifications. However, in any case design pressure shall not be lower than 10%
over the maximum anticipated operating pressure and design temperature should be 25°C
higher than the maximum anticipated operating temperature for all equipment unless
otherwise specified.

2.1.2 Design pressure is normally specified at the top of vertical vessel or at the highest point of
horizontal vessel. The design pressure at any lower point shall be determined by adding the
maximum operating liquid head and any pressure gradient within the vessel.

2.1.3 Wind forces shall be increased by 20% to cater for the effect of piping system, platforms and
ladders etc. Vertical vessels with height/diameter ratio equal to or greater than 10 shall be
analyzed for vibration due to vortex shedding when critical wind speed does not exceed
30m/s. For guidelines of Dynamic Wind Analysis refer Annexure-I.

2.1.4 Forces and moments acting on nozzles shall be considered in the equipment design. The
exact forces & moments shall be indicated after piping layout which shall be considered by
equipment supplier with out any commercial implication to Owner.

2.1.5 All Carbon Steel (CS) and Low-Alloy Steel (LAS) pressure parts shall have 3 mm corrosion
allowance unless specified otherwise. All internal CS & LAS parts shall have at least 1.5 mm
Corrosion Allowance on either side. No corrosion allowance shall be considered for SS. In
general, the recommendation of Process Licensor shall be adopted for construction.

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2.1.6 Design of supports and anchor bolts considering soil and importance factors shall be
performed for compressive and tensile loading. In no case shall diameter of anchor bolts be
less than M24 for skirt support and M16 for other type of support.

2.1.7 Lifting lug, lifting trunion, tailing lug etc. shall be designed with shock factor 2.

2.1.8 Bolt of size M 48 and above shall be designed and spaced so as to permit tightening with a
hydraulic stud-tensioner. The bolts shall have an extra threaded length at one end of
approximately 1 bolt diameter, and shall be provided with threaded projection caps. Hex nuts
shall have suitable holes for manual tightening. The requisite no. of hydraulic stud-tensioner
device with necessary adopters/insertions based on varying sizes of studs shall be supplied
by LSTK Contractor as per mechanical design of the equipment.

2.1.9 When design pressure is more than 600# class and/or shell thickness is 50 mm and above,
selfreinforced forged nozzle shall be provided. Nozzle size ≥ 3” NPS Shell to SR nozzle
welding shall be set-in type welding.

2.10 In case of nozzle with butt-end construction, extra length shall be provided to facilitate
hydraulic testing and subsequently cutting and edge preparation to suit piping welding at site.

2.11 Orientation of longitudinal seams and position of circumferential seams shall be clearly marked
in the fabrication drawing. Nozzles, support and other attachments shall be located clear of
welded joints.

2.12 LSTK Contractor shall mark tangent lines, the position of the main axis and the center of
gravity for orientation in a clearly identifiable and permanent way on the vessel. Centre of
gravity shall be clearly marked.

2.2 INSPECTION AND TESTING

2.2.1 Equipment shall be inspected by TPIA. The Inspection and testing shall be in accordance
with the relevant codes, standards, specifications, including mandatory NDT requirements
indicated under Inspection and Testing clause 2.2.3 & Inspection guidelines (Annexure-2).
All equipment & bought -out items shall be inspected during various stages of manufacturing
starting from identification of materials to final completion as per agreed QAP which shall be
prepared by LSTK Contractor and shall duly approved by Owner/ It’s authorised

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representative. In case of site fabricated/assembled equipment same inspection agency shall

be responsible for inspection and testing at site. The guidelines for minimum inspection
requirements are listed in Annexure-2 & also defined under Inspection & Testing clause of
the design philosophy.

2.2.2 All testing accessories, measuring instruments including NDT testing equipment, etc. shall be
arranged by LSTK Contractor.

2.2.3 The following NDT requirements are mandatory in addition to code /spec requirements:

a) UT examination:

i) All butt-welds in thickness greater than 50mm as supplement to radiography.

ii) FPW of nozzle attachments of thk. above 50mm as supplement to radiography
iii) Clad Plates and formed heads from clad plates in all thicknesses

b) MP/PT examination

i) All edges of plates and opening in shell of CS having thk. above 40mm and
LAS/SS having thk. More than 25mm
ii) Root and final layer of all butt welds
iii) Fillet welds of 3.5% Ni & SS
iv) Each layer of weld deposit in SS overlay
v) Knuckle surfaces of dished ends, expansion bellows and pipe bends

c) Radiography:

i) All weld seams of formed head, if made in more than one segment shall be fully
Radiographed after forming.
ii) All the welded T- Joints shall be fully radiographed.
iii) When spot radiography is specified all T-joints & min. 10% of total weld length
excluding T-joints shall be radiographed
iv) Radiography of welds in C- 1/2 Mo & Cr- Mo - Steel preferably is carried out after
heat treatment

d) Hardness test on welds of Cr-Mo, Materials after final heat treatment. The value shall not

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exceed to:

i) 215 HB for steel having Cr content less than 2%

ii) 240 HB for steel having Cr content more than 2%

2.2.4. Following are mandatory requirements in addition to codes/standards for Ammonia

Storage Tank

A) Radiography:

i) All L-seams welds shall be 100% Radiographed

ii) Circumferential welds of bottom most two courses shall be 100% Radiographed &
remaining C-seam shall be 15% radiographed.
iii) All Butt-weld joints shall be 100% radiographed.
iv) All Butt-weld joints of internal nozzles in vapour zone shall be 100% radiographed
v) All remaining ‘T’ joints shall be 100% radiographed
vi) Dish end caps for inner & outer shall manholes

B) Magnetic Particle Examination:

Before hydro testing: -

i) Weld joint between shell & annular plate

ii) Final layer of all Butt-welds
iii) All lap joints of bottom & roof plates
iv) All welds on connections/attachment after stress relieving, if any
v) All Butt-weld joint which are not Radio graphed shall be examined inside & outside

After Hydro testing:

i) Annular plate to shell

ii) L-seam of bottom most two courses
iii) Compression plate to roof plate
iv) All joints of annular plate bottom

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C) DP Examination:

i) After back gauging of root run

ii) All lap joints of bottom & roof plates
iii) Rafter splice joint

D) Bottom & Annular plate joints shall be vacuum box tested.

2.2.5 Additional Inspection requirement for pearlite concrete of Ammonia storage tank

The pearlite concrete ring shall be casted & cured at a facility to be created at site by LSTK
Contractor. In order to achieve the desired properties blocks of suitable product mix shall be
designed. While casting the pearlite concrete blocks in-situ, samples are drawn from each
batch before commencement of work & shall be subjects to the following tests:

i) Dimensional Inspection
ii) Visual Inspection
iii) Moisture Content
iv) Compressive Strength
v) Density
vi) Thermal Conductivity

The most suitable mix shall be selected for casting the pearlite concrete after examining the
test results which shall be subjected to approval by Principal/ Concerned inspection agency.

2.2.6. All completed equipment shall be tested hydraulically as per the requirements of
Specification/codes in presence of the inspecting authority. Pneumatic test of completed
Equipment shall be carried out only when specially mentioned in the specification sheets.
Chloride content in water used for testing shall not exceed 30 ppm for SS equipment and 40
ppm for CS and low alloy steel equipment. Duration of test shall be 1 hour minimum. After
hydro testing stainless steel vessels shall be dried thoroughly immediately after draining to
prevent the possibility of evaporation & concentration of chlorides

2.2.7 All process equipments shall be supplied with Nitrogen filled. In case of equipment
assembled and welded at site, it shall be filled with N2 after testing at site. Dry Nitrogen shall

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be filled at a pressure of 0.5 Kg/cm2g and equipment shall be fitted with a pressure gauge
and valve along with nitrogen cylinder.

2.2.8 Special tools/tackles as recommended by equipment manufacturer shall be included in the

scope of contractor. Hydraulic bolt tensioners where specifically recommended by Process
Licenser’s specification shall be supplied with 4 bolt tightening heads.

2.2.9 Equipment under preview of statutory bodies shall be inspected during various stages of
fabrication by their authorised inspecting agency. It is the responsibility of the LSTK
Contractor to get the design calculations and fabrication drgs. approved by concerned
statutory bodies before commencing fabrication.

2.2.10 All raw materials shall be inspected at source and test certificates to enable proper
identification shall be submitted.

2.2.11 Unless otherwise stated gasket during testing shall be same as specified for operating
conditions. After testing, gaskets used during testing shall be replaced by new gaskets.

2.2.12 After hydrostatic testing, the tightness of lining welds shall be tested by helium. The sensitivity
of leak detection shall be as per ASME SEC V.

2.3 PAINTING

2.3.1 All external surfaces of shop fabricated equipment shall be painted in the vendor’s shop. For
guidelines of painting refer Annexure-3.

2.4 PICKLING AND PASSIVATION

All SS material shall be Pickled & Passivated as per following procedures:

2.4.1 PICKLING

Aqueous pickling solution shall be as follows:

Nitric acid (Tech grade)-10 to 25% plus Hydrofluoric acid-1 to 8% (to be used only for
stabilized SS grades). Temperature 50 to 60° C for 10% Nitric acid and 20° C for 25% Nitric
acid. When size and shape of product permit, total immersion in the pickling solution is

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preferred. Where immersion is impractical, pickling may be accomplished by wetting the

surface by

i) Swabbing or spraying

ii) Partial filling the item with pickling solution and rotating or rocking so that the entire
surfaces receive the required chemical treatment.

The maximum period for which the pickling solution shall be allowed to remain on the surface
is 30 minute. During pickling removal of oxides may be hastened by brushing with a hard fiber
or SS wire brush. Over pickling shall be avoided.

The pickling agent shall be washed off with plenty of water so as to leave no trace behind.

2.4.2 PASSIVATION

After pickling and water rinsing, an aqueous caustic permanganate solution containing NaOH
10 weight % and KMnO4 4 weight % shall be used for neutralizing pickling solution. This shall
be followed by thorough water rinsing.

Water used for pickling and washing shall not have chloride contents exceeding 30 ppm.

2.5 FIRE PROOFING

2.5.1 Fire proofing, if required shall be considered as per Process Licensor’s recommendations.

2.6 INSULATION

2.6.1 The equipment shall be insulated as defined in Piping Design philosophy.

2.7 OPERABILITY AND MAINTENANCE

2.7.1 Equipment design and layout shall provide for ease of access, operability and maintenance.

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2.8 DESPATCH

2.8.1 Equipment intended for ship transportation shall be transported in the hatch of the ship.
Suitable seaworthy packing/painting shall be applied to avoid any damage during
transportation.

2.8.2 The complete transport, packing & forwarding of equipment shall be the responsibility of
bidder. In case of inland transportation, equipment shall be properly lashed/fixed on the
wagon/trailer to avoid any damage due to shocks during transport. In case of ODC (Over
Dimensional Consignment) movement, ODC sanction for movement either by rail/road shall be
arranged by bidder from appropriate authorities.

2.8.3 All spares shall be properly packed, marked & sent separately along with equipment.

2.8.4 Equipment shall be despatched with nitrogen filling. Dry nitrogen shall be filled at a pressure of
0.5 kg/cm2g and equipment shall be filled with a pressure gauge and a valve along with
nitrogen cylinder.

2.9 GUARANTEES

2.9.1 MECHANICAL GUARANTEE

LSTK Contractor shall guarantee the equipment & their components against faulty design with
regard to their mechanical adequacy, improper material of construction & poor workmanship
for the period specified in contract.

2.9.2 PERFORMANCE GUARANTEE

LSTK Contractor shall stand Guarantee of equipment as per respective technical

specifications/Process Data sheets.

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3.0 TECHNICAL REQUIREMENTS

PART A - DESIGN PHILOSOPHY FOR PRESSURE VESSEL

3.1 GENERAL

SCOPE

This specification covers the minimum requirements for the design, materials, fabrication, and
inspection of welded pressure vessels which are defined in U-l of ASME Code Section VIII,
Division 1 Latest Edition and Addenda.

3.2 REGULATIONS, CODES AND STANDARDS

3.2.1 Unless otherwise specified, the design, materials, fabrication and inspection of welded
pressure vessels shall comply with ASME Code Section VIII, Division 1 latest edition.

Process licensors guidelines/standards may be adopted complying minimum requirements of

this design philosophy of static equipment. Details of such selected guidelines/standards along
with the list shall be furnished in the bid.
Unless specifically required, ASME Code stamp is not required.

Vessels will be sized according to inside diameter and 2:1 elliptical heads or hemispherical
heads. Minimum inside diameter shall be 500 mm. Top cover shall be flanged if the ID is equal
or less than 900 mm.

3.2.2 Vessels shall conform to the requirements of ASME Section VIII Division 1 & 2 Pressure Vessels
codes and Technical Specifications mentioned in the design criterion.

3.2.3 Design of vessel skirt shall be based on seismic/wind/thermal considerations and

fireproofing/insulation requirements.

3.3 ALLOWABLE STRESS

3.3.1 Vessel stresses during hydrostatic tests shall not exceed 90% of the minimum yield strength of
the material.

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3.3.2 Vessels to be hydrostatically shop tested in the horizontal position shall be supported
adequately to keep local stresses in the shell not exceeding 90% of the yield strength of the
material.

3.4 CORROSION ALLOWANCE

3.4.1 For an intermediate head, corrosion allowances shall be added to both sides.

3.4.2 For the inside of shells, heads, nozzles and manholes, the specified corrosion allowances shall
be added.

3.4.3 For non removable internal parts, the specified corrosion allowances shall be added to both
sides.

3.4.4 For removable internal parts, the specified corrosion allowances shall be added to one side
only.

3.5.1 HEAD / DISHED ENDS

a) Dished ends shall be of seamless construction. However, dished ends with one chordal weld
seam are acceptable. In such cases, the chordal seam shall preferably be in the middle one
third of the blank. Intermediate heat treatment, if considered necessary, shall be carried out
by the LSTK Contractor.
b) Whenever a dished end is made of more than two plates, it must have a crown plate.
Whenever a nozzle or a manhole is positioned at the centre of the dished end, the crown
plate should be larger than the nozzle /manhole reinforcing pad.
c) Tori spherical heads shall be used for Pressures up to 6.86 bar (g). For tori spherical heads,
ratio of Knuckle to Inside Crown Radius shall not be less than 6 %.
d) Beyond 6.86 bar g, heads shall be of ellipsoidal type having a ratio of major axis to minor axis
2:1 or hemispherical type. Alternatively, Hemispherical Heads with minimum weld joints may
also be used.

3.6 Vessel skirts for carbon steel vessels shall be designed from the same material as the shell
or the head. Vessel skirts for other than carbon steel vessels shall be the same material as
the shell or the head for the top 500mm. All skirt supported equipment shall be provided with

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templates.

3.7 All nozzles above 24” NB shall comply with ASME B16.47 Series B (API 605).

3.8 Local vessel stress calculations for external structural attachments, such as platform clips,
pipe support clips and lifting lugs shall be performed.

3.9 Vessels with skirts having eight or more anchor bolts shall be required to be supplied with an
anchor bolt template. The template shall be of box type (no annulus type) to avoid problem
during final erection and installation. The template shall have adequate strength against
deformation.

3.10 Design of supports and anchor bolts considering soil & importance factors shall be performed
for compressive & tensile loading. In no case, diameter of anchor bolts shall be less than M24
for skirt support & M16 for other type of support.

3.11 The lifting lug, lifting trunion, tailing lug etc. shall be designed with shock factor 2.

3.12 Maximum permissible deflection for tall vessels/columns when subjected to design wind
loadings shall not exceed 0.005 x Vessel height. For guidelines of Dynamic Wind Analysis
refer Annexure-I.

3.13 For vessels, the minimum thickness of shell & heads, including corrosion allowance shall be
as indicated below:

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S. No. Shell Diameter (mm) Thickness (Min.) mm

CS / LAS HAS

1 ID < 500 5 3

2 501 < ID < 1200 5 4

3 1201 < ID <2000 6 5

4 2001 < ID < 2600 8 6

5 ID > 2600 10 8

CS = Carbon Steel
LAS = Low-Alloy Steel
HAS = High-Alloy Steel

3.14 Vessel man-ways shall be shown on the data sheets. Minimum man-way size shall be equal
to 24” nominal pipe size.

3.15 Horizontal vessels of large size and thin wall shell on saddle supports shall be investigated
for buckling, local circumferential bending and shear stress. The method of L. P. Zick
(Supplement to Welding Research, 1971) may be used for this investigation.

3.16 Manhole/hand hole/blind holes covers shall be equipped with davits or hinges to facilitate
handling.

3.17 Manhole size of 24” is preferred. However, for shell dia. 1000 mm & above minimum size of
manhole shall be 20" and for shell dia. 1000 mm & below 18" manhole size shall be minimum.

3.18 Use of structural steel shall be limited to non-pressure parts only.

3.19 Unless otherwise specified all C.S and low alloy steel materials including forging used for
pressure parts shall be fully killed and in normalised condition.

3.20 INTERNALS

3.20.1 For Tray design worst of the following conditions shall be considered:

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a) For tray design minimum loads of 100 kg/m2 in active areas and 320 kg/m2 in down
comer area shall be considered.
b) For atmospheric, pre flash & vacuum distillation columns for trays under flash area
uniform load of 500 kg/m2 shall be considered. This loading shall be applicable to first
three trays above flash section.
c) A concentrated live load of 150 kg at any point on the installed assembly
independent of other design live loads.
d) Maximum horizontal deflection at effective tray loading shall not exceed 1/900 of the span
or 7 mm. whichever is less.
e) Corrosion allowance shall be added to both sides of trays, support rings and other fixed
internal non pressure parts.

3.20.2 All internal bolting shall be of corrosion resistant material.

3.20.3 Support for packing and internal shall be designed for the worst condition. In the condition of
packing liquid hold up of minimum 20% of packing volume shall be considered. Tray support
beams shall have height not exceeding 20% of distance between trays for diameter up to
2400 mm and 15% of the distance between trays for higher diameters.

3.20.4 Each tray shall be so designed as to ensure liquid tight construction. Each tray shall be
provided with a man-way suitable for opening both from top and bottom unless otherwise
specified.

3.20.5 MINIMUM THICKNESS OF INTERNALS SHALL BE AS FOLLOWS:

S. No. Parts CS & LAS HAS

(MM) (MM)
1. Chimney tray 10 6
2. Tray decks partition, down comers, weirs pans 3.5 2.0
etc.
3. Tray support rings & bolting bars 6.0 6.0
4. Bubble caps 3.5 1.5
5. Valves for trays 1.5 1.5
6. Non-integral main & secondary supporting beams 5.0 2.0

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Note: - 1) All bolting size shall be minimum of M10. All nuts shall be hexagonal.
2) The min. thickness of Urea Trays shall be as per the recommendation of Process
Licensor.
3) Allowable stress criterion for design of internals shall be as per ASME Section
VIII Div. 1

3.20.6 All necessary approval on Hydraulic design and internal drawings shall also to be obtained
from Process Licenser as applicable.

3.20.7 All removable internals shall be designed so that they can pass through the vessel man-way
internal diameter / shell flange if any.

3.20.8 The LSTK Contractor shall meet the process and hydrodynamic guarantee of towers along with
their internals. All instruments including of special instruments required to verify the above
requirements shall be arranged by the LSTK Contractor.

3.20.9 For an intermediate head, corrosion allowances shall be added to both sides.

3.20.10 Internal distribution pipes shall have flanged connections with gaskets unless otherwise
specified. Internal pipes shall be divided into suitable lengths to pass freely through the
vessel manholes and internal man ways, and shall be suitably supported from shells or tray
decks.

3.20.11 Demisters shall be securely fastened to support ring by bolting or clamping.

3.20.12 Internals (trays, distributors, support beams) shall be so designed that any expansion of it
wouldn’t affect shell deformation.

3.20.13 Hiccups load in vapour flow up the column shall be taken into account in the tray design.

3.21 CLADDING AND LINING

3.21.1 Cladding & lining is not allowed. If it is allowed in special case after taking permission of
OWNER than Integrally clad metal and weld overlays shall not be considered as contributing to
the strength of the vessel wall thickness of the Equipment. It should not be considered in the
minimum thickness calculation.

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3.21.2 Strip liners shall not be used in vessel shell for hydrogen service.

3.21.3 Cladded plates shall be supplied as per ASTM A 264 material specification. All clad plate shall
be UT examined at the steel works in accordance with ASTM A 578 level S8.

3.22 ACCESSORIES

3.22.1 Clips for platforms, ladders and piping supports shall be furnished and attached to the vessel by
the vessel manufacturer.

3.22.2 Top davits of vertical vessels shall be so designed and fabricated so that heavy valves around
the vessels and internal parts of vessels can be removed and grounded without being
interrupted by piping and steel structures.

3.22.3 INSULATION SUPPORT RINGS

1) Insulation support rings shall be suitable provided as per the specified insulation thickness.
2) Maximum longitudinal interval of insulation support rings shall be 3600 mm when preformed
insulating material are used.
3) Stiffening rings may be used as insulation support rings.

3.22.4 Lifting lugs of appropriate size shall be provided to ensure complete safety during erection of
the Vessel.

3.22.5 Grounding lugs shall be attached to the vessel support for the ground connection.

3.22.6 TEMPLATES

1) Templates for vertical vessels with skirts shall be provided for lying out of anchor bolts at
site. The template shall have adequate strength against deformation. Template shall be
identical to the Vessel Base Frame having double ring.
2) It shall be confirmed that markings of the bolt hole orientation on the templates coincides
With those shown on the approved drawings.

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3.23 PLATE LAYOUT

1) Shell plate shall be laid out so that there will be minimum of welded seams.
2) Longitudinal and circumferential welded seams shall not interfere with nozzle openings,
reinforcement plates, saddle pads, and other attachments as far as possible
3) Longitudinal welded seams on adjacent shell segments shall be separated by at least 4
times the wall thickness of the thicker plate but not less than 100 mm.

3.24 CONNECTIONS

3.24.1 Unless shown in data sheets, nozzles, manholes, and hand holes shall be ground flush and
smooth inside the vessel. The edges of internal projections for both nozzles and manholes
shall be rounded to a radius of 2 mm minimum. Reinforcement pads shall be external.

3.24.2 Main vessel seams shall not pass through openings for connections as far as possible. When
unavoidable, the portion of the weld seam covered by a reinforcing pad shall be ground flush
with the parent metal and 100% radio graphed prior to attachment of the pad.

3.24.3 All reinforcing pads shall be provided with at least one telltale hole of NPT 1/8".

3.25 HEAT TREATMENT

3.25.1 Fabricated vessels shall be post weld heat treated in accordance with ASME Code Section VIII,
Division 1, and requirements specified in the data sheets.

3.25.2 The complete post weld heat treatment procedure including temperature and holding time shall
be submitted to the purchaser for review.

All machined surfaces shall be protected against scaling during post weld heat treatment.

3.25.3 All internal and external attachments, clips, insulation studs, name plate bracket, and the like
shall be welded to the vessel before post weld heat treatment.

3.25.4 No welding, hammering or deforming is permitted on the pressure retaining parts after post weld
heat treatment except as permitted by the codes or standards and when approved by the
purchaser.

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3.25.5 Simulation Heat Treatment for the Alloy Steel Material shall be carried out as per the CODE
Requirement.

3.25.6 PICKLING
When specified, all internal / external surfaces of stainless steel shall be cleaned by pickling
before hydrostatic test.

1) Care shall be taken so that stainless steel surfaces shall not be subject to any scratch or
damage during pickling.
2) Weld scale and other foreign material deposited on the surfaces shall be removed.
3) Pickled surfaces shall be completely neutralized, and washed by freshwater

3.26 FABRICATION TOLERANCE

Dimensional tolerances shall be in accordance with the design codes or standards, whichever is
more stringent.

3.27 PREPARATION FOR SHIPMENT

3.27.1 All vessels shall be drained, clean, and free of grease, oil, scale, weld spatter, and any other
foreign substance.

3.27.2 All flange faces and other exposed machined surfaces shall be properly protected with
substantial metal shields or covering against damage during shipment.

3.27.3 All inside surfaces and internal parts of carbon steel shall be coated with suitable rust
preventive before shipment.

3.27.4 All openings shall be provided with metal closures.

3.27.5 Test holes of reinforcing pads for nozzles and manholes shall be plugged with steel or plastic
plugs.

3.27.6 Vent holes of saddle pads shall be plugged with plastic sealant or hard grease prior to
shipment.

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3.27.8 All threaded connections shall be plugged with threaded round bars or covered with standard
pipe caps of the same material as the equipment. Covers, flanges, gaskets, bolts, and nuts
furnished by the fabricator shall be shipped in place.

Internals shall be tied or braced as necessary to avoid damage or dislodgment during Shipping
and installation.

Baselines indicating four directions with figures of 0°, 90°, 180" and 270° shall be marked by
paint on the shell. The paint colour shall be white for carbon steel and black for stainless Steel.

PART B - DESIGN PHILOSOPHY FOR HEAT EXCHANGERS

3.28 SHELL AND TUBE HEAT EXCHANGERS

3.28.1. General

a) SCOPE

This specification covers the minimum requirements for the design, materials, fabrication and
Inspection of shell and tube type heat exchangers.

b) The Design Philosophy for the Shell & Tube Heat Exchangers shall be read in conjunction with
the Design Philosophy for Pressure Vessels, as per Part – A above.

3.28.2 All tubular heat exchangers shall be of the type specified and shall be designed for the
service and performance conditions given in the specification or data sheets.

Design of the Shell & Tube Heat Exchangers shall be as per TEMA – R only. (TEMA Class ‘C’
may be used for auxiliary heat exchangers for rotating and packaged equipment exchangers.)

3.28.3 Gaskets for Synthesis Gas, Hydrogen & other lethal services shall be of “LIP SEAL GASKET”
Design unless otherwise specified.

3.28.4 Tubular heat exchangers of auxiliary component for machine units such as lube oil coolers is to
be designed, fabricated, inspected and tested in accordance with the manufacturer's standards
and ASME Code Section VIII, Division 1, provided written approval is obtained from the
purchaser.

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3.28.5 Mean metal temperature of tube & shell be considered in the design of fixed tube sheet
exchangers.

3.28.6 Parts such as tubes, tube sheets, floating heads etc. which simultaneously come in contact with
both shell side and tube side fluids, shall be designed considering pressure acting on one side
only or the combination of pressures, whichever results in higher thickness of parts.

3.28.7 Attachment of tube to tube sheet will be rolled and expanded (with seal welding), strength
welded or seal welded as specified on data sheets. However, as a minimum following shall be
adopted:

For tube sheet joint, tubes shall be expanded in grooved holes into the tube sheets. The
expanding operation shall extend from the outer face of the tube sheets to a depth not < 90% of
the tube sheet thickness. Welding shall be done in minimum two passes and each pass shall
be DP checked. For tube-to-tube sheet joint GTAW (Gas-Tungsten Arc Welding) welding is
required.

(A) Tubes shall be expanded and light seal welded if all the following conditions occur
simultaneously:
a) Design pressure of shell/tube < 20 kg/cm2
b) Shell / Channel design temperature < 350 ºC
c) Fluid not containing lethal substances.
c) Hydrogen partial pressure <7 bars

(B) Tubes shall be strength welded & light expanded for any condition other than listed
under (A).

3.28.8 Procedure shall be qualified for tube-to-tube sheet joints. Mock-up test shall be carried
Out for heat exchangers having shell/tube side design pressure 100 Kg/Cm2 & above to
establish all the requirements.

3.28.9 The sample for tube sheet and tube for mock up test shall be drawn from the same heat
Material from which the equipment shall be fabricated.

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3.28.10 Process Shell and Tube Exchangers will comply with the requirements of ASME SEC VIII Div
I & TEMA Class ‘R’. TEMA Class ‘C’ may be used for auxiliary heat exchangers for rotating
and packaged equipment exchangers.

3.28.11 ASME Section VIII, Div. 1, Appendix “S” shall be considered mandatory for bolted flange
connections.

3.28.12 All tube sheet for the exchangers shall be designed as per ASME Sec VIII Div 1 & also comply
the requirement of section UHX of ASME Code.

3.28.13 Tube sheets in vertical exchangers shall be provided with drain and vent arrangement with
threaded plug seal welded.

3.28.14 Exchanger saddle and foundation design shall include additional loadings generated from
bundle pulling. The load shall be 1.5 times the bundle weight.

3.28.15 Shell side “hot” nozzles shall be located at the top of the shell at the channel end whenever
possible.

3.28.16 Lifting lugs for heads or bonnets shall be specified where frequent dismantling is required.

3.28.17 Bundle weights shall be limited to 10 tonnes. In case the bundle weight increases by 10 Tones,
Bidder shall take care necessary precaution in the design and fabrication of exchanger e.g. by
Providing rollers arrangement, support plates etc. to avoid excessive loading on shell while
Pulling of tube bundle, proper reinforcement in equipment support etc.

3.28.18 Saddle wear plate material shall be the same as the shell material.

3.28.19 Tube sheets and Girth Flanges shall be shall be of Forged Quality & Ultrasonically tested. It
shall not have any segmental joint.

3.28.20 All heat exchanger tubes shall be seamless, cold drawn and formed from single length. CS
tubes shall be normalized. LAS tubes shall be normalized and tempered.

3.28.21 The minimum radius of U tubes shall be not less than 2xOD of tube. Thickness of 2 inner
most rows will be higher than other rows with minimum difference of 2 gauges.

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3.28.22 For U tube bundle, the following requirements shall also be met:

i) Each U tube shall be formed from a single straight length.

ii) All U tubes shall be cold bent.
iii) All C.S, C-Mo, Cr-Mo tubes shall be annealed after bending.
iv) Bent portion of all U tubes shall be examined by PT and hardness check on four
opposite points of bent portion shall be carried out.
v) Unless otherwise specified, after bending each tube shall be tested hydraulically.

3.28.23 Where fixed tube sheet heat exchangers are specified, thermal stress shall be checked in
accordance with the TEMA standard to determine if an expansion joint is necessary.

3.28.24 Tube to tube sheets joints shall be leak tested with air & soap solution at pressure of 2.0
kg/cm2 g wherever specified leak testing with halogen shall be carried out.

3.28.25 Impingement plates shall be provided if required by TEMA or indicated as a part of Licensor’s
requirement.

3.28.26 Impingement baffles shall extend at least 1.1 times of the inside diameter of nozzles, or
nozzle inside diameter plus 50 mm, whichever is the larger.

3.28.27 For stack type of heat exchangers, nozzles shall be designed to carry the loads of shells after
installation in operating conditions. Saddles shall be used for erection purpose only.

3.28.28 For stack type Heat Exchangers, complete assembly shall be hydraulically tested as a single
unit except when the test pressures for individual heat exchangers are different.

3.28.29 Stacked exchangers shall have the lower shell(s) designed to withstand the superimposed
load of the upper exchanger(s) full of water without distorting the shell and causing binding of
tube bundle(s).

3.28.30 The lower fixed support of stacked exchangers shall be designed for bundle pulling loads for
removal of the upper bundle.

3.28.31 When two or more exchangers are stacked, the entire stack shall be shop-assembled and
checked for accuracy of saddle and nozzle fit-up.

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3.28.32 Horizontal exchangers with removable tube bundles shall have the supports designed to
withstand a horizontal pulling load equal to 150% of the bundle weight, applied at the
centerline of the exchanger. The lower supports of stacked exchangers shall be designed for
the loads of removing the upper bundle.

3.28.33 Bolts for connecting nozzles of stacked exchangers shall be removable without moving
exchangers.

3.28.34 Removable tube bundle shall be provided with pulling York and suitable sliding arrangement.

3.28.35 Flow induced vibration analysis shall be carried out for all process heat exchangers.

3.28.36 Process Heat exchangers tubes shall be Eddy current tested at mill and the specified
thickness of tube shall be minimum (and not average).

3.28.37 Floating head exchangers with test ring shall be procured as per TEMA for locating tube leaks.
Drawing and calculations for test rings and test gland shall be provided by vendor for all
Exchangers of applicable type.

3.28.38 Tube sheets shall have the corrosion allowance on each side. Tube Sheets from Plates shall
not be used.

3.28.39 Slip-on flanges are not permitted for exchangers in hydrogen service, lethal service or low-
temperature services below -29°C.

3.28.40 Pass partitions shall be provided with a weep hole of about 6 to 12 mm in diameter at low
points of pass partitions.

3.28.41 Dowels or match marks shall be provided to prevent misassemble of floating head covers and
channels with pass partitions, channel covers with grooves, and stationary tube sheets to shell
flange.

3.28.42 In horizontal exchanger cross baffles and support plates shall be provided with notches for
draining and venting.

3.28.43 Minimum SS 304 as MOC for tubes shall be used for Heat Exchangers having Cooling Water

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All tubes shall be seamless only.

3.28.44 All heat Exchanger Tubes shall be Eddy Current Tested in addition to Hydro testing.

3.28.45 Copper & Copper Alloy tubes shall not be used for any Exchangers
.
3.28.46 Corrosion allowance shall be added to the inside diameter of flanges. Gasket surfaces of flange
Shall have no corrosion allowance.

3.29 EXPANSION JOINTS

3.29.1 Where fixed tube sheet heat exchangers are specified, thermal stress shall be checked in
accordance with the TEMA standard to determine if an expansion joint is necessary.

3.29.2 Expansion joints shall be designed for the most severe conditions of differential expansion that
can occur during normal operations, start up, shutdown, or upset conditions.

3.29.3 Expansion joints shall be of the single layer standard one-piece construction unless otherwise
approved by purchaser. Length of the bellow and preset shall be specified on the
manufacturer's drawings.

3.29.4 For floating head type exchangers with single pass which are provided with bellows, permanent
restraining bars or other means shall be fitted to allow the tube side of the exchanger to be
pressure tested with the shell cover removed.

3.29.5 Expansion bellows shall be designed for min. 5000 cycle, as per TEMA.

3.30 GIRTH FLANGES

3.30.1 All girth flanges joining two parts with different design conditions shall be designed for the
severer condition.

3.30.2 All girth flanges for carbon and low-alloy steel exchangers shall be integrally forged welding
necks, unless otherwise specified in the data sheets. i.e. Girth Flanges shall be WNRF /
WNRTJ type only.

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3.30.3 Lined Flanges shall not be used.

3.30.4 All flanges designed with bolts greater than M 48 & above shall have sufficient clearance to
permit the use of hydraulic bolt tensioning instrument. Bidder has to supply such hydraulic bolt
tensioning instrument along with the supply of exchangers & its spares.

3.30.5 The Contractor shall guarantee tightness compatibility of closure designs. The differential
thermal growth of gasketed joints of dissimilar materials (including gaskets) shall be considered.

3.30.6 All girth flanges shall be provided with jack screws to facilitate dismounting.

3.31 PASS PARTITIONS

3.31.1 All pass partitions shall have a gasket contact surface of 9 mm width minimum, and shall be
machined to a common plane at the gasket face.

3.31.2 The depth of pass partition grooves in tube sheets and flat cover plates shall be a minimum of 5
mm. For alloy cladding or facing, there shall be at least 3 mm of alloy after machining beneath
the pass partition groove or gasket face.

3.31.3 When space permits, pass partitions shall be continuously welded from both sides. In cases
where space is too small for both side welding, weld shall be continuous on one side in so far as
possible.

3.31.4 Pass partitions shall be provided with a weep hole of about 6 to 12 mm in diameter at low points
of pass partitions.

3.32 TEST RINGS

Floating head type heat exchangers as well as U-tube type without full diameter stationary tube
sheets shall be provided with test rings and test gland so that the exchanger shells may be
pressure tested with the channels removed. Drawing and calculations for test rings and test
gland shall be provided by vendor for all exchangers of applicable type.

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3.33 HYDRO TESTING

3.33.1 Each heat exchanger shall be hydro tested in accordance with applicable codes and standards.

3.33.2 The shell side test shall be performed in such a manner that the Tube–to- tubesheet joints can
be adequately inspected during testing.

3.33.3 Hydro Testing sequence & procedure for testing Exchangers having Lip Seal Gasket shall be
approved by the Purchaser.

3.33.4 Stacked units shall be hydraulically tested in the fully assembled condition.

3.33.5 Each heat exchanger shall be air leak tested & helium leak tested at the pressure specified in
the data sheet.

3.33.6 After testing, all exchangers shall be completely dried.

3.33.7 Service bolts shall be used in all shop hydrostatic tests.

3.33.8 Unless otherwise stated gaskets used during testing shall be same as specified for operating
conditions. After testing, gaskets used during testing shall be replaced by new gaskets.

3.34 AIR COOLED HEAT EXCHANGERS

3.34.1 Detailed design calculations of all pressure parts shall be made. Design calculations of air
cooler structure shall be performed by LSTK Contractor considering local wind & seismic
requirements.

3.34.2 Air cooled Heat Exchangers shall have spiralled fins mechanically embedded type (G-type).
L-type fins are not acceptable.

3.34.3 Fans having pneumatic actuator shall be supplied with positioner.

3.34.4 Tube to tube sheet joints shall be seal welded and expanded. Air/soap bubble test shall be
carried out after welding prior to expansion.

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3.34.5 The following painting specifications shall be followed:

a) All surfaces shall be sand blasted to SA 2.5

b) All structure including bundle frame shall be hot dip galvanised in accordance with ASTM
Specification. Refer to API 661.
c) Components like plenum chamber, fan deck/guard fan cylinder etc. shall be zinc sprayed.
Minimum and average thickness of zinc layer shall be 450 & 500 gm/M² respectively.

3.34.6 Air side performance for air flow rate, static pressure drop, power consumption, noise
level etc. shall be guaranteed. All mechanical guarantees as required for complete Air
cooler assembly shall also be met with by LSTK Contractor.

3.35 PLATE TYPE HEAT EXCHANGER

3.35.1 The plate type exchanger shall be designed in accordance with” API 662"

3.35.2 All plates shall be pressed from a homogeneous single metal sheet in one placing and normal
thickness of plate being pressed shall not be less than 0.5 mm

3.35.3 Nozzle neck attachments shall be with full penetration weld. Set on nozzles are not permitted.

3.35.4 Lock washers shall be provided for all rotated nuts.

3.36 WASTE HEAT BOILER

3.36.1 The following as a minimum are included in the scope of work: Material selection, provision of
proper corrosion allowance, all necessary piping, valves, filling and instrumentation etc,
provision of access for maintenance and operation, refractory lining and anchor nuts etc.,
thermal and mechanical design and calculation, stress analysis of piping and pressure parts,
loading data for civil design, engineering for plot plan, equipment layout, P&ID, process flow
diagram, utility and chemical consumption etc., fabrication including forming, welding, heat
treatment, testing etc., transportation, site erection and performance guarantee, over
pressure protection, compliance with regulatory inspection requirements etc.

3.36.2 Material of construction shall be selected by manufacturer considering service conditions

and special conditions with respect to prevention against metal dusting and nitriding.

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3.37.3 In addition to requirements of ASME Sec VIII Div 1 & UHX tube sheet shall be analysed using
finite element analysis method (FEM) along with design calculation and other fabrication
drawings of boiler.

3.37.4 Calculations showing adequacy of tube bundle against flow induced vibration shall be the
responsibility of LSTK Contractor.

3.37.5 Thin stiffened tube sheet design with lip joint between tube to tube sheet is not acceptable.
The weld joint between tube to tube sheet shall be full penetration weld.

3.37.6 IBR Approval for Design Calculations drawings, documents. Testing as per IBR requirements
& Certification shall be in the scope of LSTK Contractor. All vendors, sub-vendors, fabricators
& welders etc should be IBR approved.

3.38 POWER BOILERS

3.38.1 Boilers shall be designed, manufactured and tested in accordance with ASME Sec. I & IBR

3.38.2 All necessary statutory approval shall be under LSTK Contractor’s scope.

3.38.3 The boiler shall be furnished complete with refractory setting and insulation for satisfactory
performance and safety of the personnel.

3.38.4 Quality of refractory material covering furnace floor shall be at least high duty bricks.

3.38.5 Insulation shall be of standard quality suitable for boilers.

3.38.6 Boiler shall be equipped with access doors as required for proper maintenance.

3.38.7 Manufacturer shall provide air sealed observation ports for observing furnace conditions and
burner fire. Observation ports shall be equipped with Pyrex glass.

3.39 STORAGE TANKS

3.39.1 The following design codes shall be adopted for tank design as applicable:

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a) API 620:- Design and Construction of Large Welded Low Pressure Storage Tanks.
b) API 650:- Welded Steel Storage Tanks for Oil Storage.
c) API-625 Tank Systems for Refrigerated Liquefied Gas Storage.

3.39.2 For Storage tanks the minimum thickness shall be based on stability considerations.
Minimum thickness for roof & shell shall be 5 mm, and bottom plate 6 mm, excluding
corrosion allowance.

3.39.3 Storage tanks up to 4meter in diameter shall be shop fabricated items. Tanks with diameters
greater than 4 meter shall be field erected.

3.39.4 Tanks constructed of stainless steel shall comply with API 650, Appendix S.

3.339.5 Shell seams shall be located to clear openings to the maximum extent possible in accordance
with API 650.

3.39.6 Bottom plates may be lap-welded with the lap toward the direction of drainage. Buttwelded
bottom plates shall be furnished when specified on the tank drawings or data sheets or when
tanks are specified to have rubber lining.

3.39.7. For each surface in contact with product/vapor, the specified corrosion allowance shall be
added to the required thickness of all load-carrying components including shell, roof, bottom
and roof supports. & One-half the specified corrosion allowance shall be added to each
surface of nonload-carrying internal components.

3.39.8. All walkways, stairways, and platforms shall be furnished with handrails on open or exposed
sides.

3.39.9 Tanks having design temperature more than 100 ºC shall have thermal isolation barrier
(Suitable fire bricks) between tank bottom and foundation.

3.39.10 Anchor bolts shall be provided based on design considering wind/seismic loads, uplift due
to internal pressure etc. However, tanks having diameter ≤10 meter shall be provided with
anchor Bolts and shall be spaced at approximately 1.8M of circumference.

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3.39.11 Maximum height of unstiffened shell shall be calculated based on the corroded thicknesses
of shell courses. Section modulus of wind girders shall also based on corroded thickness of
shell courses.

3.39.12 All storage tanks shall be designed as per code considering liquid height up to top curb
angle of shell.

3.40 Double Wall Ammonia Storage Tanks

For ammonia tanks below are the design codes/standards shall be followed as minimum in
their latest edition:

a) API 620
b) API-625
c) EJMA
d) ASME B16.5/B.16.47 , as applicable
e) EEMUA publication 147
f) Statutory regulations
g) Other referred codes

3.40.1 General

LSTK Contractor shall carry out the following

a) Mechanical design Calculations showing adequacy (for all components:

Shell/bottom/roof/nozzles/ Anchor straps e.t.c for both inner & outer tanks) of ammonia
Storage tanks for all the Design condition Including wind/ seismic, residual design e.t.c.

b) Strength calculation for bottom insulation system.

c) Design calculation for Expansion bellows ( for nozzles on Inner tank & coming out outer
Tank)

d) The design of the tanks shall be in accordance with API 620 (including appendix R) /API
625 and the requirements specified here in. Minimum required thicknesses of various
components shall be calculated based on design parameters considering different types
of loadings conditions including effect of wind pressure, force of moment owing to

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connected piping & other attachments as platform etc. Ammonia Storage Tank shall also
be designed for hydrostatic condition. Final thickness of tank shall be decided giving due
consideration for corrosion allowance & thinning allowance.

e) All parent material (Primary & Secondary Components), weld and HAZ shall be Impact
tested at Minimum Design Metal Temperature (i.e. minimum service temperature or the
temperature to be computed as per applicable codes standards & specifications) by
LSTK Bidder and shall have impact energy values as per the applicable codes, standards
& specifications.

3.40.2 Tanks shall be designed for the following conditions in accordance with API 620.
i. Erection condition.
ii. Erection condition with combined loading (Wind/Seismic)
iii. Normal operation with 20% safety valve accumulation.
iv. Normal operation with combined loading (Wind / Seismic)-inner tank filled with
Product, outer tank empty.
v. Normal operation with combined loading (Wind / Seismic)-inner tank failure i.e.
both tank filled with product
vi. Hydrotest conditions with combined loading (Wind / Seismic)-outer tank empty.
vii. Hydrotest conditions with combined loading (Wind / Seismic)-both tank filled with
test Water.

3.40.3 Mill under - tolerance shall be added in calculated thickness.

3.40.4 Tank shall be design checked in new as well as in corroded condition also.

3.40.5 In case of double wall or double integrity tanks, a common base plate carrying both Shells
should not be used.

3.40.6 Statutory approval from any authority as per statutory rules and regulation of state/ central
government shall be LSTK contractor’s responsibility. The application on behalf of Owner for
submission to relevant authorities along with copies of required certificates complete in all
respect shall be prepared by LSTK contractor well ahead of time so that the actual construction/
commissioning of work is not delayed for want of approval/ inspection by concerned authorities.

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3.40.7 All insulation shall be designed as per the applicable codes & standards taking into account the
wind velocity, rainfall as per project site condition. The thickness of the insulation shall be
sufficient to prevent condensation and ice formation on the surface of insulation. The insulation
material shall have fire retardant properties. Polyurethane insulation (cast in-situ) required for
outer tank shell must be capable to withstand wind loads and disbanding forces considering
project site.

3.40.8 All workmen working at unsafe elevation during the insulation work shall have safe and
adequate passage & should be properly instructed to take the necessary precautions &
Observe the safe practices to prevent accidental fall. Safety belt shall be used wherever
Necessary

3.40.9 Passage nozzles in roof shall have pipe caps end (as end closures). Flat closure shall not be
Accepted.

3.40.10 A concentrated live load of 150 kgs located at any position of the suspended deck shall be
Considered in suspended deck.

3.40.11 Nozzle on suspended deck through dome roof shall be provided with sleeve pipes (of sufficient
Size) and to be insulated properly.

3.40.12 Material requirement

a) All materials, whatsoever, required to complete the supplies shall be procured by the supplier
and all such materials shall be covered with due identifiable material test certificates.

b) Unless otherwise specified all C.S and low alloy steel materials including forging used for
pressure parts shall be fully killed and in normalized condition.

c) Unless more restrictive prescription given by material specification the maximum carbon content
of carbon steel used for fabrication as shown by ladle analysis shall be
1. 0.23% for plates, pipes & tubes
2. 0.25% for forging.

d) Additionally one of the requirements for carbon equivalent based on heat analysis shall be also
satisfied :

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1. C + Mn/6 + (Cr+Mo+V)/5 +( Cu+Ni)/15 ≤ 0.43 %

2. Ceq. = C + Mn/6 ≤ 0.42 %

e) Primary component materials including their impact requirements shall conform to API 620
appendix R/ API 625 and impact requirements of ASTM A20 S5. ASTM A 516 Gr.70 modified 2
material shall not be used.

The use of copper on copper base alloys shall be completely avoided for Ammonia service.

f) Tolerance on thickness of plates shall be positive only.

g) All the carbon steel material exposed to the ammonia atmosphere (both liquid and vapour) shall
be impact tested as per API 620/API 625 and the minimum energy value shall be as per API 620
( App R)/ API 625.

h) Anchor strap material shall be SS304, unless otherwise specified.

3.41 DESIGN & SELECTION OF RUBBER LINING

3.41.1 The type of rubber (i.e. Natural, Butyl, Nitrile, Ebonite, and Hypalon etc.), its minimum
Thickness & hardness shall be decided as per design code/specification.

3.41.2 For vacuum service, the Triplex lining shall be adopted. It shall consist of 3 layers:

1st layer : 60 ±5 shore A

2nd layer : 35 ±5 shore B
3rd layer : 60 ±5 shore C

3.41.3 In general for all other services the preferred hardness of rubber shall be 65 ±5 shore A.

3.41.4 Lining up to 6 mm may be applied in single layer. Above this thickness it shall be applied in 2
or more layers. Except when the sheets shall be prepared by calendaring as follows:

Thickness of Lining (mm) Minimum no. of Plies

up to 3 2

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3 to 5 3
6 4

3.41.5 The surfaces which are to be covered with rubber shall be easily accessible & free from
pitting or other physical imperfection.

3.41.6 Spark testing shall be done for Lining.

3.41.7 The internal surfaces requiring rubber lining shall be prepared by Tank Fabricator to suit
rubber lining. All welds shall be ground smooth and radiused to min. rubber lining thickness.
All welds shall be free from pin holes, pits, pockets and nipples. Porous welds are to be
peened until tight. Since the internal surface preparation of the tank including roof (like
grinding of the weldments etc.) is to be done by the tank contractor, the same surfaces will
also be inspected and approved by the rubber lining contractor during tank fabrication and/or
on handing over of the tank to him for rubber lining.

In the event of any surfaces found unsuitable, the tank contractor shall carry out necessary
rectifications and make all surfaces suitable as per instructions of the rubber lining contractor
or his authorised representative without any implication

4.0 HRSG

4.1 SCOPE

This specification defines the requirements governing the design, engineering, procurement and
supply of materials, fabrication, inspection, testing, painting, insulation, refractory (wherever required),
Heat Recovery Steam Generator Modules (which hereinafter called HRSG) and related
equipment/auxiliaries.

4.2 CODES AND STANDARDS

In general the following codes & standards (latest editions) including their latest addenda shall be
followed unless specified otherwise.

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1 Indian Boiler Regulation latest edition

2 Flanges and flanged fittings shall be in accordance with ANSI B 16.5 latest edition.
3 Piping shall be in accordance with ANSI / ASME B 31.1 latest edition within the limits
established in this code. Other piping shall be as per ASME B 31.3
Performance Testing Standards
1 ASME PTC 4.4 - Power Boiler Test Code

4.3 TECHNICAL REQUIREMENTS

4.3.1 GENERAL

4.3.1.1 HRSG shall be of single drum, single pressure type, vertical / horizontal layout with
supplementary firing, with pressurized casing capable of delivering steam at the conditions
specified. However both type of Circulation (forced and natural) can be acceptable with
technical reasons for selection.

4.3.1.2 HRSG shall be designed to normalize the turbulences in the flow of the Gas turbine exhaust.

4.3.1.3 The emphasis for the HRSG design shall be on the optimization, and also full utilization of the
waste heat of Gas Turbine exhaust. The exit gas temperature from HRSG shall be kept to the
bare minimum, to achieve the highest possible efficiency at normal load condition.

4.3.1.4 All Platforms/walkways/stairways/critical equipments /valves shall be provided with rain covering/
sunshade. No rain water ingress into HRSG is to be allowed.

4.3.1.5 The HRSG will be completely insulated for minimum heat loss and personnel protection and
externally cladded with Aluminium sheet cladding in case of externally insulated. The insulation
material shall be ceramic wool/light resin bonded mineral wool of approved quality and suitable
for continuous service at maximum expected operating temperatures of the HRSG. The external
cladding shall not have any pockets where rain water can collect or have crevices where
seepage can take place.

4.3.1.6 Adequate access and inspection doors of approved type and size shall be provided to allow free
access for maintenance and cleaning of the HRSG gas path, headers, and other pressure parts.

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HRSG shall be designed to permit easy access to all tubes and permit easy removal/replacement
of tubes.

4.3.1.7 All headers shall have adequate draining facilities and shall be arranged in such a way that they
do not impede the fittings or removal of heating surface. Air vents shall be provided on drum,
headers and high points of piping.

4.3.1.8 The HRSG and auxiliaries shall be sized and designed to meet minimum requirements specified
in this bid package.

4.3.1.9 The height of the HRSG flue gas main stack above finished grade level shall be as per design
specification and shall be self supporting type. Design of the stacks shall meet the requirements
of various codes & rules/regulations. A pollution monitoring nozzle of (with blind flange) shall be
provided, and necessary ladders and platform for access to the same shall be provided.

4.3.1.10 The HRSG walls and casing shall be made gas tight, to reduce leakage of gases to the
atmosphere.

4.3.1.11 Seamless steel tubes finned type shall be employed in HRSG construction.

4.3.1.12 The HRSG response rate shall be suitable to achieve the guaranteed cold start-up, warm start-
up and hot start-up time for the cogeneration plant

4.3.1.13 The heating surfaces shall be designed taking into account the expected variations in the gas
turbine exhaust gas flow and temperature variations which will occur under differing loads and
ambient conditions and the expected spread of the exhaust gas temperature. The expected
spread of temperature of exhaust gas shall be obtained from the gas turbine manufacturer.

4.3.1.14 The HRSG shall be arranged such that the total pressure parts comprising steam drum, super
heaters, evaporators, economizers, headers, down comers and integral pipe work form a self
contained unit supported by its own steel structure. This structure shall be independent of other
structures, buildings, except for normal interconnection points like access galleries, platforms,
etc. Steam drum and headers shall be located outside the flue gas path.

4.3.1.15 In arranging the layout of tubes and tube banks of the HRSG, adequate care shall be taken to
ensure that flow induced vibrations are minimized and necessary baffle plates for this purpose

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shall be provided.

4.3.1.16 The material of tube supports shall be appropriately selected considering the maximum
temperature of exhaust gases coming in contact with them. Tube supports shall be capable of
supporting the tubes filled with water and shall withstand stresses resulting from restricted
expansion.

4.3.1.17 Double entry/exit shall be provided in all HRSG Platform as an alternate escape route in case of
emergency.

4.3.1.18 All utility consumption should have flow meters installed and should give trouble free operation.

4.3.1.19 The supplementary firing chamber shall be provided with refractory lining. In addition to this if
the bidder requires protective refractory in any other region; the same shall also be included.
The refractory shall be capable of withstanding the following:

a. Temperature surge and sudden thermal shock due to unit trip.

b. Frequent thermal cycling.
c. Continuous attack by erosive high-velocity particles.
d. Both oxidising and reducing atmosphere, which may occur at any point under normal
operation and transient condition.
e. Flow Disturbances arising out of turbulences at the GT exhaust.

5.0 SPARE PARTS

5.1 COMMISSIONING SPARES

5.1.1 All commissioning spares shall be included by LSTK Contractor in their scope of supply and
shall be part of the main equipment

5.2 SPARES FOR 2 YEARS OPERATION

5.2.1 2 years operation spares shall be supplied by the contractor as per Section-9 of ITB.

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6.0 DOCUMENTATION SCHEDULE

6.1 Documents shall be submitted as per “Documentation schedule” in Section-8 of ITB.

7.0 VENDORS LIST

All equipment shall be procured/ fabricated as per approved vendor list (Section -13). For
Non-critical items, LSTK Contractor may include the name of local vendors. Any equipment
for which vendor list is not enclosed, the LSTK Contractor may furnish a list of their proposed
vendors along with their references for supply of similar type of equipment along with bid.
However all the additional proposed vendors shall have well proven track record and shall be
subjected to consultant/owner’s approval.

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ANNEXURE-1

CALCULATION METHOD
DYNAMIC WIND ANALYSIS (GUIDELINES)
FOR VERTICAL EQUIPMENT

Check of the towers for dynamic wind moments due to vortex shedding shall be performed based on
following assumptions :

Vcr = f * D/St

Vcr = Critical wind velocity

D = Outside diameter of tower
F = First natural frequency of tower considering foundation complete rigid (s-1)
St = Strouhol number, may be taken as 0.15 for Re > 106 and 0.2 for Re < 106
Re = Reynolds number at critical wind velocity

For Vcr < 30 m/s following shall be considered :

The tower shall be checked for additional moments due to vortex shedding in 2 cases.

1. Operating condition
2. Shut down condition

Dynamic wind moment shall be calculated as follows :

Md = Pd * Ck * S * Pi/d * H

Pd = Wind pressure at critical velocity = 0.5 * den* (Vcr)2

Ck = Crosswind oscillatory force coefficient may be taken as 0.5 + ( 4 - Log10 Re)/5.7 for
Re < 106 and 0.17 for Re > 106
d = The logarithmic decrement of damping. For towers with trays or packing it is estimated
0.035
S = Surface on which dynamic wind forces are acting (height * diameter)
H = Height from base ring of point of application for dynamic wind force
Pi = 3.14
Den = Density

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For tapered construction only the tip diameter shall be considered in calculation.

Moments to be considered for dynamic wind:

Mres = ( Md 2 + Mst 2
Mst = Static wind moment at critical wind velocity

Only if Mres exceeds moments due to static wind or earthquake moments, it shall be considered for
equipment design.

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ANNEXURE-2

INSPECTION GUIDELINES

1.0 GENERAL

The min. Inspection to be carried out by Authorized approved Inspection agency:

1.1 VESSELS

a) All carbon steel plates shall be identified against mill-test certificates at the VENDOR'S
works before commencement of fabrication.
b) Establish that welding procedure and welders are qualified and welding electrodes are
approved before commencement of fabrication.
c) Check fit-up and witness chipping-back of welded seams.
d) Wherever applicable, select spots for radiography, D.P and M.P Tests.
e) Witness any crack detection, hardness checks, ultrasonic tests etc. which may be
specified. (1)
f) Review radiographs and in case it is unsatisfactory re-radiograph. (1)
g) Witness hydrostatic test.
h) Dimensionally check and carry out final internal and external inspection for quality of
workmanship.
i) Check that all material test certificates and, where applicable, heat treatment charts
are in order. Ensure that VENDOR is familiar with the requirements regarding data
books and ensure that the documentation is submitted without any delay.
j) Check internal lining of reactors and vessels (if applicable) to specifications.
k) Witness any further test recommended by Process Licenser/Inspection agency and/or
OWNER.

Note (1): X or Gamma rays

1.2 VESSEL INTERNALS

a) Leak testing & final inspection only is required.

b) Check one tray of each diameter and type, mock assembled in the shop.
c) Spot check for interchangeability of parts, where applicable.
d) Ensure that any uncommon down comers are fully assembled and offered along with
their respective trays.

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e) Where new designs and/or new VENDOR’s are concerned, check that any applicable
leakage tests have been carried out on prototype.
f) Check that materials including welding electrodes are in accordance with the
requirements of the order and all applicable specifications and standards.

1.3 STORAGE TANKS

a) Shell plates to be dimensionally checked (including diagonals for square-ness) before

rolling to curvature.
b) All shell plates to be inspected and dimensionally checked after rolling to curvature.
c) Check material test certificates and ensure that all shell plates are clearly stamped
with the cast and plate number, so that they can be identified against the relevant test
certificates.
d) Check material test certificates for roof and bottom plates.
e) Select the spot radiographs, D.P & M.P test as per codes.
f) Review the radiographs. (1)
g) On completion of inspection of shell plates ensure that VENDOR provides a chart
giving all plate numbers, tier by tier.
h) Inspect fabrication of all fabricated fittings. This is to include checking of material test
certificates also.
i) Inspect tank gauging equipment.
j) For shop fabricated tanks, witness hydrostatic tests to applicable standards.
k) Check welding material electrodes.

Note (1): X or Gamma rays

1.4 HEAT TRANSFER EQUIPMENT

1.4.1 SHELL AND TUBE EXCHANGERS

a) All carbon steel plates shall be identified against mill test certificates at the VENDOR'S
works before commencement of fabrication.
b) Establish that welding procedure and welders are qualified before commencement of
fabrication.
c) Check fit-up and witness chipping-back of welded seams.
d) Wherever applicable, select spots for radiography.

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e) Witness any crack detection, hardness checks, ultrasonic tests etc. which are
specified in drawing, specification, data sheet etc.
f) Review radiographs. (1)
g) Witness all hydrostatic tests on shell and tube sides.
h) Complete dimensional check for stacked units. This is to be carried out in the full
assembly stage.
i) Check that all material test certificates and where applicable, heat treatment charts are
in order. Ensure that VENDOR is familiar with the requirements regarding data books
and see that the documentation is submitted without any delay.
j) Witness any further test recommended by Process Licensor/ Inspection agency and/or
OWNER.

Note (1): x or Gamma rays

1.4.2 DOUBLE PIPE EXCHANGERS

a) Welding procedure and welders to be qualified.

b) Check fit-up of pipes.
c) Witness hydrostatic, D.P. & M.P. tests.
d) Check material certificates and identify the same.
e) Carry out final inspection and dimensional checks, review radiographs (note (1)) and
check material test certificates.

Note (1): X or Gamma rays

1.4.3 AIR FIN EXCHANGERS

a) All carbon steel plates to be identified against mill test certificates at the VENDOR'S
works before commencement of fabrication.
b) Check test certificates of all materials for piping, accessories, motors, gear box.
c) Establish that welding procedure and welders are qualified before commencement of
fabrication.
d) Where applicable, select spots for radiography and other non-destructive tests.
e) Witness any crack detection, hardness checks, ultrasonic tests etc. which may be
specified.
f) Review radiographs. (1)
g) Witness hydrostatic test on complete bundle.

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h) Dimensionally check and carry out final inspection of complete bundle for quality of
workmanship.
i) Balancing of fans to be witnessed, and fans to be finally inspected.
j) Fan rings to be dimensionally checked.
k) Motors to be finally inspected. This included checking of test certificates to ensure that
performance tests have been carried out in accordance with applicable specifications.
l) Running tests on gearboxes to be witnessed, and gearing to be examined on
completion.
m) Structural steel work to be checked for quality of workmanship and spot-checked for
dimensional accuracy.

Note (1): X or Gamma rays

1.4.4 VACUUM EQUIPMENT, INCLUDING CONDENSERS

a) Tests on ejectors to be witnessed.
b) Inspection and tests of condensers shall be done as for shell and tube exchangers as
far as applicable in addition applicable codes and standards shall be taken into
account.
c) Check all material test certificates for tubes, plates etc.
d) Check and witness other tests as applicable as per the Tender documents as well as
applicable codes and standards, for rotary equipment.

1.4.5 STEAM GENERATORS AND BOILERS

a) Inspection of drums as for vessels.
b) Mill certificate shall be provided for tubes.
c) All mountings to be inspected and hydraulic tests witnessed at sub-supplier's works.
d) Check test certificates for all materials and identify the same at VENDOR'S works
before start of fabrication.
e) Check fit-up and witness back chipping of weld seams.
f) Establish that welding procedure and welding electrodes as are qualified before start of
fabrication and welding.
g) Steel stacks to be finally inspected and dimensionally checked. Spots for radiography to
be selected, where applicable, and radiographs reviewed.
h) Ducting to be inspected for quality of workmanship and spot checked for dimensional
accuracy.
i) Shop hydrostatic test to be witnessed and final inspection to be carried out on fully
assembled packaged boilers.
j) Witness all tests applicable for steam generators.

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1.6 SPECIAL REQUIREMENTS FOR UREA GRADE

a) Ferrite content check

b) Intergrannular check
c) Helium/Inert gas leak test for liners

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ANNEXURE-3
PAINTING SPECIFICATION

S. No. Application Generic Coating System Minimum DFT Surface

1.0 Uninsulated Primer: Inorganic ethyl zinc Primer: 75 micron As per SA 2½ (Min.)
C.S. to 400 0C silicate primer Repair: 75 micron
where topcoat Total: 75 micron
is not required. Repair of damaged paint
(to 120 0C if surface: Two component,
surface is metallic zinc rich epoxy
repaired) primer.
2.0 Uninsulated Primer: 75 micron As per SA 2½ (Min.)
Primer: Epoxy zinc
C.S. to 83 0C Finish Coat: 150
phosphate
where topcoat micron
is required. Total: 225 micron
Finish: Recoat able high-
(intermittent to
build Epoxy
120 0C )
3.0 Uninsulated Primer: Inorganic ethyl zinc Primer: 75 micron As per SA 2½ (Min.)
C.S. to 260 0C silicate primer. 1st Coat: 40 micron
where topcoat 2nd Coat: 40 micron
is required. Finish: High Temperature Total: 155 micron
Silicone Acrylic
4.0 Uninsulated Primer: Inorganic ethyl zinc Primer: 75 micron As per SA 2½ (Min.)
C.S. 201 0C to silicate primer. 1st Coat: 25 micron
540 0C where 2nd Coat:25 micron
topcoat is Finish: Modified Silicone Total: 125 micron
required. Aluminium 2 coats
5.0 Insulated CS Primer: High Temperature 1st Coat: 100 micron As per SA 2½ (Min.)
normally to 200 Phenolic Epoxy 2nd Coat: 100 micron
0
C, or having Total: 200 micron
cyclic, Finish: High Temperature
intermittent or Phenolic Epoxy
dual operating
temperatures
up to 230 0C.
6.0 Insulated C.S. Inorganic Zinc Primer Total : 75 micron As per SA 2½ (Min.)
up to 540 0C.
7.0 Structural Hot Dip Galvanising
Steelwork with
operating
temperature up
to 90 0C
8.0 High Primer/Finish Coat : Intetherm Total : 75 micron As per SA 2½ (Min.)
Temperature 50 or Equivalent (Total 3
equipment coats)

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