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SURIA ENGINEERING
DOSSIER FOR TT306 Re-Welding of Tubes

ENGRO POLYMER

18TH JUNE 2020

CLIENT:

M/S ENGRO POLYMER & CHEMICALS PVT LTD.,

KARACHI - PAKISTAN

D – 50 TEXTILE AVENUE S.I.T.E

KARACHI – PAKISTAN.
Call: 92 2 1 32584377
Fax: 92 21 32588802
Cell: 92 300 8238213 / 92 321 2159684
Suriaengineering@yahoo.com

www.suriaengineering.com
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TABLE OF CONTENTS
DOC NO.:-QC-FIL-001

Sr. No. DOCUMENTS DESCRIPTION

1. QUALITY INSPECTION PLAN (QIP) 4

2. WPS & WQT 6-8

3. DPT OF TUBES 10-13

4. HYDROSTATIC TESTING 15-21

5. RANDOM PICTURES 23-29

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1. QUA
LITY
INPE
CTIO
N
PLA
N
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2. WPS AND WQT

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S U R IA E N G IN E E R IN G

W E L D IN G P R O C E D U R E S P E C IF IC A T IO N (W P S )

C li e n t : EPCL D a te :
W e ld in g P r o c e d u r e S p e c ific a tio n N o .: S E -Q C -W P S -T T 3 0 6 -0 2 P ro je c t
R e v is io n : S u p p o rtin g P Q R N o .: S E -Q C -P Q R -T T 3 0 6 -0 3
W e ld in g P r o c e s s ( e s ) : G TA W T y p e (s ) : M anual
C ode / STD : A s p e r A S M E S e c tio n IX

N o te :
a = 1 .5 m m
t = 2 .0 m m

A c c e p ta b le w e ld jo in ts w h e r e a is n o t le s s t h a n 1 .4 t

W e ld J o in t T y p e a n d D e t a ils : S t r e n g t h W e ld , t u b e t o t u b e s h e e t

B A S E M E T A L (Q W .4 0 3 )
P .N O . 1 G ro u p N o . 1 to P .N o . 1 G ro u p N o . 2
O R

S p e c ific a tio n ty p e a n d G r a d e A 17 9
to S p e c ific a tio n ty p e a n d G r a d e S A -5 16 G r 7 0
O R

B a s e M e ta l: T u b e : ≥ 2 .1 1 m m T u b e S h e e t : 1 2 0 m m th ic k n e s s F ille t A ll th ic k n e s s
D ia m e te r o f T u b e : A ll O th e r
T u b e H o le s : 2 5 m m T r ia n g u la r P itc h

F IL L E R M E T A L S PO STW E LD H E A T TR EA TM E N T
(Q W .4 0 4 ) (Q W .4 0 7 )
G TAW SM AW
R O O T H O T PA SS F IL L /C A P R O O T F IL L C A P T e m p er a tu re R a n g e : N /A
S p e c . N o . (S F A ) 5 .1 8 5 .1 8 T im e R a n g e : N /A
A W S N o . ( C la s s ) E R -7 0 S -3 E R -7 0 S -3 S o a k in g T im e a t M a x T e m p : N /A
F .N o . 6 6
A .N o. 1 1
S iz e o f F ille r M e t a ls 1 .6 m m 1 .6 m m G A S
W e ld M e ta l G T A W -0 7 4 8 2 4 G T A W -0 7 4 8 2 4 (Q W -4 0 8 )
F ille t A ll T h ic k n e s s A ll T h ic k n e s s S h ie ld in g G a s ( e s ) : A rgo n
E le c tr o d e F lu x ( C la s s ) BAR E M ETAL P e r c e n t C o m p o s itio n ( m ix tu r e ) : 9 9 .9 0 %
F lu x T ra d e N a m e M A G M A W E L D /L IN K O N / E SS A B F lo w R a t e : 8 - 1 0 L I T / P .M
C o n s u m a b le I n s e r t ` G a s B a c k in g : N /A
O th e r T r a ilin g S h ie ld in g G a s C o m p o s it io n : N /A
E a c h b a s e & fille r m e t a l c o m b in a t io n s h o u ld r e c o r d in d iv id u a lly

Q W .4 8 2
P O S I T IO N S (Q W .4 0 5 ) P O S T W E L D H E A T T R E A T M E N T ( Q W .4 0 7 )
P o s itio n (s ) o f G r o o v e S p e c ia l T e m p e ra tu re R a n g e
W e ld in g P o s itio n : 5F T im e R a n g e -
P o s i t i o n ( s ) o f F i lle t t u b e s h e e t v e r t ic a l, t u b e h o r iz o n t a l

P R E H E A T ( Q W .4 0 6 ) G A S (Q W .4 0 8 )
P e r c e n t C o m p o s itio n
P r e h e a t T e m p . M in . 1 0 D e g C G a s (e s ) (M ix tu r e ) F lo w R a t e
I n te r p a s s T e m p M a in t a in . 2 5 0 D e g C S h ie ld in g A R G O N 9 9 .9 0 % 8 - 1 0 L IT / M .P
P r e h e a t M a in te n a n c e ( I f R e q u ir e d ) B y P r o p a n e T o r c h T r a ilin g - - -
B a k in g o f e le c t r o d e B a c k in g - - -

E L E C T R I C A L C H A R A C T E R I S T I C S (Q W .4 0 9 )
C u rren t A C o r D C D C SM AW
P o la r it y
A m p s. (R a n ge) SMAW G TAW R E V (E P )
GTAW 8 0 -14 0 V o lts (R a n g e ) 18 -2 8

E le c tr o d e w ir e fe e d s p e e d r a n g e
T u n g s te n E le c tr o d e S iz e a n d T y p e D ia 1 .6 m m 2 % T H O R A T E D

T E C H N I Q U E ( Q W .4 1 0 )
S tr in g o f W e a v e B e a d A ll S tr in g
O r ific e o r G a s C u p S iz e 4 - 6 m m
I n itia l a n d in t e r p a s s C le a n in g (B r u s h in g , G r in d in g , e tc .) B r u s h in g & G r in d in g / P o w e r g r in d in g

M e th o d o f B a c k G o u g in g P ow er B ru sh
O s c illa t io n P o w e r G r in d in g
C o n ta c t T u b e to W o r k D is ta n c e
N /A
M u ltip le o r S in g le P a s s ( p e r s i d e ) M u ltip le s (if R e q )
M u lt ip le o r S in g le E le c t r o d e s S in g le
T ra v e l S p e e d (R a n g e ) 1"-2 "
P e n n in g
O th e r

F ille r M e ta l C u rren t
W e ld T yp e A m p V o lt O th e r
L ayers P ro c ess C la s s D ia . P o la r R ange R ange T ravel S p eed
R O O T G T A W E R 70 S -3 1 .6 D .C 9 0 - 120 1 8 -2 8 1 " -1 .5 "
FILLING (if req) G T A W E R 70 S -3 1 .6 D .C 9 0 - 120 1 8 -2 8 1"-2 "
C A P P I N G ( if r e q ) G T A W E R 70 S -3 1 .6 D .C 8 0 -2 0 0 1 8 -2 8 1"-2 "

Prepared By Reviewed By Approved By

Suria Engineering Suria Engineering EPCL

Name Syed Faizan Name: Nauman Suria Name:

Signature: Signature: Signature:

Date: Date: Date:

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SURIA ENGINEERING
PROCEDURE QUALIFICATION RECORD (PQR)

C om pany N am e : S u r ia E n g in e e r in g P r o je c t: TT-306
P r o c e d u r e Q u a lific a tio n R e c o r d N o . : S E -Q C -P Q R -T T 3 0 6 -0 3
W PS N O . S E -Q C -W P S -T T 3 0 6 -0 2
W e ld in g P ro c e s s (e s) : G TA W
M a n u a l, A u to m a tic S e m i-A u to . : M anual
C o d e / S td : A s p e r A S M E S e c t io n I X

BASE METALS (QW.403) PREHEAT (QW.406)

M a te r ia l S p e c . A 179 Preheat Temp.
T ype of G rade A -5 1 6 G r.7 0 Interpass Temp.

P .N o . 1 to P .N o . 2 POST WELDED HEAT TREATMENT (QW.407)

T h ic k n e s s o f T e s t C o u p o n 2 .0 m m
D ia m e te r o f T e s t C o u p o n 25m m T e m p e r a tu r e

O th e r T im e
O th e r

ELECTRICAL CHARACTERISTICS (QW.409) GAS (QW.408) TYPE O F G AS

% C o m p o s itio n
C u r r e n t & P o la r ity
A m p s. D C 5 0 -1 2 0 V o lts 7 -1 5 G a s(es) (M ix tu r e ) F lo w R a te
T u n g s te n E le c tr o d e S iz e S h ie ld in g - - -
O th e r T r a ilin g - - -
B a c k in g - - -

POSITION (QW.405) TECHNIQUE (QW.410)

P o s itio n o f G r o o v e S p e c ia l S tr in g o r W e a v e B e a d
W e ld P r o g r e s s io n ( u p h ill, D o w n h ill) U p h ill M u ltip a s s o r S in g le P a s s ( p e r s id e )
P o s itio n o f W e ld 5F S in g le o r M u ltip le E le c tr o d e
O th e r

F ille r M e ta l Current
W e ld Travel Speed
Process A W S N o . (C la s s ) D ia A m p. Others
L ayer F N o. A N o. P o la r ity Volt Range (in / mm)
(m m ) R ange
1 G TAW E R 7 0 -S 3 6 1 1 .6 m m D .C 9 0 -1 2 0 2 2 .2 4 3"-4"

Page No. 001

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3. DPT PROCEDURE & DPT

OF TUBES
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Document No.: NDE, PR-016

LIQUID DYE PENETRATION EXAMINATION Revision : _0 0_

Page 01 of 03

1.0 Scope.

This Procedure Provides a System of general conditions and Specific Instructions to perform Liquid
Penetrant Examination in accordance with the applicable ASME code edition for Examination of
Carbon Steel, Stainless Steel, Welds and on Porous Material.

2.0 Equipment and Material.

2.1 Penetrant Material used Shall be water Washable, Visible Colour contrast of the
Following Specifications
2.1.1 Brand
Magnaflux Spot Check
2.1.2 Material Specifications
Penetrant SLK-SPI in aerosol can.
Cleaner SKC-S in aerosol can.
Developer SKD-S2 in aerosol can.
2.2 Any change in Material from the above list shall require requalification of Procedure
2.3 Intermixing of Penetrant Materials of different manufacturers is not permitted.

3.0 Procedure.

3.1 Surface Preparation.

Surfaces to be Examined may be in the as Welded, as rolled condition Grinding may be

necessary in certain cases where surface Irregularities Could Mask unacceptable
Discontinuities.

3.2 Pre-Examination Cleaning.

3.2.1 Prior to Penetrant application the Surface to be Examined and all the adjacent Areas
Within 25mm Shall be Cleaned by Mechanical Means and Solvent to remove dirt, grease
Scale, Welding flux or other matter which could interfere with the Examination
3.2.2 Operations that may Close the opening and Compromise the integrity of the Examination
Such as sand blasting are not recommended when these operations are being performed.
3.2.3 A Minimum of five minutes Shall be allowed for drying the surface to be Examined
Accomplished by evaporation before applying Penetrant.
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Document No.: NDE, PR-016

LIQUID DYE PENETRATION EXAMINATION Revision : _0 0_

Page 02 of 03

3.3 Techniques for Standard Temperature.

3.3.1 The Temperature of the Penetrant and the Surface of the part to be Examined Shall
not be below 5˚c nor above 52˚c, Local Heating or Cooling is permitted.

3.3.2 Penetrant Application.

The Penetrant Shall be Applied by Spraying, so that all Surface under Examination
Shall be Thoroughly and uniformly covered by Penetrant.

3.3.3 Penetrant Dwell Time.

After Application excess Penetrant is drained out from the part allowing suitable Dwell
Time of minimum 5 minutes. The area to be examined Shall remain covered by Penetrant
throughout the Dwell time.

3.4 Penetrant Removal.

3.4.1 After Dwell time the Penetrant on the Surface Shall be Removed by using Clean with
Cloth This operation Shall Continue until most traces of Penetrant on the surface is
Removed.
3.4.2 The Remaining Traces of Penetrant Shall be Removed be wiping the Surface Clean
with Cloth moistened with solvent remover, to Minimize removal of Penetrant from
discontinues, care Shall be taken to avoid excess Solvent Remover.
3.4.3 Flushing the surface with solvent remover following application of the penetrant and
prior to developing is strictly prohibited.

3.5 Application of Developer.

3.5.1 The developer is of Solvent, Suspended wet type and shall be applied as soon as possible
after excess penetrant has been removed and part is dried Developer Shall be Sprayed in
such a manner to assure complete coverage with a thin uniform film. The Second coat
may be applied across the first coat.

4.0 interpretation of indication.

4.1 All examination Shall be performed in ordinary sun light

4.2 Observation of the formation of indications Shall be performed during the application of
Developer. If defects are present they will show up as red indications on white Developer
Coating.
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Document No.: NDE, PR-016

LIQUID DYE PENETRATION EXAMINATION Revision : _0 0_

Page 03 of 03

5.0 Acceptance standards

5.1 The Following acceptance standards shall apply which have been referred from ASME
Sec-I, Sec VIII Division -I
5.2 All Welds Such as Longitudinal and Circumferential seams, including fillet weld
Pressure Parts. Joining of Nipples. Header Shall be Free of all relevant Indication
5.2.1 All Cracks. Lack of fusion and relevant imperfections

x______________________________________x
 S.NO 13 | P aPART-PART
ge WELDED JOINTS DIMENSION
NO. OF TEST
ACCEPT REJECT
JOINTS RESULT
2040 Tubes to
01 Tubes to Tube Sheet Tubes to Tube Sheet Joint
Tube Sheet
4080 Satisfactory  —
Doc. No. SRI-QC/019 A

REV: 00
SURIA ENGINEERING
LIQUID PENETRANT EXAMINATION REPORT DATE: 01-11-2019

Page: 01 of 01
Client: Project: Manufacture No. Procedure No.
Engro Polymer Exchanger Re-Welding TT-306 NDE, PR-016
Component: Report No.:
Drawing No.: - N/A
Smoke Tubes, Tube Sheets TT306-08-20
Acc Std. PWHT: N/A
NDT Ref. Code: ASME SECTION V Material Specification: SA-36
ASME SEC-V
Penetrant SLK-SPI Make Magnaflux Spot Check Test Temperature °c Light Equipment

Cleaner SKC-S Make Magnaflux Spot Check 27˚C Sun Light

Developer SKD-S2 Make Magnaflux Spot Check Extend of Examination:

100%
Date & Time 19-08-2020 11:30 AM to 12:30 PM

(i)
R Root
FC Filling Capping

COMPLETED BY Q.C INSPECTOR SURIA INPECTION DEPT.

Signature
Name M.Shakeel Altaf Khan
Date 13-06-2020 13-06-2020
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4. TUBE EXPANSION
/HYDROSTATIC TESTING
PROCEDURE AND REPORT

SURIA ENGG.
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Suria Engineering

REWELDING, EXPANSION & HT PROCEDURE FOR E-1461

Following processes will done for re-welding and expansion of tube to tube sheet joints.

1- Power brushing of tube sheet.

2- Re-welding of tubes to tube sheet as per WPS approved by EPCL.

3- Light Expansion of Tube to Tube Sheet Joints.

4- Hydrostatic Testing

TUBE EXPANSION PROCEDURE

Scope

This Procedure describes and specifies the technique, acceptance standards, and
documentation requirement for tube expansion in heat ex-changers.

Reference.
The current edition or addenda of the following documents has been referenced in the
preparation of this procedure and shall be considered a part of this procedure as applicable

1. ASME section VIII div. 1 – Rules for construction of pressure vessel.

Equipment to be used for the expansion.

1. Pneumatic Expansion unit shall be used for carrying out the expansion.

2. The roller to be used shall have a generous radius at both the ends so as to ensure that
there are no sharp steps on the expanded tube ID & to ensure that there is a smooth
transition from expanded to unexpanded zone of the tubes.
3. Measuring instrument like Dial gauge & outside Micrometer / Vernier.
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Expansion Mock – Up.

4. Take 300 x 300 mm sides mock up block with thickens equal to tube sheets with same
material as that of tube sheet. Drill the tube holes in the mock up block, of diameter &
pitch as per Tube sheet drawing.
5. Measure and record the tube hole inside diameter (ID).
6. Cut tube 150 mm long other than tube sheet thickness and tube projection length as per
drawing from the same material & wall thickness to be used in job.
7. Measure & record tube ID & tube OD.
8. Put mandrel of proper length, based on required expansion length.
9. Carry out expansion of tube of at least of 09 nos. Tube by mechanical expansion (Tube
rolling).
10. Measure & record increase in the tube ID.
11. Calculate % of thinning of tube using the following formula.

Notes:

-Thinning the tube should be in the range of 1 – 5 %.

Inspection after expansion.

- 100% tubes shall be inspected to ensure that the tubes are expanded.
- Tube to tube sheet joint shall be examined during hydro test to detect leakage, if any.
- In the event of leakage, the tube shall be re – expanded. Care shall be taken to ensure
that there is no excessive thinning of the tubes.
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HYDROSTATIC TEST OF E-1461

DOCUMENT CHANGE RECORD

Page Rev. Date Rev: Description Reviewed by Approved by

M.R G.M

01 As per client comments

Name Designation Signature

Prepared By

Approved By

STANDING OPERATING TITLE: HYDROSTATIC TEST

PROCEDURES

DOC. NO. SE-QC-HT-E1461 REV DATE:05-May-20 Page 1 of 4

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CONTENTS
1) Purpose

2) Scope

3) Preparation

4) Storage of Water

5) Water Quality

6) Procedure

7) Safety

8) Inspection and Rectification

9) Reference document

STANDING OPERATING TITLE: HYDROSTATIC TEST

PROCEDURES

DOC. NO. SE-QC-HT-E1461 REV DATE:05-May-20 Page 2 of 4

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2) PURPOSE

Hydrostatic pressure test is carried out to ensure mechanical integrity of the

fabricated vessel and the ability of it to sustain internal hydro pressure.

3) SCOPE
This procedure is applicable to all hydrostatic tests of vessels being performed by
Suria Engineering.

 PREPARATION:
Vessel shall be placed in horizontal position on bags filled with fine sand.
Test shall be carried out after completion of all welding activities, Radiographic
tests, and DPT (if applicable) but before surface treatment.

It shall be insured that 100% welding has been completed and all weld seams
shall visually be inspected from inside with proper lighting arranged.

All cleats, erection attachments, remaining weld tacks near weld seam shall be
removed by proper grinding. In case of excessive grinding during removal of
attachments, that portion shall be built-up by tack welds.

All loose material and debris shall be removed from vessel.

All openings shall be blanked-off and temporary rubber sheet gaskets shall be
used for sealing purpose.

One vent shall be provided to remove the air pockets/ bubbles. (Filling shall be
continued till the over flow from the vent.)

Connect the water piping for supply and drain.

All nozzles will be boxed up prior to filling of water with temporary rubber
gaskets, seals, and Teflon except vents, inlet and outlet nozzles.

Two calibrated pressure gauges shall be installed out of which one will be at
the highest point of the vessel.

A temperature gauge will also be available to ensure the required water/metal

temperature.
 STORAGE OF WATER:
Water shall be stored in underground concrete tanks already constructed
and available at shop.

4) WATER QUALITY:
Sweet water shall be used for leak test. In case of stainless-steel vessel, the
chloride content of the water shall not be exceedingly more than 50 ppm (mg/l). The
water shall also be clear of any solid particles.

STANDING OPERATING TITLE: HYDROSTATIC TEST

PROCEDURES

DOC. NO. SE-QC-HT-E1461 REV DATE: 05-May-20 Page 3 of 4

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 PROCEDURE:
Blind flanges of all the highest point nozzles and vents shall be kept loose.
Water shall be filled through any nozzle until it starts to overflow from all the
nozzles to remove entrapped air.
Loose blind flanges shall be tightened and air shall be removed from filling
point.

Pressure shall be increased gradually. Test pressure should be 1.3 times of

working or design pressure.
During Hydrostatic Test metal surface temperature should neither be below
160C nor above 480C.

Once the pressure is increased to the working/ design pressure and all tubes,
nozzles, bolting and the weld seams should be checked for any leek.

After satisfactory result the pressure shall be increased to the required mark.
Once the pressure is reached to the required mark it should be maintained for
30 minutes or for the time specified by the vessel designer.

All joints, connections and welds shall be examined for leakage.

Drop the pressure back to working/ design pressure and maintain it for
another 30 minutes and check for any leakages.

Gradually release the pressure to avoid bulging of the vessel caused by

sudden vacuum created upon rapid release of water.

All the highest points nozzles blind covers shall be loosen before
draining of water from the column. After that water to be drained from
any suitable nozzle as per physical situation.

Any left-over water shall be removed by blowing air.

 SAFETY:
All tools being used should be appropriate and in proper operating condition.
Only qualified and skilled personnel appointed by the QA/QC manager shall
be allowed to conduct the test.

Sign shall be displayed to indicate the pressure test is in progress and the
area shall be barricaded.
 INSPECTION AND RECTIFICATION:
Any leak shall be identified and marked on the vessel. The area shall be
documented. The vessel shall be completely drained and defective welds /
joints shall be repaired.

All leaks shall be repaired by approved weld repair procedure. Dye Penetrate test
of all repairs shall be carried out.

The vessel shall be retested until it is satisfactorily passed.

Applicable forms and documents shall be filled which will become part of the
Manufacturer’s Data Report to be submitted to the client at the time of delivery.

 REFERENCE DOCUMENTS
Fabrication codes: ASME VIII div. 1.
Client’s/ Designer’s procedural documents.

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