TPL 19162 G147 00002 - 1

PETROCHEMICAL AND LUBE INTEGRATION PROJECT “LuPech” (J-18)” AT
IOCL GUJARAT REFINERY, VADODARA, GUJARAT,INDIA

EPCC-5 PACKAGE (MS BLOCK AND OCTAMAX UNIT)
PURCHASE ORDER NO.: SBU - O & G (OIL, GAS & HYDROCARBONS)/LUPECH J18-IOCL-MS BLOCK/500054/19162
SR NUMBER:
VENDOR NAME: ENGINEMATES HEAT TRANSFER PVT. LTD.
PMC DOCUMENT NO.: 077154C-27794927-0000-EHT01-QCA-B2003-001
CONTRACTOR DOC NO.: 500054-TPL-19162-G147-00002
TTSJ MOCK UP PROCEDURE - ALL TAGS
DOCUMENT TITLE:
ITEM DESCRIPTION COMMON FOR ALL TAGS
TAG NO: COMMON FOR ALL TAGS
REVISION NO: 1 REV. DATE 16-Sep-23

DOCUMENT CATEGORY A REV. OBJECT IFA
Refer below attachment for TPL Approval
Technip Energies Review Stamp
Additional information which Contractor wants to mention
1 16-Sep-23 IFR - ISSUED FOR REVIEW SP SN PS
0 27-Jun-23 ISSUED FOR APPROVAL SP SN PS

PURPOSE/ DESCRIPTION OF
REV. DATE Written by Checked by Approved by
REVISION
ENGINEMATE HEAT TRANSFER PVT. LTD.
Mock up Procedure for Strength Welded with Contact Expansion

for Air Cooled Heat Exchanger
EMHT/MUP/QCP/13
Sr. No. Rev.No. Date Prepared by Checked by Approved by

QCE QCE Head QA & QC
1 0 19/09/2022
25.06.2023
2 0101 16.07.2023
2 17/11/2022
Page 1 Of 4
Procedure no. EMHT/MUP/QCP/13
Mock up Procedure For Air Cooled Heat
Page No. 2 of 4
Exchanger 01
Revision
Date 17 16.09.2023
1.0 Scope:
This procedure covers the details of Strength Welded & Contact expansion of tubes in tube
sheet/header holes
2.0 Applicable Codes & Documents:
 ASME Sec-VIII Div.1 2021

 ASME Sec-IX Ed 2021
 API-661 Seventh Ed 2013 Reaffirmed 2018.
 Job specification for supply of Air cooled heat Exchangers :077154C-000-JSS-0710-001 REV B
 Approved Drawings. & Welding spec 077154C-000-JSS-6300-001_0
3.0 Material of Construction
For both Carbon steel & Stainless Steel.
4.0 Qualification.
Thickness
Welding of the tube
procedure sheet usedasfor
qualification perprocedure testing
NRL specs: shall be
NZ-0ZZZZ MEsame as used
SPE 0042 for job,no:
A1 Clause except
4.0
Welder
that forqualification
carbon steel as
andper NRL specs:
austenitic NZ-0ZZZZ
stainless steelME SPE 0042itA1
materials, Clause
need no: 5.040 mm,
not exceed
unless otherwise indicated.
5.0 Mock Up test sample.
Following dimensions are to be maintain for Mock up :
 Tube sheet thickness & size

 Nos. of tube holes .
 Tube pitch & Pitch pattern.
 Tube sheet hole details, Tube OD & thickness.
 Expansion length: Contact expanding shall begin 12 mm from the tube sheet face and
extend to 3 mm from the back face
6.0 Parameters to be recorded:
Following parameters are to be taken into consideration during tube expansion

 Tube diameters
 Tube thickness
 Tube sheet hole diameter
 Torque applied for expansion
 Percentage of tube thinning
Page No. 3 of 4
Exchanger 01
Revision
Date 16.09.2023
7.0 Required expansion:
For Contact expansion, Expansion shall be in the range as per Approved Drawing.
8.0 Mock up procedure:
 Prepare mock up test block as per detail given above.

 Mark tube layout on mock up block as per drawing.
 Drill, ream & groove tube holes on mock up block.
 Before tube welding Mock up to be offer TPI to verify Tube sheet hole size, Tube thickness
& Diameter, Tube sheet hole surface finish, Verification of MTC for Tube, Tube sheet &
consumables.
 Insert tubes inside tube holes with 3mm projection from front side of the tube sheet &
carryout welding, record voltage, current & travel speed during welding.
 Visual Examination shall be carried out after Root run & Final weld.
 Liquid Penetrant test shall be carried out after Root run & Final weld.
 After completed welding tube shall be contact expanded. Percentage of thinning can be
calculated by using following formula.
Percentage Thinning: [1- (Dh-IDf)/(OD – IDi)] X 100
Where, Dh : Tube hole Diameter in Tube Sheet
IDf : Inside Diameter of Tube after complete Expansion.
OD: Outside Diameter of Tube before Expansion.
IDi : Inside Diameter of Tube Before Expansion.
Calculate percentage thinning for all tube holes & ensure that, it is within limit as given in drawing
or specification.
 After Contact Expansion % of thinning to be checked by TPI .

 After above inspection Mock up piece to be hard stamped by TPI.
9.0 Testing
Send the test piece to laboratory for pull out test, Macro, Micro photographic &Tear test. All test
shall be witness by TPI.
The complete test sample shall be cut (by sawing) as per specs:
& These shall- NZ-0ZZZZ ME SPE
be subjected Appendix
0042 A1test.
to various
- NZ-0ZZZZ ME SPE 0042 A1Clause no: 4.4d
Page No. 4 of 4
Exchanger 0101
Revision
Date 16.09.2023
Calculations :
Required minimum pull out load can be calculated as per non mandatory appendix A
of ASME Sec. VIII Div. 1
fr(test) = ___ L(test)_
AtST
Where Fr(test) = test efficiency = 1 for (a >1.4 t) Welded & expanded joint, as per table 2
At = Tube cross sectional area =Π( do-t)t
do=Nominal tube outside diameter.
t = Nominal tube wall thickness.
ST = Tensile strength for tube material from material test report.
After getting result from laboratory Calculate fr. Value as per attached format.
If it meeting the requirement then apply same procedure on job.
*Examination of test piece & summary of tests required as per 077154C-000-JSS-6300-001_0

welding Spec.
*Testing shall be as per EEMUA 143
*Production mock up test shall be carried out con currently with the production work.

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PETROCHEMICAL AND LUBE INTEGRATION PROJECT “LuPech” (J-18)” AT

IOCL GUJARAT REFINERY, VADODARA, GUJARAT,INDIA

ITEM DESCRIPTION COMMON FOR ALL TAGS

TAG NO: COMMON FOR ALL TAGS

REVISION NO: 1 REV. DATE 16-Sep-23

Refer below attachment for TPL Approval

Technip Energies Review Stamp

Additional information which Contractor wants to mention

1 16-Sep-23 IFR - ISSUED FOR REVIEW SP SN PS

0 27-Jun-23 ISSUED FOR APPROVAL SP SN PS

Mock up Procedure for Strength Welded with Contact Expansion

Sr. No. Rev.No. Date Prepared by Checked by Approved by

2.0 Applicable Codes & Documents:

 ASME Sec-VIII Div.1 2021

3.0 Material of Construction

For both Carbon steel & Stainless Steel.

unless otherwise indicated.

5.0 Mock Up test sample.

Following dimensions are to be maintain for Mock up :

 Tube sheet thickness & size

6.0 Parameters to be recorded:

Following parameters are to be taken into consideration during tube expansion

7.0 Required expansion:

8.0 Mock up procedure:

 Prepare mock up test block as per detail given above.

Percentage Thinning: [1- (Dh-IDf)/(OD – IDi)] X 100

Where, Dh : Tube hole Diameter in Tube Sheet

IDf : Inside Diameter of Tube after complete Expansion.

OD: Outside Diameter of Tube before Expansion.

IDi : Inside Diameter of Tube Before Expansion.

 After Contact Expansion % of thinning to be checked by TPI .

of ASME Sec. VIII Div. 1

fr(test) = ___ L(test)_

At = Tube cross sectional area =Π( do-t)t

do=Nominal tube outside diameter.

t = Nominal tube wall thickness.

ST = Tensile strength for tube material from material test report.

If it meeting the requirement then apply same procedure on job.

*Examination of test piece & summary of tests required as per 077154C-000-JSS-6300-001_0

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