8_1_1c

Toledo Refinery

Site Technical Practices EP 8-1-1C

TEMA Shell and Tube Heat Exchangers Inspection Checklist

April 2008 Revision 0.1

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Maintained by E2G – Shaker Heights, OH

PROJECT

PROJECT NO.

INQUIRY NO.

LOCATION

UNIT

EQUIPMENT ID

JOB NO.

DOCUMENT NO.

DATA ISSUED FOR

IN-HOUSE REVIEW

TOLEDO REFINERY APPROVAL

QUOTATION

PURCHASE

CONSTRUCTION

THIS SHEET IS A RECORD OF EACH ISSUE OR REVISION TO THE SUBJECT DATA. EACH TIME THE DATA IS CHANGED ONLY THE NEW OR REVISED DATA SHEETS NEED TO BE ISSUED. THE EXACT SHEETS CHANGED AND THE NATURE OF THE CHANGE SHOULD BE NOTED UNDER REMARKS. THESE REMARKS ARE NOT A PART OF THE DATA. THE REVISED DATA SHEET(S) BE COME PART OF THE ORIGINAL DATA AND SHALL BE COMPLIED WITH IN THEIR ENTIRETY.

ALL DATA SHEETS ATTACHED

REVISED DATA SHEET(S) ONLY ATTACHED

REV. DATE BY CHECK APPROVALS REMARKS

SECTION PROJECT TOLEDO REFINERY

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EQUIPMENT ID JOB NO. DOCUMENT NO. REV.

THE MANUFACTURER OF EQUIPMENT PURCHASED BY THE TOLEDO REFINERY SHALL BE RESPONSIBLE FOR MEETING ALL APPLICABLE REQUIREMENTS OF SITE TECHNICAL PRACTICES AND OTHER DOCUMENTS REFERENCED THEREIN REGARDLESS OF WHETHER THE ITEMS ARE INSPECTED BY A TOLEDO REFINERY REPRESENTATIVE.

REFERENCES

THE LATEST EDITION OF THE FOLLOWING STANDARDS AND PUBLICATIONS ARE REFERRED TO HEREIN

SITE TECHNICAL PRACTICES EP 7-1-1 PRESSURE VESSELS EP 7-1-3 HEAVY WALL AND SPECIAL SERVICE PRESSURE VESSELS EP 7-1-4 SUPPLEMENTAL REQUIREMENTS FOR PRESSURE VESSELS EP 7-1-5 WELDING REQUIREMENTS FOR PRESSURE VESSELS EP 7-1-6 METAL LINING AND CLADDING EP 7-1-7 PRESSURE VESSEL DETAILS EP 8-1-1 TEMA SHELL AND TUBE HEAT EXCHANGERS EP 8-1-8 TUBE TO TUBESHEET JOINTS EP 8-1-9 TUBE MATERIAL AND SELECTION EP 10-2-2 SUPPLEMENTAL REQUIREMENTS FOR METALLIC MATERIALS EP 10-2-3 MATERIAL HARDNESS REQUIREMENTS EP 10-3-1 PAINTING EP 10-3-7 INTERNAL LINING AND RESIN REPAIR EP 15-1-4 POSITIVE MATERIAL IDENTIFICATION (PMI)

FREQUENCY OF CONTACT BY THE INSPECTOR (CHECK ONE)

LEVEL l: ON CALL BY FABRICATOR

LEVEL 2: ONCE EVERY TWO WEEKS

LEVEL 3: EVERY WEEK

LEVEL 4: DAILY

LEVEL 5: RESIDENT

LEVEL 6. OTHER, SPECIFY

LEVEL OF INSPECTION BY THE INSPECTOR (CHECK ONE)

LEVEL l: PREFABRICATION MEETING, DOCUMENT REVIEW, AND FINAL INSPECTION

LEVEL 2: PREFABRICATION MEETING, DOCUMENT REVIEW. REVIEW ITEMS. AND FINAL INSPECTION

LEVEL 3: PREFABRICATION MEETING. DOCUMENT REVIEW, REVIEW ITEMS. WITNESS POINTS, AND FINAL INSPECTION

LEVEL 4: PREFABRICATION MEETING, DOCUMENT REVIEW, REVIEW ITEMS, WITNESS POINTS, HOLD POINTS, AND FINAL INSPECTION

LEVEL 5. OTHER, SPECIFY

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EQUIPMENT ID JOB NO. DOCUMENT NO. REV. DOCUMENT REVIEW (SHOP INSPECTOR SHALL REVIEW)

DOCUMENT DESCRIPTION

(REFERENCES TO EP 7-1-1, UNLESS OTHERWISE NOTED)

INSPECTOR’S INITIALS (REVIEW

COMPLETE) DATE

TOLEDO REFINERY PURCHASE DOCUMENTS

DRAWINGS AND SPECIFICATIONS

DOCUMENTATION (EP 7-1-4, 6.0)

QUALITY CONTROL MANUAL (EP 7-1-4: 5.3)

QUALITY CONTROL PLAN (5.0, EP 7-1-4: 5.3.3)

MATERIAL RECEIVING SIGN-OFF

MATERIAL REQUISITIONS (6.1)

MATERIAL TEST REPORTS

UT REPORT OF PLATE (EP 7-1-3: 6.2)

UT REPORTS OF FORGINGS AND THICK PLATE (EP7-1-3:6.2)

TEST EQUIPMENT CALIBRATION CERTIFICATIONS

WELDING PROCEDURE SPECS (EP 7-1-5:7.0)

WELDER QUALIFICATION RECORDS (EP 7-1-5: 9.0)

NDE PROCEDURES

NDE TEST REPORTS

NDE PERSONNEL CERTIFICATION

FAB. PLAN/SHOP TRAVELER

IDENTIFICATION OF CRITICAL DIMENSIONS

DAILY COATING INSPECTION REPORT (EP 10-3-1)

SUB-CONTRACTOR Q/C REPORTS

AS-BUILT DATA SHEET (4.1)

NAME PLATE RUBBINGS AND/OR CODE

PRESSURE VESSEL DATA BOOK (EP 7-1-4:6.3)

PWHT PROCEDURES ( 8.5)

AUTHORIZED WAIVERS AND/OR DEVIATIONS REVIEW

REVIEW OF SUBORDERS OF UNPRICED PURCHASE ORDERS TO SUB-VENDORS FOR COMPLIANCE WITH THE ENGINEERING PRACTICE

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GENERAL FABRICATION INSPECTION REQUIREMENTS (ALL FABRICATED EQUIPMENT)

R CHECK: THE SHOP INSPECTOR SHALL REVIEW DOCUMENTED RESULTS OF INSPECTION PERFORMED BY VENDOR'S INSPECTOR OR SUBCONTRACTED INSPECTOR.

W CHECK: INDICATES THE SHOP INSPECTOR SHALL WITNESS ITEMS DURING FABRICATION SHOP SHALL NOTIFY INSPECTOR 2 DAYS IN ADVANCE OF FABRICATION POINT BUT NEED NOT HOLD PRODUCTION FOR INSPECTION.

H CHECK: INDICATES THE SHOP INSPECTOR SHALL INSPECT ITEMS DURING HOLD ON FABRICATION. SHOP SHALL NOTIFY INSPECTOR FIVE DAYS IN ADVANCE OF FABRICATION POINT AND SHALL NOT CONTINUE AFFECTED PRODUCTION UNTIL INSPECTOR PERFORMS AND IMPROVES FABRICATION AFTER INDICATED INSPECTION.

R W H INSPECTION/TESTING ACTIVITY

(REFERENCES TO EP 7-1-1 UNLESS OTHERWISE NOTED)


COMPLETE)

DATE

SPECIAL MATERIAL REQUIREMENTS (EP 10-2-2)

PWHT STEP COOLING REQUIREMENTS (EP 10-2-2)

SPECIAL MATERIAL TENSILE AND IMPACT TESTING REQUIREMENTS (EP 10-2-2)

FIT-UPS WELD ROOTS/WELD BEVELS

SPECIAL FORGINGS TESTING REQUIREMENTS

GENERAL FABRICATION CHECKS (8.1)

GENERAL WELDING FABRICATION CHECKS (8.2)

HEAD AND TRANSITION SECTION THICKNESS REQUIREMENTS (8.3)

REINFORCING PAD GAP ALLOWANCE (8. 3)

SPECIAL FORGING FORMING REQUIREMENTS (8.4)

PWHT PREPARATIONS (8.5)

REVIEW OF COLD WORKED PARTS PWHT REQUIREMENTS

NAMEPLATE REQUIREMENTS (8.6)

DIMENSIONAL CHECKS (8.7)

TEMPLATE CHECK (8.7)

CLEANLINESS CHECK PRIOR TO FINAL INSPECTION (9.1)

PMI OF ALL APPLICABLE MATERIALS (EP 15-1-4)

RT LOCATION SELECTION

RT REVIEW (9.2)

RT OF WELDS IN COLD WORKED PARTS (9.2)

UT OF NOZZLES IN THICK SHELLS (9. 3)

WFMT OF WELDS IF VESSELS IN AES (9.4)

MT/PT OF DOUBLE WELDED GROOVE JOINTS (9.4)

MT/PT OF SPECIFIED AREAS (9.4)

MT/PT OF SPECIFIED AREAS OF 100% RT VESSEL (9.4)

NOZZLE REQUIREMENTS (7.7)

GIRTH FLANGE CONTACT SURFACE REQUIREMENTS (7.11.1)

NON-STANDARD FLANGE GASKETING REQUIREMENTS (7.11.1)

FLANGE REQUIREMENTS FOR CLAD VESSELS (7.11.1)

MT/PT OF UNRADIOGRAPHICABLE NOZZLES (9.4)

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GENERAL FABRICATION INSPECTION REQUIREMENTS (ALL FABRICATED EQUIPMENT)




COMPLETE)

DATE

ALL MAJOR REPAIRS PERFORMED IN ACCORDANCE WITH ACCEPTED PROCEDURES (10.0)

ALL OTHER REPAIRS PERFORMED IN ACCORDANCE WITH ACCEPTED PROCEDURES (10.0)

HYDROSTATIC LEAK TEST (11.0)

CHLORIDE CONTENT OF HYDROTEST FOR STAINLESS STEEL (11.0)

REINFORCING PAD PRESSURE TEST (11.0)

PROGRESSIVE FORMING/MACH.

ASSEMBLY AND MATCH MARKS

REMOVAL OF TEMPORARY ATTACH. AND NDE INSPECTION OF AFFECTED AREA

SURFACE CLEANLINESS/PROFILE

FINAL SHIPPING PREPARATION/CLEANLINESS/PRESERVATION (EP 7-1-4: 5.5)

STAMPING AND MARKING (EP 7-1-4: 5.4)

WELDING INSPECTION (SEE EP 7-1-5)

WELDING PROCESS REQUIREMENTS (6.0)

WELDER PERFORMANCE QUALIFICATION TESTS (7.0)

WELD JOINT DESIGN (8.0)

PREHEAT AND INTERPASS REQUIREMENTS (9.1)

FILLER METAL REQUIREMENTS (9.0)

WELDING TECHNIQUE REQUIREMENTS (9.0)

WELDER IDENTIFICATION (9.0

PRODUCTION TEST PLATE QUALIFICATION (9.0)

PWHT REPORT - ASME CODE (10.0)

PWHT - AES SERVICE (11.0)

WELD HARDNESS REQUIREMENTS AFTER PWHT (EP 10-2-3)

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SHELL AND TUBE HEAT EXCHANGER INSPECTION AND TESTING




COMPLETE)

DATE

TUBESHEET DRILLING/MACHINE PROCESS (EP 8-1-8)

TUBE EXPANSION/ROLLING PROCESS(EP 8-1-8: 6.0)

TUBE STRENGTH WELDS WITH THROAT THICKNESS EQUAL TO TUBE THICKNESS (EP 8-1-8: 7.4.4)

TUBE BUNDLE INSERTION/REMOVAL CHECK (8.1)

WELDED TUBE ROLL LEAK TEST (EP 8-1-8: 8.4)

EXCHANGER HYDROSTATIC TEST REQUIREMENTS (8.2)

VERIFY UNIT DRYOUT AFTER HYDROTEST

CLADDING AND WELD OVERLAY INSPECTION WHEN REQUIRED (EP 7-1-6)

INSPECTION REQUIREMENTS FOR CLAD PLATE (11.0)

REQUIREMENTS FOR CLAD PLATE (5.0)

PT OF WELD OVERLAY OF SEAMS (11.0)

RT OF MAIN SEAM AFTER WELD OVERLAY (11.0)

VERIFICATION OF WELD OVERLAY THICKNESS (11.0)

PMI OF WELD OVERLAY (11.0)

PT OF 1ST LAYER OF WELD OVERLAY (11.0)

FINAL PT EXAMINATION OF OVERLAY (11.0)

RT OF P3, P4, AND P5 FOLLOWING PWHT (11.0)

FERRITE CONTENT OF OVERLAYS (11.0)

INSPECTION REQUIREMENTS FOR STRIP LINING (11.0)

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HEAVY WALL AND SPECIAL SERVICE VESSEL INSPECTION WHEN REQUIRED




COMPLETE)

DATE

VESSEL ATTACHMENT WELD REQUIREMENTS (5.4)

SUPPLEMENTAL UT OF PLATE MATERIAL (6.2)

SUPPLEMENTAL UT AND MT OF FORGINGS (6.2)

REPAIRS OF PLATES AND FORGINGS (6.2)

SUPPLEMENTAL RT REQUIREMENTS (8.1)

SUPPLEMENTAL UT REQUIREMENTS (8.2)

SUPPLEMENTAL MT AND PT REQUIREMENTS (8.3)

AE REQUIREMENTS (9.0)

PRODUCTION TEST PLATE QUALIFICATIONS (EP 7-1-5)

EXTERIOR COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-1)

SAND BLASTED SURFACES (10.0)

COATINGS PREPARATION (10.0)

WET FILM THICKNESS MEASUREMENTS (10.0)

DRY FILM THICKNESS MEASUREMENTS (10.0)

HOLIDAY TESTING OF COATING (10.0)

REPAIR AND FINAL INSPECTION

INTERNAL COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-7: 12.0)

INITIAL SURFACE INSPECTION

SAND BLASTING OPERATION

SURFACE PREPARATION PRIOR TO APPLICATION

CONDITION FOR APPLICATION OF COATING

DRY FILM THICKNESS MEASUREMENT

HOLIDAY TESTING OF COATING

REPAIR AND FINAL INSPECTION

INITIALS NAME COMPANY

EQUIPMENT ID JOB NO. DOCUMENT NO.

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SUMMARY:

8_1_1c

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