valve procurement specs

Upload: josephmaquez24

Post on 15-Oct-2015

67 views

Category:

Documents


0 download

DESCRIPTION

Valve Procurement Specs

TRANSCRIPT

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 2 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    CONTENTS

    1.0 SCOPE 3

    2.0 GENERAL REQUIREMENTS 3

    2.1 REFERENCE CODES AND STANDARDS 4

    2.2 ENDS 6

    2.3 FACE FINISH 6

    2.4 CARBON STEEL 6

    2.5 AUSTENITIC STAINLESS STEEL 7

    3.0 DESIGN 7

    4.0 MATERIAL 11

    5.0 INSPECTION AND TESTING 11

    6.0 MARKING AND PAINTING 14

    7.0 DESPATCH / PREPARATION FOR SHIPMENT 14

    ANNEXURE-01 (Terms of delivery, General requirements, LB-08-901) 14 Pages ANNEXURE-02 (Surface treatment of stainless austenitic steel PS-08-008) 10 Pages

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 3 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    REQUIREMENTS BIDDERS

    COMPLIANCE

    1.0 SCOPE:

    The document lists the mandatory technical and associated requirements for purchase of various piping valves to be used in QSTec Polysilicon Project - Phase I, Qatar. These requirements are in tandem with requirements of Piping Material Specification (PMS).

    2.0 GENERAL REQUIREMENTS:

    2.0.1 All valves and their dimensions, tolerances, chemical composition, physical properties, heat treatment, hydrotest and other testing and marking requirement shall confirm to the latest codes and standards specified in the valve material requisition (MR). Vendor shall strictly comply with the stipulation and no deviations shall be permitted.

    2.0.2 The requirement given below is to be read in conjunction with the Valve Specification Data Sheet.

    2.0.3 Vendor shall supply valves in accordance with the valve specification sheets along with auxiliaries if any, such as gear operator, bypass, drains etc. Whenever specified in the specification sheets, subject notes and other enclosures to the material requisition (MR).

    2.0.4 All flanged valves shall have flanges integral with the valve body, flange finish shall be normally specified in valve specification sheet as serrated finish, 125-250 ARRH etc. Forged valves can have weld on flanges with 100% radiography.

    2.0.5 Any scale and oxides on valves resulting from heating operation shall be removed.

    2.0.6 Valve body / bonnet shall be forged / cast as specified. Forgings are acceptable in place of castings but not vice-versa.

    2.0.7 Valves heavier than 500 kg and 250 kg shall be supplied with supporting lugs and lifting lugs respectively and such standard devices shall be provided as per manufacturer standard.

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 4 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    REQUIREMENTS BIDDERS

    COMPLIANCE 2.0.8 Where gear operator is not called for as per clause 3.14 but vendor

    recommends a gear operator, he shall highlight such case(s) and quote separate prices for the valve and gear operator.

    2.0.9 Gate valves shall be provided with by- pass arrangement as per the following: Class Size

    150 DN 650 and above 300 DN 400 and above 600 DN 150 and above

    By-pass piping, Fitting and Valves shall be of compatible material and design. The by-pass piping arrangement shall be such that clearance between main valve body and by-pass assembly shall be the minimum possible for the layout reasons.

    2.0.10 By-pass valve shall be a globe valve. The sizes shall be as under:

    Main Valve Size By-pass Valve Size

    DN 100 & smaller DN 15

    DN 150 to DN 200 DN 20

    DN 250 & Larger DN 25

    Vendor shall supply by-pass valve duly tested and fitted to the main valve. Valves with by-pass shall have the direction of flow marked on the main valve. By-pass attachment to the main valve body shall not be screwed. All fillet welds for by-pass installation shall be 100% examined by DP/MP test. NDT of by-pass valve shall be in line with main valve.

    2.0.11 Service such as oxygen, cryogenic and other special process applications may require valves to be thoroughly degreased, cleaned and assembled in a clean and dry room.

    2.1 REFERENCE STANDARDS AND CODES: The latest editions along with addenda (if applicable) of all the international, national, state and local codes and standards shall be applied, unless

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 5 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    REQUIREMENTS BIDDERS

    COMPLIANCE otherwise specified.

    CODE/STANDARD DESCRIPTION ASME/ANSI CODES AND STANDARDS

    B 16.5 Pipe Flanges and Flanged Fittings B 16.10 Face -To-Face and End-To-End Dimensions of Valves B 16.25 Butt-Welding Ends B 16.34 Valves - Flanged, Threaded and Butt Welding End B 16.47 Large Diameter Steel Flanges B 46.1 Surface Texture

    ASTM STANDARDS

    A 105 Carbon Steel Forgings for Piping Applications A 182 Forged or Rolled Alloy Steel Pipe, Flanges, Forged Fittings

    and Valves and Parts for High Temperature Services. A 216 Steel Castings Suitable for Fusion Welding for High

    Temperature Service. A 262 Standard Practices For Detecting Susceptibility

    to Intergranular Attack in Austenitic Stainless Steel A 351 Steel Castings, Austenitic for high temperature service

    API STANDARDS API 594 Wafer and Wafer Lug Check Valves API 598 Valve Inspection and Testing API 600 Steel Gate Valves - Flanged and Butt Welding Ends, Bolted

    and Pressure Seal Bonnet API 602 Compact Steel Gate Valves - Flanged, Threaded, Welding and

    Extended Body End API 607 Fire Test for Soft Seated Quarter Turn Valves API 609 Butterfly Valves: Double Flanged, Lug and Wafer Type API 6FA Specification for Fire Test for Valves

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 6 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    REQUIREMENTS BIDDERS

    COMPLIANCE MSS STANDARDS SP-25 Standard Marking System for Valves, Fittings, Flanges and

    Unions

    BS STANDARD

    BS 1868 Spec for Steel Check Valves (Flanged & Butt Welding Ends) BS 1873 Steel Globe Valves (Flanged and Butt Welding Ends) BS EN ISO Specification for Ball valves 17292 BS 5156 Diaphragm Valves BS 6755 P 2 Testing of valves : Specification for fire type-testing

    requirements BS 6364 Valves for Cryogenic Service

    AWWA STANDARDS

    C 207 Steel Pipe Flanges for Waterworks Service-Sizes 4 in through 144 in

    C 504 Rubber-Seated Butterfly valves

    2.2 ENDS: Unless otherwise specified, the ends shall be to the following standard: B.W. ENDS : ASME B 16.25 FLANGED : ASME B 16.5 AND AWWA C207 Cl. D

    2.3 FACE FINISH: Face finish for flanges shall be Serrated Finish to 125-250 in AARH shall be to MSS-SP-6 / ASME B46.1 / ASME B16.5.

    2.4 CARBON STEEL 2.4.1 All forging material shall be normalized. 2.4.2 Wall thickness of all carbon steel valves shall be as per respective design

    standard.

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 7 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    REQUIREMENTS BIDDERS

    COMPLIANCE

    2.5 AUSTENITIC STAINLESS STEEL: 2.5.1 All items / parts shall be supplied in solution annealed condition. 2.5.2 Intergranular Corrosion (IGC) Test shall be conducted as per the following for

    all the grades of Austenitic stainless steels. ASTM A262 Practice B with acceptance criteria of 60mils/ year (max) for casting. ASTM A262 Practice E with acceptance criteria of No cracks as observed from 20X magnification and microscopic structure to be observed from 250X magnification for other than casting.

    2.5.3 For IGC test, two sets shall be drawn from each solution annealed lot; one set corresponding to highest carbon content and other set corresponding to the highest rating / thickness. When testing is conducted as per practice E, photograph of microscopic structure shall be submitted for record.

    3.0 DESIGN

    3.1 Gate and globe valves shall have backseat arrangement to permit repacking while valve is fully opened and under service pressure.

    3.2 Face-to-face and end-to-end dimensions shall be in accordance with ASME B 16.10.

    3.3 Hardness difference between wedge and seat/seat ring of valves shall be minimum 50 BHN. Seat rings shall have higher hardness. Stelliting / hard facing by deposition shall be minimum 1.6mm. Renewable seat rings shall be seal welded for valves of size DN50 & above to prevent loosening in service.

    3.4 Cryogenic ball, butterfly, gate and globe valves shall be supplied with the extended stems / bonnets because extended bonnet allows a reasonable temperature gradient up to the gland and point of operation. Stem / bonnet extention shall be as per the following:

    Size (DN) 15-50 80-100 150-200 250-300 350-400 450-600 Up to -100C (MM) 125 150 175 200 225 250

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 8 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    REQUIREMENTS BIDDERS

    COMPLIANCE

    3.5 No leakage is permitted from the stems in cryogenic service as leakage could freeze affecting the plant balance. Stem leakage may result in stem seizure and packing failure.

    3.6 Valves shall be as per the following standards.

    3.7 All soft seated ball valve shall be supplied with antistatic devices. 3.8 The ball valves shall be of floating ball / trunnion mounted type as per

    following.

    Valve Size Rating Design Std. Testing

    Std.

    Gate / Globe / Lift Check DN15 - DN40

    150 /300 /600 API-602 API-598

    Gate DN50 DN600

    150 /300 /600 API-600 API-598

    Globe DN50 DN600

    150 /300 /600 BS-1873 API-598

    Swing Check DN50 DN600

    150 /300 /600 BS-1868 API-598

    Dual Plate Check

    DN300 DN1200

    150 /300 /600 API-594 API-598

    Dual Plate Check

    DN1600 DN2200 150 MNF STD API-598

    Ball DN15 DN200 150 / 300

    BS EN ISO 17292 API-598

    Butterfly DN200 DN600

    150 /300 /600 API-609 API-598

    Butterfly DN650 DN1600

    150 /300 /600 AWWA C504 API-598

    Butterfly DN2200 DN2200 150 MNF STD API-598

    Diaphragm DN50 DN200 150 BS-5156 API-598

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 9 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    REQUIREMENTS BIDDERS

    COMPLIANCE

    150#

    DN 200 and smaller Floating Ball

    DN 250 and larger Trunnion Mounted (Soft Seat) DN 50 and larger Trunnion Mounted (Metal Seat)

    300# & 600#

    DN 40 and smaller Floating Ball

    DN 50 and larger Trunnion Mounted

    3.9 Bore of the reduced bore ball valve shall be as per ISO 17292. 3.10 Face to face dimension of double flanged butterfly valve shall be as per

    AWWA C 504. 3.11 Generally the valves shall be hand wheel or lever/wrench operated. However

    suitable gear operator in enclosed gearbox shall be provided for valves as follows. For Gate / Globe Valves

    Totally enclosed bevel in grease case with grease nipples / plugs

    For Ball / Butterfly / Diaphragm Valves

    Totally enclosed helical worm or combination of helical worm and spur gear in grease case with grease nipples / plugs

    3.12 Gear operation shall be provided as under :

    Valve type Class Size Requiring Gear Operator

    Gate / Globe / Diaphragm Valve

    150 / 300 DN 350 and larger 600 DN 300 and larger

    Ball / Butterfly Valve 150 / 300 DN 150 and larger

    600 DN 100 and larger For sizes lower than these ranges, hand wheel, lever / wrench shall be provided.

    3.13 Hand wheel diameter shall not exceed 750mm and lever length shall not exceed 500mm on each side. Effort to operate valve shall not exceed 35kgf at hand wheel periphery. However, failing to meet the above requirement, vendor shall offer gear operation.

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 10 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    REQUIREMENTS BIDDERS

    COMPLIANCE 3.14 Quarter turn valves shall have open position indicators with limit stops. 3.15 Gear operator shall be so designed to operate effectively differential pressure

    across the closed valve equal to maximum permissible pressure as per the class rating.

    3.16 All Valves shall have a facility to Pad-lock in open or close position. 3.17 All Valves shall be suitable for full vacuum condition. 3.18 The ball of Ball valve and disc of Butterfly valve shall not protrude outside the

    end flanges. 3.19 Bellow seal is required for globe valve for valve tag numbers VL11FS,

    VL31FS, VL12FST, VL12FKST, VL32FST, VL32FKST, VL32FHST and VL32FHKST.

    3.20 Bellow seal valves shall have non-rotating stem to prevent torsion of bellows. 3.21 Packing shall be a minimum five ring packing system with inconel and

    corrosion inhibitor. Packing material shall be as follows: ASME Class150:- Graphite Yarn Braided Packing ASME Class 300 & 600:- Pre- Formed Die-moulded Graphite Packing with stem finish as per 32 micro finish AARH

    3.22 Lantern ring to be provided in between stem packing ring. 3.23 Valve design shall ensure repair of gland packing under full line pressure. 3.24 Blowout-proof stems that do not rely on gland components for stem retention. 3.25 Stem packing for all ball & butterfly valves shall be flexible Graphite (Fire

    safe). 3.26 Seal and internals for ball valve shall be suitable for the fluid composition and

    Pressure / Temperature rating of valve. 3.27 Diaphragm valve shall have weir pattern body configuration to ensure tight

    shut-off. 3.28 All diaphragm valves shall have spindle isolated from service fluid. 3.29 Diaphragm shall be capable of being replaced. 3.30 Vendor shall provide Recess or Groove inside bolt hole circle for fixing /

    restricting rubber lining on flanged end of the valves. 3.31 Weld repair on casting and forging is not allowed.

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 11 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    REQUIREMENTS BIDDERS

    COMPLIANCE

    4.0 MATERIAL

    4.1 Material of construction of Yoke shall be at least equal to body material. 4.2 Stem shall be forged or machined from forged/ rolled bar. No casting is

    permitted. 4.3 If an overlay weld-deposit is used for the body seat ring, seating surface, the

    seat ring base material shall be at least equal to the corrosion resistance of the material of the shell.

    4.4 Hand wheels shall not be made of gray iron or non-metallic materials. Butt Welding Carbon Steel Valves shall have a 0.25% maximum Carbon Content; Free machining Steel is not acceptable.

    4.5 Lined Valves 4.5.1 EPDM Rubber Lined Valves

    Material : EPDM Rubber Hardness : SHORE A 70 Lining Thickness : 3 mm

    4.5.2 PTFE / PFA Lined Valves Material : PTFE / PFA Lining Thickness : 3 mm

    5.0 INSPECTION AND TESTING

    5.1 Every valve, its components and auxiliaries must be subjected to all the mandatory tests and checks called for in the respective codes, data sheets etc. by the manufacturer.

    5.2 Material test certificates (physical property, chemical composition and heat treatment report) shall also be furnished according to EN10204 type 3.1 for the valves supplied for all pressure containing parts. However certification to EN10204 type 2.2 shall be acceptable for all non pressure wetted parts.

    5.3 Though the extent of inspection shall be as under but extent with hold points shall be decided by purchaser and recorded in the form of inspection plan. In case of third party inspection the inspection plan shall be approved by the

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 12 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    REQUIREMENTS BIDDERS

    COMPLIANCE purchaser.

    a Visual and dimensional inspection. b Review of material test certificates. c Any mandatory or supplementary test. d Review of radiographs/radiographic reports or any other NDT tests for cast

    valves e Hydrostatic test 100% for body, 10% seat leakage selected on random basis.

    5.4 Gate and globe valves shall be subjected to back seat test. 5.5 Fire safe test as per API 607 / API 6FA shall be supplied for a previously

    tested soft-seated valve. The test should have been witnessed and certified by a third party inspection agency for the same design of the valve offered.

    5.6 All supplied valves shall be of radiographic quality. Valve castings shall undergo radiographic examination as specified below.

    Material Rating Size Range Radiography

    All

    150# DN 50 DN 600 5% DN 650 and larger 100%

    300# DN 50 DN 400 10% DN 450 and larger 100%

    600# All sizes 100% 5.7 Valves used in hydrogen service are applicable for following requirements

    - 50% of the valve castings shall be radiographed for sizes up to DN 600 in 150# class rating and up to DN 400 in 300# class rating. For all remaining size and rating 100% radiography is required.

    - Whenever random radiography is specified, at least one valve against that item shall be radiographed.

    - Casting and test bar shall be heat treated together. Valves casting shall be in solution heat treated and pickled condition.

    5.8 Valves used in low temperature / cryogenic service are applicable for following requirements - 20% of the valve castings shall be radiographed for sizes up to DN 600 in

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 13 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    REQUIREMENTS BIDDERS

    COMPLIANCE 150# class rating and up to DN 400 in 300# class rating.

    - For all remaining size and rating 100% radiography is required. 5.9 Acceptance criteria and areas to be radiographed, for valve castings shall be

    as per ASME B16.34. However for type of valves not covered in ASME B 16.34, vendor shall enclose details in line with ASME B 16.34.

    5.10 For random radiography wherever specified, the sampling shall be per size of the quantity ordered on each foundry.

    5.11 Radiography shall be done by X-ray to get the required sensitivity. 5.12 EPDM Rubber Lined Valves a Visual Inspection

    Lining shall be free from blisters, cracks or other surface imperfections, porosity, voids, inclusions or other defects which would impair satisfactory performance.

    b Lining Thickness Test Lining thickness test shall be carried out by magnetic thickness gauge at minimum 3 locations arbitrarily.

    c Adhesive Strength Test Adhesion between rubber lining and substrate shall be homogenous and without any defect or air pocket. At locations where adhesion is broken or air pocket has occurred, curing of lining shall be done.

    5.13 PTFE / PFA Lined Valves a Visual Inspection

    Lining shall be free from blisters, cracks or other surface imperfections, porosity, voids, inclusions or other defects which would impair satisfactory performance.

    b Lining Thickness Test Lining thickness test shall be carried out by magnetic thickness gauge at minimum 3 locations arbitrarily.

    c Electrostatic / Spark Test Electrostatic / Spark Test shall be done before pressure testing of valve. Lining shall be inspected for defects with high voltage alternating current

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 14 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    REQUIREMENTS BIDDERS

    COMPLIANCE spark tester. Lining should not produce spark when clean and dry surface is tested at 25 KV.

    5.14 Fugitive emission test, wherever specified in valve material specification, shall be carried out as per ISO 15848-2 & tightness Class B shall be achieved.

    5.15 In case of motor operated or actuator operated valves, functional / operational checks as per the requirements of the specifications shall be made on each valve.

    5.16 PMI shall be performed as per the scope and procedures as defined in PS1053-G0000-04-SP-A4-0011 Specification for PMI of piping at site and at supplier Works.

    6.0 MARKING AND PAINTING

    6.1 All items shall be marked (stamped/ etched) in accordance with the applicable code/ standard/ specification.

    6.2 Valves marking, symbols, abbreviations etc. shall be in accordance with MSS-SP-25 or the referred in specification sheet as applicable, Vendors name, valve rating, material designation, nominal size, direction of flow (if any) etc. shall be integral on the body.

    6.3 Carbon steel valves shall have surface preparation to Sa 2 1/2 and shall be painted with one coat of inorganic zinc silicate (min DFT 65 to 75 microns).

    6.4 All items shall have attached corrosion resistant tag providing salient features 6.5 Fire safe markings wherever applicable shall be clearly marked. 6.6 Steel die marking with round bottom punch may be permitted on body of butt

    weld CS, but for SS fitting, the same should be marked by electro-etching only.

    6.7 Paint or ink for marking painting shall not contain any harmful metal salts such as zinc, lead or copper which causes corrosive attack on heating.

    7.0 DESPATCH / PREPARATION FOR SHIPMENT

    7.1 The product touched surface may neither contain oil and grease nor oxygen grease or other impurities.

  • TECHNICAL SPECIFICATION FOR PROCUREMENT OF

    VALVES

    CONTRACT No. DOCUMENT No. REV No. SHEET 14333 PS14333-G0000-PD-SP-A4-0009 2 Page 15 of 15

    FORMAT: PS 14333/PLL/Doc REV.0

    REQUIREMENTS BIDDERS

    COMPLIANCE 7.2 Medium touched interior zones may not be blasted respectively retreated with

    anticorrosive agents. 7.3 Every tool and adjuvant which is used for production and/or cleaning must be

    completely free from non-ferrous metal (i.e. revising tools, mandrels, welding materials etc.)

    7.4 Additional requirement for cleanness shall be as per clause no. 9 of ANNEXURE-01 (Terms of delivery, General requirements, LB-08-901) and ANNEXURE-02 (Surface treatment of stainless austenitic steel PS-08-008)

    7.5 All valves shall be dry, clean and free from moisture, dirt and loose foreign material of all kinds.

    7.6 All valves shall be protected from rust, corrosion, and mechanical damage during transportation, shipment and storage.

    7.7 Rust preventive used on machined surfaces to be welded shall not be harmful to welding and shall be easily removable with the petroleum solvent.

    7.8 Ends shall be suitably protected, and the protectors shall be securely and tightly attached. Beveled end : Metal or plastic cap

    Flange face : Metal or plastic cover

    7.9 Valves procured as per clause no. 7.4 shall be supplied in individual separate packaging so that valve internals should not be contaminated by any means during transportation, handling and storage. Valve packet shall be marked with purchase order no., tag number, size.

    7.10 End protectors to be used on flange faces shall be attached by at least three bolts or wiring through bolt holes and shall not be smaller than the outside diameter of the flange.

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 1 of 14

    Terms of delivery

    General requirements

    No.: 08-901

    Purchasing, production, delivery and conformity assessment Pressure devices and plant components

    Content Page

    Further Specifications and terms of delivery ........................................................... 2 1 Application area .............................................................................................. 2 2 Terms and abbreviations ................................................................................ 3 3 Processing of orders ....................................................................................... 4 3.1 Manufacturer .................................................................................................. 4 3.2 Subcontractor ................................................................................................. 4 3.3 Monitoring of dates ......................................................................................... 4 3.4 Correspondence / contact person ................................................................... 4 3.5 Complete delivery ........................................................................................... 4 3.6 Acceptance ..................................................................................................... 4 4 General ........................................................................................................... 5 5 Classification of fluids ..................................................................................... 6 5.1 Classification in groups ................................................................................... 6 5.2 Classification according to condition of aggregation gas or fluid................ 6 5.3 Instable gases ................................................................................................ 6 6 Material selection and processing .................................................................. 7 7 Surface treatment ........................................................................................... 8 8 Examinations .................................................................................................. 9 9 Cleanness .................................................................................................... 10 9.1 General requirements ................................................................................... 10 9.2 Additional requirements free of oil and grease execution ........................... 10 10 Preparation for delivery, transportation ......................................................... 12 Quoted documents and normative references ...................................................... 13 Annex instable gases ........................................................................................ 14

    Passing on as well as duplication of this document, utilization and report of its content is not permitted, if not expressly entitled in written form. All rights reserved in case of patent or utility model registration as well as from this resulting in patent rights.

    Offence obligate to compensation. This document is property of centrotherm SiTec GmbH.

    Creation: Inspection: Approval: Revision: 0 date 2009-02-26 date date from MM from from

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 2 of 14

    Further terms of delivery (LB) and specifications (PS)

    LB 08-902 Supply and production vessels LB 08-903 Piping LB 08-904 Fittings PS 08-001 Leakage test for reactor and converter PS 08-002 Machines, tanks and columns PS 08-003 Insulation PS 08-004 Corrosion prevention PS 08-005 Heat exchanger standard requirement PS 08-006 Heat exchanger high demands PS 08-007 Steel construction PS 08-008 Surface treatment of stainless austenitic steel VA 08-100 Leakage test VA 08-101 Welded connections at pressure apparatus from metallic materials

    1 Application area

    These terms of delivery are valid for the purchasing, production, delivery of plant components and the execution of the conformity assessment procedure of pressure devices, which have to be in conformity with the general safety requirements of guideline 97/23/EG. Pressure devices for plants in the Chemical Industry must be safe and cost-effective within the provided operation time. To ensure this, it is necessary to lay down a detailed procedural design and above all the definition of the quality.

    Besides the general requirements of these terms of delivery, further specifications determine the specific quality requirements (see further terms of delivery and specifications). These specific quality requirements have to be used for purchasing and production in connection with the General requirements. When placing the order, they will be part of it. This centrotherm SiTec specification must also be applied for pressure devices and plant components, which have been constructed for a pressure of 0 < PS 0.5 bar or they are part according to PED, article 3, paragraph 3 (designed and produced according to good engineering knowledge).

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 3 of 14

    2 Terms and abbreviations

    Vessel see guideline 97/23/EG article 1, paragraph 2.1.1 i.e. columns, tanks, heat exchangers etc.

    PED Guideline 97/23/EG (Pressure Equipment Directive)

    DN Nominal diameter according to DIN EN ISO 6708

    Fluid gases, fluids and vapours in pure stat as well as in mixtures. Fluids may contain solids. Producer is in terms of this standard the contractor, who markets the pressure device and/or plant equipment on its behalf.

    Instable gases See section 5.3

    Category Classification (I, II, III or IV) of pressure devices according to risk potential

    PN Nominal pressure according to DIN EN 1333

    PS Admissible pressure (design pressure according to DIN EN 764-1)

    Pipes see Guideline 97/23/EG, article 1, paragraph 2.1.2

    TS Admissible minimum/maximum temperature (C according to DIN EN 764-1)

    V Volume in litres

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 4 of 14

    3 Processing of orders

    3.1 Manufacturer If there are several production sites, the manufacturer must name the intended site in the offer. A change in production site needs to be approved by centrotherm SiTec in written form. If the supplier assigns subcontractors for the production, he must proceed according to section 3.2.

    3.2 Subcontractor If work shall be executed by any subcontractor, the supplier must keep supervision of the product and make sure that the subcontractor receives all necessary information which is important to fulfil his obligations according to PED. Therefore the supplier must have assigned an explicit procedure (i.e. Quality management system). He must ensure that the subcontractor is able to fulfil all quality requirements. Sub-orders may only be forwarded, if the subcontractors are admitted by centrotherm SiTec. All subcontractors must be named by the contractor in the offer and must be approved by centrotherm SiTec in written form before placement of orders. In case that the particular subcontractor is not admitted by centrotherm SiTec, centrotherm SiTec will accomplish an on-site inspection at the subcontractor. The resulting costs will be born by the contractor. The subcontractors chosen by the supplier must also be named in the technical documentation for design assessment including indication of scope of delivery and service. This specification does also oblige for the subcontractor.

    3.3 Monitoring of dates centrotherm SiTec reserves its right to carry out monitoring of dates, building inspection and inspection at the supplier and if necessary at its subcontractors according to the existing manufacturing and material procurement. Therefore free access to all production rooms and offices must be guaranteed after prior notice. If circumstances may be recognised which may delay the date of delivery, the customer must be informed by written form including detailed information about the reasons.

    3.4 Correspondence / contact person All questions (technical or commercial such as time of delivery, dispatch etc.) have to be placed directly to the departments or persons named in the order. The centrotherm SiTec order number must be indicated in each case.

    3.5 Complete delivery The delivery according to the order will be regarded as complete, if all necessary documents arrived at centrotherm SiTec.

    3.6 Acceptance In each case, the final, contractual inspection takes place of receipt or after end of installation at the production site at earliest.

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 5 of 14

    4 General

    4.1 Plant components must comply to the state of the art and with all centrotherm SiTec specifications regarding material, calculation, production, inspection and equipment. Deviations must be agreed by centrotherm SiTec in written form.

    4.2 In case that commitments in the applicable specifications for the strength of the unit components (general stress and stability check) are not sufficient, only calculation methods may be used, which are approved as state of the art. Stress analysis and stability checks have to be provided to centrotherm SiTec on demand.

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 6 of 14

    5 Classification of fluids

    5.1 Classification in groups For consideration of material property, fluids are classified into group 1 and group 2. The classification may be made via the danger criterion characteristics of each medium (R-phrases) which can be seen in the respective safety data sheets.

    Fluids Danger attributes

    R-phrases Characteristic according to 67/548/EWG and adaptations

    Group 1 (dangerous

    medium) explosive E R2, R3 (R1, R4, R5, R6, R16, R18, R19, R44)1) highly flammable F+ R12 easily flammable F R11, R15, R17 flammable (if max. allowable temperature TS lies above flashpoint)

    - Accurate inspection necessary

    very toxic T+ R26, R27, R28, R26/27, R26/28, R26/27/28, R27/28, R39/26, R39/27, R39/28, R39/26/27, R39/26/28, R39/27/28, R39/26/27/28

    toxic T R23, R24, R25, R23/24, R23/25, R23/24/25, R24/25, R39/23, R39/24, R39/25, R39/23/24, R39/23/25, R39/24/25, R39/23/24/25, R48/23, R48/24, R48/25, R48/23/24, R48/23/25, R48/24/25, R48/23/24/25

    oxidizing O R7, R8, R9 Group 2 all fluids which not

    count into group 1 - -

    1) For R-phrases in brackets, a special control of the classification in one fluid group is necessary

    5.2 Classification according to condition for aggregation gas and fluid 5.2.1 Gases This contains gases, liquefied gases, by pressure dissolved gases, vapours and those fluids whose vapour pressure at the admissible maximal temperature TS lies above the normal atmospheric pressure (1013 mbar) by more than 0.5 bar. Gases may contain fluids or solid materials. 5.2.2 Fluids This contains fluids, whose steam pressure at the admissible maximal temperature TS lies above the normal atmospheric pressure (1013 mbar) by 0.5 bar at most. Fluids may contain solid materials or gases according to their solubility (not by pressure dissolved gases).

    5.3 Instable gases Instable are gases which may cause an exothermic reaction during storage or under operation, caused by energy or catalytic impurity effects even under exclusion of oxygen (currently instable classified gases see annex)

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 7 of 14

    6 Material selection and processing

    In case that the material is presented in the technical specification, the purchaser/consumer takes the responsibility for the stability of the used fluid. In this case, a reference in the manual is necessary according to annex I, section 3.4 of PED. See also AD 2000 data sheet HP 511, section 5.3.1, period 13. The responsibility for special and professional processing of the material is with the manufacturer. Plates, forgings, flanges, pipes etc. needed for the production of the pressure devices may only be purchased from manufacturers which are certified in the VdTV-data sheet 1253/1 to /4. Welding consumable materials may only be used of certified from VdTV. Deviations are only permissible after written agreement and permission by centrotherm SiTec.

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 8 of 14

    7 Surface treatment

    All surfaces of unalloyed and low-alloyed steel components must be derusted and painted with a priming coat if not indicated differently before assembling according to centrotherm SiTec specification. Stainless steel must be treated according to centrotherm SiTec specification, if not indicated differently. For all other materials, the respective centrotherm SiTec specifications are valid.

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 9 of 14

    8 Examinations

    Assessments have to be accomplished completely and according to manufacturing process. Exceeding demands of other applicable legislation and set of rules to this specification have to be considered. In case that theres no test specification indicated in the order, the test extent must be made in accordance to the AD 2000 data sheets. In case of a final inspection at printing devices respectively plant components by centrotherm SiTec-representatives at the producers facilities, they have to be prepared accordingly (vertical installation, for functional inspection supply of connections etc.). All fees, i.e. for draft examination, acceptance (compression test, final examination, examination of the safety devices) and documentation must be shown and included in the purchase order price.

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 10 of 14

    9 Cleanness

    9.1 General requirements All instruments and plant components must be well-swept, dry and free from visible oil and grease adhesions.

    9.2 Addition requirements free of oil and grease execution This must be agreed in the order/specification separately. 9.2.1 General - The product touched surface may neither contain oil and grease nor oxygen grease or

    other impurities. - Medium touched interior zones may not be blasted respectively retreated with anticorrosive agents. - Every tool and adjuvant which is used for production and/or cleaning must be completely

    free from non-ferrous metal (i.e. revising tools, mandrels, welding materials etc.). 9.2.2 Cleanness As cleaning agent, fully demineralized water by means of a hot water high-pressure device with non-ferrous injectors at 90 to 95 degree centigrade or vapour must be used. In case of hard adhesive contaminations it may be pre-cleaned by the use of adequate agents. After cleaning, the medium touched surfaces (machines inner surfaces, sealing surfaces etc.) may only be touched with oil- and grease free gloves. 9.2.3 Drying and evacuating If N2 or compressed air is used for pre-drying, it must be considered, that gas does not contain any oil respectively residential moisture. Subsequently, all medium touched rooms must be evacuated by means of a vacuum pump (equipment design for vacuum [-1 bar] necessary). Note: Seals, which have been used during the hydrostatic test, must NOT be used any more during the evacuation. If the temperature lies less than 15 degree centigrade during the drying procedure, the vacuum drying must occur in a heated room. The equipment temperature must also not lie less than 15 degree centigrade. When pre-drying by means of a compressor, the air must be aspirated via an air filter to avoid contaminations on the inner surface. During the drying process, the equipment may be heated lightly (no open fire). The following steps must be kept during evacuation/drying:

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 11 of 14

    Complete emptying of the apparatuses after high-pressure cleaning (attention to dead spaces and undercuts)

    When closing the notches, material conform flanges have to be used (steel type steel flange, stainless steel stainless steel and/or plated steel flange)

    Flushing by means of N2 or compressed air (free from humidity and oil) for pre-drying

    Ambient air temperature and object temperature must be detected and documented directly before and after evacuation as well as after operating life (i.e. at tube plates on WT). Evacuation to the absolute pressure indicated in the table in addiction to the object temperature.

    Object temperature C

    (5) 1) (10) 1) 15 20 25 30 35 40

    Evacuation pressure mbar (abs)

    (4) (7) 12 18 27 37 51 69

    1) Drying at machine temperature of less than 15 degree centigrade after acceptance from centrotherm SiTec

    Drying process may only be finished if pressure in closed, evacuated room does not rise more than 2mbar (in case of switched off vacuum pump and closed in-between valve).

    Test of this stable condition by means of a manometer and documentation with test chart

    Immediate filling of the device with dry nitrogen without opening any flanges N2 overpressure must be adjusted at 0.5 bar (however, PS at maximum)

    Do not demount charging and back pressure valves as well as manometer for the transportation to centrotherm SiTec.

    The correct cleaning and drying procedure must be certified by the contractor and sent to centrotherm SiTec before delivery. The following advice is necessary on the container drawings as well as on the delivered devices:

    ATTENTION! Danger of suffocation Nitrogen atmosphere!

    Container under pressure!

    NOTE: The adherence of the requirements will be examined by centrotherm SiTec during the reception control. Each cleaning examination will take place by means of a wipe test with a lint-free, white drapery. The drapery must not show any colour changes after the wipe test.

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 12 of 14

    10 Preparation for delivery, transportation

    All pressure devices and equipment components must be well cleaned and well dried. For un- and low-alloyed steel, blank surfaces as i.e. shaft ends, seal contact surfaces etc. must be covered with an easy removable corrosion protection.

    Seal contacts must be protected against damages during the transportation. All outside notches must be sealed i.e. with protective caps according to DIN 3444, DIN EN 12351 or with blanking flanges according to DIN EN 1092-1. Railroad railway cars must be equipped with leaded shock indicators for the transportation of shock-sensitive pressure devices and plant components as i.e. glass, vitreous enamel or graphite. Shock indicators may only be moved by railroad agents. Shock-sensitive components must be offloaded according to defaults of the supplier.

    In case that the actual transport- respectively installation weight deviates from the weight indicated in the drawing, this must be communicated to the purchaser as soon as possible still before arrival of the pressure device / the plant component.

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 13 of 14

    Quoted Documents and Normative references

    The following quoted documents are necessary for the use of this document. For dated normative references, only the referred issues are valid. For undated references, the latest version of the referred issue is valid (including all changes). See also: Further centrotherm SiTec specifications and terms of delivery.

    67/548/EWG: 1967-06-27 Guideline of the council from 1967-06-27 for the adaptation of right and administrative regulations for classification, packing and marking of dangerous materials 97/23/EG: 1997-05-29 Guideline of the European Parliament and the council from 1997-05-29 for the adaptation of legal rules concerning pressure devices for all member states AD 2000-Data sheet HP 511:2001-01 Design Examination DIN 3444 Protective caps for pipe fittings with welded and threaded ends DIN EN 764-1 Pressure equipment Terminology pressure temperature, volume, nominal size DIN EN 1092-1 Flanges and their joints Circular flanges for pipes, valves, fittings and accessories, PN designated, steel flanges DIN EN 1333 Flanges and their joints pipe work components Definition and selection of PN DIN EN 12351 Industrial valves protective caps for valves with flanges connections DIN EN ISO 6708 Pipe work components definition and selection of DN (Nominal size) TRG 100: 1985-03 Pressure gases: general regulation for pressure gases VDTV MB WERK 1253/1 List including producers approved by technical inspection agency (German: TV) VDTV MB WERK 1253/2 List including material agents approved by technical inspection agency (German: TV) VDTV MB WERK 1253/3 List including producers of flanges approved by technical inspection agency (German: TV) by abandonment of an inspection document VDTV MB WERK 1253/4 List including producers or agents of screws and nuts approved by technical inspection agency (German: TV) by abandonment of an inspection document centrotherm SiTec PS 08-004 Corrosion prevention by means of colour coating centrotherm SiTec PS 08-008 Surface treatment of stainless austenitic steel

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Terms of delivery no.: 08-901 Page 14 of 14

    Annex instable gases

    Description according to IUPAC-rules Description according to TRG 100 Acetylen, gelst Acetylen Bromtrifluorethen Butadien-1,2 Butadien-1,2 Butadien-1,3 Butadien-1,3 Butin-1 Chlorcyan Chlorcyan 1-Chlor-2,2,2-trifluorethan Chlorfluorthan (R 133 a) Chlortrifluorethen Chlortrifluorthylen (R 1113) Cyanwasserstoff Cyanwasserstoff (Blausure) Diboran Dicyan Dicyan 1,1-Difluorethen 1,1-Difluorthylen (R 1132 a) Distickstoffoxid Distickstoffoxid (Stickoxydul) Ethylenoxid thylenoxid Jodwasserstoff Methylnitrit Methylvinylether Vinylmethylther Ozon Propadien Propin Stibin Stickstoffmonoxid Stickstoffoxid Tetrafluorethen Tetrafluorhydrazin Vinylbromid Vinylbromid (R 1140B1) Vinylchlorid (nicht stabilisiert) Vinylchlorid (R 1140) (nicht stabilisiert) Vinylfluorid Vinylfluorid (R 1141)

    P1003141TypewriterANNEXURE-01 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • Creation: Inspection: Approval: Revision: 0 date 2008-12-04 date 2009-01-26 date 2009-01-29 from MM from HR from RIE

    Passing on as well as duplication of this document, utilization and report of its content is not permitted, if not expressly entitled in written form. All rights reserved in case of patent or utility model registration as well as from this resulting in patent rights.

    Offence obligate to compensation. This document is property of centrotherm SiTec GmbH.

    centrotherm SiTec GmbH Specification No.: 08-008 Page 1 of 10

    Specification

    Surface treatment of stainless austenitic steel

    No.: 08-008

    Content Page 1 Application area .................................................................................. 2 2 Purposes ............................................................................................. 2 3 Different Treatments ........................................................................... 3 3.1 Brushing .............................................................................................. 3 3.2 Grinding............................................................................................... 3 3.3 Blasting ............................................................................................... 4 3.4 Pickling ................................................................................................ 5 3.4.1 General ............................................................................................... 5 3.4.2 Cleaning .............................................................................................. 5 3.4.3 Pickling as a Cleaning Method ............................................................ 5 3.4.3.1 Cleaning with Pickling Solution ........................................................... 5 3.4.3.2 Cleaning with Pickling Paste ............................................................... 5 3.4.4 Pickling as a Material Removal Method .............................................. 5 3.4.4.1 Material Removal with Pickling Solution .............................................. 5 3.4.4.2 Material Removal with Pickling Paste ................................................. 5 3.4.5 Follow-up treatment ............................................................................ 5 3.4.5.1 Rinsing ................................................................................................ 5 3.4.5.2 Neutralization ...................................................................................... 5 3.5 Anti-Corrosion Coating ........................................................................ 6 3.6 Special Methods .................................................................................. 6 3.6.1 Pressure Shot Blasting with Austenitic Blasting Agent ........................ 6 3.6.2 Blasting with Glass Shot for Compacting ............................................ 6 3.6.3 Electro polishing .................................................................................. 6 4 Selecting and Applying the Method ..................................................... 7 4.1 Basic surface Treatment Conditions ................................................... 7 4.2 Surface Outside (Atmosphere Side) ................................................. 8 4.3 Surface Inside (Medium Side) .......................................................... 8 5 Safety precautions .............................................................................. 9 6 Quoted Documents ........................................................................... 10

    P1003141TypewriterANNEXURE-02 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Specification No.: 08-008 Page 2 of 10

    1 Application area

    This specification applies to the treatment of all surfaces including the welding seam ranges of stainless austenitic steel of material groups 6, 7 or 8 according to AD-data sheet HP 0, board 1. Typically used materials of these groups are i.e. the German material numbers W-No.: 1.4541, 1.4401, 1.4571, 1.4404, 1.4539 and 1.4462.

    2 Purposes

    The stainless austenitic materials according to section 1 provide a smooth, close passive coat to air, thereby they are not attacked by certain media or the atmosphere, and they are chemically resistant. During treatment of those materials i.e. by welding, reshaping, drilling, turning or milling, the passive layer may be damaged or destroyed by scale, tempering colors, welding cinder residue, scoring etc. Thus, the material looses its corrosion resistance and begins to corrode. In order to reconstruct the corrosion resistance after the treatment, the materials must be treated subsequently with one of the procedures as described in section 4.

    P1003141TypewriterANNEXURE-02 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Specification No.: 08-008 Page 3 of 10

    3 Different Treatments

    3.1 Brushing Brushing is no methodical treatment for the purpose of this specification and may be used for cleaning purposes only. For brushing, austenitic steel brushes are permissible only. Austenitic steel wire brushes must not be used for cleaning of other ferrous materials.

    3.2 Grinding Grinding disks or rotor fan grinders are normally used for grinding. The selected grain size has to be adapted stepwise and in adequate form to the grit of the final cut and the cleaning effect. If no superior requirements are appointed to the surface finish, the surface must be completed with an averaged roughness depth of Rz 4m. This roughness depth can usually be obtained by grinding with a granulation of 240 or finer. It must be pointed out, that no added or blunt abrasives are used and the material surface is not strongly warmed up. Temper colors are not permissible. The abrasives my only be used for austenitic materials. The surface must be cleaned after grinding.

    3.3 Blasting Blasting as surface treatment for the purpose of this specification is permissible only if its followed subsequently by acid cleaning according to section 3.4.3. For vapour-blasting, the following points must be considered: - For blasting of austenitic materials, fe-free abrasives may be used only. - Abrasives, blasting pressure, blasting time and distance between nozzle head and

    surface material have to be adapted to the material in an appropriate way and if necessary be determined by preliminary tests.

    - Via blasting, a surface roughness of Ry5 ) < 30m must be kept. - The blasting material may not be contaminated, i.e. when working with pressure

    blast plants, a dressing plant must be present; when working according to the injection principle, only abrasives in mint conditions may be used.

    If the material is provided with a corrosion-protective coating after blasting, a surface roughness Ry5 of at least 30m up to maximum 60m must be obtained in order to enable a sufficient adhesion for the corrosion-protective coating.

    1) The roughness value Ry5 corresponds to the mean peak to valley height Rz as per DIN 4768

    P1003141TypewriterANNEXURE-02 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Specification No.: 08-008 Page 4 of 10

    3.4 Pickling 3.4.1 General - The mixture of the pickling solution must be adapted to the chemical composition of

    the working material, the desired working temperature and the effect desired by the contractor.

    - Chloride containing solutions are permissible for gap-free constructions only. - The bath temperature must not exceed 50 degrees. In general, ambient temperature is sufficient. The pickling time depends on bath composition and temperature and has to be extended only until the desired effect has been reached. - Moving the work- piece or the bath promotes the pickling process. - The pickling process must be monitored 3.4.2 Cleaning Before pickling, all materials which prevent a constant wetting of the surface as for example oil, fat, glue or color must be removed by an adequate procedure. 3.4.3 Pickling as a Cleaning Method During pickling-cleaning, no appreciable material strip will be occurred ( 3m). This procedure is usually used with a previous mechanical procedure. 3.4.3.1 Cleaning with Pickling Solution The following weak pickling solutions can, for example, be used to clean material W-No. 1.4541 or 1.4571:

    a) 5 volume parts nitric acid (1.39 g/cm3 65 mass-%), 0.5 volume parts hydrofluoric acid (1.23 g/cm3 70 mass-%), 94.5 volume parts water

    b) 20 volume parts nitric acid (1.18 g/cm3 37 mass-%), 3 volume parts hydrofluoric acid (1.39 g/cm3 65 mass-%), 77 volume parts water

    3.4.3.2 Cleaning with Pickling Paste The etching solutions indicated in section 3.4.3.1 can be prepared to a brushable paste by using an adequate, hydrofluoric acid resistant thickener as i.e. barium sulfate or aluminium oxide. 3.4.4 Pickling as a Material Removal Method Pickling is to be carried out such that from 3 to 5m material is removed.

    P1003141TypewriterANNEXURE-02 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Specification No.: 08-008 Page 5 of 10

    3.4.4.1 Material Removal with Pickling Solution The following pickling solutions can, for example, be used to remove materials W-No. 1.4541 or 1.4571:

    a) For W-No. 1.4541: 8 volume parts nitric acid (1.39 g/cm3 65 mass-%), 1.5 volume parts hydrofluoric acid (1.23 g/cm3 70 mass-%) 90.5 volume parts water

    b) For W-No. 1.4571: 8 volume parts nitric acid (1.39 g/cm3 65 mass-%), 12 volume parts hydrofluoric (1.23 g/cm3 70 mass-%), 80 volume parts water

    A pickling time of 30 minutes in the bath at room temperature is required in cases.

    c) For W-No. 1.4541 or 1.4571: 50 volume parts nitric acid (1.18 g/cm3 37 mass-%), 10 volume parts hydrofluoric acid (1.39 g/cm3 65 mass-%), 40 volume parts water

    The water used for the pickling solution must be drinking water (chlorine ion content 50ppm). If damages can be expected according to remaining chlorides (as for example stress corrosion cracking), a chloride-free pickling solution has to be used and prepared with demineralized water or clean condensate. 3.4.4.2 Material Removal with Pickling Paste For the pickling with paste with acid mixtures according to section 3.4.4.1, for a temperature of 20 degrees, an etching duration of 3 hours is necessary, in order to clear away a surface layer from 3 to 5m. Lower temperatures require an extended pickling time. According to the limited acid content in a paste, there will be no pickling damages if the respective minimum pickling time is exceeded (i.e. appealing over night). 3.4.5 Follow-up treatment 3.4.5.1 Rinsing After etching, all parts must be cleaned with drinking water (chlorine ion content 50ppm) until no more acid can be determined at the etched parts. Neutrality has to be proven by the use of indicator paper, if necessary. For the support of the cleaning process, wire brushes may only be used if they are consisting of austenitic material and if they are free from any impurities. An additional passivation after cleaning is not necessary, since the desired passive coating will be accumulated during cleaning and the effect of atmospheric oxygen

    P1003141TypewriterANNEXURE-02 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Specification No.: 08-008 Page 6 of 10

    Table 1 Anti-Corrosion Coating

    Working temperature)

    [ in degrees ]

    Type of coating

    Description of coating

    Nominal coat

    thickness) [ in m ]

    up to 150

    Base coat 1x

    2-component epoxide resin- iron/mica paint

    60

    Top coat 1x

    2-component Polyurethane top coat

    60

    150 up to 400

    Painted coat 2x

    silicone resin paint

    2 x 50

    1) Down to a temperature of -60 degrees, the choice of coating depends on the maximum operating temperature. Coatings at temperatures of < -60 C must be adjust ed with centrotherm SiTec. 2) Coating thickness to be guaranteed after drying

    3.4.5.2 Neutralization Form-difficult parts with areas difficult to access whereby pickling remains cannot be removed completely by flushing must be neutralized in a neutralization bath of at least pH 8 (i.e. drinking water with soda). Subsequently, it will be flushed with drinking water again, according to section 3.4.5.1. 3.5 Anti-Corrosion Coating Before putting on the coating, a surface roughness Ry5 of at least 30m up to 60m must be present. The anti-corrosion coating must be executed according to table 1. 3.6 Special Methods 3.6.1 Pressure Shot Blasting with Austenitic Blasting Agent During ball pressure blasting, defined compressive stresses are brought into the material surface. Thus, danger of stress cracking can be reduced. The method may be used with the agreement of centrotherm SiTec. 3.6.2 Blasting with Glass Shot for Compacting The points noted under section 3.3 must be noted when blasting with glass shot. If the angle is kept close to 90 when blasting with g lass shot, this induces compressive residual tension into the material surface. The residual compressive stress cannot be induced as precisely as with pressure shot blasting, but it does also reduce the danger of stress cracking. The method may only be used with the agreement of centrotherm SiTec. 3.6.3 Electro-polishing If there are highest demands on the corrosion resistance, purity or surface roughness, the materials have to be polished electrochemically. The method may only be used with the agreement of centrotherm SiTec.

    P1003141TypewriterANNEXURE-02 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Specification No.: 08-008 Page 7 of 10

    4 Selecting and Applying the Method

    The executed procedure can be chosen by the client after the respective range of application. The choice may be supported by centrotherm SiTec, if necessary. If there are no additional agreements made within an application or order, for the internal and external surface treatment, one of the methods characterized with in table 2 or 3 has to be chosen. If other procedures are necessary due to the range of application, they must be agreed separately by the client.

    Ordering example 1: Surface treatment according to centrotherm SiTec VA 08-008 That is, the contractor can select a method characterized with for internal and external surface treatment according to section 4.2 and 4.3.

    Ordering example 2: Surface treatment according to centrotherm SiTec VA 08-008, outside procedure O inside procedure G That is, the contractor doesnt need to accomplish a surface treatment on the outside (the atmosphere side); on the inside (the medium side), the surface treatment must be glass shot blasting with a subsequent etch-cleaning.

    4.1 Basic Surface Treatment Conditions The materials have been treated according to the state of the art appropriate procedure and show no inadmissible material damages. Inadmissible material damages are in example:

    - deep scratches or rough stress marks or - material oxidation as can occur if not enough inert gas protection is used when

    welding or tacking.

    Machined sealing surface must generally be pickled (material removal) prior to use. This also applies to sealing surfaces that have been cleaned with a spatula or wire brush (damage to the passivated layer).

    P1003141TypewriterANNEXURE-02 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Specification No.: 08-008 Page 8 of 10

    4.2 Surface Outside (Atmosphere Side)

    Table 2

    4.3 Surface Inside (Medium Side)

    Table 3

    Application area in/at

    Component

    Process

    Description Treatment steps

    according to chapter

    Normal loading

    Tubing parts

    O

    Surface treatment not necessary, if temper colors up to color golden yellow are existent; otherwise treatment like instrument

    Instruments

    S Grinding (Rz 4 m) 3.2

    AB Blasting 3.4 without 3.4.3

    STRB Blasting and pickling (cleaning)

    3.3 and 3.4 without 3.4.4

    SRB Grinding and pickling (cleaning)

    3.2 und 3.4 without 3.4.4

    High loading (danger of cavity corrosion)

    Tubing parts / instruments

    AB Pickling 3.4 without 3.4.3

    High loading (danger of stress cracking)

    Instruments G Glass shot blasting and

    pickling (cleaning) 3.6.2 and 3.4 without 3.4.4

    D Pressure shot blasting and pickling (cleaning)

    3.6.2 and 3.4 without 3.4.4

    Application area in/at

    Component

    Process

    Description Treatment steps

    according to chapter

    Normal industrial atmosphere

    Tubing parts/ instruments

    O Surface treatment not necessary S Grinding (Rz 4 m) 3.2 AB Pickling (material removal) 3.4 without 3.4.3 STRB Blasting and pickling

    (cleaning) 3.3 and 3.4 without 3.4.4

    SRB Grinding and pickling (cleaning)

    3.2 and 3.4 without 3.4.4

    Industrial atmosphere with added chloride

    Tubing parts / instruments

    K Blasting and anti-corrosive coating

    3.3 and 3.5

    Insulated plant components in open air

    Pickling and anti-corrosive coating

    3.4 and 3.5 without 3.4.3

    P1003141TypewriterANNEXURE-02 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Specification No.: 08-008 Page 9 of 10

    5 Safety precautions

    All surface treatment methods may only be carried out by briefed and experienced personnel, considering the appropriate safety requirements. Particularly, the following instructions and data sheets must be regarded:

    General Threshold values of chemicals in the working place air TRSG 900 Biological maximum limits TRGS 903 List of carcinogenic and mutagenic substances as well As substances impairing the fertility TRGS 905

    Grinding Polishing and brushing instruments VBG 49

    Blasting Blasting agents TRGS 503 Protective measures to be implemented when degreasing and abrasive-blasting surfaces prior to thermal spraying DVS 2307 part 1

    Pickling Electrolytic and chemical surface treatment; electro deposition VBG 57 Dangerous chemical substances Data sheet BG-Chemie M051 Regulations on dangerous materials Federal Law Gazette I dating 11th Feb. 1982 (ArbStoffV 1982) page 144 to 154 Data sheet Handling with health hazardous substances Data sheet BG-Chemie M502) Data sheet Handling with nitric acid, nitrogen acids Data sheet BG-Chemie M014 Data sheet for working with hydrofluoric acids and inorganic fluorides Data sheet BG-Chemie M0053)

    P1003141TypewriterANNEXURE-02 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009

  • centrotherm SiTec GmbH Specification No.: 08-008 Page 10 of 10

    Quoted documents

    AD HP 0 General principles of design, manufacture and associated tests DIN 4768 Determination of roughness parameters by means of stylus instruments, terms, measuring conditions DVS 2307 T1 Protective measures when degreasing and abrasive-blasting of surfaces prior to thermal spraying M 005 Hydrofluoric acid and inorganic fluorides M 014 nitric acid, nitrogen acids M 050 Handling with health hazardous substances TRGS 900 Threshold values of chemicals in the working place air MAK- and TRK-values TRGS 903 Biological maximum limits, BAT-values TRGS 905 List of carcinogenic and mutagenic substances as well as substances impairing the fertility VBG 49 Polishing and brushing instruments VBG 57 Electrolytic and chemical surface treatment; electro deposition ZH 1/161 Hydrofluoric acid and inorganic fluorides ZH 1/229 Irritative materials, versicant materials

    P1003141TypewriterANNEXURE-02 TO DOC. NO. PS14333-G0000-PD-SP-A4-0009