GASIFIER VESSEL REFRACTORY

SUPPORT METALLICS

SHOP INSTALLATION QUALITY CONTROLPLAN

QIG-QCP70160-02 Rev. 0

PROJECT TITLE AND JOB NUMBER: / Tees Valley Energy From Waste Project
Leeds, UK
Project 1-14-5080/9
OWNER/CLIENT: / AIR PRODUCTS
EQUIPMENT: / Gasifier F-301
QIG JOB NUMBER: / 70160
PROJECT DATES: / March 2012 – August 2013
Revision /
Date
/ Description of Revision / Prepared by /
Quantum International Group, Inc. Project Manager
0 / August 24, 2012 / First Issue for Approval / J. Jacob Dupree, P.E. / Demetry Kondrasheff

TABLE OF CONTENTS

SECTION 1 – GENERAL

Purpose

Definitions

Owner Specifications

Materials of Construction

SECTION 2 – INSPECTION, ACCESS AND NOTIFICATION

SECTION 3–REFRACTORY METALLICS SHOP INSTALLATION

General

Weld procedures

Surface Preparation

Installation tolerances

Non Destructive Examination (NDE)

ATTACHMENTS

INSPECTION AND TEST PLAN – GASIFIER VESSEL F-301 REFRACTORY METALLICS INSTALLATION (Rev.0)

SECTION 1 - GENERAL

PURPOSE

This document is intended to provide the necessary information for Quality Control and Inspection during installation of refractory support metallics inside the Gasifier Vessel F-301. This vessel will be completed in the Fabricator’s shop and will be shipped to Leeds, UK.

DEFINITIONS

OWNER or BUYER / The person, firm or Company who is purchasing refractory materials from the SUPPLIER. For this QC Plan, the OWNER or BUYER is Air Products.
SUPPLIER / The person, firm, or Company with whom BUYER has placed the Purchase Order. For this QC Plan, the Supplier is Quantum International Group, Inc.
MANUFACTURER / The plant site where refractory support metallic are processed into final products and packaged for shipment. The MANUFACTURER’s site is where the completed products will be inspected and accepted before shipment.
FABRICATOR or FABRICATION SHOP / The shop and shop supervision where the gasifier vessel F-301 will be fabricated, inspected and tested.

owner specifications

This document will be offered to the OWNER for approval and is intended to incorporate and supersede the OWNER’s specifications for topics listed in this QC Plan.

This QC plan does not cover all of the requirements listed in the OWNER’s specifications and is not intended to replace the OWNER’s specifications entirely. The OWNER’s specifications must be strictly followed for topics that are not covered in this QC Plan.

The OWNER’s specifications that cover refractory material supply for this project:

  • REFRACTORY SUPPLY EQUIPMENT SPECIFICATION, AlterNRG Corporation, 10AIR03-35-123-0004 Rev. A, February 15, 2011
  • GENERAL NOTES FOR MATERIAL REQUISITIONS, Foster Wheeler Engineering Standard, 5081-1900A Rev. F1, January 27, 2012

The FABRICTOR shall confirm receipt of the Owner’s Specifications listed above.

MATERIALS OF CONSTRUCTION

Once approved by the Owner, the Supplier, Manufacturerand/or Fabricator shall not substitute materials, either finished products or their raw materials, without prior approval.

Once materials are approved by the Owner, the Supplier, Manufacturerand/or Fabricator shall not change nominal shape dimensions and nominal spacings without prior approval.

TheSupplier, Manufacturer and/or Fabricator shall not alter manufacturing parameters (such as welding, tolerances) without prior approval.

SECTION 2 – INSPECTION, ACCESS AND NOTIFICATION

The Supplier, Manufacturer and Fabricator shall provide regular access to manufacturing, warehousing and testing facilities for the Owner or the Owner’s Engineer or Supplier for purposes of quality surveillance and inspection. Such access shall also include any subcontractor premises and third party testing facilities.

The Owner or the Owner’s Engineer has the authority to reject any production lot on the basis of the results of inspection.

The Owner or the Owner’s Engineer shall be permitted to take photographs of the products and of the testing of the products.

The Supplier, Manufacturer, Fabricator and any sub-suppliers shall extend their health and safety procedures to the Owner or the Owner’s Engineer and to any independent inspectors. This shall include providing access to the required medical tests and the supply of all required safety equipment.

The Fabricator shall give notification to the Owner or the Owner’s Engineer, at least two weeks in advance, of any witness and hold points so that quality assurance inspections can be scheduled.

The Fabricator shall identify all national, international or internal standards to which sampling and testing are to be done.

SECTION 3 – REFRACTORY SUPPORT METALLICS SHOP INSTALLATION

General

Refractory support metallics include the following items:

  • Refractory anchors such as C-clips, thrust plates, V-anchors and hairpin clips
  • Brick support shelves

Refractory support metallics shall be installed to the inside diameter surface of the gasifier vessel F-301 by welding. The weld details, weld electrodes, dimensions and locations of each type of metallics are shown on the QIG drawings.

Weld procedures and shop handling of weld consumables

For welding metallic attachments to the vessel wall, the Fabricator is responsible for development and approval of weld procedures that comply with the current version of American Society of Mechanical Engineers (ASME) Section IX.

The Fabricator is responsible for qualification of welders in accordance with ASME Section IX for shop welds.

The Fabricator is responsible for supply, control and storage of all weld consumables.

Surface Preparation

Prior to refractory support metallic installation, all metallic surfaces to be welded shall be visibly free of paint, grease, oils, scale, and rust. Metallic surfaces to be welded must comply with The Society for Protective Coatings SSPC-6.

Installation tolerances

When fitting refractory support shelves, the vessel must be in the vertical postion and must be plumb. A plumb line shall be used to determine if the vessel is out of plumb. The vessel must not deviate by more than +/- 1mm/meter (+/- 3/64 inches per foot) of vessel length or be out of plumb by more than +/- 6mm (+/- ¼”) for the entire vessel.

Refractory Support Shelves: The refractory support shelves shall be inspected to verify that their levelness does not vary by more than +/- 1mm around the circumference of the gasifier. The shelvesmeasured in the radial direction shall not vary by more than +/- 1 mm. It is recommended to use a water level or laser level to check the deviations and make adjustments before final welding. It is recommended to check the levelness of the shelves during and after welding operations to confirm that the heat from welding did not cause warpage.

Spacing between shelves: The horizontal spacing between support shelves is considered to be a nominal dimension. The spacing can be adjusted +/- 6 mm or as needed to allow evenly spaced shelves. It is recommended to layout all shelves around each circumference before welding to confirm even spacing and that there will be no interferences with existing weld seams or existing nozzles, internals, etc.

Internal Weld Seams: Refractory metallics shall not touch existing internal vessel weld seams unless approved by the Owner’s Engineer.

Fillet Weld Leg size: The attachment fillet weld leg size tolerances: Specified Nominal leg size -0 mm/+4 mm

Refractory Anchor spacing: Some general acceptable procedures for layout and welding of refractory anchors are as follows:

Spacing inside cylinders: Evenly space the anchors along the circumference while also complying with the nominal specified spacing. The spacing can be adjusted +/- 20 mm to allow evenly spaced anchors while avoiding weld seams and internal pipes, nozzles, etc. For longitudinal spacing, the center-to-center spacing can be adjusted +0/-13 mm if needed to allow evenly spaced anchors in the longitudinal direction. For nozzles with V-anchors, the distance between the first row of anchors and the edge of the nozzle shall be approximately ½ the anchor spacing dimension shown on the QIG drawings. For example, for 229mm (9 inch) V anchor spacing, the distance between the first row of V anchors and the edge of the nozzle shall be approximately 115 mm (4.5 inches).

V-anchor orientation: The desired orientation of V-anchors is to stagger the orientation of each adjacent anchor by approximately 90 degrees.

Non Destructive Examination (NDE) of welds to gasifier wall:

Refractory Support Metallic / NDE
Refractory anchors (C-clips, thrust plates, V-anchors and hairpin clips) / 100% Visual Inspection and 5% Dye Penetrant Examination
Support Shelves / 100% Visual Inspection and 100% Dye Penetrant Examination

The Fabricator is responsible for all visual examinations, NDE and the inspector’s qualifications to perform these examinations. These inspections/examinations shall be recorded and original signed documents shall be part of the vessel Production Data Book.

August 24, 2012 Page 1 of 5