Dears,
I would like to add few small notes to clarify this case:
1- The original MTC would not have simulated HT unless it is required by P.O.- We may need to run a PQR with the simulated PWHT ( 2 or 3 times).
2- For definition of Routine repair, NB-23 may be referred.
3- The manufacturer of the Heat Exchanger will not be reponsible for any damage and repair after the issue of MDR.
4- The insurance normally covers the cost of the repair however it does not cover for shipping of the Item to original manufacturer in other Country or Continent. The repair is normally performed by another and local R-stamp holder and in many cases certified by another AIA.
5- Both U-stamp and R-stamp name plates shall stay on the item.
6- NCR may not be required and an accident report will suffice.
Please consider the case where the fabricated item is stored at site for 2-3 years and damaged during the installation. we can not go back to the manufacturer and ask to issue a fresh MDR to cover the repair.
Regards
To: "Materials & Welding" <materials-welding@googlegroups.com>
From: Bali Naushad <balinaushad@gmail.com>
Sent by: materials-welding@googlegroups.com
Date: 01/15/2011 10:38PM
Subject: [MW:0] Re: HEAT EXCHANGE ACCIDENT
Dear,
> Repair can be done after AI acceptance and Repair procedure approval by the end user.
> Heat treatment can be performed 2 times after the very first HT. ( Check if original MTC comprises Mechanical testing performed after 3 Simulated HT, This is done to assure that mechanical properties are retained even after 3 cycles of HT ).
> Any repair done by/on welding shall have R-stamp in my opinion, and if the repair is done on load bearing members then it shall not be conclude as a routine repair irrespective of weather equipment is commisioned or not.
Best is,
1- Raise a Non-confirmance report
2- Prepare a corrective action report.
3- If repair required by welding or replacement of pressure containing
parts.
4- Prepair a repair procedure.
5- Get AI & End user acceptance.
6- Sign off R-stamp.
For your information, both U-stamp & R-stamp name plate can be
retained on the equipment.
On Jan 15, 9:14 pm, "masthan" <sabreenbah...@hotmail.com> wrote:
> Dear Mr. Abhijit,
>
> In my opinion U stamp can be provided by the original equipment manufacturer under the following conditions
>
> 1. Repair shall be carried out after getting acceptance of AI and end user by original manufacturer of this equipment.
> 2. MDR for the original equipment still not signed by AI.
> 3. Original U Stamp name plate shall be removed before proceeding repair and witnessed by A.I
>
> M.M
>
> _____
>
> From: materials-welding@googlegroups.com [mailto:materials-welding@googlegroups.com] On Behalf Of Abhijit
> Sent: Friday, January 14, 2011 3:15 PM
> To: materials-welding@googlegroups.com
> Subject: Re: [MW:9218] HEAT EXCHANGE ACCIDENT
>
> I am not agree for the repair with R stamp as these exchanger are not commissioned and not yet installed so will not comes in juridiction of R stamp
>
> This can be repaired and re tested with AI with approval of repair procedure
>
> Also raise NCR for end user confirmation as this is major NCR and definetely end user approval is required with repair procedure approval
>
> Abhijit
>
> Sent from my iPhone
>
> On 2011 जानेवारी 14, at 08:35, Fred Majdnia <FMajd...@technip.com> wrote:
>
> Dear Karandish
>
> You can accept the repair procedure with the following approach:
>
> * Get A.I. approval of the written repair procedure if the Item is Code stamped. The repair work shall also be done by a R-stamp holder.
> * Cut the damaged area using mechanical means( No flame cutting to be used)
> * Pull out the tube Bundle for inspection ( it is unlikely to have tubes damaged)
> * Weld the insert patch with round corners or circular shape
> * WPS/PQR should have been qualified with double PWHT meeting all requirements of SA387 -11 CL2+S5
> * Perform RT and UT on the weld
> * Grind flush the weld from inside
> * Perform Pressure Test
> * Insert the Bundle and prepare to close it up
> * Fill R1 form if the Item was code stamped. To be signed by stamp holder and A.I – Install a new R-name plate if the insert patch is done. If Nozzle is used then R-name plate may not be required if A.I agrees and accepts the repair as a routine repair per NB-23.
> * No need to do leak test, if the tubes were not damaged.
>
> Please note that a Nozzle of 4” or 5” can be welded instead of the insert patch if the proposal and design calculation accepted by Client ( end user).
>
> Good luck
>
> Regards
>
> -----materials-welding@googlegroups.com wrote: -----
>
> To: <mailto:materials-welding@googlegroups.com> materials-welding@googlegroups.com
> From: AA karandish <aa.karand...@yahoo.com>
> Sent by: <mailto:materials-welding@googlegroups.com> materials-welding@googlegroups.com
> Date: 01/13/2011 12:29AM
> Subject: [MW:9206] HEAT EXCHANGE ACCIDENT
>
> Dear all,
>
> My company has an EPCC (Engineering, Procurement, Construction and Commissioning) contract for an Ammonia plant with a contractor. During the transportation a shell and tube heat exchanger is faced to an accident which causes a severe damage on its shell side. Major defect has the size of 50 x 50 CM and bighted inside approx. 4 cm (like a bowel but not so smooth).
>
> Repair procedure submitted by the contractor is divided in two sections as follows:
>
> : Section 1
>
> 1- Performing the hydrostatic test on shell and tube side.
>
> 2- Performing the MT and UT on dented areas.
>
> 3- Performing the hardness test on all damaged joints (base metal, weld metal and HAZ).
>
> 4- If the mentioned test on this section is approved then heat exchanger is ready for shipment to site
>
> : section 2
>
> If the mentioned test in section “A” do not approved then:
>
> 1- Damaged tubes shall be replaced.
>
> 2- Dented areas on shell shall be cut and patched with the same material.
>
> 3- Performing the UT and MT on new weld seams.
>
> 4- Performing the hydro-test on shell and tube side.
>
> Specification of this heat exchanger is as follow:
>
> * Size: 1500 ID x 7900 L
>
> * Type: NEN horizontal
>
> * Code : ASME SEC viii DIV 1 & TEMA CLASS R
>
> * Shell and tube side design pressure: 180 barg
>
> * Shell side design temperature: 240 deg C
>
> * Tube side design temperature: 335 deg C
>
> * MDMT: -14 deg C
>
> * Shell and tube side are in H2 service
>
> * Shell material: SA-387-11 CL2+S5
>
> * Channel & tube-sheet material:SA-336-F11 CL2+S13
>
> * Tube material: SA-213T11
>
> * PWHT: already done after fabrication.
>
> My request from you:
>
> a- Please check the submitted procedure for its adequacy in detecting the possible damage/ and have your comment for new test if any.
>
> b- By my opinion in any case a window on shell side shall be cut to check the condition of heat exchanger tubes and renew the dented area.
>
> c- Since the heat exchanger is already PWH treated after the fabrication, please let me know your opinion regarding the second PWHT after repair and its effect on properties of base metal.
>
> Thank you for your prompt attention,
>
> --
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