SUPERHEAT INSPECTION SERVICES

1. GENERAL DESCRIPTION

The method basically consists of insulating the required surface of Dished Ends and converting the same into its own self-contained furnace. high velocity oil burners with angled

K type Chromel / Alumel thermocouples are attached on the Clean outdoor to record the temperature continuously. Control and temperature monitoring is achieved using these thermocouples connected to recording instruments.

The temperature distribution obtained by this method of heat treatment is within standard codes, E.g. ASME VIII, DIV 1.

The client is presented with a certified temperature chart of the heat treatment, together with a sketch showing the location of thermocouples.

2. SCOPE OF WORK

Type of JobDished EndsSize Various size Material of ConstructionSA 516 Gr.-70QuantitySite Location

3. HEAT TREATMENT SPECIFICATION

Unrestricted Heating Rate Up to 400 C.Heating rate of maximum above 400 C: - 170C/Hr . Holding temperature 610C + 15C.Soaking Time : 60 Minutes/inch (50min. minimum) Cooling rate of maximum upto 400 C:- 217C/Hr .Unrestricted cooling rate from 400 C (in Still Air)

4. HEATING SYSTEM

The heat treatment operation will be affected by the introduction of 02 no. high velocity Oil burner units from both sides. The burner will be designed to release maximum thermal release as follows.

Each burner rating.

a) Thermal release 1.5 x 106 kcal / hr b) Combustion air flow 3559 corm / hourThe burner are designed to give a maximum flame length of approximately 300 mm and consequently only hot combusted gases will effect heat transfer to the component .The turn down ratio will be extremely high in order to 30 : 1 and this feature gives complete and accurate control. No hot spots and produced maximum uniformity are achieved. The hot gases which are emitted from the burner at high velocity (150 m / sec) will produce effective heat transfer to the component and promote a high degree of temperature uniformity. The combustion products are accurately controlled at all times and minimum oxidation of the surface occurs. Complete combustion of the fuel shall be ensured.

Coupled to each burner via flexible hose is a combustion air fan which can be accurately controlled to deliver exact quantities of air to the burner.

The burner shall be fitted with angled / straight cones to give a uniform firing. Hot gases will be exhausted through other suitable opening The fuel supply from tank shall be routed to the combustion equipment and sufficient supply shall be available for the whole temperature cycle.On completion of insulation of the vessel, installation of combustion equipment, the Senior Technicians would carry out the firing of the vessel and produce a temperature record at the end of the stress as per specification. Two Senior Technicians would be in constant observation during the heat treatment on a continuous basis until the job has cooled down to below 300 oC.

5. THERMAL INSULATION

We propose to carry out the heat treatment by our Trolley type Bogie furnace at our Chikhali Works. All different size jobs will be placed inside the Trolley type Bogie furnace as per requirement.

The size of Trolley type Bogie furnace will be 7.5 Mtr. (Wide) X 4.25 Mtr.(High) X 12.5 Mtr. (Long) to accommodate the largest job. The Trolley type Bogie furnace will be designed to be top loading type and door will be lifted up to facilitate loading and unloading of the jobs in the Trolley type Bogie furnace.The jobs will heat treated by utilising 02 Nos burners which will be inserted form suitable opening in the Trolley type Bogie furnace side panels. The burners will be located such a manner that the clear distance between job and the flame shall be access of 1 Mtr to avoid heat spots and localising heating of jobs. The Trolley type Bogie furnace shall be insulated with high quality Ceramic Fiber insulation material. Accordingly, please find enclosed our most competitive detailed techno-commercial proposal for your consideration. We request you to go through the above and in case of any further clarification / information, please feel free to contact us.

6. SHOP ELECTRICAL SUPPLY

The various site electrical requirements are required are

a) 3 Phase 380 / 415 Volts 50 Hz, 60 Amps supply to be provided to combustion air fans and oil pumping units, adjacent to the burners to be individually switched at source.1. Combustion air fans : 02 Nos.2. Oil pumping unit : 02 Nos.3. Compressor: 02 Nos.

b) Stabilized single phase 220 V 50 Hz ,5 Amp supply to be provided to each temperature recorder

7. SITE FUEL SUPPLY.

The combustion equipment is capable of running from oil (HSD). The oil will be supplied from tank to the combustion equipments, with flexible safety hoses.

8. TEMPERATURE MEASUREMENT

TEMPERATURE RECORDING:

Temperature recorders shall be of the potentiometer self-compensating type, calibrated in degrees cellists with respect to a nickel-chromium / nickel-aluminum thermocouple, type K.

Temperature recorders shall be calibrated at intervals not exceeding 6 months. If the calibration checks yield information that the temperature recorder is not within the manufacturers specified tolerances (i.e.+0.25%.of scale deflection), recalibration will be performed. The calibrations shall be recorded and evidence to this affect kept with the instrument. The calibration certificate must show both the conditions of the instrument. Instruments utilized for calibration purposes shall certification traceable to a national standard and shall themselves be calibrated at intervals not to exceed 12 months.

In the event that the calibration check reveals that the instrument has been used with an error which would have led to the measured being outside the permitted tolerances, as specified in the heat treatment procedure, then full details of the welds involved shall be reported to the inspecting authority.

The chart speed shall be set at 25 - 30 mm / hr. and shall be checked during calibration. On artificial restriction on pen travel shall be used.

A clear print out of data shall be demonstrated before commencement of a heat treatment.

09. TEST PROCEDURE / HEAT TREATMENT FIRING CONTROL

A. fuel supply :All fuel supply hoses are to be checked for leaks by pressurizing the hoses and testing of joints at oil tank, pump, filter, regulator, valves & at injector.

Pressure regulators are to be checked for correct supply pressure settings.

B. Combustion Air Fans :After Checking that the voltage and frequency on the motor data plate comply with the supply available, the fan is to be started and checked for correct direction of rotation.

C. Burners :The burners should be test fired before commencing the heat treatment wherever possible. This should be done by removing the burner from its firing position and test firing it into the open air, provided it is safe to do so.

In the event of it being impossible to remove the burners for test firing, then all fuel supply lines are to be purged before connection to the burner.

On no account are burners to be left in position and connected to the fuel supply when not being fired.

D. Temperature Measurement System :

All thermocouples / compensating cable circuits are to be checked for continuity prior to the commencement of firing.

Immediately after the firing is started, all thermocouples are to be checked for correct polarity.

As temperature control is complex, the burner and combustion fan are fired and adjusted manually. Our Technicians will monitor the temperature constantly. The actual firing process will be attended on a 24 - hour basis.

10. DOCUMENTATION

A Senior Supervisor will ensure the procedural requirements are fully complied with. The supervisor will be responsible for completion of all documentation.The documentation information will comprise of the following:1. Specification and chart receipt form.2. Heat treatment record sheet as applicable.3. Temperature chart with specification, thermocouple locations, etc.4. Recorder test Certificate5. Thermocouple wire conformance certificateThe heat treatment section of the Specification and Chart Receipt Form will be completed by Superheat and endorsed accordingly by all parties. These would confirm all parties agreement to the heat treatment specification.

12. SAFETY PROCEDURE

Superheat will ensure that:1) All appropriate register and test certificates are up to date and valid as required by statue2) All plant provided for the contract is in good working order, properly maintained, and suitable for the purpose of the intended works.3) All personnel deployed on the contract are fully conversant with Superheat safety rules and policies, and with any special notified provisions for working at site.4) All personnel are issued with appropriate safety wear and personnel protection.

The Superheat Acting Safety Officer will be responsible for ensuring that:The Superheat Acting Safety Officer shall be authorized to enact all necessary disciplinary action in the event of any breach of Safety Rules by any Superheat personnel at shop.