12522-2300004-2_draft20091103

1.1

PROGETTO PROJECT

PORTO TOLLE

COMMESSA JOB

12522 CLIENTE CUSTOMER

ENEL S.p.A

ORDINE ORDER

200030 IDENTIFICAZIONE ESTERNA EXTERNAL IDENTIFICATION

FORNITORE SUPPLIERT __________________ DOC. n ___________ REV. ____

COMPONENTE PLANT

CALDAIA ULTRASUPERCRITICA 660MWe ALIMENTATA A CARBONE

TITOLO TITLE

PTS MEMBRANE WALLS INCL. HEADERS

ESITO SUPERVISIONE Supervision Outcome

2

REV DATA

Date

Issue

Scope

ESAMINATO

Supervised by

COLLABORAZIONI

Co-operations

APPROVATO

Approved by

EMESSO

Issued by

DIVISIONE INGEGNERIA E INNOVAZIONE AREA DI BUSINESS SVILUPPO E REALIZZAZIONE IMPIANTI

Documento / Document no

PBPTO52222

Indice Sicurezza Security Index

Uso Aziendale / P

INOLTRO A INN / SRI INN / SRI submittal

[X] PER APPROVAZIONE For approval

[ ] PER INFORMAZIONE For information only

[ ] NON RICHIESTO Not requested

SISTEMA 51A System

TIPO DOCUMENTO ST Document type

DISCIPLINA M Discipline

FILE PBPTO5222202 File

Lapprovazione di INN / SRI limitata agli aspetti relativi alle prescrizioni contrattuali, rimangono pertanto a carico del Fornitore

tutte le responsabilit della progettazione.

The INN / SRI approval refers to contractual requirements and

clauses only. All design responsibilities remain charged to the

Supplier.

PROGETTO Project

IMPIANTO DI PORTO TOLLE Trasformazione a carbone

CLIENTE Client

DIVISIONE GENERAZIONE ED ENERGY MANAGEMENT Enel Produzione Spa

JOB no : Doc. no. ---------------------------

INOLTRO AL CLIENTE Client submittal

[ X ] PER APPROVAZIONE For approval

[ ] PER INFORMAZIONE For information only

[ ] NON RICHIESTO Not requested

02 2009/xx Primary updated acc. to ConCerts comments HCL GuP ReV

01 2009/03/09 Primary updated acc. to ConCerts comments HCL GuP HCL

00 2008/09/23 GuP HCL HCL

REV. DATA DATE

DESCRIZIONE DESCRIPTION

REDATTO PREPARED

VERIF. VERIFIED/CHECKED

APPROV. APPROVED

IDENTIFICAZIONE IDENTIFICATION (PLE) 4100

FOGLIO SHEET

1 di 28

DOCUMENTO N. DOCUMENT NR. 12522-2300004

REVISIONE REVISION

0 1 2

PROGETTO PROJECT PORTO TOLLE

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12522

CLIENTE CUSTOMER ENEL S.p.A

ORDINE ORDER

200027

FOGLIO SHEET 2 di 28


REVISIONE REVISION 02

DATA DATE xx.xx.2009

DOCUMENTO N. DOCUMENT NR. PBPTO52222


Table of Content

1 INTRODUCTION .............................................................................................. 3

2 SCOPE OF SUPPLY ........................................................................................... 4

2.1 EQUIPMENT ............................................................................................................................... 4 2.2 SERVICES ................................................................................................................................. 5

3 LIMITS OF SUPPLY .......................................................................................... 6

3.1 CONNECTIONS TO FLUE GAS DUCT (OUTLET BOILER) .................................................................... 6 3.2 CONNECTIONS TO ADJACENT PRESSURE PARTS ........................................................................... 6 3.3 CONNECTIONS TO BUILDING ....................................................................................................... 6 3.4 CONNECTIONS TO COLD BUCK STAYS .......................................................................................... 6

4 OPTION ........................................................................................................... 6

4.1 OPTION 1 - DETAIL ENGINEERING AND PRODUCTION OF BOILER CEILING........................................ 6

5 RESPONSIBLE AUTHORITY.............................................................................. 7

6 DELIVERY OF MATERIALS ............................................................................... 8

6.1 MATERIALS PURCHASED AND DELIVERED BY BWE ....................................................................... 8 6.2 MATERIALS PURCHASED AND DELIVERED BY SUPPLIER ................................................................ 9

6.2.1 Requirements to supplier of pressure part material............................................................ 9 6.2.2 Purchase Specification .................................................................................................... 10 6.2.3 Technical delivery conditions ........................................................................................... 10 6.2.4 Special material requirements ......................................................................................... 11

7 REQUIREMENTS FOR DESIGN AND PRODUCTION .......................................... 12

7.1 STANDARDS ............................................................................................................................ 12 7.2 WORK SHOP IMPLEMENTATION ................................................................................................. 12 7.3 QUALITY CONTROL PLAN (QCP) .............................................................................................. 14 7.4 MATERIALS ............................................................................................................................. 15 7.5 SPECIAL REQUIREMENTS FOR MW ............................................................................................ 16 7.6 BENDING ................................................................................................................................. 17 7.7 WELDING ................................................................................................................................ 18 7.8 PREHEATING ........................................................................................................................... 21 7.9 HEAT TREATMENT .................................................................................................................... 21 7.10 GENERAL REQUIREMENTS FOR MARKING ................................................................................... 22 7.11 MACHINING AND MARKING OF WELDS ........................................................................................ 22 7.12 CLEANING, CORROSION PROTECTION AND SURFACE TREATMENT ................................................ 22 7.13 DEVIATIONS ............................................................................................................................ 23

8 PACKING, TAGS AND DISPATCH.................................................................... 23

8.1 DISPATCH DECLARATION OF CONFORMITY ................................................................................. 24

9 TECHNICAL GUARANTEE ............................................................................... 24

10 PROJECT MANAGEMENT ................................................................................ 25

10.1 PROJECT ORGANIZATION .......................................................................................................... 25 10.2 PROJECT DOCUMENTS ............................................................................................................. 25

11 DOCUMENTATION ......................................................................................... 27

11.1 GENERAL ................................................................................................................................ 27 11.2 PROJECT DOCUMENTATION ...................................................................................................... 27 11.3 FINAL DOCUMENTATION (QUALITY-DOCUMENTATION) ................................................................. 27 11.4 MODIFICATIONS OF DOCUMENTATION ........................................................................................ 28


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1 INTRODUCTION

This technical specification comprises of the technical requirements for manufacturing and delivery of the membrane boiler walls (MW) including welded on details, tie bars, headers and connection tubes and warm buck stays. The walls will be installed at the utility power plant Porto Tolle (PBPTO) situated in Italy owned by ENEL. The new plant will consist of three (3) identical 660Mwe coal fired tower type USC boilers. The boilers are to be installed by a consortium consisting of STF, Burmeister & Wain Energy A/S (BWE) and SICES / Irem starting 2010 and ready for commercial operation 2012.

The boilers will be designed and manufactured in accordance with PED, EN12952, BWE and special customer requirements which are stated in this specification.

The following subjects are specified in this technical specification:

o Scope of supply and options.

o Responsible Authority.

o Delivery of materials.

o Work shop implementation.

o Manufacturing.

o Control and documentation.

o Packing and dispatch.

o Project management.


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2 SCOPE OF SUPPLY

The scope of supply comprises partly delivery of materials, work shop implementation, manufacturing, quality control, corrosion protection, packing, dispatch and documentation of MW for all three (3) boilers, including items connected to the walls, according to following clauses.

2.1 Equipment

The scope of supply includes the below mentioned items (for one (1) boiler).

Membrane walls

The MW is split into the below listed main units which again is divided into several wall sections due to transportation ability.

o Upper pass.

o Transition between coil and upper pass.

o Coil (spiral).

o Hopper (spiral).

Headers including connection tubes

The headers incl. welded on nozzles, Heads and connection tubes must be regarded as complete units for which only site assembly at the limits of supply are necessary, depending on the Suppliers total scope of supply.

o 4 pcs. of Upper pass outlet headers. (Each divided into site units specified on BWE dwg.).

o 4 pcs. of Coil outlet headers. (Each divided into site units specified on BWE dwg.).

o 2 pcs. of Hopper inlet headers. (Each divided into site units specified on BWE dwg.).

o Connection tubes.

o Nozzles.

o Heads for nozzles < OD100

Tie bars including Tie bar heads

o Tie bars and tie bar heads for coil and hopper.

Warm Buck Stays

o All warm buck stays (UNP300) including weld on details placed inside insulation (400 mm) except links to cold buck stays.


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Additional details

These below mentioned details are also part of the scope:

o Boiler openings including plate casings where relevant for e.g. burners, air supply, inspection holes, access doors and soot blowers.

o Forgings welded to wall tubes.

o Welded on details for mounting of warm buck stays.

o Welded on details for mounting of cold buck stays (cold buck stays is outside scope of supply).

o Welded on details for tie bar and tie bar head.

o Welded on MW flat bar suspensions including plate with bush for connection to suspension bars at ceiling and flue gas outlet.

o Wall penetrations for heaters.

o Lifting and fixation details for handling and joint welding on site PBPTO.

o Lifting eyes and steel frames for handling the goods in the work shop, for loading on and off trucks and for transport.

2.2 Services

The following services are part of the supply:

o Partly purchase and delivery of materials necessary for manufacturing and transportation

including consumables.

o Production plan.

o Quality Control Plans (QCP).

o Progress reports.

o Project management and coordination of all activities with BWE.

o Work shop implementation including preparation of additional drawings (if necessary).

o Production procedures.

o Production.

o Production control and tests.

o Pressure test (if any).

o Surface treatment.

o Assembly test.

o Packing and loading on trucks.

o Documentation.

o Involvement of BWEs representative inspection company.

o Declaration for compliance of conformity.

o Transport to site PBPTO in Italy.


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3 LIMITS OF SUPPLY

The limits of supply appear in detail on BWE drawings included in Attachment to the contract. Placement in boiler appears on the following drawing also included in Attachment to the contract:

12522-0100001 BOILER SECTION

The components mentioned below as limits of supply are part of the supply if not option. Any internal division of the supply for transportation is not meant as and are not mentioned below as limits of supply.

3.1 Connections to flue gas duct (outlet boiler)

o Outlet plate welded to MW.

3.2 Connections to adjacent pressure parts

o Penetration MW for heaters.

o Forgings open ends bevelled for site welding.

o Headers open ends bevelled for site welding.

o Connection tubes open ends (small number if any) bevelled for site welding.

o MW tubes, headers and connection tubes open ends bevelled for site welding, if not welded in work shop.

3.3 Connections to building

o Welded on MW flat bar suspensions including plate with bush for connection to suspension bars at ceiling and flue gas outlet (the boiler is hanging in an external supporting steel structure above the boiler).

3.4 Connections to cold buck stays

o Welded on details for connection to cold buck stays. (Cold buck stays not part of scope).

4 OPTION

4.1 Option 1 - Detail engineering and production of Boiler ceiling.

Equipment

Complete boiler ceiling made of plate with welded on stiffeners.


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. Detail engineering

Detail engineering based on basic engineering drawings from BWE. BWE decide choice of materials and if not specified to be approved by BWE. All strength calculations are to be made by BWE. Materials

All materials including consumables are part of the supply. Outside scope of supply

Mounting of the ceiling is not a part of the supply and will be done by the Consortium on site PBPTO. Specification

Design according to the attached BWE drawings as examples; see attachment to the contract. BWE will make specific drawings later on.

5 RESPONSIBLE AUTHORITY

For all Boiler pressure parts within BWEs scope of supply to PBPTO Conformity assessment

procedure PED97/23EC Module G is chosen. The User Inspectorate involved as responsible authority

is:

ConCert s.r.l.

Viale Edison, 18

20099 Sesto s.Giovanni (MI)

Italy

Design approval

Design approval of drawings, production procedures for welding and calculations are ordered by BWE

and issued by ConCert.

o BWE drawings and welding plans: BWE drawings of pressure parts will uncover enough

details and types of welds sufficient for design approval of the supply. The corresponding

welding plans must however be completed with information received from the Supplier, see

clause 7.7. The BWE drawings and corresponding welding plans are part of the

documentation BWE will submit to ConCert for their design approval prior to production start.

Consequently Supplier must inform BWE promptly of any changes needed on BWE drawings

and or welding plans caused by his detail work shop implementation.

o Production procedures for welding: Suppliers PED approved WPS and WPAR are part of the

documentation BWE will submit to ConCert for their design approval prior to production start.


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The Supplier must submit his PED approved WPS and WPAR to BWE in good time prior to

production start. Manufacturing inspections and approval of production

ConCert is the superior approving authority and will be approving the production procedures for design approval, see above. They will be the official approver of the manufactured parts as third party inspector for inspection and test and will be signing the dispatch declaration of conformity. Prior to any work shop activity BWE will check all the production procedures mentioned in this technical specification and upon approval BWE will release the respective work shop activity. Some of the production procedures are part of the design approval and will also need ConCert's official approval. To assist BWE in check of production procedures and quality check of the goods in the work shop / appliance with this technical specification during manufacturing, BWE might use external expertise. The external company such as Lloyds, TV etc. will act as BWEs representative inspection company only and not as responsible authority. Suppliers tender must include a list of preferred inspection companies; however final choice can only be made by BWE. Ordering of this external company and coordination of his presence in the work shop during manufacturing is to be determinate prior to contract.

6 DELIVERY OF MATERIALS

6.1 Materials purchased and delivered by BWE

The following will be delivered to Supplier by BWE including material certificates and custom

documents. The supply is specified in detail including time of delivery in the document BWE

Materials Scope of supply in Attachment to the contract.

o All MW tubes.

o All MW forgings manufactured.

o All main pipes for headers and connection tubes.

o Material for nozzles > OD100.

o All spherical Heads for headers manufactured.

o All pipes > OD100.

Upon receipt of the tubes and pipes in the work shop, the materials must be collected and clearly

marked with:

BWE - Order no. - PBPTO Drawing no. Pipe spec. no..


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They may not be stored outdoor without sufficient weather shield and natural air circulation and

without special approval of conditions by BWE.

The forgings and spherical Heads must only be stored indoor and clearly marked with:

BWE - Order no. - PBPTO MW Drawing no. Pos. no. Pipe spec. no..

Spare tubes for production

Spare tubes for production or production loss are included in the BWE purchase of tubes specified in

this clause to an extent estimated by BWE. In case the Supplier needs more tubes for production it is

his responsibility to inform this to BWE prior to contract, for this not to cause any delay of final delivery

time. Consequently Supplier must give his official approval of BWE purchase of materials prior to

contract. Unforeseen need of extra materials found during work shop implementation and production

is Suppliers responsibility to supply promptly and must always be informed to BWE.

The spare tubes and forgings (left-over from production) must be stored and protected indoor for

delivery to an address informed by BWE after end of production. Prior to delivery the tubes must be

cleaned inside by compressed air and dried by circulating clean dry air ending by mounting air tight

internal end caps/plugs, type slatted end cap.

The tubes must be collected and clear marking must appear on the tubes at all times in the workshop

and during storage.

BWE Order no. PBPTO MW Spare tubes Tube dimension Pipe spec. no.

6.2 Materials purchased and delivered by Supplier

All materials except from above mentioned in clause 6.1 must be delivered by the Supplier including

consumables and all non-pressure parts necessary for production and transportation such as fixtures

etc.

Purchase and delivery of materials must be kept updated on Suppliers time schedule and additionally

in the progress report.

Prior to purchase BWE must approve the steel manufacturer.

6.2.1 Requirements to supplier of pressure part material

1. Material delivered from a manufacturer:

o The manufacturer must be PED approved and the field of validity on the certification

specifies production of material and shall indicate the relevant material type for the

purpose of PED application.


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2. Material delivered from a stockist:

o The stockist must have a certificate QM System according to EN764, Part 5, chapter 6.

o The manufacturer must fulfil the requirements of the previous point 1.

o The original material certification according to EN10204, Type 3.2 must comply with the

requirements of both PED and this specification.

If the requirements of point 1 or 2 are not fulfilled additional test are required in order to comply with

the present specification. These test must be performed under ConCert surveillance or, if authorised

by Concert, under purchaser surveillance. In this case, a certification according to EN10204, Type 3.2

is required.

6.2.2 Purchase Specification

o Tubes and pipes: The Supplier must use the purchase specification, Doc. No.: 12522-

2300002, made by BWE for his purchase.

o Plates and forgings/bars: The supplier must make his own purchase specification based on

the following requirements in this Clause. If the material is 15NiCuMoNb5, see next point.

o Forgings/bars in material 15NiCuMoNb5 (if relevant): The supplier must make his own

purchase specification based on the PMA Doc. No.: 12522-2200025 respectively, Doc. No.:

12522-2200023.

6.2.3 Technical delivery conditions

Materials must be delivered according to following EN standards:

Plates: EN10028-2, Test class S3 + E4 acc. to EN10160 (UT)

Forgings/bars: EN10222-2, Test category 2 acc. to EN10216-2, NDT acc. to EN10228-1, 2, 3

All materials must be delivered with material certificates according to BWE drawings, EN10204; 2004:

Pressure parts: 3.2

Alloy-steel non-pressure parts: 3.1

Ferritic steel non-pressure parts including non-pressure parts welded on pressure parts: 2.2

On the certificate for pressure parts it must be stated by the steel manufacturer: Conformity to the

PED 97/23/EG appendix 1 clause 4.1 and 7.5 is guaranteed. Copies of the certificates must be

sent to BWE as soon as possible. Originals must be placed in the final documentation.


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6.2.4 Special material requirements

All pressure part material grades must have the minimum specific absorbed energy not less than 50

J/cm2 (for specimen in transverse position) and 75 J/cm2 (for specimen in longitudinal position)

measured at 20C. Whenever the applicable standard specifies more stringent requirements, this

latter shall be applied.

Plates for pressure retaining parts (plates used as Heads)

The ultrasonic test (UT) for laminar imperfection according to EN10160 with acceptance criteria

S3+E4 is required.

Additionally the plates shall be fully inspected by UT and MT examination before rolling or forming.

Impact test according to EN10045 shall be performed for all plates with thickness above 6 mm.

The result of the above mentioned requirements shall be documented on the certificate.

Forgings/bars

Both UT and MT/PT on 100% of volume according to EN10228 is required.

Impact test according to EN10045 shall be performed for forged tubes above or equal to OD 42, 4 x

6,3mm. For forged material / steel bars used for e.g. Heads the lower limit is thickness 6 mm.

The result of the above mentioned requirements shall be documented on the certificate

Chemical composition

For material quality X10CrMoVNb9-1 the aluminium content may not exceed 0.02% (Al


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All materials designed for creep rupture are noted on the drawings in the label for design data.

7 REQUIREMENTS FOR DESIGN AND PRODUCTION

7.1 Standards

The Supply must fulfil the performances according to the design basis. Apart from this technical

specification, BWE drawings and welding plans, the supply is subject to the following rules and

standards:

Pressure parts:

o PED97/23/EC.

o EN12952 (all relevant parts)

Dimension tolerance:

o ISO 13920 linear class A / straightness and flatness class F for connection tubes.

o ISO 13920 linear class A / straightness and flatness class F for headers and MW.

All deviations from above standards must be specified by the Supplier and accepted by BWE prior to contract.

7.2 Work shop implementation

Basic design, special requirements, testing of welds (NDT), surface treatment etc. are specified by BWE drawings, the document NDT in the work shop for boiler pressure parts Doc. No.: 12522-2200043 and this technical specification.

Stress calculations

Calculations for design approval are made by BWE. Stress calculations in Suppliers scope are only relevant for any transport and lifting details. Work shop coordination drawings

Only BWE drawings will be design approved and as such they must be used as base for production. During the Suppliers work shop implementation BWE can revise the drawings in order to integrate requirements that enable the Supplier to use the drawings as work shop drawings in his production. Should the Supplier have the need of making further detailed drawings for his production, this must be done fully in accordance with BWE drawings and this specification. These drawings must be part of the final documentation if BWE finds it relevant.


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The correspondence from Supplier to BWE for stating requirements for changes is done electronically directly on the AutoCAD drawing. BWE will implement the changes and eventually send the drawings to ConCert for approval. Specific procedure for this interface must be agreed before contract signing. It is very important and Suppliers project managements responsibility to implement new revisions of BWE drawings promptly and ensure that all relevant persons in his organisation including the production always posses the latest revision. Old or handmade revisions implemented in Suppliers work shop will not be accepted. Production procedures

Production Procedures are detail descriptions of production methods, test methods and extent, working sequences, special requirements for handling of materials etc., QCP (Quality Control Plan), WPS (Welding Procedure Plan), WP (Welding Plans), heat treatment, bending procedure, pressure test procedure and surface treatment plan are all considered included in this category. All production procedures must be in English. Supplier is responsible for translation to national language if needed in the work shop.

Distribution and acceptance

Prior to production start production procedures must be submitted to and approved by BWE. Approval of procedures releases the respective work shop activity. In case of comments the Supplier must incorporate the indicated comments and submit a new revision of the procedures. Approval by BWE must never constitute cause for delay of the works. The Supplier is responsible for submitting the documents in sufficient time and for possible modifications and re-submittal. Review and approval by BWE does not release the Supplier from full responsibility for compliance. The Supplier alone is responsible for performing the work according to this Technical Specification, including BWEs basic engineering and the contract conditions. Should the Supplier have the need of making detail working instructions, translation documents etc. for implementation in the work shop, such documents must be made fully in accordance with the approved production procedures. It is very important and Suppliers responsibility to implement new revisions promptly and ensure that all relevant persons in his organisation including production always possess the latest revision. Old revisions or handmade revision implemented in Suppliers work shop will not be accepted.


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7.3 Quality Control Plan (QCP)

Supplier must forward a preliminary QCP to BWE prior to order.

Prior to manufacturing and according to the Time Schedule Attachment G the Supplier must send a

final QCP for BWEs approval, which must state the following information as a minimum. It must be

made in chronological manufacturing order:

o Reference to drawing numbers and this technical specification.

o Activity (What to be inspected/tested? Reference to drawing no.)

o Description (how the inspection/test will be carried out?)

o Type of certification (Chemical analysis certificates, inspection and testing certificates).

o Extent (how comprehensive is the inspection/test?)

o Basis for acceptance (what is the criteria for approval?)

o Form for documentation (how is the inspection/test to be documented)

o Inspector (who shall perform the inspection/test?)

o Column for BWE marking of witness or hold points.

o Column for BWEs representative inspection company with name at column head.

o Column for Sices (erection company).

o Column for ENEL for marking of witness or hold points.

o Column for ConCert for marking of witness or hold points.

o Space for Suppliers marking of result and date of checking.

Furthermore the Supplier must prepare and forward more detailed test program for each test if

required by BWE.

For inspections/tests witnessed by BWE/the end customer Supplier must advise BWE for this activity

minimum 15 working days before the date.

At any time BWE can require additional test and inspections and further, visits of the end customer

ENEL and ConCert or their representatives must be granted by the Supplier at any time.

All test reports including NDT-reports must state Pipe spec. no.


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7.4 Materials

Entry control

Suppliers entry control procedure (check of materials on receipt in work shop) and following traceability during production must be accepted by BWE.

It must be possible at all time to identify each material item during manufacturing, by means of at least

the charge number and mark specified in clause 6.1

PMI (Positive Material Identification) is mandatory for all materials.

Hardness test must be performed as follows for the material X10CrMoVNb9-1:

o On the surface 100mm from ends in position 4,8 and 12 oclock and if length exceeds 2 m the

test is repeated for every 2 m.

Accept criteria:

X10CrMoVNb9-1: 175-250 HB

The result of the hardness test must be documented in a report signed by BWEs representative for inspection and send to BWE prior to production.

Re-stamping

Suppliers permission and procedure for re-stamping of materials must be accepted by BWE.

Test ring

Before production of Headers in X10CrMoVNb9-1, one test piece, with a length of 50 mm, from each charge number must be cut of the raw pipe and marked according to the following and delivered to BWE.

BWE - Order no. - PBPTO TEST RING Material Pipe dimension Charge no. Pipe spec. no.

Requirements for martensitic materials during production

For material X10CrMoVNb9-1 the Supplier must implement a special work shop procedure for handling these materials. The procedure must be approved by BWE and must as a minimum include the following:

o Entry control (hardness test).

o Electrical preheating.

o Period between welding/hot forming and heat treatment: No hard stamping, no vibration, no hammering or shocks, no machining or grinding, no contact with water/moisture.


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o Exit control (hardness test). Each point is specified in this technical specification.

Exit control for martensitic materials

After production but prior to surface treatment the Supplier must perform another hardness test for the material X10CrMoVNb9-1 as follows:

o On the surface 100mm from ends in position 4,8 and 12 oclock and if length exceeds 2 m the test is repeated for every 2 m.

Accept criteria:

X10CrMoVNb9-1: 175-250 HB

The results of hardness test must be documented in a report signed by BWEs representative for inspection and send to BWE prior to dispatch.

7.5 Special requirements for MW

General

Sharp edges dangerous for erection and repair personnel, burrs from drilling, cutting etc. must removed and prevented. Site joints / division of supply

The walls must be manufactured so that all parts are able to be transported to site PBPTO and

manageable to handle on site, but at the same time in as large parts as possible for standard size

truck transportation in order to minimize erection time. On BWE drawings the suggested divisions are

specified. Suppliers approval / own suggestions must be submitted.

Lifting eyes and or beams are part of the supply. Preparations for Boiler Wall site welds

To allow possible adjustment of tube alignment on site, each wall section ending with tube-membrane for site joint must be provided with slots on every second membrane fin. Dimensions for slots are acc. to BWE standard drawing no. 00000-4441020. Only exception for this is wall endings with forgings.

Slots must be cut using cutting machine (not flame cut) with smooth surface without any transversal

notch.

Membrane ends with no connecting site joint must be made acc. to BWE standard drawing no.

00000-4441020.


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Dimensional and alignment checks

In order to secure that the supply fits geometrically without any necessary adjustments on the erection site at the limits of supply the Supplier must make dimensional and alignment checks during production and a final check as delivery control.

For MW: The minimum amount of check dimensions to be reported appears on the BWE drawings for each

panel surrounded by a line.

Prior to the final check the Supplier must submit a drawing for BWE approval specifying which dimensions with tolerances that will be checked.

The final dimensional and alignment check must appear in the Quality Control Plan.

Accept criteria are stated on BWE drawings. General criteria are stated in clause 7.1 Any corrections by e.g. bending that stresses the welds of the component must be followed by new NDT of the welds. Results must be documented by protocol and sent to BWE after performance and included in the final documentation. Assembly test of Boiler Walls

In addition to above mentioned dimension and alignment checks an assembly test shall be made in Suppliers work shop where each individual wall section is laid down as a puzzle on trestles placed in final position (not welded together) for visual inspection of internal site joints, welded on details and pre-mounted warm buck stays.

The test includes dimensional check of both internal site joints within the limits of supply as well as overall dimensions for joints at the limits of supply.

The test must be demonstrated to and accepted by BWE in good time before delivery, so that any corrections can be made without influencing the delivery time.

Results must be documented by protocol and sent promptly to BWE after performance and included

in the final documentation.

The assembly test must appear in the Quality Control Plan.

7.6 Bending

All tubes must be cold bended according to specified requirements on BWE drawings without post

heat treatment.

Bends of bended pre-welded membrane-tube walls is preferable in boiler corners but in some areas

only single tube bends are possible.


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Ovalization and NDT must be acc. to EN12952-5.

NDT for gang bends is acc. to the document NDT in the works shop for boiler pressure parts, Doc.

No. 12522-2200043.

Specified radius on BWE drawings must be approved by the Supplier or alternative suggested in good

time prior to bending.

BPAR (Bending Procedure Approval Record) acc. to EN12952-5 Annex A must be signed by

recognized 3rd party and approved by BWE and ConCert prior to bending.

7.7 Welding

General

Tube to tube welds must be kept to a minimum. This must be planned prior to production according to the specified length of tube delivery from BWE. All welded joints shall be arc welded, using approved and qualified procedures according to the EN15614-1 edition 2006, integrated by PED rules and applicable EN Standards additional requirements. At least first pass must be performed by method TIG 141 on pressure retaining welds.

NDT extent Furthermore welding and testing of welds must be performed according to the welding plans, this technical specification and the document NDT in the work shop for boiler pressure parts Doc. No. 12522-2200043. Destructive testing of welds (DT) is according to the norm EN12952-5 Annex C for membrane steel longitudinal to tube. This means that prior to production start the required run test must be performed for each dimension and quality of material.

Non-pressure parts:

o EUROCODE 3

Minimum quality level C according to EN5817.

General:

In case of conflicts between the above mentioned documents for any order relevant activity in general

the stringer requirements shall prevail and BWE must always be informed prior to implementation.

Weld repairs


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All joints that does not meet the acceptance criteria, as defined by the design approved BWE welding plans, shall be repaired using following procedure:

1. Removing defect using mechanical tool and finishing by grinding.

2. Checking for cracks and similar defects using MT or PT.

3. Repair weld using approved WPS.

4. Weld examination of repaired weld by the same non destructive test method previously used for defect detection. In case of negative result, this procedure 1-5 must be repeated.

5. Issuing repair welding certification (NDT report).

Procedures for extension of NDT in case of imperfections is acc. to EN12952-6.

Welders

Only welders with valid certificates according to EN287 and requirements acc. to PED for the actual

material group and actual welding process and position may perform the welding work.

Welders traceability is mandatory.

During the production, the Supplier must keep record of the welders performance in order to exclude

and re-certify welders with systematic repeated failures.

Welding test for martensitic materials

For material X10CrMoVNb9-1 only welders which have passed a special welding test on these

materials may be assigned. The test requirements are as follows:

Each welder shall prepare a sample for the relevant WPS with martensitic materials included. The

sample must be checked for:

o Micrographic absence of hard or soft zones, i.e. tungsten compound aggregates not

completely transformed austenite. The micrographic picture must be with a 500x magnification.

o Impact test according to EN10045 for tubes above or equal to OD42,4 x 6,3mm. The impact test

must include test of root, intermediate and upper side of the weld material. Accept criteria is

minimum specific absorbed energy not less than 50 J/cm2 (for specimen in transverse position)

and 75 J/cm2 (for specimen in longitudinal position) measured at 20C.

The above mentioned special welding test in martensitic materials must appear in the QCP and

documentation must be available for BWE to review.

NDT personnel


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NDT-personnel must possess the required certificates for the performance of the actual tests

according to EN473-1993. The Supplier is responsible for ordering and coordination of NDT work.

The company of NDT personnel must be approved by BWE prior to order.

Welding Procedures

Prior to welding activity the Supplier must send his Welding Procedure Specification (WPS) and

Welding Procedure Approval Record (WPAR) for BWE approval. The documents are part of the

design approval from ConCert.

All WPAR must include impact and hardness test. However hardness test only if post welding heat

treatment (PWHT) is specified.

The WPAR must include the micrographic test pictures for all-weld material, HAZ and base material at

500x magnification.

For the attachments to pressure parts (e.g. Lifting devices) besides WPS only cover page of WPAR is

required with information that guarantees that impact and hardness test has been performed and

approved according to PED.

All WPS must state heat input and/or travel/feed speed. Beside that the WPS must state compliance

with PED.

If data for PWHT is not included on WPS, there must be stated a document no., where these data are

specified. This separate document must also be send to BWE for approval prior to welding activity

and is also part of the design approval.

If welding sequence for tag welding and/or part welding of layers are important for e.g. deflection of

the construction this must be stated on the WPS or as an attachment to this. Same requirement for

BWE approval as for PWHT.

On request BWE can demand a welding procedure test under conditions similar to the scope of

supply (materials, welding positions etc.) at any time and without any cost effect. Such a test must be

witnessed and be accepted by BWE prior to production start or alternatively prior to proceeding of

production if the request has been given during manufacturing and caused by welding problems.

Welding plan

The welding plan is the interface document between the drawing, WPS, PWHT and NDT. It states the overall parameters for each weld such as weld numbers, WPS no., welding method, heat treatment, method, extent and acceptance criteria of NDT etc.


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The layout for the welding plan is made by BWE and partly or completely filled out by BWE prior to

order. Completion and changes made by the Supplier must always be accepted by BWE prior to

implementation.

Based on agreed changes and or completion it is within BWEs scope to issue new revision of the

document. Revision of the welding plan always causes revision of the drawing and vice versa.

Consequently the revision number for drawing and welding plan is always the same.

If the Supplier chooses to use his own welding plan in the work shop, he alone has the responsibility

for full compliance with the latest revision of BWE welding plan.

Only BWEs welding plan are part of the design approval.

7.8 Preheating

Only controlled electrical preheating is allowed for martensitic materials, like X10CrMoVNb9-1.

7.9 Heat treatment

Heat treatment procedure must be approved by BWE along with WPS and WPAR. PWHT temperature must be 15C below the tempering temperature of the base material stated in the material certificate from the mill. The Supplier must issue a certificate of compliance concerning the accuracy of temperature controls of the heat treatment for X10CrMoVNb9-1. This applies for both the heat treatment in furnace and with electrical heat belts. The heat treatment batches for treatment in furnace must be classified by wall thickness so that every batch covers only one wall thickness. However if a given component consists of different sizes of wall thickness e.g. welded together components, the biggest wall thickness represents the component in this respect. Prior to treatment the equipment/facilities must be checked and continuously monitored during the operation. For weld seams in material X10CrMoVNb9-1 that are locally heat treated with electrical heat belts the Supplier must specify more detailed information such as annealing zone width, placement of thermocouples, internal insulation etc. For thick walled components it must be proven by measuring tests that the required temperature has been attained over the entire cross section of the weld before soaking time start. These requirements must be included in the Suppliers heat treatment procedure.


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7.10 General requirements for marking

o All hard stamps must be made with stamp tool type low stress.

o Hard stamping is not allowed on martensitic materials between welding/hot forming and heat treatment.

o Hard stamps must be visible after surface treatment.

7.11 Machining and marking of welds

o Materials may not be overheated during grinding.

o Fillet welds at nozzles and attachments must have an even concave shape. End of welds towards base material must have radius 3mm or above.

o For tubes with ID less or equal to 30mm max. Height of weld inside the tube is 1mm (excess penetration).

o Welds must be as minimum contain identification number and initials.

o Machining/grinding of welds must always be followed by surface test MT/PT.

o To secure proper conditions for NDT and to reduce risk of surface cracking initiated by surface irregularities, some butt welds must be machined externally by grinding to ground of the pipe surface with smooth surface.

The position of the welds must be marked permanently 50 mm from the centre of the weld using hard stamp dot type low stress.

This applies e.g. for materials in group 3 and 6 according to EN15608 with OD above or equal to 101,6mm and wall thickness larger then 15mm. Same requirements applies also for materials designed for creep rupture with OD above or equal to 101,6 mm.

Requirement for grinding to ground is always specified for each weld on BWE-drawing and /or the belonging BWE-welding plan.

7.12 Cleaning, corrosion protection and surface treatment

After all prefabrication operation both inner and outer surface of the tubes and the headers must have a maximum degree of cleanness. It means that all surfaces have to be free of burrs, iron scales, flakes, dents, welding drops, grains of sand etc.

All the surface treated components must be stored in a water sheltered area (not on the ground

outdoor) until dispatch.

The Supplier must submit a detailed surface treatment plan for approval by BWE.

External

Degreased and painted with work shop primer 70m except on the bevelled ends where the primer must be weldable 20m. Hard stamps must be visible after painting e.g. by the use of transparent Tectyl locally or completely.


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Internal

Sandblasting to SA2 acc. to ISO8501-1 is required, if the following requirements are not fulfilled:

o Adherent oxide less than 0,04 mm for OD up to 127mm.

o Adherent oxide less than 0,04 mm for OD above or equal to 127mm and carbon steel.

o Adherent oxide less than 0,06 mm for OD above or equal to 127mm and low alloy steel

material.

o Adherent oxide less than 0.08 mm for OD above or equal to 127mm and high alloy steel

material (i.e. X10CrMoVNb9-1)

For OD above or equal to 177,8, the tubes shall be submitted shop blasting, in all cases.

For securing a dry surface internally until erection the tubes and headers must be blown inside by compressed air and dried by circulating clean dry air ending with insertion of a suitable quantity of dehydrating material (silica gel or powder to be sprayed inside e.g. Cortec VC I 309) before mounting of air tight internal end caps/plugs (type slatted end cap for the smaller tubes and as per agreement with BWE for the larger ends) and also external end cap for protection of the bevelled ends. Regarding Suppliers purchase please note that internal caps type slatted/ribbed type are in some cases depending on dimension not on stock by manufacturer. Consequently these caps must be ordered in suitable time.

7.13 Deviations

BWE must always promptly be informed of any deviations from the specifications and contract

documents. The use of repaired components or of permanent deviating products must only take place

with a written approval of BWE in a non-conformity report. The report must be included in the final

quality documentation.

8 PACKING, TAGS AND DISPATCH

The supply must be delivered to the PBPTO site with a suitable protection against rain, dust, salt etc., and manageable to handle on site without damaging the supply.

A detailed packing list must be provided to BWE including numbers of packing, contents, weight and dimension.

Lifting eyes and steel frames for loading, transport and unloading are part of the supply.

All individual components must be supplied with clear marking by large scale capital letters, using water resistant paint, indicating:

BWE Order no. PBPTO MW name/Header name Pipe spec. no.


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8.1 Dispatch declaration of conformity

For each dispatch / eventually sub-deliveries the Supplier shall make a dispatch declaration of conformity for the actual dispatch that must follow the goods to the erection site. Quality documentation including the final declaration of conformity shall be in possession of BWE at latest 2 weeks after the delivery of the goods according to the contract time schedule. On the erection site BWE and ConCert will make entry control for each sub-delivery upon arrival prior to installation. When the dispatch declaration of conformity is verified with the corresponding quality documentation, the sub-delivery will be "released" for installation. The content of the declaration shall include the following and be signed by the Supplier and ConCert: We hereby declare that the production of the pressure equipment listed in this Dispatch Declaration of Conformity comply with the requirements of the Pressure Equipment Directive 97-23-EC.

o Name and Address of the Supplier

o Identification number for the dispatch

o Description of the pressure Equipment (wording and drawings / tag number)

o Conformity Assessment Procedure (Module G)

o Harmonized European Standards (EN 12952-5+6 etc.)

o Name of the Responsible authority for the project ( ConCert ) ConCerts signing of the dispatch declaration of conformity document must appear in the Quality Control Plan. It will take place on the premises of the Supplier after ConCerts control of the goods.

9 TECHNICAL GUARANTEE

All technical requirements must be strictly fulfilled and in case of deviations found within the warranty

period it must be corrected and repaired promptly by the Supplier.


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10 PROJECT MANAGEMENT

It is essential to BWE that the Supplier posses an up-to-date Quality Assurance System which

assures the supply from the time of order to the final delivery.

For Suppliers with no recent co-operation with BWE, as enclosures to the tender the Supplier must

send a copy of the Quality Assurance System, list of references and examples of relevant Quality

Control Plan (QCP) and Welding Procedure Specifications (WPS).Further the Supplier must include

filled out Manufacturers competency declaration form in his tender.

10.1 Project organization

For the execution of the order the Supplier must appoint one person in his organisation that will be

assigned to the project from start to finish. This person must be the contact person for BWE in all

matters and must be responsible for coordination of all activities with BWE. It is absolutely necessary

that this person is very well technical qualified and speak and write English. He must be detailed

familiar with all the requirements in this technical specification as it is his responsibility to ensure that

all requirements are implemented in every field of his company involved in execution of the order.

Standard procedures for the Supplier will not be accepted where special requirements are specified in

the order.

Furthermore the Supplier must send a list of all key persons involved in the project (Proj.

Management, Material purchase, Engineering, work shop and NDT personnel) their responsibilities,

e-mail, and the internal work flow for the order.

Incompliance with this clause cannot be accepted. It is essential for good co-operation, quality and

delivery time.

10.2 Project documents

All correspondence and project documents such as Production Plan, QCP, Drawings, Production

Procedures including Welding Plans, WPS, Welders Certificates, NDT certificates, NDT reports etc.

must be in or have a translation in English.

All project documents must as a minimum have initials, date and a revision number. Below is a

description of the planning documents that secures correct quality and delivery time.

Production Plan

The Supplier shall draw up a detailed production plan including purchase of materials and detail

engineering. The production plan with up-dated progress marked with percentage of finish work must

be forwarded to BWE at a regular interval specified in the contractual time schedule. The production


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plan must also specify the percentage of finish work divided in to each main activity. Any delay and

deviation must be described in the additional progress report.

Progress report

The progress report is a written report that describes the status of all activities with the above

mentioned production plan enclosed. During production pictures must be included.


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11 DOCUMENTATION

11.1 General

CAD-drawings, lists, etc. must be provided in original electronic format as well as PDF-format.

Wherever references to drawings are made in the documentation, the TAG no. and drawing number must be used.

Beside the required hardcopies of the documentation 2 CD-Rom copies containing the complete

quality documentation shall be forwarded, with all documents as PDF-files and placed in sub-

directories corresponding to the table of content.

The state of the final documentation must allow an immediate forwarding to the end customer.

Final approval of documentation will take place after the end customers approval. Until final approval the Supplier must revise his documentation according to requests from BWE and or the end customer.

11.2 Project documentation

All documentation that is specified in this technical specification and required during execution of the order respectively prior to any given work shop activity must be send electronically by mail. Further requirements are stated under the chapters Work shop implementation and Project documentation.

11.3 Final documentation (Quality-documentation)

By dispatch BWE will make first check of the documentation in its preliminary version. This check must appear in the Quality Control Plan. The final documentation must be finalized and send to BWE two weeks after dispatch at the latest. 2 set of paper copies a 2 CD-ROM including as a minimum and collected in the following order, meaning that the table of content look like this:

1. Table of content.

2. Declaration for compliance of conformity.

3. Third party inspection bodys approval.

4. Design approval.

5. Design approved drawings with ConCert stamps.

6. Design approved welding plans with ConCert stamps

7. Work shop drawings (if any)

8. As built drawings.


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9. QCP.

10. Material certificates, re-stamping reports and filler material for welding.

11. PMI reports.

12. Drawing with placement of welds (Traceability)/ (if any).

13. WPS

14. Welders certificates.

15. NDT- personnels certificates.

16. NDT reports for welds.

17. PWHT specification and charge

18. NDT reports for bends.

19. Dimensional check reports.

20. Assembly check reports.

21. Surface treatment plan.

22. Special order specific production procedure (if any)

23. Result of special test (if any)

24. Hardness test for X10CrMoVNb9-1

25. Approved deviations, repairs and non-conformity reports (if any).

11.4 Modifications of documentation

Not later than one (1) month after the expiration of the warranty period, Supplier must forward correction sheets if modifications have been made during the warranty period.

Documents

12522-2300004-2_draft20091103