DOCUMENT TITLE : FABRICATION PROCEDURE FOR STEEL STRUCTURE

PTI-ID V/P NO :
SECL V/P NO :
REQUISITION NO : MBA719 / 2B-207-1-1-H-RQ-0005
PURCHASE ORDER NO : PTI-ID-PROC-49-2020
ITEM DESCRIPTION : FIRED HEATER

□ APPROVED □ WITH COMMENT

□ REVIEWED □ RESUBMIT

This approval or review does not relieve the vendor /

subcontractor of his responsibilities to meet all
requirements of the purchase order

ORIGINAL CHECKED APPD(PRJ)

SIGN

DATE
SAMSUNG ENGINEERING CO., LTD

A 28-JAN-2021 FOR APPROVAL Posco S.O.PARK S.H.HWANG

REV DATE DESCRIPTION PREPARED CHECKED APPROVED

Dos Bocas New Refinery Project

PTI-Infraestructura de Desarrollo, S.A. de C.V. (PTI-ID)

SAMSUNG Ingeniería Manzanillo, S.A. de C.V.

JNK Heaters Co., Ltd.

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J- 10276- REQ- 003
FABRICATION PROCEDURE FOR
STEEL STRUCTURE Rev. No. 00

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- CONTENT –

Page

1. Scope . . . . . .. (3)

2. Project information .. . . . .. (3)

3. References . . . . . . .. ( 3 )

4. Fabrication . . . . . .. ( 36 )

5. Painting . . . . . .. ( 6 )

6. Inspection & Tolerances of Steel Structure . . . . . . .. ( 6 )

7. Packing . . . . . . .. ( 6 )

8. Marking . . . . . . .. (6)
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1. Scope
This procedure describes general requirements for fabrication of Steel Structure for DOS BOCAS
NEW REFINERY PROJECT.

2. Project information:
1.1 ITEM NO. : BA-71001A/B, BA-71002A/B, BA-71003.
1.2 QUANTITY: The quantities listed in this requisition are for (5) unit of heaters.
1.3 TOTAL NO. OF HEATERS REQ'D : Five (5) Heaters.

3. References
Following code and standard shall be form a part of this procedure.
3.1 Specifications

3.2 Codes and Standards

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(1) ASME: American Society of Mechanical Engineers – Boiler & Pressure Vessel Code:
- ASME Section I Rules for construction of power boilers
- Section II Material Specifications.
- Section V Nondestructive Examination.
- Section VIII Unfired Pressure Vessels, Division 1 and Division 2
- Section IX Welding and Brazing Qualifications.
- B1.20.1 Pipe Threads, General Purpose (Inch).
- B16.5 Pipe Flanges and Flanges Fittings NPS ½ Through NPS 24.
- B16.20 Metallic Gaskets for Pipe Flanges (Ring Joint, Spiral-Wound, and Jacketed).

(2) ASTM: American Society for Testing and Materials

- Material Specifications
- ASTM G 146 (latest) Standard Practice for Evaluation of Disbanding of
Bimetallic Stainless Alloy/Steel Plate for Use in High – Pressure, High –
Temperature Refinery Hydrogen Service Steel Material.

(3) AWS: American Welding Society

AWS D1.1 Structural Welding Code – Steel.
(4) SSPC: The Society for Protective Coatings.
4. . Fabrication
Fabrication and assembly work of steel structures shall be performed in accordance with the
fabrication drawings and relevant documents which are issued for governing this project.
4.1 Materials ( St eel & We l di ng)
Shape pattern of shape steels, such as H-Beam, Channel, Angle, shall conform to approved
Drawings, data sheets and project specifications.
Materials shall be used accurately as per dimension and shapes indicated on the applicable
drawings.
4.2 Storage of materials
Material shall be stored on the adequate platform in tidy and sound conditions in order to avoid
deformations, erosions or corrosions and to prevent them from mixing with other unrelated
materials.
4.3 Pre-fabrication
(1) Prior to proceeding with fabrication, layout work shall be performed in accordance with the
shop detail drawings.
(2) Cut size and length, location of holes, location of stiffeners etc., shall be traced accurately on
pattern plates and/or steel straps.
(3) The tapeline, to be used for layout work, shall be a first class tape.
4.4 Marking
Marking with pattern plates and/or straps, which were provided at layout work, shall be performed
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accurately on the steel.

4.5 Cutting
(1) The following equipment are suitably used for the purpose of cutting and fabrication.
- Cutting machine : Angle, Channel and H-beams Shapes
- Shearing machine : Plates and flat bars of proper thickness
- Auto oxygen cutter : Plates and flat bars of proper thickness
- Oxygen cutter : Miscellaneous, multi-purpose
(2) Cut edge shall be straight and free from slag and notch.
(3) Defects in cut edge shall be repairing welding and smooth grinding.
(4) Warping and bending shall be removed after cutting.
(5) Plate cutting arrangement shall be made so carefully that main weld lines shall not come to
the location of openings.
4.6 Bolt Holes
- The following equipment are suitably used for the purpose of fabrication.
- Multi boring machine
- Punching machine (Plate THK. 12mm or under)
- Handy boring machine
- The specified size of holes shall be drilled and/or punched accurately at clearly marked on the
steel.
- The rims of holes shall be cleaned completely by grinding.
4.7 Welding
- WPS/PQR shall be submitted for approval before welding is started.
- All structure welding shall be done in accordance with AWS D1.1 and approved WPS.
- Welding works shall be performed by welder only who has passed performance qualification
tests with AWS D1.1.
- And a welder list, which certifies the qualification of each welder, shall be submitted for
approval before welding is started.
- Welding electrodes shall have a chemical composition matching that of the base metals being
joined.
- Welding electrodes shall conform to the requirements of approved WPS and AWS.
3.7.1 Control of welding consumables
- Electrodes shall be clearly identifiable in color classifications and undistinguishable electrodes
shall not be used.
- All consumables shall be stored and handled with care.
- Electrodes, filler wires that show signs of damage or deterioration, i.e. cracked or flaked
coatings on covered electrodes, rust or dirty electrodes shall be discarded.
- If the covered electrode has been exposed to the ambient air for more than eight hours, they
shall be dried again prior to use.
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- Remained electrodes shall be returned to storage at the end of welding work.

3.7.2 Welding works
- Slag, moisture, dust, rust or other foreign materials on the surfaces to be welded shall be
removed by proper method such as grinder or wire brush.
- In case of butt welding joint, edge preparation shall be done accurately in accordance with the
requirements of WPS and relevant drawings.
- The bevel shall be followed approved drawing.
- Gouging, gas cutting and grinding shall make edge preparation.
- Butt weld shall secure full welding penetration so that the front and back welding have to make
full alignment.
- Complete joint penetration groove welds to be made without the use of backing shall be root
gouged before the backside welding.
- Fillet weld shall be performed in accordance with AWS D1.1 and WPS.
- In principle, welding position shall be performed by type of flat, horizontal or vertical as
practicable.
- In vertical position, only up-hill progression shall be applied.
- Welding method and working sequence shall be decided so as to minimize residual stress, and
welding shall be performed without causing any defects and deformations.
- In any case cracks should occur to the tack-welded bead, they should be removed up to the
bottom of deposit metal and welded.
- For straightening up of distortion after welding, the distortion caused in welding work shall be
corrected in the following treatments.
- Mechanical Treatment: by means of press
- Heating Treatment: by means of gas burner
- Heat treatment shall be performed the temperature which does not injure the material.
- Heating temperature shall be less than 650℃.
3.7.3 Repair works for welding defects
- After the completion of welding, slag and spatter shall be removed and cleaned up by proper
method.
- In case defect is found out it shall be repaired by the following method:

Repair Method
Kind of Defects Treatment
After surface flaws are removed by air arc gouging
Surface flaws of base
or grinding and welded, the weld metal shall be
metal
ground.
The base metal with lamination cracks shall be
Lamination cracks changed to new base metal
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Cracks or blemishes caused by arc strikes shall be

Arc strikes ground to a smooth contour and checked to ensure
soundness.
Cracks in weld (including The extent of cracks should be ascertained and
tack weld) and base removed including 50mm from each side of them by
air carbon gouging
metal or grinding and re-welded.
Overlap and excessive
Excess weld metal shall be removed by grinding.
convexity
Excessive concavity of
Surface shall be ground and additional weld metal
weld or crater undersized
shall be deposited.
welds, undercutting
Excessive weld porosity,
Unacceptable portion shall be removed by air carbon
excessive slag infusion
arc gouging or grinding and re-welded.
incomplete fusion

5. Painting
Painting works shall be done in accordance with requirements of protective painting specification and
refer to R2B-P3-206-02-K-ET-00005, ET-009-PEMEX-2019, Surface preparation and painting procedure.
6. Inspection and Test
6.1All fabricated materials shall be inspected at the shop prior to shop painting.
The fabricated materials shall be assembled and inspected at shop.
6.2 Dimensions of the furnace and its parts shall be checked to meet drawing as approved by the
customer, and their record shall be submitted to the inspector.
6.3 Testing and inspection shall be carried out to the extent VENDOR deems it necessary to assure
that all work, materials, and products conform with this specification and the Design Drawings.
7. Packing
7.1 Fabricated steel shall be packed with special care to avoid any damages during transportation.
7.2 Each module shall be reinforced strictly in accordance with relevant drawing and instructions.
7.3 Packing items shall be strictly checked with supply list.
7.4 Upon completion of packing, witness inspection shall be given.
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8. Tolerance:

- For modulization of radiant module tolerance for plumb : ±1mm/1meter. Max. 15mm