Qatar Fertiliser Company

Overview

This Scope of Work outlines the fabrication and lining of water boxes for surface condensers. The water boxes will be fabricated from steel, lined with rubber for corrosion resistance, and prepared for seamless integration with the surface condenser system. This includes all material procurement, fabrication, rubber lining, testing, and delivery to the client site.

Scope of Project

1. Design Review and Approval

Review and confirm client-provided design drawings and specifications.
Verify compliance with applicable standards and project requirements, including:
- Fabrication Standards: ASME Section VIII, Division 1.
- Rubber Lining Standards: ASTM D429 or BS6374.
Submit shop drawings for client approval before fabrication.

2. Material Procurement

Water Box Materials:
- Carbon steel (ASTM A516 Grade 70 or equivalent) or as specified in project documents.
Rubber Lining Materials:
- High-grade natural or synthetic rubber (Butyl rubber) with a thickness of 3mm, suitable for the operating conditions (temperature, pressure, and chemical exposure).
Ancillary Materials:
- Gaskets, bolts, welding consumables, and adhesives for lining.

3. Fabrication

Cutting and Shaping:
- Cut steel plates as per the approved drawings using plasma cutting.
- Form and weld the plates to achieve the required box dimensions and geometry.
Welding:
- Use welding procedures compliant with ASME Section IX.
- Conduct necessary weld inspections (visual, magnetic particle, and ultrasonic testing).

4. Surface Preparation

Perform surface cleaning (sandblasting to SA 2.5) to remove rust, scale, or contaminants.

5. Internal Rubber Lining

Surface Preparation for Lining.
Rubber Application.
Seam Finishing.
Inspection.

6. Quality Assurance and Testing

Fabrication Testing:
- Conduct dimensional inspections to confirm compliance with design specifications.
- Perform non-destructive testing (NDT) on welds (e.g., ultrasonic or radiographic testing).
Rubber Lining Testing:
- Conduct adhesion testing (ASTM D429).
- Perform hydrostatic or pneumatic pressure testing of the water box after lining.
- Perform spark or holiday testing for lining integrity (ASTM D5162).

7. Delivery and Handover

Package the finished water boxes carefully to prevent damage during transportation.
Deliver water boxes to the client site with all documentation, including:
- Material test certificates (MTCs).
- Rubber lining inspection and testing reports.
- As-built drawings.