PT.

PHE ONWJ Mock Up Procedure

REVISION LOG REGISTER

Document Number : MMF-AX-BX-VDR -0033

Document Title : MOCK UP PROCEDURE
Revision :B

Page Date Revision PHE ONWJ Review

All 31 August, 2015 Issued For Review

All 16 September, 2015 Re-Issued For Review

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PT. PHE ONWJ Mock Up Procedure

TABLE OF CONTENT

Revision Log Registration ................................................................................................................

1
Table Of Content .............................................................................................................................
2
1. Purpose .......................................................................................................................................
3
2. Reference ....................................................................................................................................
3
3. Procedure.....................................................................................................................................
3
4. Documentation............................................................................................................................
4

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PT. PHE ONWJ Mock Up Procedure

1. Purpose
This procedure shall cover requirements of Mock-Up Test of Project FIN-FAN
COOLER FOR MMF 1ST & 2ND STAGE, of PT. PERTAMINA HULU ENERGI
OFF-SHORE NORTH WEST JAVA.

2. Reference
2.1. ASME Section VIII Div. 1, 2013 (Appendix A)
2.2. API 661, 7th Edition
2.3. API 660, 8th Edition
2.4. Client Specification No.: PHEONWJ-M-SPE-0057, Rev. 0

3. Mock Up Procedure
Mock Up test header box for tube to tubesheet joint ACHE will be carried out at IPK
workshop before fabrication process, this mock-up condition shall be same as the
equitment to be build especially for thickness of plate, tube, pitch of tube holes.

3.1. Preparation
a. The part of Mock-up test :
1. Plate for header box (Tube Sheet & Plug Sheet with 25 mm and 40 mm)
2. Bare tube OD 25.4 mm thk 1.83 mm
3. Mill Certificatre (heat number of tube & plate) shall be as per actual
material that is fabricated
b. Mock-up Test equipment :
1. Expand tools
2. GTAW Machine Welding

3.2 Application
a. Prepare the tubesheett & plug sheet as per drawing below :
1. Cut plate as per drawing attached
2. Drill the tube hole at tube sheet & plug sheet
a. Pilot drill with diameter 3 mm
b. Final drill as per drawing attach
3. Machining for expand groove for tube sheet hole
4. Cut the bare tube for 100 mm total length (the Mill certificate shall be
same as per actual tube that will be use.

b. Joint the tubesheet, plug sheet, and top bottom plate as per drawing
fabrication for header box, for welding joint follow actual approved WPS.

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PT. PHE ONWJ Mock Up Procedure

c. Setting distance of tube to tube sheet at internal 3 mm min as per drawing,

than to make sure the tube not move / slide do light expand tube to tube
sheet with maximum 1 % reduction than Expand all tube from tube to tube
sheet as per sketch below, process expand from tube to tube sheet shall be
follow the expand procedure ( Doc MMF-AX-BX-VDR -0013).
The maximum tube reduction indicate as per code A and B as per listed
above ( code a maximum reduction is 6 %. Code B maximum reduction is 8
%) as per API 660.

And for AX indicate the tube to tube sheet is seal Weld + Heavy Expand with
2 groove, for C30&C50 indicate only Heavy Expand with 2 groove, and for
BX indicate for Seal Weld + Heavy Expand with 2 groove to check the
maximum reduction not more than 8 %.

d. After complete weld and expand check all joint with PT (Dye Penetrant) and
report all actual thickness tube after expand.

3.3 Pull Out / Push Out Test

For process pull out / push out will be held by third party, and the pull out test
process shall be follow as per ASME Sec VIII Div 1 Nonmandatory Appendix A.

All process of pull out test / push out shall be reported and record.

3.4 Metallography Test

For further metallography test sample with dimension of 2 x 1 will be
prepared which covered the completedseal weld area + HAZ

3.5 Conclution and Acceptance Criteria

AS per Mock-Up test and several test pull / push out test, and metallography
test, we can take a conclution taht for joint tube to tube sheet will use seal weld
and Heavy Expand with double groove

Ten Tube to Tube Sheet weld joints (at the minimum) are required to qualify
this Mock Up Test Procedure of Tubes to Tube Sheet Joint.

The mockup test piece shall essentially duplicate the tube hole configuration
and tube-to-tube sheet joint design (actual product of header box) within the
limits of the essential variables of QW-288 of ASME Section IX.

The tube sheet which will be used for the mockup test assembly shall be
taken from the material same batch number with the material which will be
used for the production tube sheet of header box.

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PT. PHE ONWJ Mock Up Procedure

Perform assembly the test piece of tube sheet and plug sheet to top plate,
bottom plate and end plate

3.2. Mock Up
a. Cleaning the tubes prior to insert to Tube Sheet Mock Up, as following
sequences:
Internal and external surface tubes shall be cleaned for distance of at least
50 mm from fusion face prior to welding.
Welded surfaces shall be brushed with stainless steel wire brush and
degreased immediately.
Degreasing agents shall leave no chloride or sulphide containing residues
on the surface.

b. Insert tubes to tube sheet and tack weld from back side to ensure that no
shifting during seal welding.

c. Seal weld tube to tube sheet from plug sheet holes.

d. Welds accessible surfaces shall be examined visually with no magnification

required. The welds shall show complete fusion and no evidence of burning
through the tube wall, and shall be free from cracking or porosity.

e. Perform mechanical roll expansion in accordance with procedure no. MMF-

AX-BX-VDR-0013 and followed by dimension check the inside diameter of

f. Tubes after expanded to get the correct expand ratio.

3.3. Test and Examination

This test and examination can only be done on a mock-up test piece and the
results are deemed to represent the actual product of header boxes.

a. Uninstall the top plate, bottom plate, end plate and plug sheet.

b. Perform Liquid Penetrant Test to meet the requirements of QW-195.2.2 of

ASME Section IX.

c. The mock up test will be qualified by following test:

i. Together with other specimen test of other WPS qualification like

Metallographics Test, Ferrite Test, Pitting Corrosion Test, and
Intergranullar Corrosion Test

ii. Pullout Test

Mock up test result shall be recorded as reference to be used when perform weld on
production tube to tube sheet of header box.
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PT. PHE ONWJ Mock Up Procedure

4. Documentation
Following documents are needed to prove that the tube to tube sheet welding has been
carried out properly and correctly.

a. Dimension Check Report + Visual Check

b. Expansion Report
c. Dye Penetrant Test Report
d. WPS/PQR
e. Ferrite Test Report
f. Hardness Test Report
g. Inter-granular Corrosion Test Record
h. Pull Out Test Report
i. Metallography Examination Report
j. Etc

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