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WI/INSP/02/00

Effective date:
October 2004

Work Instructions-Heat Exchanger


Inspection

Page 1 of 6

TUVIPL Surveyor shall verify/confirm the following requirements for


inspection/testing of Heat exchangers & in addition to the specific
requirements of Project. The specific requirements of project shall be
as addressed in vessel manufacturers QAP/ITP
Referencing Document:
Applicable Specification/Approved drawing/Data Sheet/ASME SEC
VIII Division I/TEMA
Supplementary test requirements shall be per Project/PO
specification.
Approved QAP/ITP
Inspection & Tests:
Review applicable WPS/PQR in-accordance with ASME code section IX
and or to project specification.
Identify all material used in fabrication of heat-exchanger shell or
part.
Examine materials before fabrication to make certain that they have
the required thickness, to detect defects, and that traceability to the
material identification has been maintained.
Verify that the material used in fabrication of shell comply with
requirement of material specification & supplementary test
requirement per PO specification
Review material test certificates of all pressure containment parts
and that of parts welded to pressure parts for conformity to
applicable material specification/project specification, including
additional & supplementary tests (NACE, HIC, Inter-granular
corrosion (IGC), SSC, Hardness, Heat treatment,
Normalizing/tempering).
Verify impact tests results have been documented when such tests
are required
Prepared by: NG Prabhu
Date : Octobr, 2004
Signature

Approved by:G Chandrasekhar


Date : October, 2004
Signature:

Issued by:G Chandrasekhar


Date : October, 2004
Signature:

WI/INSP/02/00
Effective date:
October 2004

Work Instructions-Heat Exchanger


Inspection

Page 2 of 6

Ensure that the concurrence of client has been obtained in writing


prior to any repairs undertaken on materials.
Verify NDT operators are qualified in accordance with requirement of
ASME SEC V- Clause T-140, SNT-TC-1A
Verify applicable non-destructive tests have been performed on
materials to the requirement of material specification and or to PO
specification.
Examine the shell & channel heads to confirm that they have been
properly formed to the specified shapes with in permissible tolerances
Verify that applicable welding procedures have been qualified.
Verify that all welders & welding operators have been qualified.
Examine all parts prior to joining to make certain they have been
properly fitted for welding and that the surfaces to be joined have
been cleaned and the alignment tolerances are maintained
Examine parts as fabrication progresses, for material marking that
defects is evident and the dimensional geometries are maintained.
Ensure the exchanger shell circularity is within tolerance of TEMA and
or as specified on the approved fabrication drawing.
Inspect tube sheet after drilling for tube hole diameter, tube hole
configuration, finish, pass- partition groove, ligaments, gasket
seating surface etc., are within TEMA tolerance.
Examine tubes after bending to confirm the ovality, thinning and
bend radius are within TEMA tolerance

Prepared by: NG Prabhu


Date : Octobr, 2004
Signature

Approved by:G Chandrasekhar


Date : October, 2004
Signature:

Issued by:G Chandrasekhar


Date : October, 2004
Signature:

WI/INSP/02/00
Effective date:
October 2004

Work Instructions-Heat Exchanger


Inspection

Page 3 of 6

Inspect Tube bundle assembly for overall dimensions, baffle cut


orientation, number of baffles, tie bars, & impingement plate location
etc. per approved drawing.
Verify the tubes are contact rolled in tube sheet in accordance with
approved drawing.
Inspect tube to tube-sheet welds are adequate in size & defect free.
Inspect tube to tube-sheet welds by dye penetration test technique
as applicable.
Verify required heat treatments, including PWHT are performed on
the completed shell/tube bundle.
Review records of nondestructive testing examinations performed on
the shell/channel parts.
Verify that the material imperfections by welding were acceptably
repaired to code of construction.
Verify that the weld defects were acceptably repaired.
Make a visual inspection of shell sections, to confirm that the
material, weld areas of shell and internals are free from defects,
including dimensional defect.
Witness pneumatic test of shell side of exchanger to confirm the tube
welds are not leaking.
Ensure that chloride content of water used for hydrostatic test is less
than 50 PPM or as specified in PO specification where material of
construction of heat exchanger is austenitic stainless steel.
Verify that as on test date the pressure gauges deployed for tests are
calibrated and the calibration status is valid.

Prepared by: NG Prabhu


Date : Octobr, 2004
Signature

Approved by:G Chandrasekhar


Date : October, 2004
Signature:

Issued by:G Chandrasekhar


Date : October, 2004
Signature:

WI/INSP/02/00
Effective date:
October 2004

Work Instructions-Heat Exchanger


Inspection

Page 4 of 6

Carry put internal & external inspections, witness hydrostatic test


from shell side as well as channel side of exchanger and perform
required inspection during such test.
Verify the tube and shell side of exchanger is completely dried of
hydrostatic test water.
Stamp the exchanger vessel and or nameplate
Examine internals during fabrication for weld control /distortion.
Inspect the tube bundle for dimensional accuracy and for proper
fitment.
Verify that the hydro test water has been fully drained from
shell/tube side completely & the equipment is dry.
Verify that the exchanger vessel painting is carried out in accordance
with approved painting procedure and required paint thickness is
available. Ensure that the painted surfaces are free from
unacceptable pinhole defects.
Inspect the exchanger vessel for readiness for shipment and issue
release note to the fabricator
Check List
1) Review applicable WPS/PQR & welder qualifications.
2) Identify materials & review MTC-pressure part, welded
attachments, tube bundle parts & examine material surface
condition (shell, channel shell/cone, heads).
3) Verify that the MTC include results of supplementary tests such
as UT/MT, impact test, HIC, IGC, SSC hardness & heat
treatment details, and conformance to NACE etc. as
required/specified on PO specification.
Prepared by: NG Prabhu
Date : Octobr, 2004
Signature

Approved by:G Chandrasekhar


Date : October, 2004
Signature:

Issued by:G Chandrasekhar


Date : October, 2004
Signature:

WI/INSP/02/00
Effective date:
October 2004

Work Instructions-Heat Exchanger


Inspection

Page 5 of 6

4) Verify NDT operators are qualified in-accordance with ASME/PO


specification.
5) Inspection during fabrication- cutting & edge preparation, Fit
up- long seam/circ. Seam, Back chip- visual/MT, weld
appearance- before/after PWHT, Forming & bending-Shell-coneheads-Heat treatment after forming-shell-cone-head, PWHT
chart review-at furnace-local.
6) NDT examination: RT-Shell side/tube side-spot/full, UT-before
PWHT/after
PWHT,
MT-before
PWHT/after
PWHT,
PTbefore/after PWHT/after hydro test.
7) Dimensional/visual inspection; Shell-cone-heads, nozzles, tube
bundle, channel, legs, Lifting lug, base plate, template & anchor
bolts, clips & other attachments.
8) Verify type & size of nozzles-nozzle size, rating, flange type,
flange facing, & nozzle neck thickness.
9) Verify shell & channel flange type/thickness, facing & grooving.
10) Examine visual & out of roundness/shape of Shell/dished heads,
for conformity to construction code/PO specification.
11) Review for staking condition (one over the other) as applicable.
12) Inspect tube sheet thickness, facing & grooving, tube length,
size & thickness, tube numbers & arrangement, tube bundle
workmanship & dimension, u-bend portion of tube for radius,
ovality & wall thinning, heat treatment, ease of tube bundle
insertion, tube sheet joints expansion, welding, MT/PT tests, air
soap solution test & number of pass confirmation.
13) Ensure all applicable NDTs performed with satisfactory results
before release of equipment for hydro test.
14) Pressure tests: Witness hydrostatic/pneumatic test of
equipment from shell side/tube side, duration & test medium inaccordance with PO specification.
15) Leak test with air: Nozzle reinforcement pad/sleeve liner.
16) Verify test medium condition (chloride content) for conformity
to PO specification.
17) Review pressure gauge position, calibration & numbers.
18) Review Test pressure time chart recorder calibration.
Prepared by: NG Prabhu
Date : Octobr, 2004
Signature

Approved by:G Chandrasekhar


Date : October, 2004
Signature:

Issued by:G Chandrasekhar


Date : October, 2004
Signature:

WI/INSP/02/00
Effective date:
October 2004

Work Instructions-Heat Exchanger


Inspection

Page 6 of 6

19) Review any special caution to be exercised: Differential


pressure designed tube side/shell side.
20) Ensure that stacked units tested in position.
21) Review production weld test results as applicable.
22) Review specific test requirements: Hardness test-main seams,
nozzle welds, overlay weld UT/Mt/Chemical analysis tests.
23) Verify that the hydro test water has been drained from
shell/tube side of exchanger & the equipment is fully dry.
24) Review painting/coating certificate.
25) Verify application of cover on nozzles & providing
packing/blanking for gasket seating areas.
26) Review Mfr.s QC dossier, stamp equipment & issue release
note.

Prepared by: NG Prabhu


Date : Octobr, 2004
Signature

Approved by:G Chandrasekhar


Date : October, 2004
Signature:

Issued by:G Chandrasekhar


Date : October, 2004
Signature: