Professional Documents
Culture Documents
F.4.RADIOGRAHIC
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STANDARDCONSTRUCTION
PROCEDURE
TESTPROCEDURE
RADIOGRAPHIC
( | T E MN O .2 0 - T - 0 1 - C A P A C T T1Y0 , 0 0 0M T )
CLIENT FERTILISERS
M/S.GODAVRI & CHEMICALS
LTD.
TEILJOBNO. ozJ+
INDrALrmrrnr
Tovo ENcTNtBRTNG
M U M B AI N D I A
REVISIONHISTORY
Description
T o r o E r c r r e n n r r rI;r r r r r l - r o . D O U B L EI N T E C R I T C
YRYOCENIC
A M M O N I AS T O R A C TEA N K
IrlUi\'ttsAt Page I of ,l
RA.DIOGRAPHICPROCEDTIRE
1. Q U A L I F I C A T I OO
NF R A D I O G R A P H P
YE R S O N N E L
2. SCOPE
3. S U R F A C EC O N D I T I O N
The Weld surfaceshouldbe such that the weld ripplesor any irregularities
on both sidesof the
componentto such degreesthat the resultingradiographiclmage or any flaws / discontinuity
shouldnot be maskedor be confusedwith the surfaceindications.
4. S O U R C EA N D F I L MT Y P E
n o u r c e: l R l D l U M- 1 9 2- m a x i m u ms o u r c es i z e2 . s m mx 3 m m
R a d i a t i oS
5. SCREEN
6. RADIOGRAPHICTECHNIOUE
A S i n g l eW a l l E x p o s u r e
T e c h n i q useh a l lb e u s ef o r R a d i o g r a p h y .
F o r S i n g l eW a l l S i n g l el m a g eT e c h n i q u e( S W S I )m i n i m u mS o u r c et o F i l m D i s t a n c e( S F D )
s h o u l db e 1 0 "f o r S i n g l ee x p o s u r e .
/7"
t\-/
tl
STANDARD ('ONSTRL]CTIONPROCI]DTJRI] JOBNo.6214
M t rN{ur\ l P a g e2 o f 4
RADIOGRAPHIC PROCEDTIRE
7. T I M EC A L C U L A T I O N S
EXPOSURE
8. DENSITYLIMITAIONS
The Film Densitythrough the area of interestof the radiographicimage shall be followed
D e n s i t yM i n .2 . 5 t o M a x . 3 . 8H & D m e a s u r e do n P a r e n m
t e t a li m a g e .
M i n .2 . 0 t o M a x . 3 . 5H & D m e a s u r e do n t h e w e l di m a g e .
9. RADIOGRAPHICSENSITIVITY
2% or betterFilm Sensitivity
shall be requiredfor radiography
of Tanks.
Calculationsof Sensitivity
10. (IMAGEQUALITYINDICATOR)
TYPE / DESIGNOF PENETRAMETERS
Thickness of Wire
Diameterof Wire Mt\4 3.20 2.50 2.00 1.60 1. 2 5 1.00 0.80 0.63
inmm& No. 1 2 3 4 5 6 7 8
Corresponding MIVI 0.50 0.40 0.32 0.25 0.20 0.16 0.'t25 0.1
numbers No. 9 10 11 12 13 14 15 16
Size of Penetrameter
11 C A L C U L A T I O NO
S F UNSHARPNESS
un=+
Where Uo= Geomentrical Unsharpness
F = Sourie Size: The maximum projecteddimensionof the radiatingsource / effective
focal spot in the plane perpendicularto the distance from the weld or object is being
radiographed.
(tl
PROCEDtIRII JOBNo.6234
STANDARD('ONSTRUC'TION
N,lI ]M I]A I
RADIOGRAPHI(] PROCEDTIRE Page-l of '1
U N S H A R P N E SP
SE R M I S S I B L E
THICKNESS
OF OBJECT
In inches ln mm
From to & through From to & through lnches MM
13. PROCESSTNG
. Processingwill be a manual.
. Development time of 3-5 minutesin developersolutionat 20 degreetemperaturewith
intermittent agitation,agitationbeingconstantfor the first30 secondsmanually.
. Followingdevelopmentacetic acid (stop bath) for 30 second to 1 minute with
agitationfor the first20 seconds.
. Film to be fixedfor at leasttwicethe developmenttime or 4 minuteswhicheveris the
grearerDy manuaIy.
. W a s h i n gw i l lb e f o r a t l e a s t1 2 - 1 5m i n u t e si n r u n n i n gw a t e ri n m a n u a l l y .
. Radiographwill be 1 minutein waitingagentbath with agitationsafter40 seconds.
. F i l ms h a l lb e d r a i n e da t l e a s tt h o u r .
14, IDENTIFICATION
S i n g l e e x p o s u r e s h a l l c o n t a i n a l l t h e d e t a i l s m e n t i o n e db e l l o w w i t h l e a d , N u m b e r s
c o r r e s p o n d i nt g
o J o i n t ,X - r a y N o . , W e l d e rN o . , J o b N o . P o r t i o nN o . D a t e ,R e p a i ro r R e t a k e
marksand propertype of penetrameter.
M i n i m u mo v e d a p p i nbge t w e e nt w o s u b s e q u e nf itl m so f s a m ej o i n ts h a l lb e 1 i n c h .
R T s e g m e nat n d R T u n i q u en u m b e rs h a l lb e w r i t i n gb y p e r m a n e nm t a r k e ro n t h el o b
,I5. V I E W I N GO F T H E R A D I O G R A P H S
NlIJMBAI P a g e4 o f 4
R{DIOGRAPHIC PROCEDTIRE
16. W E L DA G C E P T A N C E
CRITERIA
As per followingcodes
A S N / ES e c .V l l l D i v . 1
ASI\4E831.3
17. S T O R A G EO F F I L M S
Filmsshallbe stored,usingnon-hygroscopic
paper,safetyin air-conditioned
room.
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UIRI
CONSUTTAN
NDT& INSPECTION
SRIVIJAYADURGA
-27,"BAtA,l',SusorloColonY' Bulchiroiupolem, 7
Visokhopolom-53002
58-21
Ph: +91 (E9l)257267I
Fox: +91 a69l)2572675
E-Moil: cs-murty@ Yohoo.co.uk' Cell : 9848145223
NDE CERTIFICATION
ASPER
AMERICAN SOCIETY FOR NONDESTRUCTIVETESTING
Valid UP to o9-o1-20(l8
RevalidityDate
Valid Up to
Minimum
DascripEion Besults Grode re,euied
Generol 90.00 30.00 23.33
Specific 8s.00 28.33 23.33
Procticol. 85.00 28.33 23.33
Composite 86.66 80.00
PltysicolExanindion:
NearVision OK 3 L*\r-.A-
B.K. SETHUPA'
Colour Vision OK
ASNT Level - III, (RT, PT)
Cclt No. 1,19507
cenificateNo.: svDAr'sP/RT/Q/LM0O5l05 Itvel nl Ex.min€r
SRIVIJNYNOUNCAi,iNT&INSPECTIONCON
Visokhopdtom'530027
'BALAJ|"Susorlocolonv' Bulchiroiupolem,
58-21-27 , 8
Ph: +91 (89I) 257267
Fox: +91 l191l257267 E Cell : 9848145223
uk'
i-r,rloit: cs-murtY@ Yohoo'co
NDE CERTIFICATION
ASPER
TESTING
AMERICAN SOCIETY FOR NONDESTRIICTIVE
RevaliditYDate :
Valid UP to :
Mlnimum
Dascription Besults Grode re4vtre'd-.
85.00 28.33 23.33
Gonerol
80.00 9.6.66 23.33
Spocific
90.00 30.00 23.33
Procti(ol
84.99 80.00
Composite
PlrrsicolExaninolian:
OK a tr*[r-
-'s.
/-NtY
NearVision
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ColourVision OK l"' t I l l, ( .i t, PT)
C e f t N c . 1 4 95 u /
l'evel lll Examiner
L-lI/2005i06
CenificareNo.: SvD/VSP/RT/Qi
F-5.VACCUMBOXTESTPROCEDURE
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STANDARD
CONSTRUCTION
PROCEDURE
Box
VACUUMTESTPROCEDURE
^
( | T E MN O .2 0 - T - 0 1 - C A P A C T T1Y0 , 0 0 0M T )
PROJECT AMMONIASTORAGE
TANK.
CLIENT M/S.GODAVRI
FERTILISERS
& CHEMICALS
LTD.
TEILJOBNO. 6234
Tovo ENcrNnnRrNG
INDrALrnrrrsn
MUI/BAINDIA
Plsv:;.,-t
'f--=-- 6'.Jt-.,/
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REVISIONHISTORY
\lt \18.\| P a g eI o f 2
VACTITI}T BOX TESTIN-G PROCEDTJRE
1. Scooe
2 . Reference
3 . Qualification of Personnel
J. Equipments
4. Surface Preparation
5 . Method
After cleaningof weld joint approximately750 mm of the lap joint under tesl is
brushedwith the soap solutionor linseedoil. The vacuum box is placedover the
coated section of the lap joint. Open bottom of vacuum box is sealed against
plate surface by sponge rubber gasket. Vacuum box is connectedto vacuum
pumpthroughvalves,hoseand vacuumgaugeand thenvacuumis appliedto the
box. lf the requiredvacuum is not achieveddue to impropersealing/ defective
sponge rubbergasket i uneven surfaceclay / flour paste, putty will be used to
seal the vacuumbox with platesurface.The presenceof any leakageor porosity
in the lap weld joint is indicatedby bubblesor foam producedby air sucked
throughthe welded lap joint. Suitable& calibratedvacuum gauge shall be
provided.An overlapof 2 inch minimumfor adjacentplacementof the vacuum
box shallbe usedfor eachsubsequent examination.
w PROC'llI)URE JOBNo.6234
STANDARDCONSTRLIt'TION
'Iirvo D O t J B T ,I E
NTECRITC Y RYOCENlC
Ercrrecnrr<; l.'.'otrLro,
AN4MONIA S T O R A CT
EA N K
MIIMI]AI
VACLILIM BOX TESTIN(; PROC]EDITRE
6. Inspection
7. Acceptance
11.Documentation
H*,.@
Lv^st-<
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TESTPROCEDURE
F.6.LIQUIDPENETRANT
INou Lmrrno
Tovo ENcrNnnRrNc
M T J M B A II.N D I A
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STANDARDCONSTRUCTION
PROCEDURE
LIQUIDPENETRANT
TESTPROCEDURE
(ITEI\4NO. 20 - T - 01 - CAPACITY10.000MT)
PROJECT AMMONIASTORAGE
TANK.
CLIENT M/S.GODAVRI
FERTILISERS
& CHEMICALS
LTD.
TEILJOBNO. ozJ+
PREPARED
BY
Tovo ENcrNBsRrNc
INul Lrmrrnn
I\,lUMBAI
INDIA
H@) (*
v-r-;-*
rv?re
REVISIONHISTORY
Description
MUI\,4BAI Page 1 of 2
LIQUIDPENETRANT
TESTPROCEDURE
1. Scope
Qualification of Personnel
4. Material
5. Surface Preparation
6. Technique
6.2 Penetrantapplication
After the part has been cleaned,the temperatureof the surfaceand penetrantare
withinthe rangeof 60'F to'125'F the penetrantshallbe sprayeddirectlyon the
a PROCEDURE JOB No. 6234
STANDARDCONSTRUCTION
MUMBA] Page 2 ol 2
LIQUIDPENETRANT
TESTPROCEDURE
6.4 DeveloperApplication
Inspection
8. Acceptance
11. Safety
Safetyprecaution
as perapprovedPolicyshallbe adopted.
ry@)
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F.7.MAGNETICPARTICLETESTPROCEDURE
a
:oYc110
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STANDARD
C O N S T R U C T I OPNR O C E D U R E
MAGNETIG
PARTICLE
TESTPROCEDURE
4 O .2 0 - T - 0 1 - C A P A C T T1Y0 , 0 0 0M T )
( | T E NN
PROJECT AMMONIASTORAGE
TANK.
CLIENT M/S.GODAVRI
FERTILISERS
& CHEMICALS
LTD.
TEILJOBNO. 6234
PREPARED
BY
Tovo EwcrNnnRrNc
lxnrl Lrnrrrel
I\,4UMBAI
INDIA Fouiau,.,u,4-
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v! r i ' f lY,.
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REVISIONHISTORY
Tovo Errr;rrr:r:rrr,,r;
Iror.r Lrn. DOI-BLEINTIGRITYCRYOGENIC
A M N I O N I AS T O R A C T
EA N K
1. Scope
2. Reference
3. Qualificationof Personnel
4. Material
PortablemagneticequipmentHWACi DC Yoke
6. Method
6.1 MagneticParticleExaminationMedium:-
The particle used as the test medium shall be finely divided ferromagnetic
materialand averagegrain diameternot to exceed20 microns.
a S T A N)I A R I )CC ) N ISR LC I t O NP R O C I : I I U R L JOllNo.6234
T o r o E r r ; r r e r n r r rI ;r o r ^ [ , r r r . D O t T B L IEN T E C R I T (Y' R Y O C E N I C
AMI\4ONIASI'ORAGE TANK
The surfaceto be examinedand all adjacentareas withinat least 1" shall be dry
and free of all dirt, grease, lint, scale, welding flux and spatter, oil or other
extraneousmatterthat couldinterferewith the examination.
Where surface irregularitiesare found, grindingshall be done of facilitatethe
examination.
6.3 MagnetizingFieldAdequacy
6.5 InspectionCondition
6.6 ExaminationTechniques:-
M I J \ {I ] , \ I
NIAGNETIC PARTICI,E PROCEDTTRE
-l
Interpretation& Acceptance of Indications
lf any lineardiscontinuity
observedduringMPI interpretation,
the same shall be rectifyby
suitablemethodand then re-examination will be conductedwith MPI to confirmthat no
defectsexist.
L Post Cleaning
10. Demagnetization
Demagnetization
shall be canied out by contrnuously
reversingthe field direction.
11. Safety
INora Ltlrrrno
Tovo ENcrNnBRrNc
M U M B A I .I N D I A
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( lirnl t l\tgt\ itu ltu|n< ( ott't I'ng? ottul R.isuri Hi\!a\ \h!1)
STANDARDCONSTRUCTION
PROCEDURE
cP- 003
HYDRO-PNEUMATIC
TESTPROCEDURE
(ITEMNO.20-r -U - CAPACTTY
10,000
t\,4T)
CLIENT M/S.GODAVRI
FERTILISERS
& CHEMICALS
LTD.
TEILJOBNO. 6234
lt)
MUMBAI Page 1 of 6
HYDRO-PNETI}IATI(]TEST PROCEDT]RE
CONTENTS
SECTION
NO. TITLE
01 SCOPE
02 REFERENCE
DOCUMENTS
03 PRELIMINARY
04 HYDROTESTOF INNERTANK
05 PNEUMATICTEST OF OUTERTANK
06 PNEUMATIC
TEST
O7 TESTINGOF SAFETYRELIEFVALVES
08 INSPECTIONOF VACUUMRELIEFVALVES
10 T A N K C L E A NU P
12 F I N A LR E L E A S E
w STANDARDCONSTRUCTION
PROCEDURE
JOBNo.
6234
cP-003
'Iovo D O U B L EI N T E G R I T C
YRYOGENIC
Erc;rleenrrr;I)iDrALTD.
AMN,4ONIA STORAGETANK
MUMBAI Page2 of 6
HYDRO-PNETIMATIC
TEST PRO(]EDIIRE
0 1 . SCOPE
02. REFERENCE
DOCUMENTS
this procedureduringConstruction
The followingdocumentsshallbe referredwhile interpreting
for doublewall doubleintegrityAmmoniaStorageTanks
(ltemno.20-T-01).
03. P R E L I MI N A R Y
Caution
D,I Preparation
2. Visually inspect all expansionjoints for damage after they are welded in place.
Expansionjoint protectivewrappingsmust remainin placeas long as possibleprior
to leavingthe job site. lmmediatelyafterwelding(or bolting)bellowsin placeon both
ends,removethe tie bars or keep it loosened.
a) Cleanwater.
b) W a t e rh a v i n gn o o b j e c t i o n a bol ed o u r( i . e .n o h y d r o g e ns u l p h i d e ) .
c) Chloride c o n t e nnt o t e x c e e d i n 4g 0 P P N 4 .
di Watertemoeraturebelow:4B'C.
e) lf water meetingabove requirementis not available,tank shall be tested with
soft water and after the tests are over, the tank surfacesshall be washedwith
Dl\4watertill the final chloridecontentof the washedwater comes to 40 PPM or
oetow.
g STANDARD
CONSTRUCTION
PROCEDURE
JOBNo.
6234
cP-003
Tovo Erclrrr.nrrr; Irurr L t o. D O U B L EI N T E G R I T C
YRYOGENIC
AMN,4ONIA STOMGE TANK
IVUI\,4BAI Page3 of 6
HYDRO-PNETiMATICTEST PROCEDTTRE
a) Filling shall be done in stages as shown below. The rate of water filling shall be
approximately'175to 200m' per hour.After every stage the fillingshall be haltedfor at
leastfour hoursfor observationof settlementat one quarter,one half,threequarters,full
water leveland visualexaminationfor any deformation/ leakage.
l\4aximum levelof waterto be filled 18.163t\4tr.
Totalvolume(TestLevel) 15534m3
H o l d i n gt i m ea t f u l lw a t e rl e v e l 24 hrs.
b) V i s u a li n s o e c t i o n
Check the surfacesof shell includingwelds,for leaks and signs of distress.lf any leak
appears, lower the water level below the marked spot, carryout the repair (as per
approvedproceduresin consultationwith TEIL EngineerIncharge)and continuethe
waterfillino.
24 HrsHolding
1 0 0%
Dewatering
q) 75 o/" after
0) pneumatic
J
test
o,)
(u 50%
Fillingrate- MAX.
( for 20-T-01)
Time
c) FoundationSettlement
D u r i n gf i l l i n g ,c h e c k t h e e l e v a t i o n sof settlementduring one quarter, one half, three
quarterand full of water at marked locationson foundationwith referenceto elevatron
0 STANDARD
CONSTRUCTION
PROCEDURE
J O BN o .
6234
cP-003
Tovo Er<;rrccnrr<;llor.l Lro. D O U B L EI N T E G R I TC
YR Y O G E N I C
AI\,4MONIA STORAGETANK
MUI\,4BAI P a g e4 o f 6
HYDRO-PNETI}IATICTEST PROCEDTIRE
initiallymarkedon the verticalmemberby Theodolite/ levelinstrumentand same shallbe
recoroeo.
b) With water at test level at 16.43Mtrs.in outer tank completeall weldingof holdingbars
with anchor straps as shown in drawing.NDT on anchor strap as requiredshall be
carriedout and clearedby TEIL / TUV.
'U'
c) Installone manometerwith measuringtapes on one of the roof nozzlesand another
'U'
tube manometerfrom the same nozzle to ground level for monitoringand safe
access.Fillwith plain/colouredwater in manometertubesfor easy inspection.
Arrangementshall be made in such a way that air can escapein case of over pressure
pressure(1875mmW.C.).
in the tank exceedingthe dasig{r
'IG:J
.\"""!{- _
c) Installa ballvalveon a roof nozzleN10 (4" NB) or any othersuitablenozzlefor quickair
release.
d) Installmanualvalves for safety valvesfitted on nozzlesN12 AJB (8" NB) on roof fop.
Installblind flangesbetweensafetyand manualvalves to protectsafety valvesduring
overtest pressure.Installpilotpipingfor all pressuresafetyvalves.
06. PNEUMATIC
TEST
Closethe top manholeand any otherfittingsleft open duringfilling. Open the valveat the start
of air pressurisation.As soon as air is freelyblowingthroughthe valves,close the valve and
solutionfilm test (with soap solution)the valve seat and stem. lf either is leakingtightenthe
stem or inserta plug in the outletand retestto determjnethat leakagehas been stopped.
a) Caution
Do not allowany unauthorized personon/nearthe tank whilepressureis beingincreased
for the firsttime and the same shallbe monitoredfrom qroundlevel.
b) Testinq
While carefullyobservingthe manometer,slowlyincreasethe air pressureto one half of
t e s tD r e s s u rien s t e o so f 1 0 0m m W . C . G .
MUMBAI Page5 of 6
HYDRO.PNET]N'IATIC
Tf,ST PROCEDT]RE
e) theair pressure
Slowlyincreased to fulltestpressure
carefully
observing
themanometer.
Hnld lacl nrascr irp fnf One hOUf.
T e s tp r e s s u r e : 1 8 7 5m m W . C .
S) VisualInspection
08. N F V A C U U MR E L I E FV A L V E S
I N S P E C T I OO
d) O p e nt a n kv a l v ea n d m a k ea i r p r e s s u r e
to 0'mm W.C.G.
09. O F T A N K W A T E RA N O R E S I D U A LW O R K S
EMPTYING
a STANDARDCONSTRUCTION
PROCEDURE
JOBNo
6234
cP-003
T o v o [ l < ; r r r c n r r r ;h u r r L r u , D O U B L EI N T E G R I T C
YRYOGENIC
AMN4ONIASTORAGETANK
N,4UI\,4BAI Page6 of 6
HYDRO-PNETIMATIC
TEST PROCEDTIR.E
After the test is over the entirevapour space is ventedto atmosphereby opening3-4
big size nozzles& roof manhole.
Water emptyingshall to be done in stages during day and night under supervision.
Dischargingof water shall be performedthroughthe shell nozzleCaution: first outer
10. T A N K C L E A NU P
After completionof hydrostatictest as per drawingweld joint of both the dish end of outertank
and innertank is to be cut, removeearth (mud),rubbishetc. from ansidethe tank which may
haveaccumulatedduringwaterfill up and mop the tank bottomuntilit is dry.
After tank cleanup is completed the suspended deck insulationshall be started. After
completionof deck insulationroof man hole dished ends shall be installedand NDT to be
carriedout. (Deckinsulationcan be carriedout whiletank internalcleaningis in progress).
ffgr.:i,;v,'s:-t
\tr:t:
P C-L*
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