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TESTPROCEDURE

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 )

PROJECT AMMONIA TANK.


STORAGE

CLIENT FERTILISERS
M/S.GODAVRI & CHEMICALS
LTD.

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REVISIONHISTORY

Description

For Review/ Approval


w S I'A]\DARD( ()N5I RI.CI IONPROt'tDL'Rt JOB No. 62-14

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

wiil be performedunderthe jurisdictionof BARC Site-in-charge


Radiography & ASNT level

As a Minimumall personnelconductingradiographic examinationshallbe certified,BARC RT


Level| & Levelll/ ASNT Level| & Levelll. All qualification
certificates
shallbe valid

Only a BARC Site-in-charge


or ASNT Levelll Personnelshallcarryout interpretations
of
radiographs.

2. SCOPE

This procedureestablishedthe requirementsof Radiographicexaminationsof 10,000 MT


AmmoniaStorageTanksas follows

OuterTank - 19.6Mts. with Max.ShellThk. 16 N,'lt\4 & Min.6.4 MM


I n n e rT a n k - 1 8 . 6M t s . w i t hM a x .S h e l lT h k . 1 3 . 9M N I& N 4 i n6.. 4 1 , 4 N 4

TEST REQUIREMENT:As per approvedQAP and Drawings

3. S U R F A C EC O N D I T I O N

The Weld and adjacentareasshallbe free of arc strikes,spatterand debris.

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

FilmType :Afga - D4 (Speed: Slow,Contrast: Very High,Graininess: Ultrafine

5. SCREEN

The Lead screenwill be use for Gamma Radiationsnormally0.125 mm for frontsscreenand


0 . l 5 m m f o r t h e b a c k s c r e e n s .A l l s c r e e n sw i l lb e o f t h e c a s s e t t e - l o a d tevdo e .

6. RADIOGRAPHICTECHNIOUE

Techniquefor the radiographicshall be as illustratedin the MandatoryAppendixof article2,


ASME APV Code SectionV.

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"
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STANDARD ('ONSTRL]CTIONPROCI]DTJRI] JOBNo.6214

T o v o E r c r n . ' r r n r r tI;r o r r L r o . DOUBt,EI N T E C R I TC


YR Y O C E N I C
AI\{MONIASTORACE TANK

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

This is basedon basematerialthickness,sourceto film drstanceand sourcestrength.

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

Diameterof thinnestwire visibleon radioqraph X 100


Penetratedthicknessat areaof interest.

10. (IMAGEQUALITYINDICATOR)
TYPE / DESIGNOF PENETRAMETERS

Minimumone penetrameter shall be usedfor each radiograph.Penetrametershallbe of similar


m a t e r i atlo t h a tm a t e r i abl e i n gr a d i og r a p h e d .

DIN 54109 (1962)wire type penetrametershall be used to indicateradiographicsensitivity.


These penetrameterare three sizes of indicators,each containingseven equal distances
parallelwiresof variousthicknessin geometricalprogression.

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

lndicators No. of Wires Job Thickness of material


D t N1 I S O 7 1234567 Above 50 mm
D t N6 r S O 1 2 67 891Q11 12 '18mm
to 50mm
D r N1 0 t s o 1 6 1 0 11 12 1 3 1 4 1 5 t o Uoto 19mm

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

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A M N , I O N IS
AT O R A CT
EA N K

N,lI ]M I]A I
RADIOGRAPHI(] PROCEDTIRE Page-l of '1

D = Dist.from the sourceof radiationto the weld or objectbeingradiographed.


d = Dist.from sourceside of weld or objectbeingradiographed to the film.

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

00 2" 00 50.8 0.020 0.50


2" 3" 50.8 76.2 0.030 0.75
3" 76.2 1 0 1. 6 0.040 1.0
4" & Above 101.6 & Above 0.070 1.75

12. BACK SCATTERRADIATION

Backscatterradiationfallingon the film shouldbe avoided. To determinethe amountof back


scatteredradiation.A lead number'B'of minimum%" heighIand '116" thick shallbe attachedto
'B'
the back of the film holder. lf a white image of appearson the darker backgroundof the
paragraphs.lt means that the protectionfrom backscatteris insufficientand radiographshall
'B'
be consideredunacceptable.Howevera dark image of letter on the laghterbackgroundis
not the causeof rejection.

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

For radiographic interpretations shall providea variablehigh-density


lightsource(Viewer)
O n l ys i n g l ef i l mv i e w i n gt e c h n i q u seh a l lb e a p p l i e d .
& STANDARDCONSTI{U['TION
PRO('lrDtIRE JOB No. 623;l

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A]\IMONIASTORAGE TANK

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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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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

issuedto sri CHINTALAPUDMNKATESWARA


certiJicate RAO of

INDUSTRIAL RADIOGRAPHS CORPORATION, WSAKHAPATNAM fOT


having satisfactorily completeda training courseand pqssedthe examinationas
of SNT-TC-IA1996of ASNT.
detailedbelowin occordancewith the requirements
Method (RT) t evel
TESTTNG
: RADIoGRAPHY Il (Two)

Educational : B.Com Training Venue VISAKHAPATNAM


Qualification
TrainingHours 'l20 Hours
e
Work Experienc : 12 Years
Results : PA$
Examination Dateof Issue 10-or-2005

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

Sri MAVUDARU DURGAGANESWARARAO of


to
issued
Cerrificate
RADIOGRAPHS CORPORATION,VISAKHAPATNAM fOT
INDUSTRIAL
as
completeda training courseand passedthe examination
havingsatisfactorily
with the requirementsof SNT-TC-IA1996of ASN7"
deniled belowin accordance
kvel : ll (Two)
Method : RADIoGRAPHY TESTING 1nr1
Training Venue: VISAKHAPATNAM
Educational : INTERMEDIATE(M'P'c')
Qualification
TrainingHours : 120 Hours
Work ExPerience : 2O Years
Dateof Issue : 1O'01'2oo5
ExamimtionResuls : PAss
ValidUp to : o9'o1-2ooa

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
r. sbrsunnlnY
-eS[r
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

Tovo ENcrNnnRtNcIntn Lrnntrrl


M U M B A I .I N D I A

g
icYaMct!
I lolol 4 Pap(. n.l ding ( t)\\'t |d<.t d Rt\irion Hkton.rhd)

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-.,/
-'--.:-(11
1.f.7 od
REVISIONHISTORY

Rev. Date Description

0 A u g1 8 , 0 6 For Review/ Approval


0 STANI)ARD ( ONSTRUCTIONPROCIiDURE JOBNo.6214

Tovo Ercrr cEnr:,r<;


Ir.'or,r
l,ro. D O t J B t -IFN T E C R I TC
YR Y O C E N I C
A M M O \ l A S T O R A CT t TA N K

\lt \18.\| P a g eI o f 2
VACTITI}T BOX TESTIN-G PROCEDTJRE

1. Scooe

This procedurecoversthe methodologyfor VacuumBox Test to be conductedby


vacuum-box.This methodof non-destructive testingfor detectingleakagein the
Annularweldjoints,Bottom(Longseam,shortseam),Annularto sketch,Shellto
bottomplates.

2 . Reference

(TenthEdition,Addendum1, June 2004)Article10


R.8.2.1API 620 Appendix-R
of ASME SectionV.

3 . Qualification of Personnel

Personnel conductingVacuum Box Test shall have sufficientexperienceto


conductthis type of test.
The test will be performedunderthe supervisionof qualifiedsupervisor.

J. Equipments

VacuumBox (metaltestingbox 150 mm x 750 mm withglasswindowin the top),


Hoses,vacuumpump, valves,suitablevacuumgauge,sealingmaterials,(i.e.
clay / flour paste/ putty,spongerubbergasket,hand lamps)

4. Surface Preparation

In general satisfactoryresults are obtainedwhen the surface of the weld is


properlycleaned.Prior to vacuum box test the surfaceto be examinedand all
adjacentareas withinat least 1 inch shall be dry and free of all dirt, grease,lint
scale, welding flux spatter and other extraneousmatter that could obscure
openingsor otherwiseinterferewith the examination.The surfacetemperature
shall be 4"C to 52"C throughthe examination

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

Inspectionof lap weld joints will be performedafter minimumgauge vacuumof 3


PSI (155.14mm of Hg) achieved(ReferAPI-620).Observation will be madefor
any indicationof bubblesor foamgenerated on the lap weldjoint.

7. Acceptance

Lap weldjointsare acceptedif no bubbleor foam is generatedat 3-PSl(155.14


mm of Hg)vacuum.

9. Defect Rectification& Re-Testinq

lf any leakageis observedduringVacuum Box Testing,furthergrindingand


weldingas per approvedWPS of the defectivesectionof joint shall removethe
same. After the weld repairedre-testingby vacuum box methodwill be done, as
given in pt. 6 of this procedure.

10. Post Cleaninq

After removingvacuumbox, platesurfaceto be madefree from Clay/ Flourpaste


/ soap/ linseedoil to avoidany slippagemishap.A suitabletechniquesuchas a
simplewater rinseor compressedair may be usedfor cleaning.

11.Documentation

Properrecordshallbe maintainedas per approved format.

H*,.@
Lv^st-<

iL1 1 .tt
TESTPROCEDURE
F.6.LIQUIDPENETRANT

INou Lmrrno
Tovo ENcrNnnRrNc
M T J M B A II.N D I A

g
ioY0titDtt
I lntul t htg(\. in.lldinq ( ovr I,n{ ntl Rrrt\tot llt\tor\ \hr.t)

STANDARDCONSTRUCTION
PROCEDURE

LIQUIDPENETRANT
TESTPROCEDURE
(ITEI\4NO. 20 - T - 01 - CAPACITY10.000MT)

PROJECT AMMONIASTORAGE
TANK.

CLIENT M/S.GODAVRI
FERTILISERS
& CHEMICALS
LTD.

TEILJOBNO. ozJ+

For Review/ Approval

PREPARED
BY

Tovo ENcrNBsRrNc
INul Lrmrrnn
I\,lUMBAI
INDIA

H@) (*
v-r-;-*
rv?re
REVISIONHISTORY

Description

A u g1 8 , 0 6 For Review/ Approval


6S STANDARD PROCEDURE JOBNo.6234
CONSTRUCTION

Toro Err.rrrrnrrt.Irurr Lrrr. D O U B L EI N T E G R I T C


YRYOGENIC
AMI\4ONIASTORAGETANK

MUI\,4BAI Page 1 of 2
LIQUIDPENETRANT
TESTPROCEDURE

1. Scope

This general procedure covers the procedure for liquid penetrationinspectionto be


conducted by solvent removableliquid penetrationprocess is non-destructivetesting
methodsfor detectingdiscontinuitiesthat are open to the surface.They are applicablefor
process, final and maintenanceinspection.They can be effectivelybe used in the
inspectionof nonporous,metallicmaterials,both ferrousand non-ferrousmaterialssuch
as ceramic,plasticsand glass. Discontinuitiesopen to the surfaceas cracks,seams,laps
and cold shut laminations,throughleaksor lackof fusionare indicatedby this method.

2. Reference: ASMESec.V / ASMESEC.VIllDIV - 1

Qualification of Personnel

Personnelconductingliquid penetrationtest shall have sufficientexpenenceto conduct


this type of test.

4. Material

1 ) Penetrant- VisibleDye penetrant lo l5-3658- 1981,


confirming
2 ) Developer- Non-aqueousdeveloper.
? \ Cleaner - Solventtype
(Penetrant& developershallbe same manufacture.

5. Surface Preparation

In generalsatisfactoryresultsare obtainedwhen the surfaceof the part is in the as weld.


Surfacepreparationby buffingmay be necessarywhere surfaceirregularities could mask
indications
of unacceptable disconlinuities.

Prior to all liquid penetrationexamination,the surfaceto be examinedand all adjacent


areaswithinat least1 inchshallbe dry and free of all dirt,grease,lintscale,weldingflux
spatterand other extraneousmalter that could obscureopeningsor otherwiseinterfere
with the examination.

After cleaning,drying of the surface to be examinedshall be accomplishedby normal


evaporationor with forcedhot air.

6. Technique

6.1 Pre cleaning


After removal of any rust, scale, welding flux, spatter etc. the surface lo be
inspectedshall be cleanedwith a dry, lint free cloth,subsequently with a lightly
moistenedcloth of cleaneriremoveT.The dryingprocessshall be accomplishedby
normalevaporation.

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

Tot o El,;rrttntr,, Irotr Lro. D O U B L EI N T E G R I T C


YRYOGENIC
AI\4MONIASTORAGETANK

MUMBA] Page 2 ol 2
LIQUIDPENETRANT
TESTPROCEDURE

surfaceto be inspected suchthatthe entirepart


by meansof an aerosolcontainer,
of areaunderinspection coveredwithpenetrant.
is completely

6.3 Removalof ExcessPenetrant

Afterthe requiredpenetratron dwelltime,the penertantremainingon the surface


shallbe removedby wipesof clean,lint free cloth,repeatingthe operationuntil
mosttracesof penetrant havebeenremoved. Thenlightlymoistenedsolventcloth
willbe usedto wipeuntilall remainingtracesof excesspenetrant
is removed.

On removalof all excesspenetrant,dryingshall be accomplished


by normal
Minimum
evaporalion. timefordryingshallbe oneminule.

6.4 DeveloperApplication

The non-aqueouswet developerwill be sprayeddirectlyto the surfaceof lhe part


from an aerosolcontainerfrom a distanceof minimum 150mm.The non-aqueous
developerevaporatesrapidlyat room temperature.ParVareasshall be sprayedin
a mannerso as to have completecoveragewithina thin even film developer.

Developerdwelltime shall not be lessthan sevenminutes.

Inspection

Inspectionof test surfaceswill be performedafterthe developmenttime to assureproper


bleed out of penetrantfrom discontinuitieson to the developer coating. To aid in
evaluationthe observationshall commencewith the applicationof developer.

8. Acceptance

willbe acceptedas perASMEsec Vlll Div .1 App-8.


Discontinuity

o Defect Rectification& Re-examination

lf any discontinuityobservedduring LPI inlerpretation,the same shall be removed by


furthergrindingand then re-examination
will be conductedwith LPI

10. Post Cleaning

Post cleaningis necessaryin cases where residualpenetraleor developercould interfere


with subsequentprocessingor service requirements.A suitable techniquesuch as a
simplewaterrinseor solventcleaningmay be employed.

11. Safety

Safetyprecaution
as perapprovedPolicyshallbe adopted.

ry@)
i;#
F.7.MAGNETICPARTICLETESTPROCEDURE

Tovo ENcrNnnRlNcINora Lrvurno


M U M B A I .I N D I A

a
:oYc110
t
I tl)tnl i l'tt(\ itt(ludt g(ottt l'ot!..tnd R!tision lli\tot| \ht\1)

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

For Review/ Approval

PREPARED
BY

Tovo EwcrNnnRrNc
lxnrl Lrnrrrel
I\,4UMBAI
INDIA Fouiau,.,u,4-
*;,e=- ,':!l
v! r i ' f lY,.
oe
REVISIONHISTORY

Rev. Date Description

0 A u g1 8 , 0 6 For Review/ Approval


w S T A N T ) A R IC
} ' ) N S I R I C I I O N P R O ( ' I . D IR I - J O BN o . 6 2 l z l

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

N,lt rN, l.{ l Pagel o f - 3


NIAGNETI(]PARTICI,E PROCEDIIRE

1. Scope

Thisprocedure describes techniquesfor magneticparticleexamination


of discontinuities
at or nearthe surfacein ferromagnetic
matenalsby usingwet magneticparticlemethods
andlongitudinal magnetism at ambient
temperature

2. Reference

ASMESec. VArticle-7 (SE-709)


ASMESec - Vll Div - | and ll
APt -620

3. Qualificationof Personnel

PersonnelconductingMagneticParticleExaminationshall have sufficientexperienceto


conductthis type of test

The test will be performedunderthe supervisionof at leastone of the followingor


equivalently qualified
supervisor

a. ASNT/ ISNTLevel- ll in accordance with SNT- TC - 1A


b. Any internationally qualification
recognized for NDT personnel.

4. Material

-V'' / Magnetic Particle powder of reputed manufacturerwill be used, Kerosene, bath


r - J, concentration 0:1 ml to H ml per 100 ml of
(checkedat the startingof the examination
k e r o s e n e.)f - e . r ' . - 1r.",'<':-l i 'L 2+
..,*r-tp
5. Equipment

PortablemagneticequipmentHWACi DC Yoke

The magnetizingforce of yoke shall be checkedat least once a year by liftingpowerof


yokes.

yoke shall have a liftingpowerof at least4.5 kg


Each alternatingcurrentelectromagnetic
(10 lb) at the maximumpolespacingthatwillbe used.
Each directcurrentyokes shall have a liftingpowerof at least 18.1 kg (40 lb) at the
maximumpolespacingthatwillbe used.Maximumpolespacingthatwrllbe 6".

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

Nll it\1B l Page2 of -i


MAGNETIC PARTICLE PROCEDTTRE
The suitablecolor (Black or Brown) shall be providedto the article in order to
makethem highlyvisibleagainstthe background of the surfaceexamined.

Water shall be used as vehiclefor wet magneticparticles.Suitableconditioning


agentsshall be added to provideproperwet disposing.When examininghigh
alloy chromiumsteels,austeniticsteel and nickelbase alloy,the chlorineand
sulfur contentsof water shall be checkedand not to exceed one percentageof
residueindividuallyby weight in water. The water should be portableand have
good wettingcharacteristics

6.2 Surface Preparation:-

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

The magnetizing field directionand adequacyshall be verifiedusing Magnetic


ParticleIndicator(ASTM)
By using this indicatorsuitableflux or field strengthis indicatedwhen a clearly
definedline of magneticparticlesforms across the copper face of the indicator
when the magneticparticlesforms across the copperface of the indicatorwhen
the magneticparticlesare appliedsimultaneously with the magnetizingforce.

6.4 Extendand Time of Examination

The area weld to be testedshall be the weld surfaceand the heataffectedzone


of minimumwidthof halfinchof the area.shallbe tested100%
The examinationmust be performedin the final conditionafter weldingor heat
treatment.

6.5 InspectionCondition

The inspectionshall be executedunder ample of light. The temperatureof the


part surfaceand the suspensionshall not exceed57"C, duringthe magnetrzation
penoo.

6.6 ExaminationTechniques:-

. The partto be testedshallbe preparedas mentioned.

. White or any other suitablecontrastpaint shall be appliedon lhe test


surfaceand 1" eitherside of the lest surface.

. The pole spacingshall be adjustedso as to ensurepropercoverage.The


pole spacingshall be between3" & 6".
@) STANI)ARD('ONS'IRUC'I'ION
PROCI]DURE JOBNo.623.1

Tot,, Err,rrrrntr,, Ilot r Lro. D O U B T ,IE\ T E C R I T YC R Y O C E N I C


AN4I\4ONIA STORACETANK

M I J \ {I ] , \ I
NIAGNETIC PARTICI,E PROCEDTTRE

The legs of the yoke shallbe positionedacrossthe weld or part to be


testedprovidingmagnetizationperiodsof at least30 seconds.

The wet ferrousmagneticparticlesshallbe sprayedon the test surface


simultaneouslywith the initiationof the magnetizing currentwill form
patternscausedistortion in the normalmagneticfield,thesepatternsare
usuallycharacteristic
of thetypeif discontinuity
thatis detected.

The weld or part shallbe examinedfor any relevantindications.lf any


relevantindications
areobservedits acceptance/ rejection
shallbe based
on the relevantacceptancecriteria.

in a directiongO0to the earlier


The legsof the yokeshallbe positioned
position.

Step6.6.5to 6.6.7shouldbe repeated.

-l
Interpretation& Acceptance of Indications

Indicationobservedduring examinationshali be interpretedto be either relevantor non


relevantand will be acceptedas per relevantcode and applicablespecification.

R Defect Rectification& Re-examination

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

Posttest cleaningshallbe carriedout with brush.

10. Demagnetization

Demagnetization
shall be canied out by contrnuously
reversingthe field direction.

11. Safety

Safetyprecautionas per approvalPolicyshall be adopted.

12. Reporting Of Result

The resultand parameterusedfor magneticparticletestingshallbe reportedin


"MagneticparticleExaminationReport"
8::';ierr.r.,i
TESTPROCEDURE
F.8.HYDRO.PNEUMATIC

INora Ltlrrrno
Tovo ENcrNnBRrNc
M U M B A I .I N D I A

g
!$rc h0lt
( 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)

PROJECT AMMONIA TANK.


STORAGE

CLIENT M/S.GODAVRI
FERTILISERS
& CHEMICALS
LTD.

TEILJOBNO. 6234

lt)

Tovo EncrNnrnrncINorl Lrmrrno


M U M B AIIN D I A
i . . . _ .r ., , 1 .
6_,
ryudx:g; '- \s< '
\:-_-,_-:-:
REVISIONHISTORY

Rev. Date Description

0 A u g1 8 , 0 6 For Review/ Approval


O STANDARD PROCEDURE
CONSTRUCTION
JOBNo.
6234
cP-003
T()Yo lli\cl\EERtNC; I\DtA LTD. D O U B L EI N T E G R I T C
YRYOGENIC
AMMONIA STORAGETANK

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

09 EMPTYINGOF TANK WATER & RESIDUALWORKS

10 T A N K C L E A NU P

11 INSTALLATIONOF DISH ENDS

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

This procedurecovers hydro-pneumatictesting for double wall low temperatureand low


pressureAmmoniastoragetank (20-T-01)is being constructedfor M/s. GFCL Kakinada, in
accordancewith referredcode,drawingsand engineeringspecifications.
- 1O,OOOMT.
T A N KC A P A C I T Y

02. REFERENCE
DOCUMENTS

this procedureduringConstruction
The followingdocumentsshallbe referredwhile interpreting
for doublewall doubleintegrityAmmoniaStorageTanks
(ltemno.20-T-01).

TEIL Drawingno. . C - 6231- 4301 -- GENERALARRANGEI,4ENT.


A p p l i c a b lC
e ode : API-620-R( 1 0 " E D I T I O NA, D D E N D U M1, J U N E - 2 0 0 4 . )

03. P R E L I MI N A R Y

Caution

After fabricationis completed& tank is releasedfor hydrolesting,check vapor-spaceto


make sure that it is free from explosivegases beforemakingany repairsor performing
any work that mightcausea spark.

D,I Preparation

1. Test all pressure-vacuumreliefventsfor accuracyat operatingpressureand vacuum


prior to testingthe tank. lf permanentvents are not available,it is mandatorythat a
temporarypressure/vacuum vent be providedfor emergencyventingso that test
pressureand vacuumloadingare not exceeded.

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.

3. Visualinspectionshall be carriedout beforeHydrotestand ensuredthat all activities,


whichare to be completedbeforehydrotest,are completed.

4. Make certainthat roof manholeand/orother roof fittingshavingas large an area as


the waterinletare open beforefillingtank with water.
5. Qualitvof test water

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

6. l\4arkreferenceelevationson foundationsat 8 circumferential


intervals. Reference
marking on a column little away from foundationshall be marked and the same
marking shall be transferredby water level on foundationsor with a help of
Theodolite/Levelinstrument.
Same referencepointshall be takenduringsettlementinspection.

7. Appropriatelevel markings(25%, 50o/o,75o/o


and water test level)shall be made on
the outersurfaceof outerTank and monitoredmanuallv

04. Hvdro-testof lnner tank

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.

05. TEST OF OUTERTANK


HYDRO-PNEUMATIC

a) After successfulhydro-testing of innertank and jnnertank full of water,fill the outertank


with water.Nilaximum levelof waterto be filledshall be 16.43N4trs.
Alternatively drainoff
the water from innertank to outertank usingdrain nozzlesto equalizethe water levelin
boththe tanksor till the outertank levelreaches16.43Mtrs.
Gaution: In no case level of water in outer tank exceeds the test water level of
i nn e r t a nk .
Afterdesiredwaterlevel is reached,checkoutertank surfacesincludingweldsfor leaks.

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.

e) Blankoff all nozzlesnot used for pneumatictest.

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 .

Slowlyincreaseair pressureto three-quarters '100%


c) and designpressure.
D e s i g np r e s s u r e1: 5 0 0m m W . C .

d) Visual inspectionshall be carried out for crack on welds of Tank anchorageand


deformationof tank surface.
& STANDARDCONSTRUCTION
PROCEDURE
JOBNo.
6234
cP-003
Toro Err;rrr:t:rl:r; l\DtA LTD. D O U B L EI N T E G R I T C
YRYOGENIC
AMlilONlA STORAGETANK

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 .

f) The air pressureshallbe reduceduntilthe designpressureis reached.

S) VisualInspection

h) All welds above hydrotestwater level includingfilletwelds undertest pressureare to be


testedby applyingsoap solutionwith consistency.
lf leaks are observed,de-pressurizethe tank, repairs are attendedas per approved
weldingproceduresin consultation with inspectionauthorityand retestedafternecessary
NDT checks.

i) Tank surfacesare to be inspectedvisuallyfor any deformationand all tank anchoragefor


signsof distress.

07, TESTINGOF SAFETYRELIEFVALVES

a) Reducedthe pressureup to 1300mmwcbeforeopeningblind flangesbetweenmanual


valvesand safetyreliefvalves.
Open one of the safety reliefvalves isolationvalve fittedon Nozzleno. N12 A & B (8"
NB)

b) While carefullyobservingthe manometer,slowlyincreasethe air pressureup to safety


reliefvalveset pressure(1350mmWC)
Readingson poppingand closingof safetyvalveshallbe noted.

c) The same procedureshall be repeatedfor the remainingsafetyvalves.

d) These readingsshall be comparedwith the inspectionreportssubmittedby the valves


suoolrer.

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

a) test, tank pressure is carefully


After successfulcompletionof the hydro-pneumatic
reteaseo.

b) With tank closed,slowlywithdrawwaterfrom outertank untilvacuumdesignpressureis


reached.
Vacuumer€fl set pressure:(-) 50 mm W c.
C A R E S H O U L DB E T A K E N W H I L ED R A I N I N GW A T E RF R O MT A N K O N L Y O U T E R
T A N K W A T E RS H O U L DB E D R A I N E DF I R S T

c) These readingsshall be comparedwith the inspectionreports submittedby valves


S UD D I I E T .

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

Rateof dischargingwater- 160 - 180 m /hr. (N4AXIN4UM)

b) Foundation settlement measurementreading during emptying of water shall be


recoroeo.

10. T A N K C L E A NU P

After completionof dewatering,removeearth (mud),rubbishetc., from insidethe tanks which


may haveaccumulatedduringwaterfill up and mop the tank bottomuntilit is dry.

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.

11. INSTALLATIONOF DISHEDENDS

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).

12. FINAL RELEASE

After carryingout final NDT tests as stipulatedin approveddrawings,InspectionTest Plan


(lTP) and propercleaning,the tank is releasedfor furtherwork afterfinalacceptanceby GFCL
/ T U V& T E I L .

Documentsregardingall tests beingcarriedout successfullyshall be prepared& endorsedby


G F C L/ T U V & T E I La s r e c o r d s .

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P C-L*
:a- =- -;

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