Professional Documents
Culture Documents
Thre
e
Two
One
Responsibility of
Engineer Inspection
Fabrication
stage
2) Input - Approved Drg, Check List, ITP, NDT
plan,
Testing Plan
3) IncludeCustomername,Description&W.O.
4) BasedonInspectionCheckListHold,witnesspoints markin
Seamwisechecklist
5) DetailedchecklistshallbereviewedsignedoffbyAI
6) DistributetoHeadManufacturingorProductionEngineer.
7) Maintainthedetailedchecklist
Material Clearance
Record
AfterissueofdrawingforConstructionthematerialshallbe
1)
identified&maintainthetraceability(MCR).
2) Input - Approved Drg, AI Signed IMIR, Inspection
request
3) Section VIII, Div 1, UG-77 & 93
4) Material specification with Grade or Class, Heatno,
IMIRNo.,Drawingno,Partno,WOnoaremarkedoneach part
oftheplate.Itshallbevisible.
5) Inspect for Pitting, Surface Damage on both side.
6) Basic dimensions such as length, breadth and
thickness
are
to be checked w r t Drawings.
7) Identification to be transferred to balance Piece of Plate
before cutting operation.
8) QC inspector stamps the inspection punch mark on
each part during inspection.
Material Clearance
Record
9) Wherever full details of identification are not possible to
IDENTIFICATIO
NLOCATION
L
K1
K2
ROLLINGDIR.
Material Clearance
Record
Fit up Inspection
LONGSEAMFITUPSTAGEINSPECTION:
Physical Verification & Inspection on the Job:
1.
2.
3.
4.
5.
6.
IDmaxIDmin=1%
ofNominalID
I/DCHECKIN
HORIZONTALPLANE
D/
4
TE
M
P
P
EM
4T
D/
PEAKOUT
D/4Template:TemplateLength
PEAKIN
PeakOut
D/4Template
D/4Template
MatchingProfile
PeakIn
TOLERANCE
ProfileTolerance
InsideDiameterof
Shell/Segment(in
mm)
Permissiblelimitsfor
peakoutor
peakin(inmm)
152
0.8
305
1.2
457
1.6
610
2.4
914
3.2
1219
4.0
1524
4.8
1905
5.6
2133
6.4
2438
6.4
2743
7.1
3048
7.9
3048
0.2%ofdia.
TOLERANCE
< 1200 mm
1201 to 2400 mm
> 2400 mm
10 mm
12 mm
20 mm
VESSEL LENGTH
5 mm PER 3000 mm, MAXIMUM 15
mm
VESSEL ALIGNMENT / STRAIGHTNESS
6 mm PER 6000 mm, MAX. 20 mm FOR
ANY LG.
Over13mmto19mm
Over19mmto38mm
Over38mmto51mm
Over51mm
Cat.:A
Cat.:B,C&D
1/4tht
1/4tht
3mm
3mm
3mm
1/16thtor
Max.10mm
1/4tht
5mm
1/8tht
1/8thtor
Max.19mm
ForJointCategoryReferUW3
Cat.A:Longitudinaljoint(Circ.JointofHemisphericalheadtoshell)
Cat.B:Circumferentialjoint(ExceptHemisphericalheadtoshell)
Cat.C:WeldedJointconnectingtoflange,Tubesheets,Flatheadtoshell
Cat.D:WeldedJointconnectingtoNozzletoshellorheads
Fit up Inspection
CIRC.SEAMFITUPSTAGEINSPECTION:
Physical Verification & Inspection on the Job:
1.
2.
Fit up Inspection
NOZZLEFITUPSTAGEINSPECTION:
Physical Verification & Inspection on the Job:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Form Head
TypesofHead
1.
2.
3.
4.
Torisphericalhead
ToriconicalHead
HemisphericalHead
EllipsoidalHead
FormHeadINSPECTION
1.
2.
Form Head
FormHeadINSPECTION:
W.E.P & adjoining area shall be cleaned 1" on either side.
4. All tacks shall be free from Defect.
5. Weld edges and shell surface shall be free from arc strikes
spatters gas cutting serration, pitting, dents etc.
6. Check W.E.P NDT (PT/MT), if applicable.
7. PTC shall be ready with all aspects near to the Head, If
applicable.
8. Offset as per UW 33, Ovality as per UG 80
9. Dimensional measurement (Circumference, Straight Face,
Height or Depth, Minimum thickness)
10. Profile shall be checked with template as per UG 81 (Inner
surface of head not deviate Outside of specified shape not
more than 1 % of NID & Inside of specified shape not more
than 5/8% of NID)
11. Knuckle Radius shall not be less than specified.
3.
Clearance of Welding
Followingpointstobeverifiedbeforereleasingforwelding
a) Fitupinspectionsatisfactory
b) SuitableWPSavailableanddisplayedattheworksite
c) Qualifiedweldersandsupervisorspositioned
d) Environmentalparametersareacceptableforwelding
e) Weldingmachinesindicatorsareproperlycalibrated
andworking
f) Weldconsumablesareasperrequirement
g) Bakingandcarryoveninorder
h) Weldingdatasheetinplace
i) Propertemporarysupportstobeprovided.
WELDVISUALINSPECTION:
Weldvisualinspectionsaretobeensured,WeldmetalaswellastheHAZis
defectfree.Followingdefectsareanticipated:
b)Cracks,undercut,porosity
c)Arcstrikes
d)Surfacedefect
*Followingdimensionalchecksaretobedone:
a)Weldprofile
b)Widthofweavingbead
c)Weldreinforcementbothheightandwidth(UW35)
*Followinginformationmustbesoughtandrecordedatthetimeofclearingthe
weldvisual:
a)WPS
b)Welderno.
NDT
Oncompletionofweldvisualthejointsareofferedfor
UT/RT/DPT/MPT/HardnesstestasrequiredasperNDEplan.
Reinforcement Tolerance
(UW-35 )
Max.Reinforcement
MaterialThickness
Below2.4mm
2.4to4.8mmincl.
Over4.8to13mmincl.
Over13to25mmincl.
Over25to51mmincl.
Over51to76mm
Over76to127mm
Over127mm
Other
Category
0.8mm
1.6mm
2.4mm
2.4mm
3.2mm
4mm
6mm
8mm
CategoryB&
C
2.4mm
3.2
4mm
4.8mm
5mm
6mm
6mm
8mm
Non conformity
A situation shall be considered as nonconforming if any activity or
operation has already performed which has resulted in noncompliance
with the applicable rules of the code, drawings, specifications, or the
requirements of Quality control manual.
NCs shall be corrected before the completion of vessel can be
considered to comply with the code.
NCs shall include, but not be limited to:
1)Material & Parts found to have deviation during receiving / in process
examination.
2)Weld material used not meeting the specification requirement.
3)Repairs affecting material.
4)Un-calibrated equipment used in measurement or test.
5)Time-Temp. cycle of HT performed deviating from specification.
6)Deviation from Design /Drawing
7)Situations not meeting requirement of this manual.
Non conformity
Inspection clearance
slip
Hydro / Pneumatic
Test
ENSUREFOLLOWINGPRIORTOSTARTTHETEST:
1. MCRSHALLBECLEARED.
2. COMPLETIONOFWELDINGONPRESSUREPARTS
3. COMPLETIONOFALLNDTTOTHEACCEPTABLE
STAGE
4. TESTINGOFPTC,IFANY,TOTHEACCEPTABLE
TESTRESULTS
5. ALLDIAMENSIONALCHECKWITHINTHE
ACCEPTABLELIMIT
6. CHECKLISTSHALLBEUPDATED.
Hydro / Pneumatic
Test
ENSUREFOLLOWINGPRIORTOSTARTTHETEST:
7. HYDROTESTARRANGEMENTASPERAPPROVED
DRAWING.
8. ALLTESTEDJOINTSFREEFROMPAINT,DUST,
RUSTETC..
9.
INTERNALINSPECTIONSHALLBECARRIEDOUT.
10. ALLFASTENERSARETIGHTENEDTOREQUIRED
TORQUE.
11. PROPERVENTTOBEPROVIDEDONTOPOFTHE
VESSELS.
12. TWOPRESSUREGAUGESTOBEAVAILABLE.
Hydro / Pneumatic
Test
ENSUREFOLLOWINGPRIORTOSTARTTHETEST:
13. GAUGESRANGE:1.5TO4TIMESOFTEST
PRESSSURE(UG102)
14. LOCATEGAUGEONTOPMOSTOFTHEVESSEL.
15. ALLGAUGESSHALLBECALIBRATEDAGAINST
STANDARDDEADWEIGHTTESTERORA
CALIBRATEDMASTERGAUGE.GAUGESSHALLBE
RECALIBRATEDATANYTIME.
16. TESTMEDIUMSHALLBENONHAZARDOUSLIQUID.
17. TESTPRESSURESHALLNOTBELESSTHAN1.3TIMES
OFMAWPFORHYDROTEST&1.1TIMESOFMAWP
FORPNEUMATICTEST.
Hydro / Pneumatic
Test
WATERFILLING,PRESSURISING&INSPECTION:
1. WATERSHALLBEFILLEDFROMTOPOFVESSEL.
2. INCREASETHEPRESSUREASPERAPPROVEDPROCEDURE.
3. WHILETESTINGMETALTEMP.SHALLNOTBELESSTHAN
17CANDNOTMORETHAN48CTOREDUCERISKOF
BRITTELFRACTURE.
4. HOLDINGTIMEASPERAPPROVEDPROCEDURE.
5. ALLPRESSUREJOINTSHALLBEVISUALYINSPECTEDAT
PRESSURENOTLESSTHANTHETESTPRESSURE/1.3
PRESSURE.
6. LEAKAGEISNOTALLOWEDATTHETIMEOFREQUIRED
VISUALINSPECTION.
Hydro / Pneumatic
Test
WATERFILLING,PRESSURISING&INSPECTION:
7.IFANYLEAKGEISOBSERVEDFROMWELDOR
PARENTMETAL,DRAINTHEWATER,REPAIRTHE
LEAKANDREPEATTHETEST.
8. TIME,TEMPERATURE&PRESSURECHART
WHEREVERSPECIFIEDSHALLBEOBTAINED.
9. REDUCETHEPRESSUREFROMTHETOPOFTHE
VESSELASPERAPPROVEDPROCEDURE.
10. DRAINTHEWATERFROMTHEBOTTOMOFTHE
VESSELWITHPROPERVENTATTOP.
11. RELIEFVALVESETTO1TIMESOFTEST
PRESSUREISRECOMMENDED.
Name Plate / U
stamping
1.
DETAILOFMARKINGISADDRESSEDINUG115TOUG119
2.
TYPEOFCONSTRUCTIONUSEDFORTHEVESSELSHALLBE
INDICATEDDIRECTLYUNDERCODESYMBOL.
TYPEOFCONSTRUCTION
LETTER(S)
ARCORGASWELDED
PRESSUREWELDED
BRAZED
RESISTANCEWELDED
3.
B
RES
INADDITIONTOABOVE,WHENAVESSELISINTENDEDFOR
SPECIALSERVICEANDREQUIREMENTCOMPLYIEDWITHLETTER
LETHALSERVICE
L
UB
UNFIREDSTEAMBOILER
DIRECTFIRING
DF
Name Plate / U
stamping
4.
WHENRADIOGRAPHICORULTRASONICEXAMINATIONHAS
BEENPERFORMEDONAVESSEL,MARKINGSHALLBEAPPLIED
UNDERCODESYMBOL:
RT1 ALLPRESSURERETAININGBUTTWELDEXCEPT
CATB&CBUTTWELDSASSOCIATEDWITH
NOZZLES
ANDCOMMUNITINGCHAMBERSTHAT
NEITHEREXCEED
NPS10NOR29MMWALL
THICKNESS
RT2
COMPLETEVESSELSATISFYREQUIREMENTOF
UW11(a)(5)ANDSPOTRADIOGRAPHY
REQUIREMENTUW11(a)(5)(b)
RT3
SPOTRADOGRAPHY
RT4WHERENONEOFTHEABOVEMARKINGAREAPPLICABLE
Name Plate / U
stamping
5. BASEDONHEATTREATMENTONVESSEL,FOLLOWING
LETTERTOSYMBOLONNAMEPLATE.
IFCOMPLETEVESSELUNDERGONEPWHT
HT
IFONLYPARTOFVESSELUNDERGONEHWHT PHT
Name Plate / U
stamping
6. WHENTHEMARKINGREQUIREDBYUG116ISAPPLIED
DIRECTLYTOTHEVESSEL.ITSHALLBESTAMPEDWITHAT
LEAST8MMHEIGHTOFLETTERS.
7. STAMPINGSHALLNOTBEDONEONVESSELINFOLLOWING
CONDITIONS(UG118):
A) MATERIALSHALLBELIMITEDTOP1GR1AND2
B) MINPLATETHK5MM,&MINPIPEWALLTHK4MM
C) MDMTCOLDERTHAN29C
D) MATERIALSHALLBELIMITEDTOALLUMINIUM
9. NOMODOFVESSEL
CHARACTERSIZE
89MMMAX
3MM
89TO114MM
5MM
Name Plate / U
stamping
10. NAMEPLATESHALLBEUSEDONVESSELEXCEPTWHEN
MARKINGSHALLNOTBESTAMPEDDIRECTLYONVESSEL
BYUG118.
11. CHARACTERSIZEFORNAMEPLATENOTLESSTHAN4MM.
12. NAMEPLATEMAYBEATTACHEDEITHERBYWELDING,
BRAZINGORSOLDERING.
13. NAMEPLATEMAYBEINSTALLEDONSKIRT,SUPPORT,OR
PERMANENTATTACHMENTTOVESSEL.
14. THEADDITIONNAMEPLATESHALLBEMARKED:
DUPLICATE
OTHER REQUIREMENT
1. HEATTREATMENTREQUIREMENT(UCS56)
2. CHARPYIMPACTTEST(UG84,UCS66,UCS67)
3. MATERIAL(TABLEUCS23)
4. MANUFACTURERDATAREPORT(MDR,UG120,
NONMANDATORYAPPENDIXW,FORMU1,U2)
ELEVATION
PROJECTION
S.F.
PROJECTION
Set Through
Nozzle / Manway
T.L. to T.L.
Hemispherical
Dend
T.L.
T.L.
2:1 Ellipsoidal
Dend
Thank
You