Inspection & Testing

of equipment's
 Authority & Responsibility

Those responsible for QC system shall be

established clearly.
QC shall have well defined responsibility, shall have
the authority and the organizational freedom to
identify QC problems and to initiate, recommend
and provide solutions.
At any time the Code rules shall not be
compromised for resolving a problem.

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 Objectives

1) Introduction To various inspection stages

2) introduction to ASME & other Relevant Code
3) Introduction to Various NDT methods .
4) Introduction to Welding Process .
5) Introduction to Various Testing Requirement &
Tolerances accepted by Code .

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 Inspection Stages

To give a Assurance to customer regarding to

quality need to follow some stages , which are
included in QAP .
Need Technical Specification Special
Requirement & Service condition .
Guideline to Mfg. Div.

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 Code
We referring Following Code
ASME For Construction , Inspection & tolerances
ASME SEC VIII Div 1 Code For Construction Of
PV
ASME SEC IX Welding & Bracing process
qualification.
ASME SEC V NDT Methods .
ASME SEC II Materials
SEC II A Ferrous Material
SEC II B- Non Ferrous Material
SEC II C Welding Electrodes
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SEC II D Properties
 Stages
Material Identification
Welder Qualification
Stage Inspection eg Layout marking, L/Seam
Setup, C/Seam Setup, Dimensional Inspection,
Nozzle Orientation & Elevation, Visual Inspection,
Leak & Pressure testing etc
Running Trial
Final Visual Inspection

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 Material Control

Pressure parts shall conform to materials comply

with UG 4 thru UG 15 and shall be proven of
weldable quality.
Non pressure parts need not conform to material
specification as required above but if attached to
vessel by welding shall be of weldable.
Materials not permitted by the Code shall not be
used unless it is specially approved by BPV
committee.(Appendix-5 of Sec II D)

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 UCS 23 Carbon & Low Alloy Steel
Materials permitted are listed in UG 23 ( plates,
forgings, pipes & tubes, bolts & studs)
UNF 23 Non ferrous materials
UHA 23 High alloy steels
UCI 23 Cast Iron (UG 24 for Casting Quality
factor)
UCD 23 Cast Ductile Iron
UHT 23 Ferriticsteels with properties enhanced
by HT
ULT 23 -Nickel alloys for low temp application
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UG 12 Bolts
Studs shall be threaded to full length or machined down to root
diameter in unthreaded portion provided threaded portions are
min. 1.5 times the diameter in length with suitable transition
UG 13 Nuts
Shall engage the threads for the full depth of the nut
If washer is used shall be of wrought material
Rods & Bars
Except for flanges, hollow cylindrically shaped parts up to DN
100 may be machined from rolled or forged bar

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 Leak testing
To check welding strength & Leakages

UG -99 Hydrostatic Testing

Water Quality ig PH , Cl , TDS , as per IS10500
Total water removal
Pressure = MAWP X 1.3 X Stress ratio

UG- 100 Pneumatic Testing

Pressure = Design Pressure X 1.1

UG -101- Proof Test

Proof test to Establish max allowable working pressure

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 Fabrication
Cutting of plates
All oxygen or arc cutting edges shall be removed
by mechanical means to remove slag and
discoloration of material
Exposed inside edges shall be chamfered off.
Material identification
All pressure parts shall have traceability to original
marking
Coded marking is acceptable

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 Tolerance

For fabrication tolerance we can refer.

1) ASME Sec VIII ( UG -80 For Out off Roundness ,
UG-81 For Dished )
2) PD 5500
3) TEMA
Mainly tolerances are given for Nozzle
orientation, nozzle location , nozzle projection ,
weld , support location, overall height & length,
dish end forming dimensions .

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 TOLERANCES
FORMING
Out of roundness 1% of the nominal diameter
At nozzle openings an additional 2% of ID of the
opening may be considered
Shape verification for over crowning & under
crowning as per UG 81 for formed heads (outside
shape shall not deviate the specified shape by more
than 1.25% of D & inside shape shall not deviate more
than by 5/8% of D)

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Diameter tolerance

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Ovality

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 Definition of NDT
The use of noninvasive techniques
to determine the integrity of a
material, component or structure
or
quantitatively measure some
characteristic of an object.
i.e. Inspect or measure without
doing harm

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 Methods of NDT

Visual

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When are NDE Methods Used?
There are NDE application at almost any stage in the
production or life cycle of a component.
To assist in product development
To screen or sort incoming materials
To monitor, improve or control manufacturing
processes
To verify proper processing such as heat
treating
To verify proper assembly
To inspect for in-service damage
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Six Most Common NDT Methods
Visual
Liquid Penetrant
Magnetic
Ultrasonic
Eddy Current
X-ray

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What are Some Uses of NDE Methods?
Flaw Detection and Evaluation
Leak Detection
Location Determination
Dimensional Measurements
Fluorescent penetrant indication
Structure and Microstructure Characterization
Estimation of Mechanical and Physical Properties
Stress (Strain) and Dynamic Response Measurements
Material Sorting and Chemical Composition
Determination
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 Magnetic Particle Inspection
The part is magnetized. Finely milled iron particles coated
with a dye pigment are then applied to the specimen. These
particles are attracted to magnetic flux leakage fields and
will cluster to form an indication directly over the
discontinuity. This indication can be visually detected
under proper lighting conditions.

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 Visual Inspection
Most basic and common
inspection method.

Tools include
fiberscopes,
borescopes, magnifying
glasses and mirrors.

Portable video inspection

unit with zoom allows
inspection of large tanks
and vessels, railroad tank
cars, sewer lines.
Robotic crawlers permit
observation in hazardous or
tight areas, such as air
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ducts, reactors, pipelines.
 Liquid Penetrant Inspection
A liquid with high surface wetting characteristics is
applied to the surface of the part and allowed time to seep
into surface breaking defects.
The excess liquid is removed from the surface of the
part.
A developer (powder) is applied to pull the trapped
penetrant out the defect and spread it on the surface
where it can be seen.
Visual inspection is the final step in the process. The
penetrant used is often loaded with a fluorescent dye
and the inspection is done under UV light to increase
test sensitivity.

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 Magnetic Particle Inspection
The part is magnetized. Finely milled iron particles coated
with a dye pigment are then applied to the specimen. These
particles are attracted to magnetic flux leakage fields and will
cluster to form an indication directly over the discontinuity.
This indication can be visually detected under proper lighting
conditions.

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Magnetic Particle Crack Indications

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 Radiography
The radiation used in radiography testing
High Electrical Potential
is a higher energy (shorter wavelength)
version of the electromagnetic waves that
Electrons
we
+ -
see as visible light. The radiation can
come from an X-ray generator or a
X-ray Generator or
radioactive source. Radioactive
Source Creates
Radiation

Radiation
Penetrate
the Sample

Exposure Recording Device

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 Joint Category
Category A:All longitudinal welds in shell and nozzles
All welds in heads, Hemisph -head to shell weld joint
Category B:All circumferential welds in shell and
nozzles Head to shell joint (other than Hemisph.
Category C and D are flange welds and nozzle
attachment welds respectively Longitudinal welds
(Category A) are more critical than Circumferential
welds (Category B) because they are under double
stress. This the reason why in different part of ASME
code we have stringent rules in category A joint
compared to category B joint.

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Joint Category

RT 1: (E=1), All butt welds-full length

radiography
RT 2: (E=1), Category A and D butt welds
full length radiography and category B and
C butt welds spot Radiography
RT 3: (E=0.85), Spot radiography butt welds
Each Welder , Each 15 Meter 1 Spot min 150 mm

RT 4: (E=0.7), Partial / No radiography

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 Film Radiography
The part is placed between the radiation source
and a piece of film. The part will stop some of
the radiation. Thicker and more dense area will
stop more of the radiation.

The film darkness (density)

will vary with the amount
of radiation reaching the
film through the test object.
X-ray film

= less exposure
= more exposure
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Top view of developed film

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Ultrasonic Inspection (Pulse-Echo)
High frequency sound waves are introduced into a material and they
are reflected back from surfaces or flaws.
Reflected sound energy is displayed versus time, and inspector can
visualize a cross section of the specimen showing the depth of
features that reflect sound. f

initial
pulse

back surface
echo
crack
echo

0 2 4 6 8 10 crack
plate
Oscilloscope, or flaw
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 Common Application of NDT

Inspection of Raw Products

Inspection Following Secondary Processing
In-Services Damage Inspection

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 WELDING
FUNDAMENTALS OF WELDING
JOINING - welding, brazing, soldering, and adhesive bonding to
form a permanent joint between parts
ASSEMBLY - mechanical methods (usually) of fastening parts
together. Some of these methods allow for easy disassembly.

WELDING A joining process of two materials that coalesced

at their contacting (faying) surfaces by the application of
pressure and/or heat.
Weldment The assemblage
Sometime a filler material to facilitate coalescence.
ADVANTAGE: portable, permanent, stronger than the parent
materials with a filler metal, the most economical method to join
in terms of material usage and fabrication costs .
DISADVANTAGE: Expensive manual Labor, high energy and
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dangerous, does not allow disassemble and defects

WPS/PQR/WPQR

WPS Welding Procedure Specification

PQR- Procedure Qualification Record
WPQ /WOPQ - Welder Performance Qualification

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Codification

P No : For base metal Grouping

Eg . P1 Carbon Steel SA 516 gr 70
P8 For Austenetic Stainless Steel SA 240

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 Welder Qualification
When qualifying a welding procedure you must
first determine the important properties of the
planned weldment which then become the
essential variables. The basic ones are;
Base metal to be welded and thickness (T)
required.
Process (es) to be used including filler metal (s).
Preheat.
Post weld heat treatment or the lack of.
Various others based on welding process used.
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Essential Variable A variable that if changed
requires requalification of the procedure by
the welding and testing of a new coupon or
support from a previously qualified
Procedure Qualification Record (PQR),
i.e. a change in the base metal thickness (T)
qualified.

Supplementary Essential An essential variable that is used

only when impact testing of a base metal is required by a
construction code, i.e. a change from one P-No. Group to
another such as P1 Gr.1 to Gr.2.

Non-Essential A variable that can be changed as needed to

suit production requirements without requalification.
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Thank You

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