1. Guide for Source Inspection and QualitySurveillance of Fixed EquipmentAn API Approach _ Part 2 of 22014-SeptemberMy Self Study Exam Preparatory NotesCharlie Chong/ Fion Zhang

2. At works https://www.yumpu.com/zh/browse/user/charliechongCharlie Chong/ Fion Zhanghttp://www.slideshare.net/charliechong/edit_my_uploadshttp://issuu.com/charlieccchong 3. At worksCharlie Chong/ Fion Zhang 4. At worksCharlie Chong/ Fion Zhang 5. 8 Source Inspection Performance8.1 Inspector Conduct and Safety8.1.1 Individuals tasked with the responsibility of performing sourceinspection activities should conduct themselves professionally while visitingan S/V facility as a representative of their employer and/or purchaser. If anyconflict should arise during the inspection activity, the source inspector shouldnotify their supervisor for resolution ASAP. It is important that the SI not beconfrontational or argumentative regardless of the importance of the issue athand; but rather simply indicate in objective terms how the SI intends toproceed to resolve the issue.Charlie Chong/ Fion Zhang 6. Attitude:SI not be confrontational orargumentative regardlessof the importance of theissue at handCharlie Chong/ Fion Zhang 7. Attitude:SI not be confrontational orargumentative regardlessof the importance of theissue at handCharlie Chong/ Fion Zhang 8. Attitude:SI not be confrontational orargumentative regardlessof the importance of theissue at handCharlie Chong/ Fion Zhang 9. 8.1.2 Safety of the individual performing the source inspection activity is oneof the most important aspects of their work. A safety program should beestablished which identifies specific safety hazards associated with the job.Source Inspectors should be adequately trained and knowledgeable in thesesafety programs in order to minimize the possibility of injury. The safetyprogram should include: Potential travel safety issues specific to the job Potential shop safety issues and hazard recognition How to handle the observation of unsafe acts in the shop8.1.3 The SI should observe the safety procedures and policies of the S/Vwhile on their premises or if more stringent, their own company safetyrequirements.Charlie Chong/ Fion Zhang 10. Keywords: Travel safety Work safetyCharlie Chong/ Fion Zhang 11. 8.2 Review of Project Documents8.2.1 General8.2.1.1 Typical project documents include but are not limited to contractualagreements (purchase orders and/or subcontracts), source ITP, projectspecifications, engineering or fabrication drawings, applicable codes,references or standards.8.2.1.2 The source inspectors should familiarize themselves with all projectdocuments and ensure that they have access to the specific edition/version ofthose documents specified in the contractual agreement at all times duringtheir inspection visits. Prior to commencing the quality surveillance specifiedin the ITP, the source inspector should confirm that the S/V has the mostcurrent documents, drawings, etc. specified in the engineering design. Latereditions of industry codes and standards do not apply if the engineeringdesign has specified an earlier edition of a specific standard. Additionally, thesource inspector should confirm that that all project documents have beenreviewed/approved by the purchaser.Charlie Chong/ Fion Zhang 12. Question:What is source ITP?Keywords: Later editions of industry codes and standards do not apply if theengineering design has specified an earlier edition of a specific standard.Additionally All project documents have been reviewed/approved by the purchaser.Hints: In practice not all project documents wereapproved/reviewed by purchaser, e.g. the shop drawings.However to pass your SI exam- All project documents need tobe reviewed/approved by purchaser!Charlie Chong/ Fion Zhang 13. 8.2.2 Contractual AgreementsThe contractual agreements including the purchase order, all specifiedengineering design documents, specified company standards, and specifiedindustry standards form the basis for the requirements for source inspectionof the purchased products.8.2.3 Engineering Design DocumentsFor engineered equipment, the SI needs to be familiar with the engineeringdesign documents and drawings that are vital to quality of the purchasedproducts.Charlie Chong/ Fion Zhang 14. Contractual AgreementsCharlie Chong/ Fion Zhang 15. Engineering Design Documents: Familiar with the engineering designdocuments and drawingsCharlie Chong/ Fion Zhang 16. Charlie Chong/ Fion Zhang 17. Engineering Design Documents: Familiar with the engineering designdocuments and drawingsCharlie Chong/ Fion Zhang 18. Charlie Chong/ Fion Zhang 19. 8.2.4 Company and Client StandardsThe SI needs to be familiar with all company and client standards that arespecified in the contractual agreements. These standards typically augmentor supplement industry standards for issues not sufficiently well covered inindustry standards. All mandatory requirements i.e. shall/must statements,included in the company specifications must be met or become an issue foran NCR and handled in accordance with standard purchaser managementNCR systems requirements.Other issues contained in the specified standards such as those suggested orrecommended i.e. should statements which are expectations of the S/V, butnot necessarily requirements may become an issue to be reported in SupplierObservation Reports (SORs) and handled in accordance with standardpurchaser management systems. Company and client standards may coverengineered and non-engineered equipment.Charlie Chong/ Fion Zhang 20. Keywords: shall/must statements - NCR and handled in accordance with standardpurchaser management NCR systems requirements. should statements - reported in Supplier Observation Reports (SORs)and handled in accordance with standard purchaser management systems.Charlie Chong/ Fion Zhang 21. 8.2.5 Industry Codes and Standards8.2.5.1 GeneralThe SI needs to be familiar with all industry codes and standards that arespecified in the contractual agreements to the extent that requirements andexpectations in those codes and standards are part of the contractualagreements and therefore part of the source inspector duties. Those industrycodes and standards are typically published by recognized industry standardsdevelopment organizations (SDOs), such as those in the followingsubsections.Charlie Chong/ Fion Zhang 22. 8.2.5.2 API Codes and StandardsThere are a wide variety of API Codes and Standards that may be included inthe contractual agreements to specify and control the quality of products forthe energy industry. A few of those that the SI should be familiar with andapply when specified are shown in the following subsections; but this list isnot all inclusive. Others that are specified in the contractual agreements maybe equally important to the quality of the delivered product. The informationcontained in the following industry standards is generic to a wide variety ofproducts and therefore should be general knowledge to the experienced SI.Charlie Chong/ Fion Zhang 23. API RP 572, Inspection Practices for Pressure Vessels. This RPincludes a description of the various types of pressure vessels and thematerials and standards for their fabrication. The source inspector should befamiliar with Sections 3 and 4 of this RP.Charlie Chong/ Fion Zhang 24. API RP 577, Welding Inspection and Metallurgy. This RP providesguidance for the source inspector on welding fabrication inspection. Issuescovered include: welding processes, procedures, welder qualifications,metallurgical affects from welding, inspection techniques, welding terminologyand symbols, how to review a welding procedure, and a guide to commonfiller metals. The source inspector should be thoroughly familiar with thecontents of Sections 3 to 10 of this RP. API RP 578, Material Verification Program for New and Existing AlloyPiping Systems. The purpose of this RP is to provide guidelines for amaterial and quality system to verify that the nominal composition of pipingalloy components is consistent with the material specifications. The primarytopics covered include: material verification test methods, evaluation of PMItest results, marking and record keeping. The source inspector should bethoroughly familiar with the contents of this RP except for the sections thatfocus on material verification for existing systems that are already in operationin a plant.Charlie Chong/ Fion Zhang 25. API Std 598, Valve Inspection and Testing. This standard covers theinspection, examination, and pressure test medium and requirements forvarious kinds of valves utilized in the energy industry. The various kinds oftests and examinations specified in this standard include: shell test, backseattest, low-pressure closure test, high-pressure closure test and visualexamination of castings. The SI should look to the appropriate purchasingdocument and spec sheets for the required characteristics of each valve,such as type, size, materials, rating, trim, etc. The SI should be thoroughlyfamiliar with the contents of API Std 598 whenever specified in contractualagreements. API Std 598 is mostly applied to standard metallic valves(butterfly, gate, globe, ball, etc.) used in ASME B31.1 or B31.3 applications.Charlie Chong/ Fion Zhang 26. 8.2.5.3 ASME Codes and StandardsThere are a wide variety of ASME Codes and Standards that may be includedin the contractual agreements to specify equipment fabrication methods andcontrol the quality of products for the energy industry. A few of those that theSI should be familiar with and apply when specified are shown in the followingsubsections; but this list is not all inclusive. Occasionally there may be othersections of the ASME BPVC that will be specified on different projects inwhich the SI will be involved.Charlie Chong/ Fion Zhang 27. ASME BPVC Section II - Materials. This section of the BPVC is divided intofour parts covering materials for the construction of piping and pressurevessels. Part A - Ferrous Material Specifications.This part contains the individual specifications for ferrous materials that areallowed in the construction of pressure vessels and piping designed to theASME BPVC. Part A covers all forms of ferrous material products likewrought, castings, forgings, plates, piping valves, bolting, etc.Charlie Chong/ Fion Zhang 28. The issues addressed by each ferrous material specification vary based onthe characteristics of the material and final use for which it is intended. Someexamples of issues covered include: ordering information, heat treatment,chemical composition, mechanical properties, tests and examinations,dimensions and tolerances and the steel making practice. The sourceinspector should be familiar with the contents of whichever materials arespecified in the contractual agreements. The only three specificationscovered in ASME BPVC Section II, Part A that the SI need to be familiar withfor purposes of the examination are: SA-20, General Requirements for Steel Plates SA-370, Test Methods and Definitions of Mechanical Testing SteelProducts SA-6, Thickness Tolerances for Steel PlateCharlie Chong/ Fion Zhang 29. Part B - Nonferrous Material Specifications.This part contains the individual specifications for nonferrous materials thatare allowed in the construction of pressure vessels and piping designed to theASME BPVC. Part B covers all forms of nonferrous material products likewrought, castings, forgings, plates, piping valves, bolting, etc. allowed for inthe construction of ASME BPVC equipment.The types of nonferrous material alloys included in Part B are: aluminum,copper, nickel, titanium, and zirconium. The issues addressed by eachnonferrous material specification vary based on the characteristics of thematerial and final use for which it is intended. Some examples of issuescovered include: ordering information, heat treatment, chemical composition,mechanical properties, tests and examinations, dimensions and tolerancesand the steel making practice. The source inspector should be familiar withthe contents of whichever materials are specified in the contractualagreements. However there will be no specific questions on the coreexamination out of Part B, but the SI should be familiar with what thestandard covers.Charlie Chong/ Fion Zhang 30. Part C - Specifications for Welding Rods, Electrodes and Filler Metals.Part C covers material specifications for the manufacture, acceptability,chemical composition, mechanical usability, surfacing, testing, operatingcharacteristics and intended uses of welding rods, electrodes and fillermaterials. The material specifications are designated by SFA numbersderived from AWS specifications. The source inspector would typicallyreference these specifications for whichever welding materials are specifiedin the contractual agreements to ensure that the right materials are beingused in fabrication. However there will be no specific questions on thecore examination out of Part C, but the SI should be familiar with what thestandard covers.Charlie Chong/ Fion Zhang 31. Part D - Materials Properties.Part D provides tables for design stress values, tensile strength, yield strength,and other important chemical and physical properties for all the materialspecifications contained in Parts A and B. This section is primarily intendedfor designers of ASME BPVC equipment. As such, there will be no specificquestions on the core examinations out of Part D, but the SI should befamiliar with what the standard covers.Charlie Chong/ Fion Zhang 32. ASME BPVC Section V - Nondestructive Examination.This section of the BPVC contains requirements and methods for NDEtechniques that are specified by other sections of the ASME BPVC and/orcontractual agreements. Most of the common methods of NDE are covered inSection V including RT, UT, MT, PT, VT, and LT. Appendix A of Section Vpresents a listing of common imperfections and damage mechanisms and theNDE methods that are generally capable of detecting them. Section V alsoprovides guidance on methods of evaluating NDE results. The sourceinspector should be thoroughly familiar with the contents of Section V forwhichever NDE method is specified in contractual agreements and/or ITP.For the purposes of SI examination, some of the content covered in ASMEBPVC Section V that applicants should focus on include:Charlie Chong/ Fion Zhang 33. All definitions in Subsection A, Article 1, Appendix 1 and Subsection B,Article 30, SE-1316 Article 1 on General Requirements for NDE Article 4 on Ultrasonic Examination Methods of Welds Article 6 on Liquid Penetrant Examination Article 7 on Magnetic Particle Examination Article 9 on Visual Examination Article 10 on Leak Testing Article 23, Section 797 on UT Thickness TestingCharlie Chong/ Fion Zhang 34. ASME BPVC Section VIII, Division 1Rules for the Construction ofPressure Vessels.Division 1 contains the requirements, specific prohibitions and non-mandatoryguidance for standard design unfired pressure vessel materials, design,fabrication, examination, inspection, testing, certification and pressure reliefrequirements. Division 1 is divided into three subsections with mandatory andnon-mandatory appendices. The source inspector should be thoroughlyfamiliar with the contents of Division 1 with regard to the fabrication,examination, inspection and testing that is specified in contractualagreements and/or ITP. Some of the content covered in ASME BPVC SectionVIII, Division 1 that the SI should be familiar with include:Charlie Chong/ Fion Zhang 35. Subsection A covers the general requirements applicable to all pressurevessels. Subsection B covers specific methods of fabrication of pressure vesselse.g. welding Subsection C covers the various classes of materials used in thefabrication of pressure vessels e.g. steels, alloys, cladding, lining, lowtemperature materials, etc.Charlie Chong/ Fion Zhang 36. For the purposes of SI examination the applicants should focus their attentionon the following sections: All definitions in Appendix 3 Materials, UG 4 to 15 Fabrication, UG 75 to 85 Inspection and Testing, UG 90 to 103 Marking and Reports, UG 115 to 120 Welding General, UW 1 to 3 Welding Materials, UW 5 Fabrication, UW 26 to 42 Inspection and Tests, UW 46 to 54 Marking and Reporting, UW 60 Postweld Heat Treatment, UCS 56 Radiographic Examination, UCS 57Charlie Chong/ Fion Zhang 37. ASME BPVC Section VIII, Division 2 - Rules for the Construction ofPressure Vessels - Alternative Rules.Division 2 also contains the requirements, specific prohibitions, and non-mandatoryguidance for advance designed unfired pressure vessel materials,design, fabrication, examination, inspection, testing, certification and pressurerelief. Division 2 is divided into nine parts, each with mandatory and non-mandatoryannexes. The source inspector need not be thoroughly familiarwith the contents of Division 2 for the core examination, but the SI should befamiliar with what the standard covers.Charlie Chong/ Fion Zhang 38. ASME BPVC Section IX - Qualification Standard for Welding and BrazingProcedures, Welders, Brazers, and Welding and Brazing Operators.Section IX of the ASME BPVC Part QW covers the qualifications of welders,welding operators and the procedures that will be employed during fabrication.The primary subjects covered include: welding general requirements, weldingprocedure specifications and qualification, and welder performancequalification. Section IX does not cover acceptance criteria forproduction welds. Section IX also covers fabrication by brazing (Part QB),so the SI inspector should be aware of that section, but will not need to befamiliar with it until and unless assigned to a project that specifies brazedconstruction. The source inspector should be thoroughly familiar with thecontents of Section IX Part QW with regard to the WPS, PQR and WPQ thatare specified in contractual agreements and/or ITP. For the purposes of SIexamination the applicants need to focus their attention on the followingsections of ASME BPVC Section IX :Charlie Chong/ Fion Zhang 39. Welding General Requirements QW 100 to 190 Welding Procedure Qualifications QW 200 to 290 Welding Performance Qualifications QW 300 to 380 Welding Data QW 400 to 490 Standard Welding Procedure Specifications QW 500 to 540Charlie Chong/ Fion Zhang 40. Keywords: Section IX also covers fabrication by brazing (Part QB), so the SIinspector should be aware of that section, but will not need to be familiarwith it until and unless assigned to a project that specifies brazedconstruction. The source inspector should be thoroughly familiar with the contents ofSection IX Part QW with regard to the WPS, PQR and WPQ that arespecified in contractual agreements and/or ITP.Charlie Chong/ Fion Zhang 41. ASME B31.3 - Process Piping.B31.3 covers the requirements for the fabrication of process pipingassociated with pressure vessels typically used in the petrochemical industry.It covers design, materials, fabrication, welding, erection, testing, inspectionand examination of process piping including flanges, fittings, gaskets, bolting,valves, PRVs. The source inspector should be familiar with the contents ofB31.3 with regard to examination, inspection and testing procedures that arespecified in contractual agreements and/or ITP. For the purposes of SIexamination some of the content covered in ASME B31.3 that the applicantsshould be familiar with includes:Charlie Chong/ Fion Zhang 42. Chapter I, Scope and Definitions Chapter III, Materials Chapter IV, Standards for Piping Components Chapter V, Fabrication, Assembly and Erection Chapter VI, Inspection, Examination and TestingCharlie Chong/ Fion Zhang 43. ASME B16.5 - Pipe Flanges and Flanged Fittings.B16.5 covers the requirements for materials, dimensions, tolerances, marking,testing of flanges and flanged fittings, as well as flange bolting and gaskets.B16.5 covers flange class designations for 150, 300, 400, 600, 900, 1500 and2500 systems for sizes from NPS to NPS 24 made from cast or forgedmaterials. These pressure classes have differing pressure and temperatureratings for different materials of construction. B16.5 also covers blind flangesand reducing flanges. The source inspector would use this standard to verifythat flanges and flanged fittings specified in the contractual document havebeen correctly supplied. For the purposes of the SI examination theapplicants should be familiar with the following sections of ASME B16.5: Chapters 1 to 8, narrative information and associated tables referencedthereinCharlie Chong/ Fion Zhang 44. Keywords: Flange class designations for 150, 300, 400, 600, 900, 1500 and 2500systems Sizes from NPS to NPS 24 made from cast or forged materials. Covers blind flanges and reducing flanges.Charlie Chong/ Fion Zhang 45. 8.2.5.4 ASNT StandardsASNT SNT-TC-1A. This recommended practice establishes a generalframework for a qualification and certification program for NDE technicians. Inaddition the standard provides recommended educational requirements andtraining requirements for different test methods. The SI should be thoroughlyfamiliar with this standard, including the duties and responsibilities for each ofthe 3 levels of NDE qualified technician.Charlie Chong/ Fion Zhang 46. 8.2.5.5 AWS Standards and ReferencesThe Welding Inspection Handbook.This Handbook provides information to assist welding inspectors andsupervisors in the technology and application of visual and nondestructiveexamination associated with welding. The SI should be thoroughly familiarwith the contents of this handbook.AWS D1.1 Structural Welding Code.This code covers the welding requirements for any type of welded structuremade from the commonly used carbon and low-alloy constructional steels.The SI inspector should be familiar with the following sections:Charlie Chong/ Fion Zhang 47. Scope and Application Requirements for the Welding Inspector Welding Inspection Operations Inspection Safety Considerations Preheating and Postweld Heat Treating Weld and Weld Related Discontinuities Destructive Testing of Welds NDE Methods Qualification of NDE PersonnelCharlie Chong/ Fion Zhang 48. 8.2.5.6 SSPC StandardsSSPC-PA 2 Coating Applications Standard No. 2, Procedure forDetermining Conformance to Dry Coating Thickness Requirements.This standard describes a procedure for determining conformance to aspecified dry film thickness (DFT) range on metal substrates using NDEthickness gauges. The SI inspector should be familiar with Sections 1 to 8 ofthis standard.Charlie Chong/ Fion Zhang 49. SSPC Surface Preparation Guide.This guideline briefly describes the scope of the 7 different SSPCand NACE Surface Preparation Standards with application to sourceinspection. The source inspector should be familiar with the scope of the 7standards listed below that are included in this guide, but need not be familiarwith the details in the specific standards for examination purposes. SSPC-SP1 - Solvent Cleaning SSPC-SP3 - Power Tool Cleaning SSPC-SP5 or NACE 1 - White Metal Blast Cleaning (SA3) SSPC-SP6 or NACE 3 - Commercial Blast Cleaning (SA2) SSPC-SP7 or NACE 4 - Brush-Off Blast Cleaning (SA1) SSPC-SP10 or NACE 2 - Near-White Blast Cleaning (SA2 ) SSPC-SP11 - Power Tool Cleaning to Bare MetalCharlie Chong/ Fion Zhang 50. 8.2.6 Welding Procedures and QualificationsFor fixed and mechanical equipment and materials, welding procedurequalifications are the responsibility of the S/V while it is the responsibility ofthe source inspector that they be verified as the ones approved byengineering.Prior to performing welding inspection, the SI should confirm that the versionof the WPS in hand has been reviewed and approved by the responsibleperson e.g. engineer/WPS/PQR SME (Subject Matter Expert).The AWS Welding Inspection Handbook, ASME BPVC Section IX, AWS D1.1and API RP 577 are the appropriate references for knowledge andunderstanding of WPS/PQRs.Hints: Reviews of WPS/PQR is not the responsibility of SI.Charlie Chong/ Fion Zhang 51. Keywords:Prior to performing welding inspection,the SI should confirm that the versionof the WPS in hand has beenreviewed and approved by theresponsible person e.g.engineer/WPS/PQR SME (SubjectMatter Expert).Hints: Reviews of WPS/PQR is notthe responsibility of SI.Charlie Chong/ Fion Zhang 52. SME - The ExpertAWS CWICharlie Chong/ Fion Zhang 53. 8.2.7 NDE ProceduresDevelopment of NDE procedures are the responsibility of the S/V while it isthe responsibility of the source inspector that they be verified as the onesapproved for use.Prior to witnessing NDE, the SI should confirm that the version of the NDEprocedure in hand has been reviewed and approved by the responsibleperson e.g. engineer/NDE SME.The AWS Welding Inspection Handbook, ASME BPVC Section V, AWS D1.1and ASNT SNT-TC-1A are the appropriate references for knowledge andunderstanding of NDE procedures and required training and certification ofNDE technicians.Hints:Reviews of NDE Procedure is not the responsibility of SI.Charlie Chong/ Fion Zhang 54. NDE procedure - TOFDCharlie Chong/ Fion Zhang 55. SME - The ExpertCharlie Chong/ Fion Zhang 56. 8.2.8 Project SchedulesWhile the responsibility of establishing and monitoring the delivery is notgenerally in the purview () of the SI and the responsibility of meetingthe schedule remains with the S/V, the SI may be requested to report onfabrication status or slippage of milestone progress. The SI should notify theinspection coordinator if he/she believes that product quality may becompromised by schedule pressures.Hints: SI is reporting to Inspection CoordinatorCharlie Chong/ Fion Zhang 57. 123333 The SmartCharlie Chong/ Fion ZhangInspection CoordinatorPoor SI 58. 8.3 Performing the Source Inspection8.3.1 Individuals assigned to perform the source inspection activity mustfollow the ITP as specified by the purchaser. Visual inspection, weldinginspection, dimensional inspections, observing NDE, and all otherexaminations and tests must be performed in accordance with the source ITP,project specification and applicable code and standards and meet theapplicable acceptance criteria. See Section 9 for Examination Methods, Toolsand Equipment.8.3.2 One important step in the source inspection work process is to verifyevidence that the S/V personnel conducting the fabrication and quality controlsteps during fabrication are properly trained, qualified and certified, asspecified in the ITP or other contractual documents. This may includeverification of such credentials as: S/V quality personnel qualifications per thespecified standards, checking welder log books, and NDE techniciancertifications per the specified standards, such as ASNT SNT TC-1A, EPRI,or API Industry Qualified Examiners.Charlie Chong/ Fion Zhang 59. EPRICharlie Chong/ Fion Zhang 60. 8.3.3 During the course of M&F, the S/V may propose work process changesthat could impact cost, schedule and/or quality. In such cases, the sourceinspector should request that the S/V propose such changes in writing forreview by the purchaser and/or owner-user of the equipment.Hints: Deviation shall be recorded and approved by purchaser.Charlie Chong/ Fion Zhang 61. 8.4 Source Inspection Work Process Scheduled Planning Events8.4.1 GeneralTypical source inspection scheduled work process events include thefollowing.8.4.2 Pre-purchase Meeting (Prior to Contract Placement)The source inspector may or may not participate in a pre-purchase meeting.The purpose of such a meeting is to cover some specific design, fabrication,and/or QA/QC requirements expected of the S/V to make sure that their biddoes not inadvertently overlook them and result in unanticipated surprisesduring fabrication and source inspection activities.Charlie Chong/ Fion Zhang 62. 8.4.3 Pre-inspection Meeting (Prior to Start of Fabrication)The source inspector assigned to the S/V facility should participate in the pre-inspectionmeeting. The purpose of this meeting is to ensure that everyone atthe S/V who will be involved in manufacturing, fabrication and monitoring thequality of the equipment fully understands specific requirements and detailsof the job, especially those requirements that may be non-routine or differentrelative to normal S/V quality surveillance. Advance preparation by the sourceinspector is important for the pre-inspection meeting to ensure the meetingcovers all necessary issues requirements as specified in the contractualagreements and source inspectors company policy/practices. Thoserequirements may include review of: PO and contractual agreements; Engineering, technical and material requirements and status; Fabrication schedules; Critical path and long-lead equipment/materials; Quality requirements e.g. ITP, NCR, inspection frequency, etc.Charlie Chong/ Fion Zhang 63. Sub-suppliers and their quality requirements; Special requirements e.g. performance or functional testing requirements; Painting, preservation and tagging; Communication requirements e.g. inspection point notification, reportdistribution, proposed changes, hold points, schedule impacts, etc.; Shipping and release plan; Final documentation requirements; Recording and reporting any observations, exceptions or deviations;These source inspection work process events may also be observed orhandled by others besides the source inspector including: project engineering,client representatives or third party inspection agency.Charlie Chong/ Fion Zhang 64. Discussion Topic: Critical path and long-lead equipment/materialsCharlie Chong/ Fion Zhang 65. Kick Off Meeting or Pre-inspectionCharlie Chong/ Fion ZhangMeetingWhy does the discussion on Criticalpath and long-lead equipment/materials in the meeting agenda? 66. 8.5 Report Writing8.5.1 A key deliverable of source inspection is the progressive inspectionreports detailing the documents reviewed, inspection activity performed,observed and/or witnessed during the source inspection visits. The report isnormally on a standard format, and follows a consistent approach to reportingas specified by the purchaser.Charlie Chong/ Fion Zhang 67. 8.5.2 The source inspector should reference the following minimuminformation in each report: Date of visit; Appropriate contract number and key information; Purpose of visit; Action items or areas of concerns; Results of inspection/surveillance; Reference drawings/data used (including drawing numbers) to performinspection/surveillance; Revisions of referenced drawings/data; Reference to the applicable requirement in the ITP; Identification of nonconforming or deviating items/issues;Charlie Chong/ Fion Zhang 68. 8.5.3 Photographs are common place in inspection reports as they assist inthe description of the inspection results. The SI should request permissionfrom the S/V prior to taking any photographs. Care should be exercised toensure that an appropriate number of photos are attached as too many canbe detrimental to report issuance due to file size. Photos should be dated andlabeled with description of area of interest or product tag reference so thatthey can be easily understood by those reading the SI reports.8.5.4 Reports should be submitted to the inspection coordinator for review ofcontent and technical clarity before they are distributed to the purchaserunless otherwise instructed.Charlie Chong/ Fion Zhang 69. Keywords: Reports should be submitted to the inspection coordinator forreview of content and technical clarity before they are distributed to thepurchaserReport submitted to theInspection CoordinatorCharlie Chong/ Fion Zhang 70. 8.6 Nonconformance/Deviations8.6.1 When deviations to the contractual agreement or its referencedspecifications, drawings, codes or standards are identified, the sourceinspector should identify them as nonconformances. The source inspectorshould notify the inspection coordinator as soon as practical once anonconformance has been identified.8.6.2 Nonconformance reports should reference the following minimuminformation: Date of inspection; Contract number and information; Description of nonconforming item and issue; Photo of discrepancy if possible; Specification, drawings, codes or standards involved; Impact on the product; S/V recommended disposition of the nonconformance;Charlie Chong/ Fion Zhang 71. 8.6.3 The source inspector should issue the nonconformance report to theinspection coordinator for review and distribution unless instructed otherwise.8.6.4 In general, deviations from specifications must be approved by theresponsible engineer/technical personnel.8.6.5 Acceptable disposition of a nonconformance (as approved by theresponsible engineer/SME) may include: Use as is; Rework/repair per original contractual documents or approved repairprocedure; Scrap the equipment/component involved and start over;8.6.6 Once the disposition of the nonconformance has been agreed by allappropriate parties and implemented, the source inspector is normallyresponsible for determining if the nonconforming item currently conforms tothe original or revised requirements based on the agreed disposition. It is SIresponsibility to verify that NCR disposition has been properly implemented.Charlie Chong/ Fion Zhang 72. Keywords:Acceptable disposition of a nonconformance (as approved by the responsibleengineer/SME).Hints: The disposition of nonconformances is the responsibility of responsibleEngineer or SME Inspection CoordinatorCharlie Chong/ Fion Zhang 73. Disposition of NCRCould the Inspection Coordinatorapproves on the disposition of NCR?Charlie Chong/ Fion Zhang 74. 8.7 Source Inspection Project Continuous ImprovementAt the completion of the source inspection activities at an S/V, the sourceinspector, inspection coordinator, and all others involved in the planning anddoing processes should review the entire planning and doing part of thePlanDoCheckAdjust continuous improvement (CI) cycle to determinewhich activities went well and where improvements/adjustments could/shouldbe made. Determinations should be made if improvements are possible andnecessary in the source inspection management systems; the sourceinspection project planning process: the creation and implementation of theITP; and the implementation of the source inspection work process events.Any such improvements should be documented and made available tosource inspection managers and coordinators to implement theimprovements. This should include an evaluation of the performance ofthe S/V.Charlie Chong/ Fion Zhang 75. The Deming Cycle: PlanDoCheckAdjust continuous improvement(CI) cycleCharlie Chong/ Fion Zhang 76. Keywords:The various positions: SI Inspection Coordinator Inspection ManagerCharlie Chong/ Fion Zhang 77. 8.8 Source Inspector Continuous ImprovementThe source inspector can/should also learn from the continuous improvementcycle how he/she can improve their performance on the job by answeringsuch questions as: Are there some industry codes and standards that I should be morefamiliar with? Are there any safety and/or personal conduct improvements I can make? Can I improve the way I write the various SI reports? Do I need to improve my review of project documents before showing upat the S/V site? Can I improve the way I conducted the pre-fabrication meeting? Can I improve the timeliness of closing out my part of the sourceinspection project?Charlie Chong/ Fion Zhang 78. 8 Source Inspection Performance Who is responsible on theacceptance of dispositions of NCR?Charlie Chong/ Fion Zhang 79. 9 Examination Methods, Tools and Equipment9.1 GeneralThis section describes the typical examination methods, tools and equipmentwith which source inspectors should be familiar during the course of theirsurveillance at an S/V. Requirements for examinations from the purchaser orreferences in the contract agreement that may be more stringent thanindustry codes/standards or the S/V normal procedures should be included inthe ITP.Charlie Chong/ Fion Zhang 80. 9.2 Review and Confirmation of Materials of Construction9.2.1 Ensuring that the S/V is using the correct material during the fabricationor manufacturing of the equipment is a critical element of qualitysurveillance. Typical reviews should consist of the following:- Material Test Reports (MTRs) - The information necessary for the sourceinspector to know and understand about MTRs is covered in API RP 577,Section 10.8 and ASME BPVC Section II, SA-370.- Any reports e.g. MTRs that have been modified, corrected, or obliteratedshould be cause for immediate rejection as these could indicate thepotential for the material or component being counterfeit material. AllMTRs must be legible.Charlie Chong/ Fion Zhang 81. - Confirming that the construction materials proposed are the actualmaterials used during construction is a typical source inspection activity.The source inspector should: Confirm the correct material type and grade. Confirm the origin of the material. Check material size and/or thickness. Verify traceability of the material to a certifying document. Verify that the material complies with specific chemical and/or mechanicalproperties as specified in the contractual documents. Check for evidence of specified heat treatment. This is typically done by verifying that material grade, type and serialnumber match the material certifying document. Some S/Vs qualityprograms as well as purchasers have various methods for ensuring thatthe correct material is used in manufacturing with the use of positivematerial identification (PMI). The source inspector should be familiar withthose methods and ensure compliance. API RP 578 is a good referencedocument for material verification and positive material identification.Charlie Chong/ Fion Zhang 82. Charlie Chong/ Fion Zhang 83. Charlie Chong/ Fion Zhang 84. Charlie Chong/ Fion Zhang 85. 9.2.2 The SI should be aware of the potential for counterfeitmaterials/documents slipping into the supply chain. Key issues to watchfor include, but are not limited to: Generic documentation which is not product specific; Material or equipment containing minimal or no documentation; Markings or logos that are questionable or obliterated; Items that have inconsistent appearance; Documents that have been altered; Items that lack material traceability or product certification; ASME or ASTM stampings that may have been counterfeited;Charlie Chong/ Fion Zhang 86. 9.3 Dimensional Inspections9.3.1 The SI should be proficient in understanding and performingdimensional inspections. Equipment such as tape measures, dial indicators,calipers, protractors, levels are all typical tools that are used for dimensionalinspection. See the Welding Inspection Handbook and API RP 577 for furtherinformation on SI tools of the trade.9.3.2 When performing dimensional inspections, the source inspector shouldbe familiar with the dimensional requirements and the allowable tolerances.Actual dimensions should be recorded in the inspection reference drawing.Dimensions which exceed the tolerances should be reported as anonconformance or deviation.Keywords:Dimensions which exceed the tolerances should be reported as a (1)nonconformance or (2) deviation.Charlie Chong/ Fion Zhang 87. 9.4 Visual Inspections9.4.1 Adequate lighting is essential when performing visual inspection. The SImust be familiar with the minimum lighting requirements defined by theapplicable code, standard or specification. If there is inadequate lightingavailable during the visual inspection which is not uncommon in some shops,the source inspector must address these concerns with the S/V andinspection coordinator to resolve. Portable lighting such as pen lights, highpower flashlights, etc. are common tools that the source inspector may needwith him/her in order to perform adequate visual inspection.9.4.2 Source Inspectors who are performing visual inspections of welding,coatings, etc. should be appropriately trained, qualified and/or certified asrequired to perform those activities in accordance with the applicable codesor standards including the visual acuity requirements.Charlie Chong/ Fion Zhang 88. Technical Training- Class RoomCharlie Chong/ Fion Zhang 89. Technical Training - Class RoomCharlie Chong/ Fion Zhang 90. Technical Training - On JobCharlie Chong/ Fion Zhang 91. Technical Training - On JobCharlie Chong/ Fion Zhang 92. Visual Acuity TestCharlie Chong/ Fion Zhang 93. Welding Inspector Certification- The ExpertsCharlie Chong/ Fion Zhang 94. Welding Inspector Training- The QualifiedCharlie Chong/ Fion Zhang 95. 9.5 Nondestructive Examination (NDE) Techniques9.5.1 General9.5.1.1 The primary source for the specific NDE techniques to be appliedduring M&F by the S/V is included in the applicable project specifications.Those documents should reference other appropriate codes/standards forNDE methods such as ASME BPVC Section V and NDE technicianqualifications such as ASNT SNT TC-1A.The source inspector should be familiar with the NDEqualification/certification processes described in ASNT SNT TC-1A,especially what NDE duties/responsibilities can be carried out by Levels I, II,and III NDE technicians.9.5.1.2 The source inspector should be familiar with NDE terminologycontained in ASME BPVC Section V, Subsection A, Article 1, MandatoryAppendix 1 and Subsection B, Article 30, SE-1316.Charlie Chong/ Fion Zhang 96. Charlie Chong/ Fion Zhang 97. Charlie Chong/ Fion Zhang 98. 9.5.2 Penetrant Testing (PT)API RP 577, Section 9.6 and ASME BPVC Section V, Article 6, T-620 covermost of what the source inspector needs to know about PT. Discontinuitiesrevealed during PT are normally recorded on an NDE report.9.5.3 Magnetic Testing (MT)API RP 577, Section 9.4 and ASME BPVC Section V, Article 7, T-750 covermost of what the source inspector needs to know about MT. Discontinuitiesrevealed during MT are normally recorded on an NDE report.9.5.4 Radiographic Testing (RT)API RP 577, Section 9.8 and ASME BPVC Section V, Article 2, T-220 andSE-797 cover most of what the source inspector needs to know about RT.Discontinuities revealed during RT are normally recorded on an NDE report.Charlie Chong/ Fion Zhang 99. 9.5.5 Ultrasonic Testing (UT)API RP 577, Section 9.9 and ASME BPVC Section V, Article 4, and SE 797and Article 5, T-530 cover most of what the source inspector needs to knowabout UT. Discontinuities revealed during UT are normally recorded on anNDE report.9.5.6 Hardness Testing (HT)API RP 577, Sections 9.10 and 10.4.3 and in Table 11 cover most of what thesource inspector needs to know about hardness testing.9.5.7 Positive Material Identification (PMI)API RP 578 covers most of what the source inspector needs to know aboutmaterial verification and PMI.Charlie Chong/ Fion Zhang 100. 9.6 Destructive Testing9.6.1 Destructive testing is defined as those tests that are performed onmetals for the purposes of determining mechanical properties and whichinvolve testing of sample coupons. Examples of such tests include tensiletesting, bend testing and Charpy impact testing.9.6.2 Tensile testing is performed to determine yield strength (point at whichelastic deformation becomes plastic/permanent deformation) and ultimatetensile strength (fracture point) of an item.9.6.3 Bend testing is commonly performed on weld coupons to check theductility and integrity of welds.Keywords:Ductility only? No!Bend Testing integrity of welds.Charlie Chong/ Fion Zhang 101. Bend TestingCharlie Chong/ Fion Zhang 102. Bend Test SampleCharlie Chong/ Fion Zhang 103. 9.6.4 Charpy impact testing is performed to determine toughness of metalsand welds. It may be specified for a variety of reasons at a variety of differenttemperatures to show that the vessel or piping system has the ability todeform plastically before failing i.e. avoid catastrophic brittle fracture. Formany construction codes, impact testing often becomes a requirement belowtemperatures of - 20F, but the engineering specifications may require impacttesting at other temperatures as well.9.6.5 Most of the information necessary for the source inspector to know andunderstand about destructive testing of metals is covered in API RP 577,Section 10.4.Charlie Chong/ Fion Zhang 104. 9.7 Pressure/Leak Testing9.7.1 GeneralPressure/leak testing is normally specified by the applicable codes/standardsand contractual agreements.9.7.2 Pressure Testing9.7.2.1 Pressure testing is normally specified to check for leaks or determinewhether or not there may be gross errors in design or fabrication that couldcause the component to fail (fracture, crack or deform) under pressure.Pressure tests in shops are usually conducted with water (hydrotesting) orwith air (pneumatic testing) or a combination of both (hydro-pneumatictesting).Charlie Chong/ Fion Zhang 105. As the name indicates, pressure testing involves testing with elevatedpressures, often above that at which the component will normally operate, sosafety is of utmost importance when witnessing a pressure test. Pressuretests must be conducted in accordance with the construction code orstandard to which the item was built e.g. ASME BPVC Section VIII for vesselsor ASME B31.3 for process piping. These codes generally indicate how towitness such a test safely after the pressure has equalized and stabilized.Whether testing by hydrotest, hydro-pneumatic or pneumatic, the pressuretesting equipment should have the means to prevent over pressuring theequipment under test. The SI should check that.Keywords:(1) Hydrostatic Testing / (2) Pneumatic Testing / (3) Hydro-Pneumatic TestingCharlie Chong/ Fion Zhang 106. 9.7.2.2 Hydrotesting is the most common method of pressure testing andinvolves the application of pressure using water. Its very important that highpoint vents be opened during filling and before the application of pressure toensure that there is no air left in the system. Water is considered non-compressibleCharlie Chong/ Fion Zhangwhile air is very compressible. The compression of air left inequipment during hydrotesting can lead to catastrophic brittle facture andsevere injury if the tested commodity were to fail during the test.9.7.2.3 Pneumatic Testing is generally conducted with air though sometimesits conducted with a combination of air and water. There are significantlygreater risks involved in higher pressure pneumatic testing, so it should neverbe conducted without the full knowledge and consent of the responsibleengineer who has been satisfied that the potential for brittle fracture duringtest is negligible. The danger lies in pieces of the equipment that fails underpneumatic pressure being propelled with great force for long distances andthereby doing a lot of damage and/or inflicting severe injury. 107. The above sentence - Thecompression of air left in equipmentduring hydrotesting can lead tocatastrophic brittle facture andsevere injury if the tested commoditywere to fail during the test.Question: How the compressed airleft in the equipment was associatedwith brittle fracture where theequipment may fail with ductile mode?Charlie Chong/ Fion Zhang 108. 9.7.2.4 Leak Testing is generally the term used to describe low pressuretesting with air or gas just to see if the joints in a piece of equipment e.g.flanges and threaded connections are leak tight after assembly. Leak testsare usually done at low pressures which are substantially below equipmentdesign pressures to minimize risk of injury. Specialized leak tests with heliumor other gases have to be specified by contractual documents which will detailthe leak test procedure and generally reference an industry standard thatmust be followed.Keywords:Used to describe low pressure testing with air or gasCharlie Chong/ Fion Zhang 109. 9.8 Performance/ Functional TestingPerformance and functional testing is generally not applicable to fixedequipment like vessels and piping and is more related to machinery,instruments, analyzers, and control systems to determine that the equipmentwill perform as specified in service. In situations where the SI is involved inperformance/functional testing, a specific procedure with acceptance criteriawill be involved and often an engineer or other SME will also witness the test.Unless otherwise specified in the contractual documents, the performancetesting of vessels and piping is generally limited to assuring that they are leakfree.Keywords:Performance/ Functional Testing generally not applicable to fixed equipment piping is generally limited to assuring that they are leak free. more related to machinery, instruments, analyzers, and control systems Often an engineer or other SME will also witness the testCharlie Chong/ Fion Zhang 110. 9.9 Surface Preparation/ Coatings Inspections9.9.1 Performance of coating systems typically depends on the how well thesubstrate or surface is prepared for coating applications. Typically on fixedequipment, visual inspection of surface preparation is recommended orrequired. Inspections typically consist of: Surface profile measurement; Visual surface comparison; Verification of blasting medium;Charlie Chong/ Fion Zhang 111. 9.9.2 Coating systems are usually specified in the contractual andengineering documents and likely will involve single or multi coatingapplications. The method of inspection of these coating systems is by the useof a dry film thickness gauge (DFT) per SSPC-PA 2, which the SI should befamiliar with.9.9.3 The SI should also be aware of specific coating requirements such asstripe coating of welds, edges, corners, etc. which are performed to insurecoating performance on rough or uneven surfaces.9.9.4 In addition to purchase order requirements and company standards,coating manufacturers recommendations will provide the details for correctcoatings application to be followed.Charlie Chong/ Fion Zhang 112. 9.9.5 Prior to releasing the fixed equipment for shipment, the source inspectorshould inspect the coated or lined surfaces for the following items: raisedareas, pinholes, soft spots, disbondment, delaminations, blisters, holidays,bubbling, fisheyes, runs and sags, uniformity, mechanical damage, orangepeel, adhesion, mud flat cracking and proper color or shade.9.9.6 Any areas found in need of coating repairs should be properly identifiedand documented (NCR) by the source inspector as well as any testing and re-inspectionperformed after repairs have been made.Charlie Chong/ Fion Zhang 113. Coating Defect: Orange peelCharlie Chong/ Fion Zhang 114. Coating Defect: Orange peelCharlie Chong/ Fion Zhang 115. Charlie Chong/ Fion Zhang 116. Charlie Chong/ Fion Zhang 117. 9 Examination Methods, Tools andEquipment What are the common methodsused? What is the standard governing thequalifications of NDT personnel? Why pneumatic testing posedhigher hazard than thehydrostatic testing? Bend test is used to check on?Charlie Chong/ Fion Zhang 118. 10 Final Acceptance10.1 Prior to final acceptance of fixed equipment, the source inspector shoulddetermine the following: All work specified in the contractual agreements is completed by the S/V; All NCRs have been closed out and resolved by the S/V QCrepresentative and owners QA representative; All punch list items have been completed; All Inspection related activities have been completed and documented All S/V work has been deemed acceptable by the owners QArepresentative in accordance with the requirements of codes, standardsand project specifications.Charlie Chong/ Fion Zhang 119. The Owners QA representative -Who is this entity? What is his/herinvolvements? How the QA entityinvolved in QC activities and affectfinal acceptance?Charlie Chong/ Fion Zhang 120. 10.2 Shipping Preparations may also be specified in the contractual andengineering documents. It is important that the SI confirm that all bracing,strapping, mounting, covering, packaging, marking, and protection from theweather, etc. is effectively completed before the equipment is released forshipment.10.3 Reviewing Final S/V Data. It is typical for the SI to perform a final reviewof the contractually required S/V data upon the completion of themanufacturing/fabrication and prior to shipment of the materials or equipment.This review is to determine that all documents are complete, with the as builtitem with all supporting documents as identified in the contractual agreement.Such documentation may include but is not limited to:Charlie Chong/ Fion Zhang 121. Final fabrication drawings MTRs Pressure test documentation NDE results Product specific QC checks NCR close outs Certification documents Code compliance documentationCharlie Chong/ Fion Zhang 122. 10 Final Acceptance Which are the 2 separate entitiesthat have to be satisfied with theequipment before the SI couldaccepts? What are the shipment activitiesthat the SI should performed? What are the final S/V data to beavailable for SI reviews?Charlie Chong/ Fion Zhang 123. 11 Manufacturing and Fabrication (M&F) Processes11.1 General11.1.1 The manufacturer/fabricator is responsible for the quality of all theirM&F products, which includes not only good workmanship, but alsocompliance with all codes, standards and specifications contained in thecontractual agreements. The source inspector is responsible as defined in theinspection and test plan (ITP) for performing the source quality surveillanceactivities at the S/V facilities in accordance with the applicable ITP.Charlie Chong/ Fion Zhang 124. Keywords The manufacturer/fabricator is responsible for the quality of all their M&Fproducts The source inspector is responsible as defined in the inspection and testplan (ITP) for performing the source quality surveillance activities at theS/V facilities in accordance with the applicable ITP.Charlie Chong/ Fion Zhang 125. 11.1.2 Specific M&F processes that are commonly used include welding, heattreatment, casting, forming, forging, machining, assembly, etc. The sourceinspector needs to be familiar with those M&F processes to confirmcompliance with codes, standards and project document requirements. For allM&F processes including rework and repair, the following information shouldbe consistent and confirmed: M&F process has a documented method describing how to perform thework; Individuals required to perform the M&F process have proof of training andqualifications; Individuals performing the work have immediate access to the relevantM&F procedures; There is acceptance criteria documented to determine if the M&Fprocesses results are acceptable; The results of the M&F processes are documented;Charlie Chong/ Fion Zhang 126. 11.1.3 Rework and repair - should be approved by the purchaser and verifiedby the SI.Keywords:Rework and repair should be approved by the purchaser.Charlie Chong/ Fion Zhang 127. Rework and repair - should be approved by the purchaserCharlie Chong/ Fion Zhang 128. Rework and repair - should be verified by the SI.Charlie Chong/ Fion Zhang 129. 11.2 Welding Processes and Welding DefectsTypical welding processes used in M&F of equipment are described in APIRP 577, Section 5, and the variety of potential welding defects are covered inAPI RP 577, Section 4.5. The SI should be familiar with these sections.Different welding processes are susceptible to different types of weldingdefects. Hence its important for the SI to know which welding processes willbe applied to the equipment during M&F and to be familiar with the typicaldefects for each welding process that can occur.Charlie Chong/ Fion Zhang 130. Welding Defects:RT RadiographCharlie Chong/ Fion Zhang 131. Typical Welding DefectCharlie Chong/ Fion Zhang 132. 11.3 Casting11.3.1 The casting process is used to create simple or complex shapes fromany material that can be melted. This process consists of melting the materialand heating it to a specified temperature, pouring the molten material into amold or cavity of the desired shape, and solidification of the material to formthe finished shape. An advantage of the casting process is that a single stepprocess can be used to produce components that are characterized by one ormore of the following attributes: Complex shapes e.g. fittings, flanges, valve bodies Hollow sections or internal cavities Irregular curved surfaces Very large sizes Materials that are difficult to machineCharlie Chong/ Fion Zhang 133. Cast Pouring in ProgressCharlie Chong/ Fion Zhang 134. Cast Pouring in ProgressCharlie Chong/ Fion Zhang 135. Cast Pouring in ProgressCharlie Chong/ Fion Zhang 136. CastingCharlie Chong/ Fion Zhang 137. CastingCharlie Chong/ Fion Zhang 138. CastingCharlie Chong/ Fion Zhang 139. 11.3.2 A disadvantage of castings for pressure components is thatmechanical properties such as toughness may not be adequate. Typicaldefects associated with the casting process that the SI should be aware ofinclude: Shrinkage voids Gas porosity Trapped inclusionsCharlie Chong/ Fion Zhang 140. Casting DefectsCharlie Chong/ Fion Zhanghttp://nptel.ac.in/courses/Webcourse-contents/IIT-ROORKEE/MANUFACTURINGh-tPtpR:/O/wCwEwS.ShEnsSa/.moergta/dlcoacs/ftoinugn/dlercyt/upraer1t35..hhttmm 141. Casting Defects Blow HolesCharlie Chong/ Fion Zhanghttp://www.hnsa.org/doc/foundry/part3.htm 142. Casting DefectsCharlie Chong/ Fion Zhang 143. Casting Defects - Flash or FinCharlie Chong/ Fion Zhang 144. Casting Defects Flash or FinCharlie Chong/ Fion Zhang 145. Casting Defects Mismatch or ShiftCharlie Chong/ Fion Zhang 146. Casting Defects Mismatch or ShiftCharlie Chong/ Fion Zhang 147. Casting Defects Shrink CrackCharlie Chong/ Fion Zhang 148. Casting Defects Shrink Cracks & CavityCharlie Chong/ Fion Zhanghttp://home.comcast.net/~oddkins/defects.html 149. Casting DefectsCharlie Chong/ Fion ZhangDispersed Shrinkage -Characteristic of cast iron, thesecavities are most oftenperpendicular to the castingsurface, with depths as great as0.8 in. (2 cm). The castingdefect is most commonlycaused in iron components bylow carbon content or highnitrogen content in the melt.http://www.afsinc.org/content.cfm?ItemNumber=6944 150. Casting DefectsCharlie Chong/ Fion ZhangBlowholes/PinholesTheinterior walls of blowholes andpinholes can be shiny, more orless oxidized or, in the case ofcast iron, covered with a thinlayer of graphite. The defectscan appear in any region of acasting. They are caused whengas is trapped in the metalduring solidification.http://www.afsinc.org/content.cfm?ItemNumber=6944 151. Casting DefectsCharlie Chong/ Fion ZhangDefect: Lustrous CarbonThese folded or wrinkled filmsare distinctly outlined and foundwithin the walls of iron castings,causing a linear discontinuity inthe structure. Generally, theyare seen only upon fracturing acasting. The defects form whenmaterials from mold or coreadditives and binders volatize,decompose and becomeentrained in the melt.http://www.afsinc.org/content.cfm?ItemNumber=6944 152. Casting DefectsCharlie Chong/ Fion ZhangDefect: Axial ShrinkageAllmetal shrinks as it solidifies.Axial (or centerline) shrinkage,most often plate-like in shape,occurs when the metal at thecenter of the casting takeslonger to freeze than the metalsurrounding it. The defect ispartly a function of the sectionthickness designed into thecasting, but it also can beinfluenced by the metalcasterspouring temperature, alloypurity, riser use and pouringspeed.http://www.afsinc.org/content.cfm?ItemNumber=6944 153. Casting DefectsCharlie Chong/ Fion ZhangExpansion ScabAnotherdefect caused by the expansionof molding or core sand,expansion scabs can occur inferrous or copper-basedcastings. The thin metallicprojections with sharp edgesare generally parallel to thesurface of the casting and havevery rough surfaces. They areusually attached to the castingat only a few points and areotherwise loose.http://www.afsinc.org/content.cfm?ItemNumber=6944 154. Casting DefectsCharlie Chong/ Fion ZhangDefect: VeiningThis defectoccurs when cracks appear ona sand mold due to sandcontraction, which is caused byheat. The metalcaster mustregulate its sand compositionand heating to keep veiningfrom occurring.http://www.afsinc.org/content.cfm?ItemNumber=6944 155. Keywords:A disadvantage of castings for pressure components is that mechanicalproperties such as toughness may not be adequateQuestions:How casting process affects the toughness of the material grade?Charlie Chong/ Fion Zhang 156. Suggested Further Reading: Casting Defects http://nptel.ac.in/courses/Webcourse-contents/IIT-ROORKEE/Charlie Chong/ Fion ZhangMANUFACTURING-PROCESSES/metalcasting/lecture15.htm http://www.hnsa.org/doc/foundry/part3.htm 157. 11.3.3 Castings are susceptible to the creation of voids during the castingprocess which could result in through wall leaks during service. ASTM gradesof casting used in the petrochemical industry typically for pump casings andvalve bodies are referenced in ASTM A703, Standard Specification forSteel Castings, General Requirements for Pressure Containing Parts.This standard prohibits peening, plugging and impregnating defects incastings to stop leaks, as opposed to making more permanent weldingrepairs. The SI should make sure that any casting repairs needed are broughtto his/her attention so that adequate repair procedures can be prepared,approved by the purchaser and implemented. ASTM 703 also providescasting grade symbols that identify the type of material in the casting.Charlie Chong/ Fion Zhang 158. ASTM A703 / A703M - 13aStandard Specification for Steel Castings, General Requirements, forPressure-Containing PartsCharlie Chong/ Fion Zhang 159. ASTM A703 / A703M - 13aStandard Specification for Steel Castings, General Requirements, forPressure-Containing PartsCharlie Chong/ Fion Zhang 160. ASTM A703 / A703M - 13aStandard Specification for Steel Castings, General Requirements, forPressure-Containing PartsCharlie Chong/ Fion Zhang 161. ASTM A703 / A703M - 13aStandard Specification for SteelCastings, General Requirements,for Pressure-Containing PartsCharlie Chong/ Fion Zhang 162. ASTM A703 / A703M - 13aStandard Specification for Steel Castings, General Requirements, forPressure-Containing PartsCharlie Chong/ Fion Zhang 163. ASTM A703 / A703M - 13aStandard Specification for Steel Castings, General Requirements, forPressure-Containing PartsCharlie Chong/ Fion Zhang 164. ASTM A703 / A703M - 13aStandard Specification for Steel Castings, General Requirements, forPressure-Containing PartsCharlie Chong/ Fion Zhang 165. 1111Charlie Chong/ Fion Zhang 166. 11.3.4 Grade symbols are required on valve castings (e.g. WCB, WC9, CF8M,and so forth) in order to indicate the type of casting material. The SI shouldverify that the casting grade symbol on products e.g. valve bodies matchesthe specified grade in the contractual documents.11.3.5 MSS-SP-55, Quality Standard for Steel Castings for Valves, Flangesand Fittings and Other Piping Components - Visual Method for Evaluation ofSurface Irregularities is the standard that is generally used to perform visualevaluation of surface irregularities that may have occurred during the castingprocess. The source inspector accepting cast products should be familiar withthis standard.Charlie Chong/ Fion Zhang 167. MSS-SP-55Charlie Chong/ Fion Zhang 168. 11.4 Forging11.4.1 Forging is the oldest known metal working process. It consists of anumber of processes that are characterized by the use of localizedcompressive forces that are applied via hammers, presses, dies,or other forging equipment to induce plastic/permanent deformation. Whileforging may be performed in all temperature ranges, most forging is doneabove the recrystallization temperature of metal. During the forging processthe grain flow follows the general shape of the component and results inimproved strength and toughness characteristics. Advantages of this changeinclude: Increased wear resistance without increased hardness/loss of ductility; Stronger/tougher than an equivalent cast or machined component; Less expensive alloys can be used to produce high strength components; Components are not susceptible to common casting defects;Charlie Chong/ Fion Zhang 169. 11.4.2 ASTM A788, Standard Specification for Steel Forgings, GeneralRequirements covers a group of common requirements that may be appliedto steel forgings for general use. Key elements of ASTM A788 include thefollowing: The purchaser may specify additional requirements Tension and hardness tests must be conducted to evaluate mechanicalproperties Repair welding is not allowed unless permitted by the product specification Supplementary general requirements may be performed by agreementbetween the supplier and the purchaser; these requirements aredesignated by an S followed by a number (e.g. S5)Charlie Chong/ Fion Zhang 170. ASTM A788 / A788M - 14Standard Specification for Steel Forgings, General RequirementsCharlie Chong/ Fion Zhang 171. Forging in ProgressCharlie Chong/ Fion Zhang 172. Forging in ProgressCharlie Chong/ Fion Zhang 173. Forging in ProgressCharlie Chong/ Fion Zhang 174. Forging in ProgressCharlie Chong/ Fion Zhang 175. Forging in ProgressCharlie Chong/ Fion Zhang 176. 11.5 Machining (Finishing Manufacturing Process)11.5.1 Machining is any of several metal working processes in which a pieceof raw material is cut into a desired final shape and size by a controlledmaterial-removal process. Typical fixed equipment components that requiremachining include: flanges, valve components, and heat exchanger tubesheets. The three principal machining processes are (1) turning, (2) drillingand (3) milling. Other machining operations include shaping, planning,boring, broaching and sawing.11.5.1.1 Turning operations are operations that rotate the workpiece as theprimary method of moving metal against the cutting tool. Lathes are theprincipal machine tool used in turning.11.5.1.2 Milling operations are operations in which the cutting tool rotates tobring cutting edges to bear against the workpiece. Milling machines are theprincipal machine tool used in milling.Charlie Chong/ Fion Zhang 177. 11.5.1.3 Drilling operations are operations in which holes are produced orrefined by bringing a rotating cutter with cutting edges at the lower extremityinto contact with the workpiece. Drilling operations are done primarily in drillpresses but sometimes on lathes or mills.11.5.2 Machining requires attention to many details for a workpiece to meetthe specifications set out in the engineering drawings or blueprints. Besidesthe obvious problems related to correct dimensions, there is the problem ofachieving the correct finish or surface smoothness on the workpiece such aflange finish. Typically there is no in-process inspection by the SI for themachining operation; however, the SI may be required to check dimensionalaspects and tolerances of machined components.Charlie Chong/ Fion Zhang 178. Keywords: Typically there is no in-process inspection by the SI for the machiningoperation; however, the SI may be required to check dimensional aspects and tolerances ofmachined components.Charlie Chong/ Fion Zhang 179. Machining: Turning & MillingCharlie Chong/ Fion Zhang 180. Machined HubCharlie Chong/ Fion Zhang 181. Floating TubesheetCharlie Chong/ Fion Zhanghttp://www.kvastainless.com/heat-exchangers.html 182. Tube SheetCharlie Chong/ Fion Zhanghttp://www.kvastainless.com/heat-exchangers.html 183. Tube SheetCharlie Chong/ Fion Zhanghttp://www.kvastainless.com/heat-exchangers.html 184. 1111Charlie Chong/ Fion Zhanghttp://www.kvastainless.com/heat-exchangers.html 185. 1111Charlie Chong/ Fion Zhanghttp://www.kvastainless.com/heat-exchangers.html 186. 1111Charlie Chong/ Fion Zhanghttp://www.kvastainless.com/heat-exchangers.html 187. Machine Flanges at BackgroundCharlie Chong/ Fion Zhang 188. 11.6 AssemblyAssembly generally has more to do with machinery, instrumentation, controlsystems, and electrical gear looking for fit/form/function. However, formechanical equipment such as skid units and other equipment that is to beassembled e.g. flanges or other connections, the SI should be looking for tightfit up of all connectors. This can be accomplished with torque wrenches orpinging bolts with a small hammer (like a slag or ball peen hammer). The SIshould check to make sure that bolted flanges and screwed fittings are leakfree when witnessing hydrotests.Charlie Chong/ Fion Zhang 189. Partial Assembly: Machined HubCharlie Chong/ Fion Zhang 190. Partial Assembly: Flange face with Locking MechanismCharlie Chong/ Fion Zhang 191. Full Assembly : Metering SkidCharlie Chong/ Fion Zhang 192. Skid Load-outCharlie Chong/ Fion Zhang 193. 11.7 Metallurgy Issues Associated with Manufacturing and FabricationProcesses11.7.1 The Structure and MetalsMetallurgy is a complex science in which many schools have four degreedprograms, but a general understanding of the major principles is important tothe source inspector, due to the wide variety of metals and alloys that may beused in manufacturing and fabrication processes including welding. Most ofthe information necessary for the source inspector to know and understandabout metallurgical issues is covered in API RP 577, Section 10, with whichthe SI should be familiar.Charlie Chong/ Fion Zhang 194. The Structure and Metals- Gray Cast IronCharlie Chong/ Fion Zhanghttp://depts.washington.edu/matseed/ces_guide/microstructure.htm 195. The Structure and Metals- SteelCharlie Chong/ Fion Zhang 196. The Structure and Metals- Duplex SSCharlie Chong/ Fion Zhang 197. 11.7.2 Physical Properties of MetalsThe physical properties of a metal or alloy are those, which are relativelyinsensitive to structure and can be measured without the application of force.Examples of physical properties of a metal are the melting temperature, thethermal conductivity, electrical conductivity, the coefficient of thermalexpansion, and density. Most of the information necessary for the sourceinspector to know and understand about the physical properties of metals iscovered in API RP 577, Section 10.3.Charlie Chong/ Fion Zhang 198. Exercise: Identify physical propertiesCharlie Chong/ Fion Zhang 199. Exercise: The following table lists the typical properties of steels at roomtemperature (25C). The wide ranges of ultimate tensile strength, yieldstrength, and hardness are largely due to different heat treatment conditions.Properties Carbon Steels Alloy Steels Stainless Steels Tool SteelsDensity (1000 kg/m3) 7.85 7.85 7.75-8.1 7.72-8.0Elastic Modulus (GPa) 190-210 190-210 190-210 190-210Poisson's Ratio 0.27-0.3 0.27-0.3 0.27-0.3 0.27-0.3Thermal Expansion (10-6/K) 11-16.6 9.0-15 9.0-20.7 9.4-15.1Melting Point (C) 1371-1454Thermal Conductivity (W/m-K) 24.3-65.2 26-48.6 11.2-36.7 19.9-48.3Specific Heat (J/kg-K) 450-2081 452-1499 420-500Electrical Resistivity (10-9-m) 130-1250 210-1251 75.7-1020Tensile Strength (MPa) 276-1882 758-1882 515-827 640-2000Yield Strength (MPa) 186-758 366-1793 207-552 380-440Percent Elongation (%) 10-32 4-31 12-40 5-25Hardness (Brinell 3000kg) 86-388 149-627 137-595 210-620http://www.efunda.com/materials/alloys/alloy_home/steels_properties.cfmCharlie Chong/ Fion Zhang 200. Physical properties: Modulus of Elasticityhttp://en.wikipedia.org/wiki/Young%27s_modulusCharlie Chong/ Fion Zhang 201. Physical properties: Modulus of ElasticityCharlie Chong/ Fion Zhang 202. Physical properties: Poisson RatioCharlie Chong/ Fion Zhang 203. 11.7.4 Hardness and Hardenability of MetalsHardenability is defined as that property of a ferrous alloy that determines thedepth and distribution of hardness induced by quenching.It is important to note that there is not a close relationship betweenhardenability and hardness, which is the resistance to indentation.Hardness depends primarily on the carbon content of the material, whereashardenability is strongly affected by the presence of alloying elements, suchas chromium, molybdenum and vanadium, and to a lesser extent by carboncontent and alloying elements such as nickel, copper and silicon.Most of the information necessary for the source inspector to know andunderstand about the hardness and hardenability of metals is covered in APIRP 577, Section 10.7.Charlie Chong/ Fion Zhang 204. Keywords: Hardness depends primarily on the carbon content of the material,whereas Hardenability is strongly affected by the presence of alloying elements,such as (1) chromium, (2) molybdenum and (3) vanadium, and to a lesserextent by (A) carbon content and alloying elements such as (B) nickel,(C) copper and (D) silicon.Charlie Chong/ Fion Zhang 205. Jominy Hardenability TestCharlie Chong/ Fion Zhang 206. Jominy Hardenability Test- Set-upCharlie Chong/ Fion Zhang 207. Hardenability- SteelIn welding, equivalent carbon content (CE) is used to understand how the different alloyingelements affect hardness of the steel being welded. This is then directly related to hydrogen-inducedcold cracking, which is the most common weld defect for steel, thus it is most commonlyused to determine weldability. Higher concentrations of carbon and other alloying elements suchas manganese, chromium, silicon, molybdenum, vanadium, copper, and nickel tend to increasehardness and decrease weldability. Each of these elements tends to influence the hardness andweldability of the steel to different magnitudes, however, making a method of comparisonnecessary to judge the difference in hardness between two alloys made of different alloyingelements. There are two commonly used formulas for calculating the equivalent carbon content.One is from the American Welding Society (AWS) and recommended for structural steels and theother is the formula based on the International Institute of Welding (IIW).The AWS states that for an equivalent carbon content above 0.40% there is a potential forcracking in the heat-affected zone (HAZ) on flame cut edges and welds. However, structuralengineering standards rarely use CE, but rather limit the maximum percentage of certain alloyingelements. This practice started before the CE concept existed, so just continues to be used. Thishas led to issues because certain high strength steels are now being used that have a CE higherthan 0.50% that have brittle failures.Charlie Chong/ Fion Zhanghttp://en.wikipedia.org/wiki/Equivalent_carbon_content 208. Harness Testing- Rockwell/ Vickers/ Brinell/ LeebRockwellCharlie Chong/ Fion Zhang 209. Harness Testing- Rockwell/ Vickers/ Brinell/ LeebCharlie Chong/ Fion Zhang 210. Harness Testing: BrinellCharlie Chong/ Fion Zhang 211. Harness Testing: LeebCharlie Chong/ Fion ZhangLeeb Hardness 212. Further Reading: Harness Testinghttp://www.twi-global.com/technical-knowledge/job-knowledge/hardness-testing-part-1-074/http://www.gordonengland.co.uk/hardness/rockwell.htmhttp://www.aeisndt.com/hardness-testing.htmlhttp://www.ndt.net/article/v06n09/frank/frank.htmFurther ReadingCharlie Chong/ Fion Zhang 213. Tensile strength vs. hardnessTensile strength vs. hardnessApproximate conversion of hardnesstotensilestrength values of steels.http://www.ruukki.com/Steel/Steel-products/Layer-pages/Physical-properties-tensile-strength-vs-hardnessCharlie Chong/ Fion Zhang 214. 11.7.5 Weldability of MetalsThe American Welding Society defines weldability as the capacity of a metalto be welded under the fabrication conditions imposed, into a specific,suitably designed structure, and to perform satisfactorily in the intendedservice. Most of the information necessary for the source inspector to knowand understand about the weldability of metals is covered in API RP 577,Sections 10.9 and 10.10.Charlie Chong/ Fion Zhang 215. WeldingCharlie Chong/ Fion Zhang 216. What is Weldability?Carbon Equivalent and Composition Parameter (Pcm)The weldability of steels depends on its hardenability.In general, the higher the hardenability, the lower the weldability. Weldabilitycan be evaluated theoretically by use of the PCM value calculatedaccording to:PCM = C + Si/30 + Mn/20 + Cu/20 + Ni/60 + Cr/20 + Mo/15 + V/tO + 5B.Read more on: http://www.kobelco.co.jp/english/welding/handbook/pageview/pageview.html#page_num=101 http://www.kobelco.co.jp/english/welding/handbook/pageview/data/target.pdf http://eagar.mit.edu/handouts/H-3371-17.pdfCharlie Chong/ Fion Zhang 217. Kobe Welding HandbookCharlie Chong/ Fion Zhanghttp://www.kobelco.co.jp/english/welding/handbook/pageview/pageview.html#page_num=101http://www.kobelco.co.jp/english/welding/handbook/pageview/data/target.pdf 218. Additional Information:What do we miss in this section?- Mechanical Properties of SteelCharlie Chong/ Fion Zhang 219. Charlie Chong/ Fion Zhang 220. Mechanical Properties of SteelCharlie Chong/ Fion Zhang 221. Charlie Chong/ Fion Zhang 222. 11.7.6 Preheating and Postweld Heat Treatment11.7.6.1 PreheatingPreheating is defined as heating of the weld and surrounding base metal to apredetermined temperature prior to the start of welding. The primarypurpose for preheating carbon and low-alloy steels is to reduce thetendency for hydrogen induced delayed cracking. It does this by slowingthe cooling rate, which helps prevent the formation of martensite (a morecrack prone microstructure) in the weld and base metal HAZ.According to B31.3, the pre-heat zone for welding of new process pipingshould extend at least one inch beyond the edge of the weld for piping.Most of the information necessary for the source inspector to know andunderstand about preheating is covered in API RP 577, Section 10.5.Charlie Chong/ Fion Zhang 223. 11.7.6.2 Postweld Heat Treatment (PWHT)Postweld heat treatment (PWHT) produces both mechanical andmetallurgical effects in carbon and low alloy steels that will vary widelydepending on the composition of the steel, its past thermal history, thetemperature and duration of the PWHT and heating and cooling ratesemployed during the PWHT. The need for PWHT is dependent on manyfactors including; chemistry of the metal, thickness of the parts being joined,joint design, welding processes and service or process conditions.The temperature of PWHT is selected by considering the changes beingsought in the equipment or structure. PWHT is the most common form offabrication heat treatment applied to fixed equipment. When PWHT isrequired by code, typical normal holding temperatures for carbon and somealloy steels is 1100F for one hour per inch of thickness with 15 minuteminimum. When PWHT is required for equipment due to in-service processconsiderations, those requirements will most likely be found in companystandards and specified in the project documents.Charlie Chong/ Fion Zhang 224. Normally the appropriate PWHT for welded equipment and piping is specifiedin the welding procedure specification (WPS). Heating and cooling rates forPWHT may be specified in the construction code or project documents.Typically heating rates for pressure equipment and piping above 800F mustbe controlled to no more than 400F per hour with no variation permitted ofmore than 250F in any 15 foot segment of the equipment. Thermocouplesmust be located in order to verify even distribution of temperature oncomponents and to ensure that no component is over or under-heated duringPWHT. Most of the information necessary for the source inspector to knowand understand about PWHT is covered in API RP 577, Section 10.6; ASMEBPVC Section VIII, Division 1, UCS-56; and B31.3, 331.Charlie Chong/ Fion Zhang 225. 11.7.6.3 Other Heat TreatmentsOther heat treatments for vessels and piping include annealing, normalizing,solution annealing, and tempering. See Section 3 for definitions of those heattreatments.Charlie Chong/ Fion Zhang 226. Post Weld Heat Treatment - PWHTCharlie Chong/ Fion Zhang 227. Post Weld Heat Treatment - PWHTCharlie Chong/ Fion Zhang 228. Post Weld Heat Treatment - PWHTCharlie Chong/ Fion Zhang 229. Post Weld Heat Treatment - PWHTCharlie Chong/ Fion Zhang 230. Post Weld Heat Treatment - PWHTCharlie Chong/ Fion Zhang 231. 11 Manufacturing andFabrication (M&F) ProcessesCharlie Chong/ Fion Zhang 232. 12 Pressure Vessels12.1 GeneralA pressure vessel is a container designed to withstand internal or externalpressure. The pressure vessels are typically constructed in accordance withASME BPVC Section VIII or other recognized international pressure vesselcodes, or as approved by the jurisdiction. These codes typically limit designbasis to an external or internal operating pressure no less than 15 psig (103kPa). However, vessels can also operate at lower pressures. Externalpressure on a vessel can be caused by an internal vacuum or by fluidpressure between an outer jacket and the vessel wall. Columns, towers,drums, reactors, heat exchangers, condensers, air coolers, bullets, spheres,and accumulators are common types of industry pressure vessels.Charlie Chong/ Fion Zhang 233. Pressure vessels are designed in various shapes. They may be cylindrical(with flat, conical, toriconical, semispherical, semi-ellipsoidal, or hemisphericalheads), spherical, or boxed (with flat rectangular or square plate heads, suchas those used for the headers of air-cooled exchangers), or lobed. They maybe of modular construction. Cylindrical vessels, including exchangers andcondensers, may be either vertical or horizontal and may be supported bysteel columns, cylindrical plate skirts, or plate lugs attached to the shell.Spherical vessels are usually supported by steel columns attached to theshell or by skirts.Spheroidal vessels are partially or completely supported by resting on theground. Jacketed vessels are those built with a casing of outer shell thatforms a space between itself and the main shell. The primary differencebetween a tank and a vessel is that tanks generally operate at lowerpressures, often at or just above atmospheric pressures.Charlie Chong/ Fion Zhang 234. Pressure Vessel Distillation ColumnCharlie Chong/ Fion Zhang 235. Pressure Vessel Heat ExchangerCharlie Chong/ Fion Zhang 236. Pressure Vessel Spherical VesselsCharlie Chong/ Fion Zhang 237. Pressure Vessel TanksCharlie Chong/ Fion Zhang 238. Pressure Vessel TanksCharlie Chong/ Fion Zhang 239. Pressure Vessel TanksCharlie Chong/ Fion Zhang 240. 12.2 Vessel Methods of ConstructionSeveral different methods are used to construct pressure vessels. Mostpressure vessels are constructed with welded joints. Shell rings are usuallymade by rolling plate at either elevated or ambient temperature. The cylinderis formed by welding the ends of the rolled plate together. This yields acylinder with a longitudinal weld. Hot forging is another method of makingcylindrical vessels. Some vessel manufacturers hot forge cylindrical shellrings for high pressure, heavy wall vessels such as those used forhydrotreater or hydro cracker reactors. This method does not produce alongitudinal seam in the cylinder.Charlie Chong/ Fion Zhang 241. Method of Construction: Hot forging VesselCharlie Chong/ Fion Zhang 242. Method of Construction: Hot forging VesselCharlie Chong/ Fion Zhang 243. Method of Construction: Hot forging VesselCharlie Chong/ Fion Zhang 244. Method of Construction: Hot forging VesselCharlie Chong/ Fion Zhang 245. Method of Construction: Hot forging Vessel HeadCharlie Chong/ Fion Zhang 246. Methods of ConstructionWhat is the advantages ofusing forged ring for vesselconstruction?Charlie Chong/ Fion Zhang 247. 12.3 Vessel Materials of Construction12.3.1 Carbon steel is the most common material used to construct pressurevessels. For special purposes, a suitable austenitic or ferritic alloy, Alloy 400(Monel- nickel-copper alloy), nickel, titanium, high-nickel alloys or aluminummay be used. Copper and copper alloys (except Alloy 400) are seldom usedin refinery vessels but are common with heat exchanger tubes and may befound in petrochemical plant vessels. Materials used to construct the variousparts of heat exchangers are selected to safely handle the service and theheat load required. Materials that will most economically resist the type ofcorrosion expected are selected.Exchanger shells are usually made of carbon steel but may be made of acorrosion-resistant alloy or clad with a corrosion-resistant material. Exchangerchannels and baffles are made of carbon steel or a suitable corrosionresistant alloy material, usually similar to the material of the tubes.Charlie Chong/ Fion Zhang 248. Clad with a corrosion-resistant material.Explosion BondedCharlie Chong/ Fion Zhanghttp://jinglei.en.made-in-china.com/ 249. Clad with a corrosion-resistant material.Explosion BondedCharlie Chong/ Fion Zhang 250. 12.3.2 Tubes for exchanger bundles may be a variety of materials. Wherewater is used as a cooling or condensing medium, they are generally made ofcopper based alloys or steel. In water applications where copper alloys orsteels will not provide sufficient corrosion protection, higher alloy materialsmay be used such as duplex stainless steel, or the tube ID may be coated(baked epoxy or similar).Titanium may be used in seawater applications. Where the exchange isbetween two different hydrocarbons, the tubes may be made of steel or asuitable corrosion-resistant alloy. Tubes, consisting of an inner layer of onematerial and an outer layer of a different material (bimetallic), may in somecases be required to resist two different corrosive mediums.Keywords:Sea water application- TitaniumCharlie Chong/ Fion Zhang 251. 12.3.3 Tube sheets for exchanger bundles are made of a variety of materials.Where water is the cooling or condensing medium, they are usually made ofadmiralty brass or steel, but may also be constructed of high-alloy steels (clador solid). Titanium may be used in seawater applications. Where theexchange of heat is between two hydrocarbons, the tube sheets may becomposed of steel or a suitable corrosion-resistant alloy. In some cases itmay be necessary to face one side of the tube sheet with a material differentfrom that facing the other to resist two different corrosive mediums.If carbon steel would not resist the corrosion or erosion expected or wouldcause contamination of the product, vessels may be lined with other metals ornonmetals. A lined vessel is usually more economical than one built of a solidcorrosion-resistant material. However, when the pressure vessel will operateat a high temperature, a high pressure, or both, solid alloy steels may be bothnecessary and economical.Charlie Chong/ Fion Zhang 252. Internal metallic layers are installed in various ways usually to provide morecorrosion resistance than would be provided by the carbon steel base layer.Those layers may be an integral part of the plate material (cladding) rolled orexplosion bonded before fabrication of the vessel. They may instead beseparate sheets of metal fastened to the vessel by welding. Corrosionresistant metal can also be applied to the vessel surfaces by various weldoverlay processes. Metallic liners may be made of a ferritic alloy, austeniticalloy e.g. 300 series stainless steels, Alloy 400, nickel, or any other metalresistant to the corrosive agent.Charlie Chong/ Fion Zhang 253. 12.3.4 Austenitic stainless steels (type 300 series) come in a variety ofCr/Mo/Ni/Fe contents. The most widely used are the 18Cr/8Mo series knownas 18/8 stainless steels, like type 304, 347, and 321 grades. Type 321 and347 are stabilized grades that will avoid sensitization of the HAZ duringwelding and therefore retain most of their corrosion resistance duringfabrication. Type 321 is stabilized with small amounts of Ti; while type 347 isstabilized with small amounts of Nb.Some type 300 stainless steels also come in L grades like 304L, 316L, and317L. The L stands for low carbon. These low carbon grades are also moreresistant to sensitization of the HAZ during welding.Some type 300 stainless steels also come in H grades like 304H, 316H, and317H. The H stands for high carbon. These high carbon grades are strongerat high temperatures than the lower carbon grades.Keywords:L / H GradesCharlie Chong/ Fion Zhang 254. Austenitic & Ferritic stainless steelsCharlie Chong/ Fion Zhang 255. Ferritic SS Family TreeCharlie Chong/ Fion Zhang 256. Austenitic SS Family TreeCharlie Chong/ Fion Zhang 257. Martensitic SS Family TreeCharlie Chong/ Fion Zhang 258. Types Stainless Steel WeldingMore Reading on: Stainless Steel- Types http://www.azom.com/article.aspx?ArticleID=470 http://www.jmcampbell.com/tip-of-the-month/2013/10/the-stainless-steel-family-an-overview/Charlie Chong/ Fion Zhang 259. Sensitization of Stainless Steel WeldingCharlie Chong/ Fion Zhang 260. Sensitization of Stainless Steel WeldingMore Rading on: Stainless Steel Sensitization http://www.keytometals.com/page.aspx?ID=CheckArticle&site=KTS&NM=232 http://www.corrosionclinic.com/types_of_corrosion/weld_decay_weldment_corrosion.htmCharlie Chong/ Fion Zhang 261. 12.3.5 All materials used for the construction of pressure vessels should havetraceability. For example, acceptable methods of traceability for plates used inthe fabrication of vessels include: Plate number Lot number Heat number12.3.6 Nonmetallic liners may be used to resist corrosion and erosion, reducefouling potential (i.e. exchanger tubes), or to insulate and reduce thetemperature on the walls of a pressure vessel. The most common nonmetalliclining materials are reinforced concrete, acid brick, refractory material,insulating material, carbon brick or block, rubber, phenolic/ epoxy coatings,glass, and plastic.Charlie Chong/ Fion Zhang 262. Glass Line VesselCharlie Chong/ Fion Zhang 263. Glass Line VesselCharlie Chong/ Fion Zhang 264. 12.3.7 Pressure vessels constructed out of nonmetallic materials are usuallymade from fiber reinforced plastic (FRP) and can be more resistant to somecorrosive servi