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7/13/20151ASME AWARENESS PROGRAM-4FABRICATION & INSPECTION1Responsibility of Engineer Inspection FabricationExhibits for Inspection FabricationInspection Check ListPrepare Inspection Checklist during prefabrication stage.Input - Approved Drg, ITP, NDT plan, Testing PlanInclude Customer name, Description & W.O.Offer to AI for marking his hold/witness stageList the stages in Inspection check ListMaintain inspection check List Stage Wise Check list shall be reviewed signed off by AIAll the check points are hold point for L&T MFYInspection Check List

Detailed seam wise Check ListDetailed seam wise Check List

Material Clearance RecordMaterial Clearance Record ROLLING DIR.IDENTIFICATION LOCATIONK1K2WLMaterial Clearance Record

LONG SEAM FIT UP STAGE INSPECTION:

Physical Verification & Inspection on the Job:

Completeness and correctness of material identification. Seam No punching (highlight the same with paints)Cleanliness of W.E.P & adjoining area 1" on either side.All tacks free from Defect. Ensure welders stamp identification for tacks on groove of fit up.Weld edges and shell surface shall be free from arc strikes spatters gas cutting serration, pitting & dents.Check W.E.P NDT (PT/MT), if applicable.Run in & run out coupon on either ends, with matching W.E.P for material above 25 mm.PTC as an extension to the seam, if applicable. Dimensional measurement (CF, Length, WEP etc.)Ovality as per UW 80 & Profile check (1% of ND)Offset as per UW 33

Fit up InspectionI/D CHECK IN HORIZONTAL PLANED/4 TEMPD/4 TEMPACTUAL THK.ID max - ID min = 1% of Nominal ID PEAK INPEAK OUTD/4 Template : Template LengthShell Profile check Matching ProfilePeak OutPeak InD/4 TemplateD/4 TemplateShell Profile check Profile ToleranceInside Diameter of Shell / Segment (in mm)Permissible limits for peak out or peak in (in mm) 1520.8 3051.2 4571.6 6102.4 9143.2 12194.0 15244.8 19055.6 21336.4 24386.4 27437.1 30487.9 30480.2% of dia.TOLERANCEOUTSIDE CIRCUMFERENCE of SHELL / HEADNOMINAL DIAMETER TOLERANCE< 1200 mm1201 to 2400 mm> 2400 mm 10 mm 12 mm 20 mmVESSEL LENGTH 5 mm PER 3000 mm, MAXIMUM 15 mmVESSEL ALIGNMENT / STRAIGHTNESS6 mm PER 6000 mm, MAX. 20 mm FOR ANY LG. Shell Ovality check

Ovality - The Maximum & Min. Inside dia. At any cross section shall not exceed 1% of Nominal Dia.Diameter may be measured Inside or outside of the vessel by using calibrated tape.

Offset Tolerance (UW-33)

Joint Thickness . tCat.: ACat.: B,C&D13 mm & Below1/4th t1/4th tOver 13 mm to 19 mm3 mm1/4th tOver 19 mm to 38 mm3 mm5 mmOver 38 mm to 51 mm3 mm1/8th tOver 51 mm1/16th t or Max. 10 mm1/8th t or Max. 19mmFor Joint Category Refer UW-3Joint category (UW-3)

Cat. A: Longitudinal joint (Circ. Joint of Hemispherical head to shell)Cat. B: Circumferential joint (Except Hemispherical head to shell)Cat. C: Welded Joint connecting to flange, Tube sheets, Flat head to shellCat. D: Welded Joint connecting to Nozzle to shell or heads

CIRC. SEAM FIT UP STAGE INSPECTION:

Physical Verification & Inspection on the Job:

Identification & Orientation for shell long seam as per DRG/DCR. Tan line (reference line) shall be transferred inside with proper punching and Painting. Seam No punching along the seam (highlight the same with paints).W.E.P & adjoining area shall be cleaned 1" on either side.All tacks shall be free from Defect. Weld edges and shell surface shall be free from arc strikes spatters gas cutting serration, pitting, dents etc.Long Seam Orientation to be checked.Check W.E.P NDT (PT/MT), if applicable.PTC shall be ready with all aspects near to the cir-seam, If applicable. Dimensional measurement (CF, Length, WEP etc.) Straightness / Alignment shall be checked.Offset as per UW 33

Fit up InspectionNOZZLE FIT UP STAGE INSPECTION:

Physical Verification & Inspection on the Job:

Completeness and correctness of material identification. Seam No punching along the seam (highlight the same with paints).W.E.P & adjoining area shall be cleaned 1" on either side.Nozzle cut out marking shall be checked.All tacks shall be free from Defect. Weld edges and shell surface shall be free from arc strikes spatters gas cutting serration, pitting, dents etc.Check W.E.P NDT (PT/MT), if applicable.Dimensional measurement (Elevation, Projection, Tilt, Straddle etc) Offset as per UW 33

Fit up InspectionTypes of Head

Torispherical headToriconical HeadHemispherical HeadEllipsoidal Head

Form Head INSPECTION

Physical Verification & Inspection on the Job:

Completeness and correctness of material identification. Seam No punching along the seam (highlight the same with paints) if Petal to Petal construction of Form Head

Form Head Form Head INSPECTION:

3.W.E.P & adjoining area shall be cleaned 1" on either side.4.All tacks shall be free from Defect. 5.Weld edges and shell surface shall be free from arc strikes spatters gas cutting serration, pitting, dents etc.6.Check W.E.P NDT (PT/MT), if applicable.7.PTC shall be ready with all aspects near to the Head, If applicable. 8.Offset as per UW 33, Ovality as per UG 809.Dimensional measurement (Circumference, Straight Face, Height or Depth, Minimum thickness)10.Profile shall be checked with template as per UG 81 (Inner surface of head not deviate Outside of specified shape not more than 1 % of NID & Inside of specified shape not more than 5/8% of NID) 11.Knuckle Radius shall not be less than specified.

Form Head Following points to be verified before releasing for welding

a) Fit up inspection satisfactoryb) Suitable WPS available and displayed at the worksitec) Qualified welders and supervisors positionedd) Environmental parameters are acceptable for weldinge)Welding machines indicators are properly calibrated and workingf) Weld consumables are as per requirementg) Baking and carry oven in orderh)Welding data sheet in placei)Proper temporary supports to be provided.

Clearance of WeldingWELD VISUAL INSPECTION:

Weld visual inspections are to be ensured, Weld metal as well as the HAZ is defect free. Following defects are anticipated:b) Cracks, undercut, porosityc) Arc strikesd) Surface defect* Following dimensional checks are to be done:a) Weld profileb) Width of weaving beadc) Weld reinforcement both height and width (UW-35)* Following information must be sought and recorded at the time of clearing the weld visual:a) WPSb)Welder no.NDTOn completion of weld visual the joints are offered for UT/RT/DPT/MPT/Hardness test as required as per NDE plan.

Weld Visual & NDT clearance

Reinforcement Tolerance (UW-35 ) Material ThicknessMax. Reinforcement Other CategoryCategory B& CBelow 2.4 mm0.8 mm2.4 mm2.4 to 4.8 mm incl.1.6 mm3.2Over 4.8 to 13 mm incl.2.4 mm4 mmOver 13 to 25 mm incl.2.4 mm4.8 mmOver 25 to 51 mm incl.3.2 mm5 mmOver 51 to 76 mm4 mm6mmOver 76 to 127 mm6 mm6 mmOver 127 mm8 mm8 mmA situation shall be considered as nonconforming if any activity or operation has already performed which has resulted in noncompliance with the applicable rules of the code, drawings, specifications, or the requirements of Quality control manual.

NCs shall be corrected before the completion of vessel can be considered to comply with the code.

NCs shall include, but not be limited to:

Material & Parts found to have deviation during receiving / in process examination.Weld material used not meeting the specification requirement.Repairs affecting material.Un-calibrated equipment used in measurement or test.Time-Temp. cycle of HT performed deviating from specification.Deviation from Design /DrawingSituations not meeting requirement of this manual.

Non conformity Non conformity

ICS shall be issued by Inspection Engineer fabrication prior to Heat treatment, Hydro test and Final painting with concurrence of AI. To ensure all stages shall be completed.

Inspection clearance slip

Hydro / Pneumatic Test

MCR SHALL BE CLEARED.COMPLETION OF WELDING ON PRESSURE PARTSCOMPLETION OF ALL NDT TO THE ACCEPTABLE STAGE TESTING OF PTC, IF ANY, TO THE ACCEPTABLE TEST RESULTSALL DIAMENSIONAL CHECK WITHIN THE ACCEPTABLE LIMITCHECKLIST SHALL BE UPDATED.

ENSURE FOLLOWING PRIOR TO START THE TEST:Hydro / Pneumatic Test

HYDROTEST ARRANGEMENT AS PER APPROVED DRAWING.ALL TESTED JOINTS FREE FROM PAINT, DUST, RUST ETC..INTERNAL INSPECTION SHALL BE CARRIED OUT.ALL FASTENERS ARE TIGHTENED TO REQUIRED TORQUE.PROPER VENT TO BE PROVIDED ON TOP OF THE VESSELS. TWO PRESSURE GAUGES TO BE AVAILABLE.ENSURE FOLLOWING PRIOR TO START THE TEST:Hydro / Pneumatic Test

GAUGES RANGE: 1.5 TO 4 TIMES OF TEST PRESSSURE (UG-102)LOCATE GAUGE ON TOP MOST OF THE VESSEL.ALL GAUGES SHALL BE CALIBRATED AGAINST STANDARD DEAD WEIGHT TESTER OR A CALIBRATED MASTER GAUGE. GAUGES SHALL BE RECALIBRATED AT ANY TIME. TEST MEDIUM SHALL BE NON HAZARDOUS LIQUID.TEST PRESSURE SHALL NOT BE LESS THAN 1.3 TIMES OF MAWP FOR HYDRO TEST & 1.1 TIMES OF MAWP FOR PNEUMATIC TEST.ENSURE FOLLOWING PRIOR TO START THE TEST:Hydro / Pneumatic Test

WATER FILLING, PRESSURISING & INSPECTION:WATER SHALL BE FILLED FROM TOP OF VESSEL.INCREASE THE PRESSURE AS PER APPROVED PROCEDURE.WHILE TESTING METAL TEMP. SHALL NOT BE LESS THAN 17 C AND NOT MORE THAN 48C TO REDUCE RISK OF BRITTEL FRACTURE.HOLDING TIME AS PER APPROVED PROCEDURE.ALL PRESSURE JOINT SHALL BE VISUALY INSPECTED AT PRESSURE NOT LESS THAN THE TEST PRESSURE / 1.3 PRESSURE.LEAKAGE IS NOT ALLOWED AT THE TIME OF REQUIRED VISUAL INSPECTION. Hydro / Pneumatic Test

WATER FILLING, PRESSURISING & INSPECTION:7 . IF ANY LEAKGE IS OBSERVED FROM WELD OR PARENT METAL, DRAIN THE WATER, REPAIR THE LEAK AND REPEAT THE TEST.8.TIME, TEMPERATURE & PRESSURE CHART WHEREVER SPECIFIED SHALL BE OBTAINED.REDUCE THE PRESSURE FROM THE TOP OF THE VESSEL AS PER APPROVED PROCEDURE.DRAIN THE WATER FROM THE BOTTOM OF THE VESSEL WITH PROPER VENT AT TOP. RELIEF VALVE SET TO 1 TIMES OF TEST PRESSURE IS RECOMMENDED.Name Plate / U stamping

DETAIL OF MARKING IS ADDRESSED IN UG 115 TO UG 119 TYPE OF CONSTRUCTION USED FOR THE VESSEL SHALL BE INDICATED DIRECTLY UNDER CODE SYMBOL.TYPE OF CONSTRUCTIONLETTER(S)ARC OR GAS WELDEDWPRESSURE WELDEDPBRAZEDBRESISTANCE WELDEDRESIN ADDITION TO ABOVE, WHEN A VESSEL IS INTENDED FOR SPECIAL SERVICE AND REQUIREMENT COMPLYIED WITH LETTER

LETHAL SERVICELUNFIRED STEAM BOILERUBDIRECT FIRINGDFName Plate / U stamping

WHEN RADIOGRAPHIC OR ULTRASONIC EXAMINATION HAS BEEN PERFORMED ON A VESSEL, MARKING SHALL BE APPLIED UNDER CODE SYMBOL:RT 1ALL PRESSURE RETAINING BUTT WELD EXCEPT CAT B & C BUTT WELDS ASSOCIATED WITH NOZZLES AND COMMUNITING CHAMBERS THAT NEITHER EXCEED NPS 10 NOR 29 MM WALL THICKNESSRT 2COMPLETE VESSEL SATISFY REQUIREMENT OF UW-11(a)(5) AND SPOT RADIOGRAPHY REQUIREMENT UW-11(a)(5)(b) RT 3 SPOT RADOGRAPHYRT4 WHERE NONE OF THE ABOVE MARKING ARE APPLICABLEName Plate / U stamping

BASED ON HEAT TREATMENT ON VESSEL, FOLLOWING LETTER TO SYMBOL ON NAME PLATE.IF COMPLETE VESSEL UNDER GONE PWHTHTIF ONLY PART OF VESSEL UNDER GONE HWHTPHT

Name Plate / U stamping

WHEN THE MARKING REQUIRED BY UG-116 IS APPLIED DIRECTLY TO THE VESSEL. IT SHALL BE STAMPED WITH AT LEAST 8 MM HEIGHT OF LETTERS. STAMPING SHALL NOT BE DONE ON VESSEL IN FOLLOWING CONDITIONS (UG 118):A)MATERIAL SHALL BE LIMITED TO P 1 GR 1 AND 2B)MIN PLATE THK 5 MM, & MIN PIPE WALL THK 4MMC)MDMT COLDER THAN -29CD)MATERIAL SHALL BE LIMITED TO ALLUMINIUM NOM OD OF VESSELCHARACTER SIZE89 MM MAX3 MM89 TO 114 MM5 MMABOVE 168 MM6 MMName Plate / U stamping

NAME PLATE SHALL BE USED ON VESSEL EXCEPT WHEN MARKING SHALL NOT BE STAMPED DIRECTLY ON VESSEL BY UG 118.CHARACTER SIZE FOR NAME PLATE NOT LESS THAN 4 MM.NAME PLATE MAY BE ATTACHED EITHER BY WELDING, BRAZING OR SOLDERING.NAME PLATE MAY BE INSTALLED ON SKIRT, SUPPORT, OR PERMANENT ATTACHMENT TO VESSEL. THE ADDITION NAME PLATE SHALL BE MARKED: DUPLICATE

OTHER REQUIREMENT

HEAT TREATMENT REQUIREMENT (UCS 56)CHARPY IMPACT TEST (UG 84, UCS 66, UCS 67)MATERIAL (TABLE UCS 23)MANUFACTURER DATA REPORT (MDR, UG 120, NON MANDATORY APPENDIX W, FORM U-1, U-2)

T.L.T.L.T.L. to T.L.ELEVATIONPROJECTIONPROJECTION2:1 Ellipsoidal DendHemispherical DendSet On NozzleSet ThroughNozzle / ManwayS.F.Over view of Pressure vessel

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