Radiography, Liquid Penetrant,Magnetic,Hydro Peneumatic Test Procedures

F.4. RADIOGRAHIC TEST PROCEDURE

Tovo ENctNnnRtNc lNuta LrtrrrnoMUMBAI . INDIA

gIOYC IiB]A

PROJECT

CLIENT

TEIL JOB NO.

I Io td l 6 l \ t r rs in . lud ing(o to I 'ognnt l R . \ i son f { t r to^ \ l t (1 )

AMMONIA STORAGE TANK.

M/S. GODAVRI FERTILISERS & CHEMICALS LTD.

ozJ+

STANDARD CONSTRUCTION PROCEDURE

RADIOGRAPHIC TEST PROCEDURE( |TEM NO. 20 - T - 01 - CAPACTTY 10,000 MT)

Tovo ENcTNtBRTNG INDrA LrmrrnrMUMBAI INDIA

REVISION HISTORY

For Review / Approval

Description

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S I 'A]\DARD ( ()N5 I RI. CI ION PROt' tDL'Rt JOB No. 62-14

DOUBLE INTECRITY CRYOCENICAMMONIA STORACE TANK

RA.DIOGRAPHIC PROCEDTIREIrl U i\'ttsA t Page I of ,l

1. QUALIFICATION OF RADIOGRAPHY PERSONNEL

Radiography wiil be performed under the jurisdiction of BARC Site-in-charge & ASNT level

As a Minimum all personnel conducting radiographic examination shall be certified, BARC RTLevel | & Level ll/ ASNT Level | & Level ll. All qualification certificates shall be valid

Only a BARC Site-in-charge or ASNT Level ll Personnel shall carry out interpretations ofradiographs.

2. SCOPE

This procedure established the requirements of Radiographic examinations of 10,000 MTAmmonia Storage Tanks as follows

Outer Tank - 19.6 Mts. with Max. Shell Thk. 16 N,'lt\4 & Min. 6.4 MMInner Tank - 18.6 Mts. wi th Max. Shel l Thk. 13.9 MNI & N4in. 6 .4 1,4N4

TEST REQUIREMENT: As per approved QAP and Drawings

3. SURFACE CONDITION

The Weld and adjacent areas shall be free of arc strikes, spatter and debris.

The Weld surface should be such that the weld ripples or any irregularities on both sides of thecomponent to such degrees that the resulting radiographic lmage or any flaws / discontinuityshould not be masked or be confused with the surface indications.

4. SOURCE AND FILM TYPE

Radiat ion Source : lR lDlUM - 192 - maximum source s ize 2.smm x 3mm

Film Type :Afga - D4 (Speed : Slow, Contrast : Very High, Graininess : Ultra fine

5. SCREEN

The Lead screen will be use for Gamma Radiations normally 0.125 mm for fronts screen and0. l5mmfor thebackscreens. Al l screens wi l l be of the casset te- loaded tvoe.

6. RADIOGRAPHICTECHNIOUE

Technique for the radiographic shall be as illustrated in the Mandatory Appendix of article 2,ASME APV Code Section V.

A Single Wal l Exposure Technique shal l be use for Radiography.

For Single Wal l S ingle lmage Technique (SWSI) min imum Source to F i lm Distance (SFD)should be 10" for Single exposure.

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Tovo Ercrn . ' r rn r r t ; I ro r r L ro .

STANDARD ('ONSTRL]CTION PROCI]DTJRI] JOB No. 6214

DOUBt ,E INTECRITY CRYOCENICAI\{MONIA STORACE TANK

RADIOGRAPHIC PROCEDTIREM t rN{ur\ l Page 2 o f4

7. EXPOSURE TIME CALCULATIONS

This is based on base material thickness, source to film drstance and source strength.

8. DENSITY LIMITAIONS

The Film Density through the area of interest of the radiographic image shall be followedDensi ty Min. 2.5 to Max.3.8 H & D measured on Parent meta l image.Min. 2.0 to Max.3.5 H & D measured on the weld image.

9. RADIOGRAPHICSENSITIVITY

2% or better Film Sensitivity shall be required for radiography of Tanks.

Calculations of Sensitivity

Diameter of thinnest wire visible on radioqraph X 100Penetrated thickness at area of interest.

10. TYPE / DESIGN OF PENETRAMETERS (IMAGE QUALITY INDICATOR)

Minimum one penetrameter shall be used for each radiograph. Penetrameter shall be of similarmater ia l to that mater ia l be ing radio graphed.

DIN 54109 (1962) wire type penetrameter shall be used to indicate radiographic sensitivity.These penetrameter are three sizes of indicators, each containing seven equal distancesparallel wires of various thickness in geometrical progression.

Thickness of Wire

Diameter of Wirei n m m &

Correspondingnumbers

Mt\4 3.20 2.50 2.00 1 . 6 0 1 .25 1 .00 0.80 0.63No. 1 2 3 4 5 6 7 8MIVI 0.50 0.40 0.32 0.25 0.20 0 . 1 6 0 . ' t 25 0 .1No. 9 10 1 1 12 13 1 4 1 5 1 6

Size of Penetrameter

lndicators No. of Wires Job Thickness of materialDtN 1 ISO 7 1 2 3 4 5 6 7 Above 50 mmDtN 6 rSO 12 6 7 8 9 1 Q 1 1 1 2 '18mm to 50mmDrN 10 tso 16 1 0 11 12 1 3 1 4 1 5 t o Uo to 19mm

CALCULATIONS OF UNSHARPNESS

un= +Where Uo = Geomentrical UnsharpnessF = Sourie Size: The maximum projected dimension of the radiating source / effectivefocal spot in the plane perpendicular to the distance from the weld or object is beingradiographed.

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Toro Err;rrr:t:ntlc; Irot,r Lro,

STANDARD ('ONSTRUC'TION PROCEDtIRII JOB No. 6234

DOUBLF, INTI]CRITY CRYOCENICAMN, IONIA STORACE TANK

RADIOGRAPHI(] PROCEDTIREN,l I ]M I]A I Page -l of '1

D = Dist. from the source of radiation to the weld or object being radiographed.d = Dist. from source side of weld or object being radiographed to the film.

12. BACK SCATTER RADIATION

Backscatter radiation falling on the film should be avoided. To determine the amount of backscattered radiation. A lead number'B'of minimum %" heighI and '116" thick shall be attached tothe back of the film holder. lf a white image of 'B' appears on the darker background of theparagraphs. lt means that the protection from backscatter is insufficient and radiograph shallbe considered unacceptable. However a dark image of letter 'B' on the laghter background isnot the cause of rejection.

13. PROCESSTNG

. Processing will be a manual.

. Development time of 3-5 minutes in developer solution at 20 degree temperature withintermittent agitation, agitation being constant for the first 30 seconds manually.

. Following development acetic acid (stop bath) for 30 second to 1 minute withagitation for the first 20 seconds.

. Film to be fixed for at least twice the development time or 4 minutes whichever is thegrearer Dy manuaIy.

. Washing wi l l be for at least 12-15 minutes in running water in manual ly .

. Radiograph will be 1 minute in waiting agent bath with agitations after 40 seconds.

. F i lm shal l be dra ined at least t hour .

14, IDENTIFICATION

Single exposure shal l conta in a l l the deta i ls ment ioned bel low wi th lead, Numberscorresponding to Jo int , X-ray No. , Welder No. , Job No. Por t ion No. Date, Repair or Retakemarks and proper type of penetrameter.

Min imum ovedapping between two subsequent f i lms of same jo int shal l be 1 inch.RT segment and RT unique number shal l be wr i t ing by permanent marker on the lob

, I5. VIEWING OF THE RADIOGRAPHS

For radiographic interpretations shall provide a variable high-density light source (Viewer)Only s ingle f i lm v iewing technique shal l be appl ied.

THICKNESS OF OBJECTUNSHARPNESS PERMISSIBLE

In inchesFrom to & through

l n m mFrom to & through lnches MM

00 2" 00 50.8 0.020 0.502" 3" 50.8 7 6 .2 0.030 0.753" 7 6 . 2 1 0 1 . 6 0.040 1 .04" & Above 1 01 .6 & Above 0.070 1 . 7 5

&

Toro Erc r r r rn r rc l r r r , r L ro .

STANDARD CONSTI{U['TION PRO('lrDt IRE JOB No. 623;l

DOI-BLE INTECRITY CRYOGENl( 'A]\IMONIA STORAGE TANK

R{DIOGRAPHIC PROCEDTIREN l I J M B A I Page 4 o f4

16. WELD AGCEPTANCE CRITERIA

As per following codesASN/E Sec. Vl l l D iv .1ASI\4E 831 .3

17. STORAGE OF FILMS

Films shall be stored, using non-hygroscopic paper, safety in air-conditioned room.

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E. SIS Institute of Nondestructive Tbsting'-J 28, Eoroii, Gorudodhri Aporrmenrs, No. tt,3lljf;il"r:lj&1"ll*n Nosor, chennoi - 600 083 lel : 2471 7182

Ameican Socizty for $[9n-Destructiae 'Tcsting. l|g:commcnle[ lPractiee SM-IC. 1A, 1996 E[itiofl

lrhk k to certitu . . Yl l::l:i ::::i:::lT .

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in accor[ance utitfi asM urittefl lPro.cticc Document Np. SNq-tC- n 896 E[itiott'

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MethoIRADIOGRAPHY TESTING

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WORK EXPERIENCE : 72 MONTHS

TRA1N1NG HOUBS : 80 HOURS

JU\J h tr,WEIGHTED

SCOREPASSINGMINIMUM

GENERAL 75.00 25.00 23.33

SPECIFIC 80 .00 26.67 23.33

PRACTICAL 90.00 30 .00 23.33

COMPOSITE SCORE 8t .67 80.00

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VISUAL ACUIry J2

COLOUR VISION ok

Qiven tfiis on 25.08 .2004

The American Societyfor Nondeskuctive Testing

FILE No. 40803/cHN

CERT.'No. 40 B 0 3,/RT

Course Director

Examinee's Signature

'ffik certifirate * ksue[ to cna\fe tfie emp[oyer to certifg thz in[ioi[uof as

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MAGNETIC PARTICLE TESTING

LetteIrr (rwo)

WORK EXPERIENCE : 72 MONTHS

TRAINING HOURS : 24 HoURS

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VISUAL ACUITY J2

COLOUR VISION OK

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The American Societylor Nondestructive Testing

FILE No . 40803/cHN

CERT. No. 40803/MPr

\pneruaS[e as per tfi-c requiretfl.nts of S1(l'TC 1A.

Course Director

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per their ,u.,rittefl practiee fiamel to tfre r.quircflcnts of S9{LtC'1A,

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SCORE WEIGHTEDJU(JTttr

PASSINGMINIMUM

GENERAL 77.50 25 .83 zJ.J.)

SPECIFIC 75.00 25.00 23.33

PRACTICAL 90 .00 30 .00 23.33

COMPOSITE SCORE 80.83 80.00

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9r{ethodDYE PENETRANT TESTING

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WORK EXPEHIENCE : 72 MONTHS

TRAINING HOURS : 16 HoURS

SCORE WEIGHTEDSCORE

PASSINGMINIMUM

GENERAL 80.00 26 .67 23.33

SPECIFIC 80 .00 26 ,67 23.33

PRACTICAL 85.00 28 .33 Z J . J J

COMPOSITE SCORE 8t .67 80.00

F ILE No . 40803./cHN

CERT. No. 4.0 B 0 3/DPrExaminee's Signature

'Iftk certifirate is issue[ to ena|fe tfte empfoger to certifg tfte in[ioilut[ asper tfieir utitten praetice frame[ to tfre rcqrirerfleflts of SN'f ''fC'1A.

Qiaen tfiis on 25.08.2004 an[ rtafid upto 24.08 .2007 .

R.4:nezua6te as per tfi,e requirem.flts of SN'I'IC 1A.

The American Socaetyfor Nondestructive Testing Course Director

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SRI VIJAYADURGA NDT & INSPECTION CONSUTTANCY58-21 -27, "BAtA,l', Susorlo ColonY'Fox : +91 a69l) 2572675E-Moil : cs-murty @ Yohoo.co.uk'

Method : RADIoGRAPHY TESTTNG (RT) t evel

Educational : B.Com Training Venue

Qualification

Work Experienc e : 12 Years Training Hours

Examination Results : PA$ Date of Issue

Valid UP to

Revalidity Date

Valid Up to

DascripEion Besults GrodeMinimumre,euied

Generol 90.00 30.00 23.33

Specific 8s.00 28.33 23.33

Procticol. 85.00 28.33 23.33

Composite 86.66 80.00

NDE CERTIFICATIONAS PER

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING

certiJicate issued to sri CHINTALAPUDMNKATESWARA RAO of

INDUSTRIAL RADIOGRAPHS CORPORATION, WSAKHAPATNAM fOT

having satisfactorily completed a training course and pqssed the examination as

detailed below in occordance with the requirements of SNT-TC-IA 1996 of ASNT.

Bulchiroiupolem, Visokhopolom-53002 7Ph: +91 (E9l) 257267ICell : 98481 45223

Il (Two)

VISAKHAPATNAM

'l20 Hours

10-or-2005

o9-o1-20(l8

Pltysicol Exanindion:

Near Vision OK

Colour Vision OK

cenificate No. : svDAr'sP/RT/Q/LM0O5l05

3 L*\r -.A-B.K. SETHUPA'ASNT Level - III, (RT, PT)Cclt No. 1,19507

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NYNOUNCAi,iNT&INSPECTIONCONSUTTANCY

NDE CERTIFICATIONAS PER

AMERICAN SOCIETY FOR NONDESTRIICTIVE TESTING

Cerrificate issued to Sri MAVUDARU DURGA GANESWARA RAO of

INDUSTRIAL RADIOGRAPHS CORPORATION, VISAKHAPATNAM fOT

having satisfactorily completed a training course and passed the examination as

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Method : RADIoGRAPHY TESTING 1nr1 kvel

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Qualification

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ExamimtionResuls : PAss

P lrr s i col Exani nol ian :

Near Vision OK

Colour Vision OK

Cenificare No.: SvD/VSP/RT/Qi L-lI/2005i 06

Bulchiroiupolem, Visokhopdtom'530027Ph : +91 (89I ) 257267 8Cell : 98481 45223

: l l (Two)

Training Venue : VISAKHAPATNAM

Training Hours : 120 Hours

Date of Issue : 1O'01'2oo5

Valid Up to : o9'o1-2ooa

RevaliditY Date :

Valid UP to :

SRI VIJ58-21-27 , 'BALAJ|" Susorlo colonv'

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GrodeMlnimumre4vtre'd-.Dascription Besults23.33

Gonerol 85.00 28.3323.33

Spocific 80.00 9.6.66

30.00 23.33Procti(ol 90.00

84.99 80.00Composite

F-5. VACCUM BOX TEST PROCEDURE

Tovo ENcrNnnRtNc Intn LrnntrrlMUMBAI . INDIA

gicYa Mct!

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BoxVACUUM TEST PROCEDURE

^( |TEM NO. 20 - T - 01 - CAPACTTY 10,000 MT)

PROJECT

CLIENT

TEIL JOB NO.



6234

Tovo ENcrNnnRrNG INDrA LrnrrrsnMUI/BAI INDIA

Plsv: ; . , - t 6'f--=-- '.Jt-.,/

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REVISION HISTORY

Rev. Date Description

0 Aug 18,06 For Review / Approval

0

Tovo Ercrr cEnr:,r<; Ir.'or,r l,ro.

STANI)ARD ( ONSTRUCTION PROCIiDURE JOB No. 6214

DOtJBt -F INTECRITY CRYOCENICAMMO\ lA STORACtT TANK

VACTITI}T BOX TESTIN-G PROCEDTJRE\ l t \ 1 8 . \ | Page I o f2

2.

3 .

J .

4.

1. Scooe

This procedure covers the methodology for Vacuum Box Test to be conducted byvacuum-box. This method of non-destructive testing for detecting leakage in theAnnular weld jo ints, Bottom (Long seam, short seam), Annular to sketch, Shel l tobottom plates.

Reference

R.8.2.1 API 620 Appendix-R (Tenth Edit ion, Addendum 1, June 2004) Art ic le 10of ASME Section V.

Qualification of Personnel

Personnel conducting Vacuum Box Test shall have sufficient experience toconduct this type of test.The test will be performed under the supervision of qualified supervisor.

Equipments

Vacuum Box (metal test ing box 150 mm x 750 mm with glass window in the top),Hoses, vacuum pump, valves, sui table vacuum gauge, seal ing mater ials, ( i .e.clay / flour paste / putty, sponge rubber gasket, hand lamps)

Surface Preparation

In general satisfactory results are obtained when the surface of the weld isproperly cleaned. Prior to vacuum box test the surface to be examined and alladjacent areas within at least 1 inch shall be dry and free of all dirt, grease, lintscale, welding flux spatter and other extraneous matter that could obscureopenings or otherwise interfere with the examination. The surface temperatureshall be 4"C to 52"C through the examination

Method

After cleaning of weld joint approximately 750 mm of the lap joint under tesl isbrushed with the soap solution or linseed oil. The vacuum box is placed over thecoated section of the lap joint. Open bottom of vacuum box is sealed againstplate surface by sponge rubber gasket. Vacuum box is connected to vacuumpump through valves, hose and vacuum gauge and then vacuum is appl ied to thebox. lf the required vacuum is not achieved due to improper sealing / defectivesponge rubber gasket i uneven surface clay / flour paste, putty will be used toseal the vacuum box with plate surface. The presence of any leakage or porosityin the lap weld jo int is indicated by bubbles or foam produced by air suckedthrough the welded lap jo int . Sui table & cal ibrated vacuum gauge shal l beprovided. An overlap of 2 inch minimum for adjacent placement of the vacuumbox shal l be used for each subsequent examinat ion.

5.

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Ercrrecnrr<; l. ' . 'otr Lro,

STANDARD CONSTRLIt'TION PROC'llI)URE JOB No. 6234

DOtJBT,E INTECRITY CRYOCENlCAN4MONIA STORACE TANK

VACLILIM BOX TESTIN(; PROC]EDITREM I I M I ] A I

6. Inspect ion

Inspection of lap weld joints will be performed after minimum gauge vacuum of 3PSI (155.14 mm of Hg) achieved (Refer API-620). Observat ion wi l l be made forany indicat ion of bubbles or foam generated on the lap weld jo int .

7. Acceptance

Lap weld jo ints are accepted i f no bubble or foam is generated at 3-PSl (155.14mm of Hg) vacuum.

9. Defect Rectification & Re-Testinq

l f any leakage is observed dur ing Vacuum Box Test ing, further gr inding andwelding as per approved WPS of the defective section of joint shall remove thesame. After the weld repaired re-testing by vacuum box method will be done, asgiven in pt. 6 of this procedure.

10. Post Cleaninq

After removing vacuum box, plate surface to be made free from Clay / Flour paste/ soap / l inseed oi l to avoid any sl ippage mishap. A sui table technique such as asimple water rinse or compressed air may be used for cleaning.

11. Documentat ion

Proper record shall be maintained as per approved format.

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F.6. LIQUID PENETRANT TEST PROCEDURE

Tovo ENcrNnnRrNc INou LmrrnoMTJMBAI . INDIA

gioY0 titDtt

PROJECT

CLIENT

TEIL JOB NO.

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ozJ+


LIQUID PENETRANT TEST PROCEDURE(ITEI\4 NO. 20 - T - 01 - CAPACITY 10.000 MT)


PREPARED BY

Tovo ENcrNBsRrNc INul LrmrrnnI\, lUMBAI INDIA

H@)v-r-;-* (*

rv?re

REVISION HISTORY

Aug 18,06 For Review / Approval

Description

6S

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STANDARD CONSTRUCTION PROCEDURE JOB No. 6234

DOUBLE INTEGRITY CRYOGENICAMI\4ONIA STORAGE TANK

LIQUID PENETRANT TEST PROCEDUREMUI\,4BAI Page 1 of 2

1 . Scope

This general procedure covers the procedure for liquid penetration inspection to beconducted by solvent removable liquid penetration process is non-destructive testingmethods for detecting discontinuities that are open to the surface. They are applicable forprocess, final and maintenance inspection. They can be effectively be used in theinspection of nonporous, metallic materials, both ferrous and non-ferrous materials suchas ceramic, plastics and glass. Discontinuities open to the surface as cracks, seams, lapsand cold shut laminations, through leaks or lack of fusion are indicated by this method.

Reference: ASME Sec. V / ASME SEC.VI l l DIV - 1

Qualification of Personnel

Personnel conducting liquid penetration test shall have sufficient expenence to conductthis type of test.

Material

Penetrant - Vis ible Dye penetrant conf i rming lo l5-3658 - 1981 ,Developer - Non-aqueous developer.Cleaner - Solvent type(Penetrant & developer shall be same manufacture.

5. Surface Preparation

In general satisfactory results are obtained when the surface of the part is in the as weld.Surface preparation by buffing may be necessary where surface irregularities could maskindicat ions of unacceptable disconl inui t ies.

Prior to all liquid penetration examination, the surface to be examined and all adjacentareas within at least 1 inch shal l be dry and free of al l d i r t , grease, l int scale, welding f luxspatter and other extraneous malter that could obscure openings or otherwise interferewith the examination.

After cleaning, drying of the surface to be examined shall be accomplished by normalevaporation or with forced hot air.

6. Technique

6.1 Pre cleaningAfter removal of any rust, scale, welding flux, spatter etc. the surface lo beinspected shal l be cleaned with a dry, l int f ree cloth, subsequent ly with a l ight lymoistened cloth of cleaneri removeT. The drying process shall be accomplished bynormal evaporat ion.

6.2 Penetrantappl icat ionAfter the part has been cleaned, the temperature of the surface and penetrant arewithin the range of 60'F to '125'F the penetrant shal l be sprayed direct ly on the

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STANDARD CONSTRUCTION PROCEDURE JOB No. 6234

DOUBLE INTEGRITY CRYOGENICAI\4MONIA STORAGE TANK

LIQUID PENETRANT TEST PROCEDUREMUMBA] Page 2 ol 2

6.3

surface to be inspected by means of an aerosol container, such that the entire partof area under inspection is completely covered with penetrant.

Removal of Excess Penetrant

After the required penetratron dwell time, the penertant remaining on the surfaceshall be removed by wipes of clean, lint free cloth, repeating the operation untilmost traces of penetrant have been removed. Then lightly moistened solvent clothwill be used to wipe until all remaining traces of excess penetrant is removed.

On removal of all excess penetrant, drying shall be accomplished by normalevaporal ion. Minimum time for drying shal l be one minule.

6.4 DeveloperAppl icat ion

The non-aqueous wet developer will be sprayed directly to the surface of lhe partfrom an aerosol container from a distance of minimum 150mm. The non-aqueousdeveloper evaporates rapidly at room temperature. ParVareas shall be sprayed ina manner so as to have complete coverage within a thin even film developer.

Developer dwell time shall not be less than seven minutes.

Inspect ion

Inspection of test surfaces will be performed after the development time to assure properbleed out of penetrant from discontinuities on to the developer coating. To aid inevaluation the observation shall commence with the application of developer.

Acceptance

Discont inui ty wi l l be accepted as per ASME sec Vl l l Div .1 App-8.

Defect Rectification & Re-examination

lf any discontinuity observed during LPI inlerpretation, the same shall be removed byfurther grinding and then re-examination will be conducted with LPI

Post Cleaning

Post cleaning is necessary in cases where residual penetrale or developer could interferewith subsequent processing or service requirements. A suitable technique such as asimple water r inse or solvent c leaning may be employed.

Safety

Safety precaution as per approved Policy shall be adopted.

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F.7. MAGNETIC PARTICLE TEST PROCEDURE

Tovo ENcrNnnRlNc INora LrvurnoMUMBAI . INDIA

a:oYc 110 t

I t l ) tn l i l ' t t ( \ i t t ( lud t g (o t t t l ' o t ! . . tnd R! t i s ion l l i \ to t | \h t \1 )


MAGNETIG PARTICLE TEST PROCEDURE( |TEN4 NO. 20 - T - 01 - CAPACTTY 10,000 MT)

PROJECT

CLIENT

TEIL JOB NO.



6234


PREPARED BY

Tovo EwcrNnnRrNc lxnrl LrnrrrelI\,4UMBAI INDIA Fouiau,.,u ,4-

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v! lY,.r i ' f o e

REVISION HISTORY

Rev. Date Description


wTovo Errr;rrr:r:rrr,,r; Iror.r Lrn.

STANT)ARI} C' )NS I RI C I ION PRO( ' I .DI RI- JOB No. 62lz l

DOI-BLE INTIGRITY CRYOGENICAMNIONIA STORACE TANK

NIAGNETI(] PARTICI,E PROCEDIIREN,l t rN, l.{ l Pagel o f - 3

1. Scope

This procedure describes techniques for magnetic particle examination of discontinuitiesat or near the surface in ferromagnetic matenals by using wet magnetic particle methodsand longitudinal magnetism at ambient temperature

2. Reference

ASME Sec. VArt ic le-7 (SE-709)ASME Sec - Vl l Div - | and l lAPt -620

3. Qualification of Personnel

Personnel conducting Magnetic Particle Examination shall have sufficient experience toconduct this type of test

The test will be performed under the supervision of at least one of the following orequivalent ly qual i f ied supervisor

a. ASNT / ISNT Level - l l in accordance with SNT - TC - 1Ab. Any internationally recognized qualification for NDT personnel.

4. Material

-V / Magnetic Particle powder of reputed manufacturer will be used, Kerosene, bathr ' '

- J, concentrat ion (checked at the start ing of the examinat ion 0:1 ml to H ml per 100 ml of

. . , * r - t p ke rosene ) . f - e . r ' . - 1 r . " , ' < ' : - l i ' L 2+

5. Equipment

Portable magnet ic equipment HWAC i DC Yoke

The magnetizing force of yoke shall be checked at least once a year by lifting power ofyokes.

Each alternating current electromagnetic yoke shall have a lifting power of at least 4.5 kg(10 lb) at the maximum pole spacing that wi l l be used.Each direct current yokes shal l have a l i f t ing power of at least 18.1 kg (40 lb) at themaximum pole spacing that wi l l be used. Maximum pole spacing that wr l l be 6".

6. Method

6.1 Magnet ic Part ic le Examinat ion Medium: -

The particle used as the test medium shall be finely divided ferromagneticmaterial and average grain diameter not to exceed 20 microns.

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STANI )ARI ) C C)NS I RL C I tON PROCI : I IURL JOll No. 6234

DOtTBLE INTECRITY ( 'RYOCENICAMI\4ONIA SI'ORAGE TANK

MAGNETIC PARTICLE PROCEDTTRENll i t \1B l Page 2 of -i

The suitable color (Black or Brown) shall be provided to the article in order tomake them highly v is ible against the background of the surface examined.

Water shall be used as vehicle for wet magnetic particles. Suitable conditioningagents shal l be added to provide proper wet disposing. When examining highal loy chromium steels, austeni t ic steel and nickel base al loy, the chlor ine andsulfur contents of water shall be checked and not to exceed one percentage ofresidue individually by weight in water. The water should be portable and havegood wetting characteristics

6.2 Surface Preparation: -

The surface to be examined and all adjacent areas within at least 1" shall be dryand free of all dirt, grease, lint, scale, welding flux and spatter, oil or otherextraneous matter that could interfere with the examination.Where surface irregularities are found, grinding shall be done of facilitate theexaminat ion.

6.3 Magnet iz ing Field Adequacy

The magnet iz ing f ie ld direct ion and adequacy shal l be ver i f ied using Magnet icParticle Indicator (ASTM)By using this indicator suitable flux or field strength is indicated when a clearlydefined line of magnetic particles forms across the copper face of the indicatorwhen the magnetic particles forms across the copper face of the indicator whenthe magnetic particles are applied simultaneously with the magnetizing force.

6.4 Extend and Time of Examinat ion

The area weld to be tested shall be the weld surface and the heataffected zoneof minimum width of hal f inch of the area. shal l be tested 100%The examination must be performed in the final condition after welding or heattreatment.

6.5 Inspect ionCondit ion

The inspection shall be executed under ample of light. The temperature of thepart surface and the suspension shall not exceed 57"C, during the magnetrzationpenoo.

6.6 Examinat ionTechniques:-

. The part to be tested shall be prepared as mentioned.

. White or any other sui table contrast paint shal l be appl ied on lhe testsurface and 1" either side of the lest surface.

. The pole spacing shall be adjusted so as to ensure proper coverage. Thepole spacing shall be between 3" & 6".

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S TANI)ARD ( 'ONS'IRUC'I ' ION PROCI]DURE JOB No. 623.1

DOUBT,E I \TECRITY CRYOCENICAN4I\4ONIA STORACE TANK

NIAGNETIC PARTICI,E PROCEDTTREM I J\ { I ] , \ I

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The legs of the yoke shall be positioned across the weld or part to betested providing magnetization periods of at least 30 seconds.

The wet ferrous magnetic particles shall be sprayed on the test surfacesimultaneously with the initiation of the magnetizing current will formpatterns cause distortion in the normal magnetic field, these patterns areusually characteristic of the type if discontinuity that is detected.

The weld or part shall be examined for any relevant indications. lf anyrelevant indications are observed its acceptance / rejection shall be basedon the relevant acceptance criteria.

The legs of the yoke shall be positioned in a direction gO0 to the earlierposit ion.

Step 6.6.5 to 6.6.7 should be repeated.

Interpretation & Acceptance of Indications

Indication observed during examination shali be interpreted to be either relevant or nonrelevant and will be accepted as per relevant code and applicable specification.

Defect Rectification & Re-examination

lf any linear discontinuity observed during MPI interpretation, the same shall be rectify bysuitable method and then re-examination will be conducted with MPI to confirm that nodefects exist.

Post Cleaning

Post test cleaning shall be carried out with brush.

Demagnet izat ion

Demagnetization shall be canied out by contrnuously reversing the field direction.

Safety

Safety precaution as per approval Policy shall be adopted.

Reporting Of Result

The result and parameter used for magnetic particle testing shall be reported in"Magnetic particle Examination Report"

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F.8. HYDRO.PNEUMATIC TEST PROCEDURE

Tovo ENcrNnBRrNc INora LtlrrrnoMUMBAI . INDIA

g!$rc h0lt

PROJECT

CLIENT

TEIL JOB NO.

( lirnl t l\tgt\ itu ltu|n< ( ott't I'ng? ottul R.isuri Hi\!a\ \h!1)



6234

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Tovo EncrNnrnrnc INorl LrmrrnoMUMBAI INDIA

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cP- 003

HYDRO-PNEUMATIC TEST PROCEDURE( ITEM NO.20-r -U - CAPACTTY 10,000 t \ ,4T)

REVISION HISTORY

Rev. Date Descript ion


O

T()Yo l l i \c l \EERtNC; I \DtA LTD.

STANDARD CONSTRUCTION PROCEDURE JOB No.6234

cP-003DOUBLE INTEGRITY CRYOGENIC

AMMONIA STORAGE TANK

HYDRO-PNETI}IATI(] TEST PROCEDT]REMUMBAI Page 1 of 6

CONTENTS

SECTIONNO. TITLE

01 SCOPE

02 REFERENCE DOCUMENTS

03 PRELIMINARY

04 HYDROTEST OF INNER TANK

05 PNEUMATIC TEST OF OUTER TANK

06 PNEUMATIC TEST

O7 TESTING OF SAFETY RELIEF VALVES

08 INSPECTION OF VACUUM RELIEF VALVES

09 EMPTYING OF TANK WATER & RESIDUAL WORKS

10 TANK CLEAN UP

11 INSTALLATION OF DISH ENDS

12 FINAL RELEASE

w' Iovo Erc;rleenrrr; I) iDrA LTD.

STANDARD CONSTRUCTION PROCEDUREJOB No.

6234


AMN,4ONIA STORAGE TANK

HYDRO-PNETIMATIC TEST PRO(]EDIIREMUMBAI Page 2 of 6

01 .

02.

03.

SCOPE

This procedure covers hydro-pneumatic testing for double wall low temperature and lowpressure Ammonia storage tank (20-T-01) is being constructed for M/s. GFCL Kakinada, inaccordance with referred code, drawings and engineering specifications.TANK CAPACITY - 1O,OOOMT.

REFERENCE DOCUMENTS

The following documents shall be referred while interpreting this procedure during Constructionfor double wall double integrity Ammonia Storage Tanks( l t e m n o . 2 0 - T - 0 1 ) .

TEIL Drawing no. . C - 6231 - 4301 -- GENERAL ARRANGEI,4ENT.Appl icable Code : API-620-R (10 " EDITION, ADDENDUM 1 , JUNE-2004.)

PRELIM INARY

Caut ion

After fabrication is completed & tank is released for hydrolesting, check vapor-space tomake sure that it is free from explosive gases before making any repairs or performingany work that might cause a spark.

Preparation

1. Test all pressure- vacuum relief vents for accuracy at operating pressure and vacuumprior to testing the tank. lf permanent vents are not available, it is mandatory that atemporary pressure/ vacuum vent be provided for emergency venting so that testpressure and vacuum loading are not exceeded.

2. Visually inspect all expansion joints for damage after they are welded in place.Expansion joint protective wrappings must remain in place as long as possible priorto leaving the job site. lmmediately after welding (or bolting) bellows in place on bothends, remove the tie bars or keep it loosened.

3. Visual inspection shall be carried out before Hydrotest and ensured that all activities,which are to be completed before hydrotest, are completed.

4. Make certain that roof manhole and/or other roof fittings having as large an area asthe water inlet are open before fil l ing tank with water.

5. Qualitv of test water

a) Clean water.b) Water having no object ionable odour ( i .e . no hydrogen sulphide) .c) Chlor ide content not exceeding 40 PPN4.di Water temoerature below: 4B'C.e) lf water meeting above requirement is not available, tank shall be tested with

soft water and after the tests are over, the tank surfaces shall be washed withDl\4 water til l the final chloride content of the washed water comes to 40 PPM oroetow.

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Tovo Erclrrr.nrrr; Irurr L t o.



AMN,4ONIA STOMGE TANK

HYDRO-PNETiMATIC TEST PROCEDTTREIVUI\,4BAI Page 3 of 6

04.

6. l\4ark reference elevations on foundations at 8 circumferential intervals. Referencemarking on a column little away from foundation shall be marked and the samemarking shall be transferred by water level on foundations or with a help ofTheodolite/Level instrument.Same reference point shall be taken during settlement inspection.

7. Appropriate level markings (25%, 50o/o,75o/o and water test level) shall be made onthe outer surface of outer Tank and monitored manuallv

Hvdro-test of lnner tank

a) Fill ing shall be done in stages as shown below. The rate of water fil l ing shall beapproximately '175 to 200m' per hour. After every stage the fil l ing shall be halted for atleast four hours for observation of settlement at one quarter, one half, three quarters, fullwater level and visual examination for any deformation/ leakage.

b) Visual insoect ionCheck the surfaces of shell including welds, for leaks and signs of distress. lf any leakappears, lower the water level below the marked spot, carryout the repair (as perapproved procedures in consultation with TEIL Engineer Incharge) and continue thewater fil l ino.

24 Hrs Holding100 %

75 o/"Dewatering

afterpneumatic

test50%

Fil l ing rate - MAX.( for 20-T-01 )

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l\4aximum level of water to be fil ledTotal volume (Test Level)Hold ing t ime at fu l l water level

18.163t\4tr .1 5534m324 hrs.

of settlement during one quarter, one half, threelocations on foundation with reference to elevatron

c) Foundat ionSet t lementDur ing f i l l ing, check the e levat ionsquarter and full of water at marked

0

Tovo Er<;rrccnrr<; l lor.l Lro.



AI\,4MONIA STORAGE TANK

HYDRO-PNETI}IATIC TEST PROCEDTIREMUI\,4BAI Page 4 of 6

initially marked on the vertical member by Theodolite / level instrument and same shall berecoroeo.

05. HYDRO-PNEUMATIC TEST OF OUTER TANK

a) After successful hydro-testing of inner tank and jnner tank full of water, fil l the outer tankwith water. Nilaximum level of water to be fil led shall be 16.43N4trs. Alternatively drain offthe water from inner tank to outer tank using drain nozzles to equalize the water level inboth the tanks or til l the outer tank level reaches 16.43Mtrs.Gaution: In no case level of water in outer tank exceeds the test water level ofin ner tan k.After desired water level is reached, check outer tank surfaces including welds for leaks.

b) With water at test level at 16.43Mtrs. in outer tank complete all welding of holding barswith anchor straps as shown in drawing. NDT on anchor strap as required shall becarried out and cleared by TEIL / TUV.

c) Install one 'U' manometer with measuring tapes on one of the roof nozzles and another'U'

tube manometer from the same nozzle to ground level for monitoring and safeaccess. Fill with plain/ coloured water in manometer tubes for easy inspection.Arrangement shall be made in such a way that air can escape in case of over pressurein the tank exceeding the dasig{r pressure (1875mm W.C.).

' I G : J . \ " " " ! { - _

c) Install a ball valve on a roof nozzle N10 (4" NB) or any other suitable nozzle for quick airrelease.

d) Install manual valves for safety valves fitted on nozzles N12 AJB (8" NB) on roof fop.Install blind flanges between safety and manual valves to protect safety valves duringover test pressure. Install pilot piping for all pressure safety valves.

e) Blank off all nozzles not used for pneumatic test.

06. PNEUMATIC TEST

Close the top manhole and any other fittings left open during fil l ing. Open the valve at the startof air pressurisation. As soon as air is freely blowing through the valves, close the valve andsolution film test (with soap solution) the valve seat and stem. lf either is leaking tighten thestem or insert a plug in the outlet and retest to determjne that leakage has been stopped.

a) Caut ionDo not allow any unauthorized person on/near the tank while pressure is being increasedfor the first time and the same shall be monitored from qround level.

b) Test inqWhile carefully observing the manometer, slowly increase the air pressure to one half oftest Dressure in s teos of 100 mm W.C.G.

c) Slowly increase air pressure to three-quarters and '100% design pressure.Design pressure: 1500 mm W.C.

d) Visual inspection shall be carried out for crack on welds of Tank anchorage anddeformation of tank surface.

&

Toro Err;rrr: t :r l :r ; l \DtA LTD.

STANDARD CONSTRUCTION PROCEDUREJOB No.

6234


AMlilONlA STORAGE TANK

HYDRO.PNET]N'IATIC Tf,ST PROCEDT]REMUMBAI Page 5 of 6

e) Slowly increased the air pressure to full test pressure carefully observing the manometer.Hnld lacl nrascr irp fnf One hOUf.

Test pressure : 1875 mm W.C.

f) The air pressure shall be reduced until the design pressure is reached.

S) Visual Inspection

h) All welds above hydrotest water level including fil let welds under test pressure are to betested by applying soap solution with consistency.lf leaks are observed, de-pressurize the tank, repairs are attended as per approvedwelding procedures in consultation with inspection authority and retested after necessaryNDT checks.

i) Tank surfaces are to be inspected visually for any deformation and all tank anchorage forsigns of distress.

07, TESTING OF SAFETY RELIEF VALVES

a) Reduced the pressure up to 1300mmwc before opening blind flanges between manualvalves and safety relief valves.Open one of the safety relief valves isolation valve fitted on Nozzle no. N12 A & B (8"NB)

b) While carefully observing the manometer, slowly increase the air pressure up to safetyrelief valve set pressure (1350mm WC)Readings on popping and closing of safety valve shall be noted.

c) The same procedure shall be repeated for the remaining safety valves.

d) These readings shall be compared with the inspection reports submitted by the valvessuool rer .

08. INSPECTION OF VACUUM RELIEF VALVES

a) After successful completion of the hydro-pneumatic test, tank pressure is carefullyreteaseo.

b) With tank closed, slowly withdraw water from outer tank until vacuum design pressure isreached.Vacuum er€fl set pressure: (-) 50 mm W c.CARE SHOULD BE TAKEN WHILE DRAINING WATER FROM TANK ONLY OUTERTANK WATER SHOULD BE DRAINED FIRST

c) These readings shall be compared with the inspection reports submitted by valvesS U D D I I E T .

d) Open tank valve and make a i r pressure to 0 'mm W.C.G.

09. EMPTYING OF TANK WATER ANO RESIDUAL WORKS

aTovo [ l< ; r r rcnr r r ; hur r L ru ,

STANDARD CONSTRUCTION PROCEDUREJOB No

6234


AMN4ONIA STORAGE TANK

HYDRO-PNETIMATIC TEST PROCEDTIR.EN,4UI\,4BAI Page 6 of 6

After the test is over the entire vapour space is vented to atmosphere by opening 3-4big size nozzles & roof manhole.Water emptying shall to be done in stages during day and night under supervision.Discharging of water shall be performed through the shell nozzle Caution: first outer

Rate of discharging water - 160 - 180 m /hr. (N4AXIN4UM)

b) Foundation settlement measurement reading during emptying of water shall berecoroeo.

TANK CLEAN UP

After completion of dewatering, remove earth (mud), rubbish etc., from inside the tanks whichmay have accumulated during water fil l up and mop the tank bottom until it is dry.

After completion of hydrostatic test as per drawing weld joint of both the dish end of outer tankand inner tank is to be cut, remove earth (mud), rubbish etc. from anside the tank which mayhave accumulated during water fil l up and mop the tank bottom until it is dry.

INSTALLATION OF DISHED ENDS

After tank cleanup is completed the suspended deck insulation shall be started. Aftercompletion of deck insulation roof man hole dished ends shall be installed and NDT to becarried out. (Deck insulation can be carried out while tank internal cleaning is in progress).

FINAL RELEASE

After carrying out final NDT tests as stipulated in approved drawings, Inspection Test Plan(lTP) and proper cleaning, the tank is released for further work after final acceptance by GFCL/ TUV & TEIL.

Documents regarding all tests being carried out successfully shall be prepared & endorsed byGFCL / TUV & TEIL as records.

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Radiography, Liquid Penetrant,Magnetic,Hydro Peneumatic Test Procedures

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Transcript of Radiography, Liquid Penetrant,Magnetic,Hydro Peneumatic Test Procedures