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All plates need to be identified against mill test certificates at the Vendonr`s
works before commencement of fabrication.
Ensuring that welding procedure and welders are qualified and welding
electrodes are approved before commencement of fabrication.
Reviewing of radiographs
Checking material test certificates and ensuring that all shell plates are clearly
The API 618 standard requirements are normally applied for the inspection and
test plan in a manufacturing shop.
TThe witness of some inspection and testing by third party inspectors is
mandatory and cannot be waived.
Some others must only be monitored and full witnessing is not necessary; for
these items, the inspection man-days etc. depend on the purchasers decision.
Some prefer stringent monitoring and even assign a resident inspector in the
manufacturing shop, and others relay to the quality control system of the
manufacturer and assign only a few days for monitoring points.
These are some of the inspection points that need to be witnessed, checked
monitored and reviewed by a third party inspector for a reciprocating compressor
construction.
Inspection and Test Plan for Reciprocating Compressor - Important Points
Reciprocating Compressor casings to be identified against foundry test
certificates and thicknesses checked to conform to approved drawings.
Witnessing hydro-static test on reciprocating compressor cylinder, cooling
jackets, piping, pressure vessels, filters and coolers.
Checking assembly of piston end clearance, crankshaft deflection, run-out
check, proper match marking and protection of machined surfaces.
Witnessing mechanical running test
Witnessing strip down inspection and test
Final visual and dimensional inspection
The API 610 standard requirements are normally applied for the inspection and
test plan in a manufacturing shop.
The witness of some inspection and testing by third party inspectors is
mandatory and cannot be waived.
Some others must only be monitored and full witnessing is not necessary; for
these items, the inspection man-days etc. depend on the purchasers decision.
Some prefer stringent monitoring and even assign a resident inspector in the
manufacturing shop, and others relay to the quality control system of the
manufacturer and assign only a few days for monitoring points.
These are some of the inspection points that need to be witnessed, checked
monitored and reviewed by a third party inspector for a centrifugal pump
construction.
Inspection and Test Plan for Centrifugal Pump - Important Points
The inspection and test plan for fan and blower article provides you information
about fan and blower test and fan and blower inspection in manufacturing
shop.The draft Inspection and test plan for fan and blower provided as well.
Inspection and Test Plan
The API 673 standard requirements normally are applied for inspection and test plan in
manufacturing shop.
The witness of some inspection and test by third party inspector is mandatory and
cannot be waived.
Some others must only monitored and fully witnessing is not necessary, for these thing,
the inspection man-days etc. depends to the purchaser decision, some prefer stringent
monitoring and even assign resident inspector in manufacturing shop and some others
relay to quality control system of the manufacture and assign only few days for
monitoring points.
These are some of inspection points which need to be witnessed, checked, monitored
and reviewed by third party inspector in fan and blower manufacture shop.
Important Points
The inspection and test plan for pressure vessel article provides you information
about pressure vessel inspection and pressure vessel test in manufacturing
shop. The draft Inspection and test plan for pressure vessel provided as well.
Click here if you like immediately review the Inspection & Test Plan for Pressure
Vessel draft sheet.
You may need to review this article in conjunction of following articles:
Pressure Vessel Inspections
The ASME Code Section VIII Div. 1 or 2 requirements normally are applied for
inspection and test plan in pressure vessel manufacturing shop.
The witness of some inspection and test by third party inspector or authorized inspector
is mandatory and cannot be waived.
Some others can only monitored and fully witnessing are not necessary, for these items,
the inspection man-days etc. depends to the purchaser decision, some prefer stringent
monitoring and even assign resident inspector in pressure vessel manufacturing shop
and some others relay to quality control system of the pressure vessel manufacture and
assign only few days for monitoring points.
These are some of inspection points which need to be witnessed, checked monitored
and reviewed by third party or ASME authorized inspector.
Checking that all material test certificates and, where applicable, heat
treatment charts are in order
Checking trays of each diameter and type, mock assembled in the shop.
(for process towers)
Ensuring that any uncommon down comers are fully assembled and
offered along with their respective trays. (for process towers)
The witness of some inspection and test by third party inspector is mandatory and
cannot be waived.
stamped with the cast and plate number, so that they can be identified against
the relevant test certificates.
Reviewing of radiographs.
The ASME Code Section 8 is the construction code for pressure vessel and
covers design, manufacturing and pressure vessel inspection and testing in the
manufacturing shop.
This Code section addresses the mandatory requirements, specific prohibitions,
and non-mandatory guidance for Pressure Vessel Materials, design, fabrication,
examination, inspection, testing, certification, and pressure relief.
In this article you will learn about the different subsections and guidelines for the
use and application of this code.
For ASME Code Section 8 scope and boundaries, review the Pressure Vessel
Definition article.
You may know ASME Code Section 8 has three divisions. Division 1 covers
pressure up to 3000 psi, Division 2 has an alternative rule and covers up to
10,000 psi and Division 3 can be used for pressure higher than 10,000 psi.
Hierarchy of Standard
1. Law and Regulation at Location of Installation
Mandatory application of ASME pressure vessel code is determined by rule and
regulation at location of installation.
For example, if you are living in the state of Minnesota, the application of ASME
Code for construction and stamping is mandatory in your location, but if you are
living in the state of South Carolina, it is not mandatory.
2. ASME Boiler and Pressure Vessel Code
The next item in this hierarchy is ASME Code itself; the ASME Code generally is
divided into three groups as following:
Group 1: Construction Codes
Some of them are: Section VIII for pressure vessel, Section I for Power Boiler,
section III for Nuclear Power Plant and Section IV for heating Boiler
Group 2: Reference Codes
These are the codes which are referenced from construction codes as explained
in group 1.
The ASME Section IX for welding and Section V for Non Destructive Testing are
in this Group.
For example, ASME Code section VIII for welding requirement such as WPS
(Welding Procedure Specification), PQR (Procedure Qualification Record),
Welder Performance Qualification, etc. refer you to ASME Section IX.
Group 3: In-Service Codes
These are the codes for in-service inspection after placing the equipment into
service.
The ASME Section VI for the heating boiler and Section VII are from this group.
It consists of Parts UCS, UNF, UHA, UCI, UCL, UCD, UHT, ULW, and ULT
dealing with carbon and low alloy steels, nonferrous metals, high alloy steels,
cast iron, clad and lined material, cast ductile iron, ferritic steels with properties
enhanced by heat treatment, layered construction, and low temperature
materials, respectively.
For example, if you need to manufacture a pressure vessel with SA 516 Gr.70
material (Carbon Steel), then you need to meet the marked items in above Fig.
Please note that ASME Code Section 8, does not provide you fabrication
tolerances except for misalignment and weld reinforcement.
For example, for nozzle orientation, projection, elevation and other required
tolerances there are no values in the code, and you may refer to pressure vessel
handbooks for such information.
Review the Pressure Vessel Dimension Inspection article for such tolerances.
If you review the ASME Forward statement it clearly says The Code does not
address all aspects of construction activities, and those aspects which are not
specifically addressed should not be considered prohibited.
In continuing it says, The Code is not a handbook and cannot replace education,
experience, and the use of engineering judgments.
For example, ASME Code Section 8 Div 1 in UG-28 mandates all loading to be
considered in pressure vessel design, but the method for calculation of all of
them has not been addressed.
For example, the formula for wind or earthquakes is not provided in the ASME
Code Section 8, and these items and other similar loading considerations need to
be designed by using the information provided in the pressure vessel handbooks.
For ASME pressure vessel manufacture certification, as well as Authorized
Inspection Agency certification, Review the Pressure Vessel Certificationarticle.
What is the Summary of Important Points in ASME Code Section 8 ?
1. ASME Code Section 8 edition is issued once every 3 years and addenda, once
a year both on July 1st. Edition and addenda become effective on the 1st of
January of next year (i.e., 6 months after issue).
2. Thickness of cylindrical shell t = PR/(SE-0.6P) + C
3. Longitudinal weld is more critical because it is subjected to double the stress
than Circ. Weld.
4. Weld joint categories A, B, C, D are based on joint locations in the vessel
and stress levels encountered. Weld Types (type 1, 2, 3, etc.) describe the weld
itself.
5. Depths of 2:1 Ellip. and hemisph. heads are D/4 and D/2 respectively. (D=
Head diameter.)
6. Weld Joint categories:
Category A:
- All longitudinal welds in shell and nozzles.
- All welds in heads, Hemisph-head to shell weld joint
Category B:
- All circumferential welds in shell and nozzles
- Head to shell joint (other than Hemisph.)
Category C and D are flange welds and nozzle attachment welds respectively.
7. Weld Types:
Type 1: Full penetration welds (Typically Double welded)
Type 2: Welds with backing strip
Type 3: Single welded partial penetration welds
Type 4, 5 and 6: Various Lap welds (rarely used)
24. ASME materials (SA) shall be used for code stamped vessel fabrication
instead of ASTM (A) materials.
25. Reinforcement pad is not required, if the size of finished opening is (UG 36)
Not exceeding 2-3/8 for all thicknesses of vessel
Not exceeding 3-, if vessel thickness is 3/8
26. Reinforcement pad with OD = 2d and thk = vessel thk is always safe (d =
diameter of finished opening)
27. Reinforcement limit along vessel wall = 2d
28. Reinforcement limit normal to vessel wall = smaller of 2.5 t or 2.5 tn
29. In reinforcement pad calculations, credit can be taken for area available in
shell and nozzle.
30. Fillet weld throat dimension = 0.707 x leg of weld
31. Adequacy of weld sizes shall be checked as required by UW-16. The nozzles
construction shall be one of the Code acceptable types.
32. The maximum permitted ovality tolerance (D max D min) shall not exceed
1% of nominal diameter of vessel. If there is opening, then the tolerance can be
increased by 2% x d (d = diameter of opening) if measurement is taken within a
distance of d from axis of opening.
33. The mismatch tolerances and the maximum allowable weld reinforcement is
more strict on longitudinal welds compared to circumferential welds (UW-35).
34. Principle of reinforcement:
Area removed = Area compensated.
Compensation area shall be within reinforcement limits.
35. For use as pressure parts, the plates shall be fully identified. Maximum
permitted under tolerance on plates is 0.01 (0.3 mm) or 6% of ordered
thickness, whichever is less.
36. All welding (including tack, seal, etc.) shall be done using qualified
procedures and welders.
37. Mandatory full radiography in ASME Code Section 8 is required for all
welding with thickness exceeding Table UCS-57, and also for lethal service
vessels and unfired boilers with Design Pr. More than 50 psig.
38. PWHT is ASME Code Section 8 requirement if thickness exceeds those
given in tables UCS-56 (given in notes under the tables). These tables also give
min. PWHT temperature and min. holding time (soaking period) based on P-Nos.
and thickness respectively.
39. For Furnace PWHT in ASME Code Section 8 , Loading Temperature shall not
exceed 800F, heating rate 400 deg F/hr/inch of thickness, cooling rate 500F
/hr/inch of thickness. Still air cooling permitted below 800F. During soaking
period, temp difference between hottest and coldest part shall not exceed 150F.
40. Minimum overlap for PWHT in multiple heats = 5 ft.
41. For the ASME Code Section 8 impact test requirement, UCS 66 curve. If
MDMT-thickness combination falls on or above the curve, impact testing is
exempted. Additional exemptions are given as per UG-20(f) and UCS=68 (c).
Category A:
Category B:
Category C and D are flange welds and nozzle attachment welds respectively
Longitudinal weld (Category A) is more critical because it is subjected to double
the stress than Circ. Weld (Category B) and this the reason in different part of the
ASME code, we have stringent rules in category A joints compared to category B
joints.
Pressure Vessel RT Test -When We Need to Do a Full Radiography Test?
When one of following conditions is existing, you need to do the full radiography:
1. All butt welds in vessels used to contain a lethal substance
2. All butt welds in vessels in which the nominal thickness exceeds specified
values
3. All butt welds in unfired steam boilers with design pressure > 50 psi
4. All category A and D butt welds in a vessel when Full Radiography is
optionally selected
As you see, the item numbers 1, 2 and 3 are really mandatory for a full RT test;
But pressure vessel manufacturers can make an optional decision for full
radiography in item number 4
Pressure Vessel RT Test - Why do pressure vessel manufacturers want to spent
more money for full radiography in item # 4?
Because the joint efficiency in the full radiography condition is 1, the higher joint
efficiency in the pressure vessel wall thickness formula causes less wall
thickness. The manufacturer might save lots of money with a lower thickness
plate material.
But code has given some bonus to manufacturers in item 4, because it is not
mandated to do full radiography in all butt welds. Manufacturers can do spot
radiography in B and C joints with the same joint efficiency of item 1.
Item number 2 describes thickness limitations. Any pressure vessel material is
designated to the specific P. Number by ASME section IX, so there are several
tables in ASME Code Section VIII Div. 1 Subsection C, which determine this
limitation.
For example, SA 516 material is P Number 1, and needs to be fully radiographed
if its thickness is greater than 1.25 of an inch. At the same time, SA 204 material
is P Number 3 and needs to be fully radiographed if the thickness is greater than
0.75 of an inch.
Pressure Vessel RT Test - Is Acceptance Criteria in Full Radiography or in
Spot Radiography More Stringent?
Acceptance criteria for welding defects in full radiography is stringent. These
criteria are stated in UW-51 and UW-52 in ASME Code Section VIII Div. 1
It means there is a defect if interpreted based on the full radiography criteria in
UW-51, and it might be rejected, but if it is interpreted by the spot radiography
criteria in UW-52, it might be accepted.
Pressure Vessel RT Test - What is the Important Spot Radiography
Requirement?
One spot shall be examined on each vessel for each 50 ft. increment
The location of the spot shall be chosen by the Inspector after the
completion of the increment of welding to be examined