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Destructive test ERECTION

Tests capable of being performed in the Single crane,Multiple crane,Gin


workshop.Laboratory tests.microscopic- poles,Jacking towers
macroscopic , chemical and corrosive. Step in DESIGN
Reason P1 Select the type of lifting attachment as an initial starting point

Defects occur during welding which affect the


STE
Determine the force T and P for all angles of erection.
P2

quality and hardness of the plate.Other defects


STE
P3 Design/check the lifting attachments for the tailing force, T, and pick force, P.

occur through lack of knowledge of and skill of the


STE
P4 Design/check the base ring assembly for stresses due to tailing force, T.

welder.For the training of welders.


STE
Determine the base ring stifening confguration, if required and design struts.
P5

Workshop test
STE
any overhang.
Check shell stress due to bending during lift. This would include midspan as well as P 6

TENSILE,BENDING,
STE
Analyze local load in vessel shell and skirt due to load from attachments. P7

IMPACT,HARDNESS,FATIGUE,CRACKING.
STE

TENSILE
-Material is sectioned and edges rounded of to LIFT END (PICK END) LIFTING
prevent cracking.Punch marks are made to see ATTACHMENT
elongation. -Head Lug
BEND TESTING Usually the simplest and most economical and
-Shows Physical condition of the weld,Determine produce at least stress.
welds efficiency, Tensile strength,Ductility,Fusion -Cone lug
and penetration. Similar to head lug but located at a conical
HARDNESS TESTS transition section of the vessel.
-This gives the metals ability to show resistance to -Top Flange Lug
indentation which show its resistance to wear and The choice for high pressure vessels where the
abrasion.The tests are,Brinell,Rockwell,Vickers top center flange and head are very rigid.
diamond pyramid,Scleroscope. -Side Flange Lug
Rarely used because it requires a very heavy
nozzle and shell reinforcement.
-Trunnions
Simple and economical. Used on a wide variety
of vessel.

Advantages to using a tailing choker:


-Save material, design, detailing and
fabrication.
-Simplifes concern with lug and shipping
WPS
orientations.
-A WPS is a document that describes how welding -May reduce overall height during
is to be carried out in production. Its purpose is to transportation.
aid the planning and quality control of the welding
operation.They are recommended for all welding Situation that could make the use of
operations and most application codes and tailing choke impractical, costly and
standards make them mandatory. possibly unsafe:
PQR The column is more than about 10ft in diameter.
-A PQR is required when it is necessary to The larger the diameter, the more difficult it is
demonstrate that your company has the ability to for the wire rope to cinch down and form a good
produce welds possessing the correct mechanical choke on the column.
and metallurgical properties. The tail load is so great that it requires the use
WPQR/PQR TESTING of sling greater than about 1 in diameter.
-Bend Test, Hardness Test, Transverse, Tensile The larger the diameter of the rope, the less
Test, All Weld Metal Tensile Test,Charpy Impact flexible it is and the more likely that it could slip
Test,Weld Metal Chemical Analysis, Macroetch up unexpectedly during erection.
Test, Torque Test.
Tail End lifting
-Tail beam
-Tail lug
Assure safe fabrication: COMMON NDT METHOD:
-The pressure vessel should be fabricated in -Visual,Liquid
accordance with:1. The design calculations and
penetrate,Magnetic,Ultrasonic,Eddy
drawings.2.The method of construction as required
by the approved code. current,x-ray
Where welding is involved:The WPS in the code Characteristic:
should be strictly followed.Ensure that the welders -Applied directly to product
are competent to carry out the type of welding -Tested part are not damaged
required by the design code. -Low time consumption.
Fabrication Applied Codes: -Low labour cost.
-ASME . -Specimen preparation not required.
Sec VIII Div. I, II, III,Sec III,Sec I.
OBJECTIVE OF NDT:
-TEMA (Tube Exchanger Manufacturer Association)
-IBR (Indian Boiler Regulations) -To make proft for the user.
-PD (BS 5500) British Standard -To aid in better product design
-AD Merkblatt German Standard -To control manufacturing processes.
Fabrication Procedures: -To lower manufacturing cost.
Study and Work Preparation, Raw Materials -To maintain uniform quality level.
Identification, Marking Off, Cutting Off, Forming, X-RAY RADIOGRAPHY:
Fitting Up, Full Welding ,Checking, Testing. -image developed on photographic
Study and Work Preparation: flm,high resolution and
-Working Drawing
contrast,expensive,time consumption is
-Fabrication Planning
-Materials Optimization
high.
-Costing & Procurement X-RAY FLUOROSCOPY:
-Applied Processes, Machines and Tools -Image is developed on flurescent screen.
-Manpower -Fair resolution & low contrast.
-Joining Processes -Inexpensive
Raw Materials Identification: -Time consumption is loW.
-Material Quality, Thickness & Size According to EDDY CURRENT APP:
the drawing -Range from crack detection to rapid
-Verify Heat No, Plate No
sorting of small components for either
-Verify NDT (UT) Requirements
-Look for Pitting, Surface damage/defects on both
flaws,size variations.
-sides. -Commonly used in
Formula of MD: aerospace,automotive&manufacturing
MD = OD T or ID + T industry.
FORMING
-Pre-bending,Pre-rolling
FITTING UP
-Prepare Jigs, Gaps and Mating Positions: Dish
head to shell, Nozzle to shell, Nozzle Orientation
Full Welding
-Welding ProcessesEg: SAW, GMAW, FCAW
-Welding Parameters
-Welders
-Weld beads appearance
Checking/Inspecting
-Dimensional checking,Shell profile, ovality and
circumference
-Circularity
-Alignment Check
-Axis
-Surface
Testing
-NDT (Non-Destructive Test)
-DPI, MPT, UT, X-RAY, etc

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