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The Pressure Vessel Plate article provides you information about the
ASME Code requirement regarding plate material and related points in
the pressure vessel inspection.
You need to take care about your Pressure Vessel Plate Materials, there
are lots of requirements and specific prohibitions in the ASME code.
Some of these requirements are ASME and Non ASME plate materials,
plate specifications, inspection requirements and material test reports.
This article describes these requirements for you.
ASME Code Sec VIII DIV 1 requires the materials that are used for
pressure containing parts to be one of:
For example, SA 283 plate material is listed in ASME Sec II, but when
you refer to subsection C in Sec VIII Div 1, you see it is not allowed to
be used for lethal substance services as well as for unfired steam
boilers. Also, you cannot use this material when you need your thickness
to be greater than 5/8 inch.
When you refer to ASME Section II Part A, you see all material with SA
prefix identification and on one side there is an ASTM logo, and on the
other side is ASME logo.
This means you can use A 516 Edition 1990 instead SA 516 2004.
Example:
Then check the plate material mechanical test result for yield stress,
tensile strength and elongation and confirm all are in specific range of
SA 516 Gr.60.
The manufacturer purchases the P265GH plate material and changes the
marking on the plate and also rectifies the material test report with SA
516 Gr.60 material. This material identification will be SA 516 Gr.60
In some other cases, this might not be possible even by extra testing for
example if the tensile strength is less than the ASME permitted material.
UG-93 in ASME Code Sec VIII Div 1 specifies requirements for plate
material inspection.
It means this requirement only can be applied for plate material; for
other material such as pipe and flange, MTR's are not required and
marking on the materials would be acceptable.
You need to inspect the plate material per specification of ASME Sec II
Part A. For example, for SA 516 Gr.60 refer to this specification and
check the chemical composition, mechanical property with your MTR.
You need to check that the Heat Number stated in MTR is the same
stenciled on the plate material marking and make sure this MTR belongs
to this material.
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.
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
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:
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
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.
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.
We have assigned a separate article for the NBIC, but as required for
this article, the NBIC is making certification for ASME Authorized
Inspectors and is also certifying R stamp for Repair services for stamped
pressure vessels.
It consists of Parts UW, UF, and UB dealing with welded, forged, and
brazed methods, respectively.
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.
Please note that ASME Code Section 8, does not provide you fabrication
tolerances except for misalignment and weld reinforcement.
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.”
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.
5. Depths of 2:1 Ellip. and hemisph. heads are D/4 and D/2 respectively.
(D= Head diameter.)
Category A:
7. Weld Types:
RT-2: (E=1.0) All Cat. A Butt welds Full length, Cat B, spot
10. For Welded Heads for E=1, all welds within the head require full
length radiography (since they are all Cat. A welds)
13. MAWP is calculated for: Working condition (Hot & Corroded). Vessel
MAWP is always taken at the Top of the Vessel and is lowest of all part
MAWPs adjusted for static pressure.
16. Pressure gauge range should be about twice the test pressure.
However, in any case it shall not be lower than 1.5 times and not higher
than 4 times the test pressure.
18. For vertical vessels, hydrostatic pressure caused due to liquid with
specific gravity = 1, 1ft of height = 0.43 psig. Or 1 mtr of height = 0.1
Bar
20. If part MAWP and elevations are known, Vessel MAWP can be
calculated by the deducting hydrostatic head from part MAWP.
22. For values of A falling to the left of material line in the material
chart:
Pa = 2AE/(3(Do/t))
23. Name plate shows The Code stamping, MAWP, design temp., MDMT,
and Extent of Radiography.
24. ASME materials (SA) shall be used for code stamped vessel
fabrication instead of ASTM (A) materials.
26. Reinforcement pad with OD = 2d and thk = vessel thk is always safe
(d = diameter of finished opening)
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.
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.
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).
PRESSURE VESSEL DEFINITION
The Pressure Vessel Definition article provides you the definition and
boundaries of pressure vessel based API code and ASME Code.
Based on the ASME Code Section VIII, pressure vessels are containers
for the containment of pressure, either internal or external.
The ASME Code is a construction code for pressure vessels and contains
mandatory requirements, specific prohibitions and non-mandatory
guidance for pressure vessel materials, design, fabrication, examination,
inspection, testing, and certification.
Also for gas fired double shell heat exchangers < 50 psi
Boundaries
Contrary of ASME Code Sec VIII, which was developed for construction,
the API STD 510 covers the in-service inspection, repair, alteration, and
rerating activities for pressure vessels.
This inspection code applies to all refining and chemical process vessels
that have been placed in service.
The Pressure Vessel Heads article provides you with information about
different types of ASME heads and related points in pressure vessel
inspection.
How many standard Pressure Vessel Heads are in the ASME Code? What
are their characteristics?
For example if you have calculated your shell thickness under internal
pressure and obtained 12 mm, your ellipsoidal head thickness also will
be approximately 12 mm.
The inside depth of your ellipsoidal head (h in above fig.) will be one-
fourth of the head inside diameter (h = D/4).
Your ellipsoidal head knuckle radius is 0.17D and the spherical radius is
0.9D.
In the same design conditions within the same design pressure, design
temperature and material, your calculated wall thickness under internal
pressure will be approximately equal to 1.77 times the shell thickness.
For example, if you have calculated your shell thickness under internal
pressure and obtained 12 mm, your torispherical head thickness will be
approximately 21.24mm.
With the same same design conditions with the same design pressure,
design temperature and material, your calculated wall thickness under
internal pressure will be approximately half of the shell thickness.
For example, if you have calculated your shell thickness under internal
pressure and obtained 12 mm, your hemispherical head thickness also
will be approximately 6 mm.
If your dished head is welded and the joint efficiency is 1, then all of
your head welds need full length radiography.
If your dished head is seamless and your joint efficiency is 1, your head
to shell needs full radiography and spot radiography for your ellipsoidal
or torispherical heads.
PRESSURE VESSEL HANDBOOK
When there is ASME Code Section VIII, why we need Handbook? What
are the applications?
All design formulas and calculations methods have not been addressed
in ASME Code and also there are no fabrication tolerances in ASME Code.
You may review ASME Code Section VIII Div. 1 in U2 (g) clauses, you
will see following statement:
“This Division of Section VIII does not contain rules to cover all details of
design and construction. Where complete details are not given, it is
intended that the Manufacturer, subject to the acceptance of the
Inspector, shall provide details of design and construction which will be
as safe as those provided by the rules of this Division.”
Here is the place manufactures use handbook for design formulas and
calculations.
etc.
You may review ASME Code Forward, you will see following statement:
“The Code does not fully address tolerances. When dimensions, sizes, or
other parameters are not specified with tolerances, the values of these
parameters are considered nominal and allowable tolerances or local
variances may be considered acceptable when based on engineering
judgment and standard practices as determined by the designer.”
etc.
So the code book is like law book, we need take care about specific
prohibitions and mandatory requirement but for design we need
handbook to facilitate our design process.
This article either provides you the answers of your questions or refers
you to the specific sources.
In the same design condition with the same design pressure, design
temperature and material, the thickness you obtain from the internal
pressure formula for spherical pressure vessel will be half that of the
cylindrical pressure vessel.
The design formula for the cylindrical shell is t = PR/ (SE-0.6P) and for
the spherical shell is t = PR/ (2SE-0.2P)
When the “t” is represent Thickness, “R” the Inside Radius,” S “the
Allowable Stress, “P” the Design Pressure and “E” the Joint Efficiency;
For example, if your design pressure is 250 psi, inside radius 20 inch. ,
allowable stress 20,000 psi and joint efficiency 1.
Your thickness for cylindrical shell will be 0.24 inch. or 6.10 mm, and for
the spherical shell, it will be 0.125 inch. or 3.175 mm.
When you need to make storage for a great amount of pressurized liquid
or gas, meaning you need a big volume, then you need a big pressure
vessel, so a spherical shell pressure vessel would be more economical.
As you see above, the thickness is half that for a similar design
condition. Also placing a long cylindrical pressure vessel might not be
suitable in regards to the regarding plant layout.
Cylindrical shell pressure vessels generally are built in the shop and then
transferred to the plant field except for long process towers, which might
be built in two pieces and completed in the field by one circumferential
weld.
But spherical shell pressure vessels are assembled in the field. The
plates generally are formed in the rolling shop and then carefully
transferred to the field for assembly.
But PWHT for spherical shell pressure vessels are done by one or more
high velocity burners that are fired into the vessel using the top or
bottom manways (or both) as burner entry and exhaust positions.
Most of the LNG (Liquid Natural Gas) and LPG (Liquid Petroleum Gas)
tanks are Spherical Vessels.
RL = (Tc-Tmin)/CR ;
API STD 510 allows the On-Stream inspection to be replaced with the
internal inspection with some conditions.
This is the definition of On-Stream Inspection per the API 510 Standard:
But only you may replace this technique if all of following conditions are
met with your vessel:
The general corrosion rate is less than 0.005 inch. per year, remaining
life is greater than 10 years, there is no corrosive character in the
contents, no questionable condition is observed in the External
inspection and the vessel is not subject to SCC cracking.
There are three sources for repair of a spherical pressure vessel; API
STD 510 has provided some repair requirements and instructions.
Based the API 510, only repair organizations are allowed to do repairs,
and the definition and condition for being a repair organization has been
provided in the API 510.
The other source is the NBIC Part 3 Code book, which similarly provides
requirements and instructions.
The ASME Pressure Vessel Joint Efficiencies article provides you with
information about pressure vessel joint efficiency requirements and their
connection with radiography testing.
You may know Pressure Vessel Joint Efficiencies are linked to the
radiography testing grades and there is a concession for full radiography
testing as per the UW-11(a) (5) (b) clause which it is a little bit
confusing.
This article provides you the ASME pressure vessel joint efficiencies
requirements and guidelines for the above clause.
They say both RT1 and RT2 are categorized in the “Full Radiography”
part in UW-11 clause ...
Category A:
Category B:
This the reason why in different part of ASME code we have stringent
rules in category A joint compared to category B joint.
Now let's get back to the ASME Pressure Vessel Joint Efficiencies subject,
to remove the above confusion about RT1 and RT2.
We need to know:
Item 2: All butt welds in vessels in which the nominal thickness exceeds
specified values (UW-11(a). You can find these values in subsection C, in
UCS-57, UNF-57, etc. For example, this value for P-No.1 in UCS-57 is 1
¼ inch.
Item 3: All butt welds in an unfired steam boiler with design pressure >
50 psi (UW-11(a)).
Item 4: All category A and D butt welds in vessel when “Full
Radiography” optionally selected from table UW-12(column (a) in this
table is selected); and categories B and C which intersect Category A
shall meet the spot radiography requirement (UW-11(a) (5) (b)).
The point is this: items 1, 2 and 3 are similar, but item 4 is completely
different. In items 1, 2 and 3 it is mandated by code; to do full
radiography in all butt welds in vessel so it means it is mandatory for
designer to select column (a) in UW-12 table.
If you review item 1, 2 and 3 one more time, you will see that the
pressure vessel RT tests are related to the type of welds and services.
You can see the pressure vessels in these items are critical from a safety
point of view, one contains a lethal substance, the other one has a high
thickness, which implicates high pressure, and the last one is an unfired
steam boiler. But item 4 has no criticality like the other items have.
But you should note all 4 items have been categorized in full radiography
clause( U-11(a)), so to differentiate item 1, 2 and 3 from item 4, the RT
symbols are used in Code (UG-116).
Do you know why? Why ASME considered the stringent rule for pressure
vessel RT test in hemispherical head joint?
For more detail, you may review the Pressure Vessel Heads article.
For Welded Heads, the joint efficiency of the vessel will be 1(E=1), if all
welds within the head's full length are radiographed (since they are all
Cat. A welds). See above figure.
For seamless heads, the joint efficiency of the vessel will be 1(E=1) if
the head to shell weld is fully radiographed for the hemispherical Head
(Cat A);
Weld Types:
Here is some clarification about the different type of welds that have
specific definitions in ASME Code SEC VIII DIV 1 and related to the
pressure vessel RT test.
The concept is to define the different types and then introduce some
restriction for using them.
You may know some fabrication tolerances have not been addressed in
ASME Code Section VIII.
So you need to refer to other sources for inspection. This article provides
you the most important dimensional inspection requirements.
Weld mismatch
Weld reinforcement
For example, if you have SA 516 Gr.70 plate with a 0.625 inch nominal
thickness, and the actual thickness is 0.615, it is acceptable, and you
may use this plate without any specific design consideration.
But if the same plate has an actual thickness of 0.595 inches, you need
to consider mill undertolarence in your design calculation.
Contrary to the plate material, your pipe and tube mill undertolrances
need to be taken into account for design consideration.
Pipe and tube undertolrances are almost -12.5 % of the nominal wall
thickness, but sometimes there are differences for different materials, so
for any specific material, it shall be referred to the suggested pipe or
tube material specification to obtain the exact amount of mill
undertolrances.
Assume that external loading is not a design controlling factor (is not
governor), so as our minimum, nozzle thickness will be the same as the
shell thickness.
You may know that there is a specific rule for dimensional checking of
formed heads, based the fact that the UG-81 inner surface shall not
deviate outside of the specified shape more than 11⁄4% of D and inside
the shape more than 5⁄8%.
You can use sweep boards, which are made by cutting a thin steel sheet
or piece of wood for checking your crown and knuckle radius.
For your skirt, the difference between the maximum and minimum inside
diameter, should not be more than 1%, and you can use a tape measure
or laser measure for dimensional control of the skirt.
Head ID = 3364 mm
So we check the depth, and the drawing is 656.3 mm and the actual is
672 mm, so it is outside of the shape. We need to check if it is in the
range of tolerance, so the maximum outside of the shape will be 42.05
+ 656.3 = 698.35 so our actual value is 672 mm. 672<698.35, so it
is OK.
We cut a sweep board equal to the head drawing crown radius (3400
mm) and other one for the knuckle radius equal to 204 mm, so we try to
fit the sweep boards in the heads for the above example of the sweep
boards. The edge distance to the head surface should not be deviate
from the above limited values.
Skirt max and min ID should not be more than 1% of the ID, which is
33.64 mm. So, in the above example skirt is also is OK. Our nominal
thickness is 20 mm, so up to 19.746 is acceptable then for the above
example. The thickness dimension is also OK.
ASME Code SEC VIII Div 1 has not specified the orientation tolerances
for nozzles and attachments, so you need refer to the pressure vessel
handbook.
Vessel OD = 97.875”
Nozzle and attachment projection is the length from the nozzle or the
attachment face to the vessel shell centerline.
You need to move one end of the level gage up to the bubble to be
placed in middle. Then measure the distance between the level gage end
and the flange face. The measured value is the X in the figure.
Then obtain α, if α is less than 0.5˚, the deflection falls within the
tolerances. And it is OK otherwise it will require cutting out and re-
welding.
ASME Code SEC VIII Div. 1 specified tolerances for weld mismatch in
UW-33. It is important to know that the limit for weld mismatch is
stringent for a category A weld (Longitudinal joint and circumferential
shell to hemispherical head).
The concept behind this is that the longitudinal joint bears double the
amount of stress, and inspectors should precisely check these joints.
For example, you have a pressure vessel with a nominal thickness of 1
inch. You do a visual and measure the mismatch by the welding gauge.
Assume you found a 0.143 inch mismatch in one longitudinal and one
circumferential joint.
The permissible weld mismatch in the longitudinal joint for your case is
0.125 of an inch, and for the circumferential joint, it is 0.1875 of an
inch.
The same concept for weld mismatch exists for weld reinforcement
tolerances. The longitudinal joint weld reinforcement limit is more
stringent than that for circumferential joints.
Let's say, you have a pressure vessel under design, process and
construction has not started yet.
There are 4 steps for impact test exemption assessment. You need to
know these steps. You might be exempted in the first, second or third
steps and might not be exempted even in step 4.
So if you are in step 4 and you have not exempted, then you need to
carry out the test. I will explain the process for exemption in this article.
Basic Concept:
You may know carbon steels and low alloy steels exhibit a drastic change
in their room temperature ductility at sub-zero service temperatures.
Different types of materials exhibit different types of transition behavior.
ASME Code Section VIII Div 1 exemption rules for ASME Impact
Test Requirement:
There are specific rules in ASME Code for exemption from ASME Impact
Test Requirement. This test is very expensive, so pressure vessel
manufacturers are trying to be exempted for this costly test.
First you have to keep your pressure vessel design data available and
then refer to UG-20 (f). If you are exempted from this clause, you do
not need proceed further.
But if you are not exempted by UG-20 (f), you have to proceed to UCS-
66(a), but again if you are exempted, there is no need for more
assessment.
But if not, you have to proceed to UCS-66(b). If you are exempted now,
there is no need for more assessment; otherwise, you have to proceed
to UCS-68(c), and again if you are still not exempted, you have to carry
out impact testing.
For some cases, You might be exempted from the ASME impact test
requirement in the first stage in UG-20 (f). In others, You might be
exempted in UCS-66(a) or UCS-66(b) or UCS-68(c). If you are not
exempted, you must prepare yourself for doing this costly test.
UG-20(f)
We will start with UG-20(f) for the ASME impact test requirement. If
your MOC (Material of Construction) is categorized in P-No. 1 or 2 (Refer
to ASME Code Section IX for P-No Definition) and your MOC thickness
has the limited value defined in this clause, then you might be exempted
from impact testing.
But you need to refer to Fig UCS-66 in ASME Code Section VIII Div 1
and see in which A, B, C or D curves your MOC is listed. All ASME carbon
steel and low alloy steel material is distributed in these 4 groups
(Curves) of materials.
You need to know that the materials listed in curve D have the best
toughness property, better than the materials listed in curve C. Similarly
materials listed in curve C have better toughness properties compared to
materials listed in curve B and materials listed in Curve B have better
toughness than materials listed in Curve A .
When you determine your MOC curve, then you have to review UG-20(f)
and look for the possibility of exemption from the ASME impact test
requirement. There are some other conditions in this clause, which you
should consider for exemption.
For example, if your MOC is a normalized SA 516 Gr.70 with 0.75 inch
thickness you will be exempted from ASME impact test requirement.
UCS-66(a)
So assume that in the above example, your MOC thickness is 1.125 inch
instead of 1 inch, you will not be exempted by UG-20(f) and you have to
refer to UCS-66(a);
But for assessment, based on this clause, you need to know your
pressure vessel MDMT (Minimum Design Metal Temperature). Assume
that is -20 degree F, so you should now go to Fig. UCS-66 and locate
1.125 inch in the horizontal axis and draw a vertical line.
In a similar way, locate -20 degree F in the vertical axes and draw a
horizontal line. These two lines will cross each other.
If the cross point falls above the curve D (because your MOC is listed in
curve D) you are exempted. Otherwise you are not, but for the current
example, you are above the curve D so you are exempted from impact
testing.
To simplify your assessment for the ASME impact test requirement, the
Fig-66 has been converted to the table(table UCS-66). For any MOC with
specific thickness you can go to this table and see what is the minimum
permissible temperature without impact testing.
UCS-66(b)
Let us explain this clause with the above example. Your MDMT from
above is -27 degree F, nominal thickness is 1.125 inch, normalized SA
516 Gr.70 listed in curve D and you are not exempted by UCS-66(a)
In the above example, your MDMT is -27 degree F, and in the UCS 66
table, the minimum permissible temperature without impact testing
designated -26 degree F. So with this clause you can reduce it to -36
degree F(-26 -8 = -34). Your MDMT is -27 degree F, so you are
exempted from impact testing with this clause.
UCS-68(c)
Let us change one variable in the above example. Let's assume you need
to have -45 degree F for your MDMT. Other variable are the same; it
means normalized SA 516 Gr.70 listed in curve D, thickness 1.125, so
you can see you are not exempted by UCS-66(b);
It says that if post weld heat treatment is not a code requirement and
your P-No is 1 and you carry out post weld heat treatment, a 30 degree
F bonus will be granted to you to reduce the minimum permissible
temperature in table UCS-66.
So, for our example, our service is not lethal and our P-No. is 1 and
thickness is 1.125 and it is less than 1.5 inch: therefore, post weld heat
treatment is not code requirement.
It means if you carry out post heat treatment, a 30 degree F bonus will
be granted by this clause. For this example our minimum permissible
temperature would be -36-30=-66 degree F, and your MDMT is -45
degree F, so you are exempted from impact testing.
Now the worst case: in the above, assume you need to have -70 degree
F for your MDMT; you can see with this new condition you cannot be
exempted even by UCS-68(c) and you have to carry out impact testing.
PRESSURE VESSEL RT TEST
The Pressure Vessel RT Test article provides you with information about
Radiography testing in the pressure vessel manufacturing process and
related items in pressure vessel inspection.
Do you know what your pressure vessel RT test requirements are? Is full
radiography mandatory for your vessel? When is full radiography
mandatory? What are the acceptance criteria? What are the RT symbols?
Before going into the RT test, we need to know about joint categories.
These categories are base on ASME Code Section VIII:
Category A:
Category B:
Category C and D are flange welds and nozzle attachment welds respectively
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
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.
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?
The location of the spot shall be chosen by the Inspector after the
completion of the increment of welding to be examined
ASME Code Section VIII Div 1 mandates that all tests shall be done based on
ASME Code Section V, article number 2.
VESSEL PRESSURE TESTING
The Vessel Pressure Testing article provides you with information about
pressure vessel hydro-static testing requirements and related item in
pressure vessel inspection.
This content covers all major requirements and provides you with
guidelines for test performance.
Please note that performing the pneumatic test instead of the Hydro-
Static Test is not allowed, and it can be replaced only when it is not
possible due to the design and process.
These are important points, which you need to take care of in vessel
pressure testing:
1. Checking all welding already finished and fully accepted by the NDT
examination per the project Inspection and test plan.
2. Making sure the inner part of the vessel is clean and free of remaining
slag or other elements.
making sure the external surface is dry for the correct execution of the
visual inspection during the vessel pressure testing.
3. Checking the pressure gauges' calibration tag and certificate and the
range of the lower limit and upper limit of the gauges. It needs to be
between 1.5 and 4 of the pressure test value.
4. Controlling testing equipment such as the test pump and housing for
soundness and tightness.
5. Making sure the test temperature will not violate the following values:
1. Making sure the filling and pressurizing are done from the lowest
point and venting from the highest point.
6. Making sure the vessel is immediately and carefully drained after the
test and dried by air.
2. If the test failed by leaking from weld joints or any other kind of
defect, it is necessary that the vessel is drained and dried and repaired
based on approved repair procedure. pressure vessel hydro-static
testing needs to be repeated.
THIRD PARTY INSPECTION FOR PRESSURE VESSEL
The Third Party Inspection for Pressure Vessel article provides you with
information about pressure vessel inspection and pressure vessel testing
in the manufacturing shop.
You may need to review this article in conjunction with the following
articles:
This content guides you through all the necessary stages in the production of the
pressure vessels, including the raw material, final inspection, preservation and
packing, and dispatch to site.
You need to take this point into account: this article is written for a typical pressure
vessel and might not be detailed for special cases.
This content may be useful for second party inspectors, pressure vessel
manufacturer quality control personnel, engineering companies, and purchasers, as
well.
You may also note that if a pressure vessel is ordered with a U Stamp,
then any Third Party Inspection Agency cannot do the inspection, and an
authorized third party ASME inspection needs to be hired. This also
called third party inspection for U stamp.
All pressure vessel inspection and testing is done against the approved drawings,
purchase order specifications, purchasers or company standards, and within the
practices and rules of the country, state or province and any government decrees,
laws, ordinance or regulation as may apply.
The applicable codes and specifications for a pressure vessel that is under the
construction process is:
Design code
Purchase order specification
Purchaser's standards
Approved drawings
The list of documents normally is agreed upon in the Pre-Inspection meeting, which
is held several weeks before the actual commencement of the inspection work.
The parties that participate in this meeting are the manufacturer, purchaser and
third party inspection agency representatives.
This already explained in the Inspection and Test Plan for Pressure
Vessel article.
The first actual inspection work on the pressure vessel is the raw
materials inspection. Based on the ASME Code, providing material test
reports for pressure vessel plates is mandatory. For other components,
the marking inspection will be enough.
But if the purchase order has mandated the MTR to be provided for all
components, such as nozzle pipes, fittings, etc., then the manufacturer
needs to provide them as well.
For more details, you may review the Pressure Vessel Plate article.
The third party inspector examines these certificates for compliance with
specifications, and where appropriate, drawings.
Certificate No.
Heat or Cast No.
Chemical Composition.
Mechanical Properties.
Heat Treated Condition.
NDE Applied and Results.
Visual inspections for surface finish and probable defects are done and
dimensional compliance with specification also needs to be controlled.
For more detail about pressure vessel raw material inspection, you may
review the Pressure Vessel Dimension Inspection article.
When the third party inspector carries out the material inspection, then provides the
inspection visit report (IVR), the report contains the following items:
When the pressure vessel raw material inspection is carried out, and the results
were satisfactory or non-conformities were closed by remedial action, then the
pressure vessel manufacturer will start fabrication.
The third party inspector checks the following points on the pressure vessel, based
on the inspection and test plan (ITP), which has already been agreed upon
between the purchaser and the pressure vessel manufacturer.
The inspection scope is determined in the ITP. Some purchasers prefer to have
stringent controls and assign the TPI for more “hold or witness points” for
inspection and test activities, and some others prefer less “hold or witness points”
and assign the TPI much more work in the “review document.”
This depends in the inspection budget, which purchasers assign for inspection.
Much more inspection will have a much larger cost and less risk, and conversely,
less inspection will have less cost but more risks.
For more detail, review the Inspection and Test Plan for Pressure Vessel
article. There is a draft of the ITP in this article, which we believe is the best
practice for pressure vessel inspection.
The third party inspector carries out the visual and dimensional check to
ensure compliance with WPS and other specifications. Where specified,
weld bevels are examined by the required code method after
grinding/machining.
It is necessary that the edges and weld bevels are clean, dry and free
from surface defects, laminations, cracks, voids, notches, etc.
Weld repairs are carried out in accordance with the code requirements
and approved by the client before welding proceeds and serious or
excessive defects normally are reported.
If the third party inspector is not in the hold or witness point in the ITP for this
inspection stage, then he/she will review the pressure vessel manufacturer quality
control report in his/her coming visit or on the final inspection day.
Tack welds are produced using the applicable WPS conditions, and it is
necessary to be visually free from defects.
Similarly, If the third party inspector is not in the hold or witness point in the ITP for
this inspection stage, then he/she will review the pressure vessel manufacturer
quality control report in his/her coming visit or on the final inspection day.
The third party inspector controls preheat heat temperature and method,
interpass temperatures, weld material control, welder and process
qualifications for conformity to the code requirements.
Similarly, If the third party inspector is not in the hold or witness point in the ITP for
this inspection stage, then he/she will review the pressure vessel manufacturer
quality control report in his/her coming visit or on the final inspection day.
The third party inspector controls the shape and dimensions of the back
gouged groove for conformity to the WPS requirement.
It is necessary that the visual appearance is clean and free from defects.
NDE examination is done in accordance with the code requirement.
Similarly, If the third party inspector is not in the hold or witness point in the ITP for
this inspection stage, then he/she will review the pressure vessel manufacturer
quality control report in his/her coming visit or on the final inspection day.
Temporary attachments are removed, ground smooth, and the areas are
checked for defects by MP or PT for defects.
Similarly, If the third party inspector is not in the hold or witness point in the ITP for
this inspection stage, then he/she will review the pressure vessel manufacturer
quality control report in his/her coming visit or on the final inspection day.
Third Party Inspection for Pressure Vessel - Non-Destructive
Examination
Similarly, If the third party inspector is not in the hold or witness point in the ITP for
this inspection stage, then he/she will review the pressure vessel manufacturer
quality control report in his/her coming visit or on the final inspection day.
The pressure vessel weld repairs are completed using an approved WPS
method and retested accordingly.
It is necessary that all repairs are approved before any post weld heat
treatment is carried out.
The third party inspector reviews the post weld heat treatment record of
the temperature and time in accordance with the approved
code/procedure.
The results of hardness tests are reviewed in accordance with the code
requirements.
The third party inspector checks all major dimensions and that the
position/orientation of attachments are in accordance with the code
requirements.
Similarly, If the third party inspector is not in the hold or witness point in the ITP for
this inspection stage, then he/she will review the pressure vessel manufacturer
quality control report in his/her coming visit or on the final inspection day.
The third party inspector witnesses the low pressure pneumatic test for
nozzle reinforcing pads, support saddles or other attachments when
specified by approved low pressure pneumatic test procedure using
soapy water as the indicating medium.
Similarly, If the third party inspector is not in the hold or witness point in the ITP for
this inspection stage, then he/she will review the pressure vessel manufacturer
quality control report in his/her coming visit or on the final inspection day.
The third party inspector controls the following items for Hydro-static
Testing:
The specified post hydrostatic test NDE needs to be completed and the
vessel closed.
The third party inspector rechecks the nozzle, saddle and bracket
locations and orientations against the assembly drawings.
The third party inspector controls spares, tools and accessories and
makes visual and dimensional inspection for materials, workmanship and
quantity according to the purchase order specification and packing list.
The third party inspector provides an Inspection Visit Report (IVR) after each visit,
as well as a final report summarizing the activities carried out during the pressure
vessel production in accordance with the contract requirements and circulated
within the time limits specified in the contract.
The report is in the format required by the client and clearly indicates final
acceptance or rejection of the pressure vessel.
Third Party Inspection for Pressure Vessel - Pressure Vessel
Release Note
When required by the contract or purchase order, a release note is issued by the
third party inspection agency and given to the manufacturer when the pressure
vessels have been accepted.
The following final documents are reviewed and signed off by the third
party inspector:
Click here if you like immediately review the Inspection & Test Plan
for Pressure Vessel draft sheet.
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.
Reviewing of radiographs
Do you what the pressure vessel certification process is? Do you know
how pressure vessel manufacturers can be ASME stamp holders?
See the following Fig. for Pressure Vessel Certification (The Stamp Item)
For U the stamp, the quality control system needs to be based on ASME
section VIII Div. 1 Appendix 10.
The industrial inspection article provides you with information about shop inspection, site
inspection and plant inspection.
The articles are about different inspection field categories such as shop inspection,
site inspection and in-service inspection requirements.
The articles present you applicable codes and standards. There will be also some
links to other articles to complete your required information.
This content explains each category with some examples and guides you to some
other links in this website to give you even more information.
Industrial Plant Inspection - If you need some information about industrial plant
inspection, this article will be useful for you. This content explains in-service
inspection requirement in the industrial plants.
This article provides you applicable in-service inspection codes and standards for
static equipment in an industrial plant. There will be some links to other articles to
provide you with more detailed information.
Inspection and Test Plan - The inspection and test plan is term, which is widely
used in the procurement and purchase of industrial equipment.
Shop Inspection - shop or vendor inspection covers inspection activities that are
done by the second party or third party inspector.
It is applied in manufacturing process of industrial equipment such as pressure
vessels, pumps, compressors, valves, etc.
Vendor Inspection - Vendor inspection is just a different name for shop inspection
and is applied in the purchase and procurement of industrial equipment.
This will describes the tasks of the vendor quality control personnel, the third party
inspector and the client responsibilities. This is very important subject in industrial
inspection application.
Industrial Quality Control - Do you need information about detailed tasks and
responsibilities of the industrial equipment vendors and manufactures?
This article will show you, the detailed tasks of the quality control team of the
manufacturers and their relationship and connection to the purchaser's inspector.
Factory Acceptance Test - This article provides you with information about the
factory acceptance test (FAT). This terminology is used for rotating, electrical and
instrumental equipment that is under construction in manufacturing shops.
Inspection scope - This article provides you information about the inspection scope
of work. More stringent scopes of work will cause higher inspection costs and higher
assurance for quality products, while less stringent scopes will cause lower costs
and higher risks of producing non-conforming products. So you need to optimize
your inspection level.
Industrial Test Systems - This article provides you information about industrial
inspections and test systems. This content explains the required test in each
inspection field such as shop inspection, pre-shipment inspection, site inspection
and in-service inspection.
The test is some part of an inspection process. Explaining -the required tests for
each equipment type is not possible in a single article.
This article only guides you to accessing more information through the other
articles in this website or by introduction to the codes and standards.
Industrial Test Calibration - This article provides you basic information about
industrial test calibration. Measuring, inspection and testing equipment calibration
is mandated by most construction and in-service codes.
The manufacturer's quality control system needs to define a process for the
calibration of measuring and testing equipment to ensure the reading values are
correct and accurate.
Material Inspection Receiving Report - This article provides you with information
about material inspection receiving reports which are very important in the
industrial inspection system. This report applies in the shop and site inspection and
controls all incoming material to shop and site for construction. It is one of the
more important inspection subjects in the industrial inspection system.
Dye Penetration Inspection - This article provides you with a example dye penetrant
inspection procedure.
Magnetic Particle Inspection - This content provides you with a draft MP test
procedure. Yon need modify this procedure based your project specifications.
Ultrasonic Testing - This article gives you a sample ultrasonic testing procedure.
This is a draft procedure and need to be modified based user requirements.
Engineering Specification for for Piping Stress Analysis - This article provides you with a
example engineering specification for piping stress analysis that is used in plant construction
projects.
Engineering Specification For Piping Hanging And Support - This article provides
you with sample piping hanging and support engineering specification.
This content will be useful for inspectors involved in construction projects for
industrial plants.
Engineering Specification for Painting - This content provides you a sample for
engineering specification for painting in the construction projects and covers both
shop and site painting activities.
Engineering Specification for Piping Design - This content is usefull for inspection
engineers that have task for inspection of ASME B31.3 piping in construction
projects.
Engineering Specification for Steam Tracing - This content provides you with a
example steam tracing specification that is used in construction projects.
Engineering Specification for Hot Thermal Insulation - This content provides you
with a sample hot thermal insulation specification. This is useful content for its
design, application and inspection.
Engineering Specification for Cold Thermal Insulation - This content provides you
with a sample cold thermal insulation specification. This content is useful for design,
application and inspection.
Engineering Specification for Piping Fabrication and Erection - Not Edited Yet
Engineering Specification for Pressure Test of Piping System - Not Edited Yet
Engineering Specification for Piping and Equipment Cleaning - Not Edited Yet
For other information on the other Industrial Fields, you may review the HotVsNot
Web Directory.
SHOP INSPECTION
So there will be a proforma invoice (PI) and a purchase order (PO). The
PI is issued by the pump manufacturer, with detailed pump
specifications and prices, and at the same time, a PO will be issued by
the oil company, which stats its agreement with the specifications,
prices, and ordering for the manufacturing of the pumps.
Before the start of the manufacturing process, the oil company will agree
with the pump manufacturer for the inspection process. Normally, this
process will be done based on the agreed upon inspection and test plan.
For more details, review the Inspection and Test Plan article.
So when the manufacturer reaches to these points, it must notify the oil
company inspector (in advance) to come for the inspection and testing.
Finally, if the result of inspection visits were satisfactory, then the
inspector will issue the inspection release note.
Please note that most of the clients such as this oil company mandate
the engineering company to hire a third party inspection agency.
The 3rd Party Shop Inspection article provides you some more
supplementary information regarding this subject.