PROCEDURE Total Page 13 Client : Project Name: P/O No. : Item No. : 3 2 1 0 FOR APPROVAL Rev Description Date Prepared By Checked By Approved By
PROCEDURE Page 1 of 8 1. General 1.1 Scope This specification covers the requirement of inspection for quality control during shop fabrication of the filters. 1.2 Applicable codes and standards This codes and standards shall be of the latest editions unless otherwise specified in specific job requirement. ASTM:American Society for Testing Materials ASTM:American Society for Mechanical Engineers < ASME Code Sec. VIII Div.1 `95Ed `96Add. > ANSI:American National Standard Institute AWS:American Welding Society SSPC:Steel Structure Painting Council API :American Petroleum Institute 1.3 Specification and drawings 1) Inspection and tests shall be carried out and based on fabrication drawing, procedure as approved by purchaser. 2) Where there are conflicts between the specification and drawings, they shall be promptly notified to purchaser. 1.4 Witness 1) Witness inspection shall, as a rule, be carried out at K-Flow shop. 2) Witness inspection shall mean inspection by inspector of purchaser, his designated representative, customers.(herein after referred to as purchaser s inspector) 3) At any time during manufacturing is under way, purchaser s inspector shall have free access to any K-Flow shop concerned with manufacture of filters. 4) K-Flow shall provide to purchaser s inspector with suitable facilities during the project performance. 5) Witness inspection shall be performed by way of interim inspection and final inspection as deemed necessary by purchaser s inspector. 6) K-Flow shall inform application for inspection by fax. at least 10 working days prior to actual inspection or test date. When a change of the inspection date occurs due to the fabrication progress,
PROCEDURE Page 2 of 8 K-Flow shall promptly submit the revised application in an appropriate manner for action. 7) K-Flow shall, at the time of witness inspection, submit to purchaser s inspector one copy of record his own inspection and tests. 1.5 K-Flow responsibility 1) K-Flow shall carry out all inspection and tests specified in this specification and shall prepare the records for each item to show that the filters have been constructed in accordance with the specification. 2) Witness by purchaser s inspector shall in no way relieve vendor of his responsibility to meet purchaser s specification. 2. Inspection and test record 2.1 K-Flow shall provide following information in the first page of all the record inspection tests. 1) P/O No. 2) Name of client and plant location 3) Job No., Item No., and inspection 4) Name of manufacturer 5) Date of manufacture and inspection 6) Project name 2.2 The following records of filters shall be included. 1) Material check list 2) Material mill certificate 3) Dimension inspection report 4) Nondestructive examination report a) Liquid penetration or magnetic particle examination b) Radiographic examination 5) Pressure test report a) Air leak test of nozzle reinforcing pads b) Hydrostatic test 6) Rubbing sheet of name plate 7) Shop painting report
PROCEDURE Page 3 of 8 3. General requirement of inspection 3.1 Dimensional tolerance of filter Dimensional tolerance of filter are referred to attachment # 1 3.2 Inspection & test plan Inspection & test procedure and acceptance standards 3.3 Material inspection K-Flow shall submit the material mill test certificates for he followings a) Shell, head and nozzle (flange, neck pipe/plate) b) Pressure retaining bolts & nuts, alloy steel bolts & nuts 1) K-Flow shall check the charge number and following items for the materials prior to fabrication of filter a) Chemical composition b) Mechanical properties c) Heat treatment d) Other items specified in the applicable cods, and purchaser s spec. 2) Inspection of materials shall be carried out in accordance with the related ASTM material code. 3.4 Visual inspection of material 1) The name or brand of the manufacturer 2) Heat No. 3) Specification number and grade, class and type 4) Quantity 5) Dimension (Include permissible variation in dimension and thickness) 6) No harmful defects on surfaces of material
PROCEDURE Page 4 of 8 4. Welding procedure qualification 4.1 Test procedures and acceptance standards of the welding procedure qualification shall be in accordance with the following codes and standards: ASME Sec. IX "welding qualification" and purchaser's specification 4.2 WPS & PQR shall be approved by purchaser prior to start of any welding fabrication 4.3 Welder and welding operators shall be qualified in accordance with ASME Sec. IX and Welder / Welding operator list shall be submitted to purchaser. 5. Welding control 5.1 Preheat The preheat shall be taken to ensure through thickness preheating of thick sections to prevent and excessive weld cooling rate. Surface temperature shall be measured by using of check chalk in the weld joint and 25mm on reverse side of the joint immediately before initiation of weld arc. 5.2 Interpass temperature Temperature shall be measured by digital thermometer or tempilsticks (check chalk) 5.3 Welding electrode 1) A filler metal qualification report listing the test results and the applicable filler metal heat, lot andbatch numbers must be prepared and attached to the applicable PQR. 2) Filler metals used in production must be from the same heat, lot and batch that were requalified by the steps listed above. Welder shall confirm the above item before welding 3) Storage The storage keeper shall be responsible for storage, drying and issuance of welding materials. Welding materials shall be stored in such a manner as to prevent intermingling with materials of different specifications and non-identified materials 4) The inspector shall check electrodes to minimize the moisture absorption after issuance from the welding material control room.
PROCEDURE Page 5 of 8 6. Inspection of welding parts Edge preparation & fit-up 1) The edge or surface of parts to be jointed by welding shall be confirmed to be uniform, smooth and clean of scale, rust, oil, grease, and other deleterious foreign material for a distance of at least 13mm from the welding joint preparation for ferrous materials and at least 51mm for non materials. 2) The inspector shall check the welding groove dimensions by angle gage in accordance with fabrication drawings under the tack welded condition prior to welding. 3) Tack welds that are to be cooperated into the final welds shall have their starting and stopping and cascaded by further grinding and/or chipping to insure corrplete fusing at the root of the joint. Alignment of section at edge to be butt welded shall be in accordance with table 1. Table 1. Nominal thickness of thinner Joint Category section at joint(t)(mm) "A"(mm) "B, C & D"(mm) t 13 13 < t 19 19 < t 38 38 < t 51 51 < t 0.25 t 3 3 3 lesser of 0.0625 t or 9 0.25 t 0.25 t 5 0.125 t lesser of 0.125 t or 19 6.1 After completion of welding the following items shall be visually inspected. (See Sec. V of ASME Code for treatment of surface irregularities on radiographer examined welds) a) Crack not permitted, repair b) Overlap remove smoothly c) Incomplete penetration and lack of fusion not permitted, repair d) Crated remove e) Bead dripping remove, repair if necessary f) Spatter remove g) Slag and porosity non exposed h) Fitting and welded spots for temporary remove i) Under cut not exceed 0.3mm
PROCEDURE Page 6 of 8 6.2 The thickness of the weld reinforcement on each face shall not exceed the value in Table 2. Material thickness Allowable thickness of t (mm) reinforcement (mm) t 12 1.5 12 < t 25 2.5 25 < t 3 7. Radiographic examination The welding joint of the main seams, longitudinal & circumferential joint, retaining pressure shall be performed with the radiographic examination on the base of the fabrication drawings prior to PWHT and following additional requirements. 1) When full RT is specified, the following welded joint shall be examined for their full length. a) All butt welds of category "A" and "B" in the shell and head of filters. b) Categories "B" and "C" butt welds in nozzle that exceed nps 10 inch. 2) When spot RT is specified, at least one spot for the following welded joint shall be examined. a) All welded seams defined as category "A" or "B" spots shall be selected to examine welds representing each welding procedure specification utilized each filter. b) Category "A" and "C" butt welds in nozzles that exceed nps 10 inch. 7.1 Radiographic examination procedures, techniques shall be in accordance with ASME Sec. V. Article 2. and the supplementary requirement specified in relevant specification. 7.2 The evaluation of indications and the acceptance criteria for radiographic examination shall be in accordance with ASME Sec. VIII Div. 1, para UW-51 for full radiography and spot radiography. 8. Magnetic particle or liquid penetrate examination 8.1 Magnetic particle or liquid penetrate examination of the following items shall be carried out before hydrostatic test. 1) The reverse side of double welded butt joint to be back chipped or ground 2) The removing parts of temporary weldment to the pressure retaining parts
PROCEDURE Page 7 of 8 8.2 Application parts of MT or PT PT and MT shall be carried out in accordance with article 6(PT), 7(MT) of ASME Sec. V 8.3 Other defects showing any of the following which are specified in appendix 6(MT) and appendix 8(PT) of ASME Sec. VIII, Div. 1. 1) Crack and relevant linear indications 2) Length of indication exceeding 4.8mm 3) Four or more rounded defects in line separated by 1.6mm or less (edge to edge) 4) Ten or more rounded indication in any 37.5cm² or area whose major dimension is not more than 150mm with the dimensions taken in the location most unfavorable for the indications 9. Visual inspection The Visual inspection shall be carried out as follows: 1) Number, size and rating of nozzle, manhole and other fitting of filter shall be checked. 2) Deformation of filter shall be checked. 3) Machined surface such as flange face shall be checked. 4) Internal cleanliness of filter shall be checked before & after hydrostatic test. 5) Defect of filter surface shall be checked. 10. Dimensional inspection 1) Dimensions of the filter and its parts shall be checked to meet data sheet, shop drawing and their records shall be submitted to purchaser. 2) Dimensional tolerances for filter shall be as shown in the attachment #1. 3) The measurement of plate thickness shall be as follows. a) The thickness of the cylindrical shell shall be measured at min.4 point per each rolled plate. b) The thickness shall be checked after forming of head. Hydrostatic and pneumatic test 10.1 Scope of apply shall be as follows: 1) Hydrostatic test shall normally be carried out for all filters by use of clean fresh water prior to painting. The filter shall be cleaned of dirt, debris, welding slag and weld spatter prior to hydrostatic test. 2) Pneumatic test shall be carried out for reinforcement pads of nozzle.
PROCEDURE Page 8 of 8 10.2 Test procedure and holding time shall be as follows: 1) The hydrostatic test pressure shall be maintained for a period of one hour. 2) The hydrostatic test pressure shall be shown on the drawing. 3) For reinforcement pads, the test shall be using shop compressed dry air. - Holding time at least 5 minutes -Holding pressure min. 5~7 kg/cm².g All welds insides and outsides shall be inspected with soap solution, and any leakage shall not be permitted 10.3 The water temperature of hydrostatic test shall be higher than 0 C 11. Painting inspection External surface of the filter shall be shop painted with anticorrosive paint and finish paint. When painting procedure is described in the specification, painting shall be performed in accordance with the specifications. 11.1 Surface of the filter to be painted shall be cleaned of rust, oil, dust deposits, slag, and etc. 11.2 Painted surfaces shall be finished evenly and smoothly, with out uneven painting portion in accordance with drawing. 12. Attachment 1. Attachment #1 --------Tolerances of Vessel (2 Sheet) 2. Attachment #2 --------Inspection and Test Plan (2 Sheet)
FIGURE 1a Orientation of nozzle and other attachments shall be within ±3 Longitudinal center line of vessel 3 Max. lateral translation Nozzle flange 1.5 Max. rotation of flanges from the indicated position. measured as shown FIGURE 1b Saddle height ±5 Diagonal length ±3 Distance between the centers of the anchor bolt holes ±3 Distance between the saddle center lines ±3