ASME AWARENESS PROGRAM4

FABRICATION & INSPECTION

7/13/15

 Coordinate with AI for inspection at

his hold points, witness points and
others as applicable
Responsible for Inprocess and Final
Examination
Resposibility of Engineer Inspection
Fabrication addressed in QCM:04-01,
cl 2.3

Thre
e
Two
One

Responsibility of
Engineer Inspection
Fabrication

Exhibits for Inspection

Fabrication

8 Exhibits are for Inspection

fabrication

Exhibit-16 Inspection check list

Exhibit-17
Detail Seam Wise Check
list
Exhibit-20
Material Clearance
Record
Exhibit-18
PTC annexure
Exhibit-27
Nonconformity Report
Exhibit-28
Hold (on job) Tag
Exhibit-21
Inspection clearance slip
Exhibit-19
Hydrotest/Pneumatic

Inspection Check List

1. PrepareInspectionChecklistduringprefabrication
stage.
2. Input - Approved Drg, ITP, NDT plan,
Testing Plan
3. IncludeCustomername,Description&W.O.
4. OffertoAIformarkinghishold/witnessstage
5. ListthestagesinInspectioncheckList
6. MaintaininspectioncheckListStageWise
7. ChecklistshallbereviewedsignedoffbyAI
8. AllthecheckpointsareholdpointforL&TMFY

Inspection Check List

Detailed seam wise

Check List
1) PrepareDetailedSeamwiseChecklistduring prefabrication

stage
2) Input - Approved Drg, Check List, ITP, NDT
plan,
Testing Plan
3) IncludeCustomername,Description&W.O.
4) BasedonInspectionCheckListHold,witnesspoints markin
Seamwisechecklist
5) DetailedchecklistshallbereviewedsignedoffbyAI
6) DistributetoHeadManufacturingorProductionEngineer.
7) Maintainthedetailedchecklist

Detailed seam wise

Check List

Material Clearance
Record
AfterissueofdrawingforConstructionthematerialshallbe

1)
identified&maintainthetraceability(MCR).
2) Input - Approved Drg, AI Signed IMIR, Inspection
request
3) Section VIII, Div 1, UG-77 & 93
4) Material specification with Grade or Class, Heatno,
IMIRNo.,Drawingno,Partno,WOnoaremarkedoneach part
[Link].
5) Inspect for Pitting, Surface Damage on both side.
6) Basic dimensions such as length, breadth and
thickness
are
to be checked w r t Drawings.
7) Identification to be transferred to balance Piece of Plate
before cutting operation.
8) QC inspector stamps the inspection punch mark on
each part during inspection.

Material Clearance
Record
9) Wherever full details of identification are not possible to

punch, Coded marking system to be used as per

Manual and record to be maintained in Register.
10)
Incase of Items like tubes, small pipes etc. where
marking on each piece is not feasible, identification done
by Tags to bundles.
11)
No Low stress hard punch is allowed below 6mm
for FM and below 13mm for NFM
12)
Identification marking on Bottom side of the plate
& in rolling
direction.

IDENTIFICATIO
NLOCATION

L
K1

K2
ROLLINGDIR.

Material Clearance
Record

Fit up Inspection
LONGSEAMFITUPSTAGEINSPECTION:
Physical Verification & Inspection on the Job:

1.
2.
3.
4.
5.
6.

Completeness and correctness of material identification.

Seam No punching (highlight the same with paints)
Cleanliness of W.E.P & adjoining area 1" on either side.
All tacks free from Defect.
Ensure welders stamp identification for tacks on groove of fit up.
Weld edges and shell surface shall be free from arc strikes spatters
gas cutting serration, pitting & dents.
7. Check W.E.P NDT (PT/MT), if applicable.
8. Run in & run out coupon on either ends, with matching W.E.P for
material above 25 mm.
9. PTC as an extension to the seam, if applicable.
10. Dimensional measurement (CF, Length, WEP etc.)
11. Ovality as per UW 80 & Profile check (1% of ND)
12. Offset as per UW 33

Shell Profile check

ACTUALTHK.

IDmaxIDmin=1%
ofNominalID

I/DCHECKIN
HORIZONTALPLANE
D/
4
TE
M
P

P
EM
4T
D/

PEAKOUT

D/4Template:TemplateLength

PEAKIN

Shell Profile check

PeakOut

D/4Template

D/4Template

MatchingProfile

PeakIn

TOLERANCE
ProfileTolerance
InsideDiameterof
Shell/Segment(in
mm)

Permissiblelimitsfor
peakoutor
peakin(inmm)

152

0.8

305

1.2

457

1.6

610

2.4

914

3.2

1219

4.0

1524

4.8

1905

5.6

2133

6.4

2438

6.4

2743

7.1

3048

7.9

3048

0.2%ofdia.

OUTSIDE CIRCUMFERENCE of SHELL /

HEAD
NOMINAL DIAMETER

TOLERANCE

< 1200 mm
1201 to 2400 mm
> 2400 mm

10 mm
12 mm
20 mm

VESSEL LENGTH
5 mm PER 3000 mm, MAXIMUM 15
mm
VESSEL ALIGNMENT / STRAIGHTNESS
6 mm PER 6000 mm, MAX. 20 mm FOR
ANY LG.

Shell Ovality check

OvalityTheMaximum&[Link]
sectionshallnotexceed1%ofNominalDia.
DiametermaybemeasuredInsideoroutsideofthevesselby
usingcalibratedtape.

Offset Tolerance (UW33)

JointThickness.t
13mm&Below

Over13mmto19mm
Over19mmto38mm

Over38mmto51mm
Over51mm

Cat.:A

Cat.:B,C&D

1/4tht

1/4tht

3mm
3mm
3mm
1/16thtor
Max.10mm

1/4tht
5mm
1/8tht
1/8thtor
Max.19mm

ForJointCategoryReferUW3

Joint category (UW-3)

Cat.A:Longitudinaljoint([Link])
Cat.B:Circumferentialjoint(ExceptHemisphericalheadtoshell)
Cat.C:WeldedJointconnectingtoflange,Tubesheets,Flatheadtoshell
Cat.D:WeldedJointconnectingtoNozzletoshellorheads

Fit up Inspection
[Link]:
Physical Verification & Inspection on the Job:
1.
2.

Identification & Orientation for shell long seam as per DRG/DCR.

Tan line (reference line) shall be transferred inside with proper
punching and Painting.
3. Seam No punching along the seam (highlight the same with paints).
4. W.E.P & adjoining area shall be cleaned 1" on either side.
5. All tacks shall be free from Defect.
6. Weld edges and shell surface shall be free from arc strikes spatters
gas cutting serration, pitting, dents etc.
7. Long Seam Orientation to be checked.
8. Check W.E.P NDT (PT/MT), if applicable.
9. PTC shall be ready with all aspects near to the cir-seam, If applicable.
10. Dimensional measurement (CF, Length, WEP etc.)
11. Straightness / Alignment shall be checked.
12. Offset as per UW 33

Fit up Inspection
NOZZLEFITUPSTAGEINSPECTION:
Physical Verification & Inspection on the Job:

1.
2.
3.
4.
5.
6.
7.
8.
9.

Completeness and correctness of material identification.

Seam No punching along the seam (highlight the same with
paints).
W.E.P & adjoining area shall be cleaned 1" on either side.
Nozzle cut out marking shall be checked.
All tacks shall be free from Defect.
Weld edges and shell surface shall be free from arc strikes
spatters gas cutting serration, pitting, dents etc.
Check W.E.P NDT (PT/MT), if applicable.
Dimensional measurement (Elevation, Projection, Tilt,
Straddle etc)
Offset as per UW 33

Form Head
TypesofHead
1.
2.
3.
4.

Torisphericalhead
ToriconicalHead
HemisphericalHead
EllipsoidalHead
FormHeadINSPECTION

Physical Verification & Inspection on the Job:

1.
2.

Completeness and correctness of material identification.

Seam No punching along the seam (highlight the same with
paints) if Petal to Petal construction of Form Head

Form Head
FormHeadINSPECTION:
W.E.P & adjoining area shall be cleaned 1" on either side.
4. All tacks shall be free from Defect.
5. Weld edges and shell surface shall be free from arc strikes
spatters gas cutting serration, pitting, dents etc.
6. Check W.E.P NDT (PT/MT), if applicable.
7. PTC shall be ready with all aspects near to the Head, If
applicable.
8. Offset as per UW 33, Ovality as per UG 80
9. Dimensional measurement (Circumference, Straight Face,
Height or Depth, Minimum thickness)
10. Profile shall be checked with template as per UG 81 (Inner
surface of head not deviate Outside of specified shape not
more than 1 % of NID & Inside of specified shape not more
than 5/8% of NID)
11. Knuckle Radius shall not be less than specified.
3.

Clearance of Welding
Followingpointstobeverifiedbeforereleasingforwelding
a) Fitupinspectionsatisfactory
b) SuitableWPSavailableanddisplayedattheworksite
c) Qualifiedweldersandsupervisorspositioned
d) Environmentalparametersareacceptableforwelding
e) Weldingmachinesindicatorsareproperlycalibrated
andworking
f) Weldconsumablesareasperrequirement
g) Bakingandcarryoveninorder
h) Weldingdatasheetinplace
i) Propertemporarysupportstobeprovided.

Weld Visual & NDT

clearance

WELDVISUALINSPECTION:

Weldvisualinspectionsaretobeensured,WeldmetalaswellastheHAZis
[Link]:
b)Cracks,undercut,porosity
c)Arcstrikes
d)Surfacedefect
*Followingdimensionalchecksaretobedone:
a)Weldprofile
b)Widthofweavingbead
c)Weldreinforcementbothheightandwidth(UW35)
*Followinginformationmustbesoughtandrecordedatthetimeofclearingthe
weldvisual:
a)WPS
b)Welderno.
NDT
Oncompletionofweldvisualthejointsareofferedfor
UT/RT/DPT/MPT/HardnesstestasrequiredasperNDEplan.

Reinforcement Tolerance
(UW-35 )
[Link]

MaterialThickness

Below2.4mm

2.4to4.8mmincl.
Over4.8to13mmincl.
Over13to25mmincl.
Over25to51mmincl.
Over51to76mm
Over76to127mm
Over127mm

Other
Category
0.8mm
1.6mm
2.4mm
2.4mm
3.2mm
4mm
6mm
8mm

CategoryB&
C
2.4mm
3.2
4mm
4.8mm
5mm
6mm
6mm
8mm

Non conformity
A situation shall be considered as nonconforming if any activity or
operation has already performed which has resulted in noncompliance
with the applicable rules of the code, drawings, specifications, or the
requirements of Quality control manual.
NCs shall be corrected before the completion of vessel can be
considered to comply with the code.
NCs shall include, but not be limited to:
1)Material & Parts found to have deviation during receiving / in process
examination.
2)Weld material used not meeting the specification requirement.
3)Repairs affecting material.
4)Un-calibrated equipment used in measurement or test.
5)Time-Temp. cycle of HT performed deviating from specification.
6)Deviation from Design /Drawing
7)Situations not meeting requirement of this manual.

Non conformity

Inspection clearance
slip

ICS shall be issued by Inspection Engineer fabrication prior to Heat

treatment, Hydro test and Final painting with concurrence of AI. To
ensure all stages shall be completed.

Hydro / Pneumatic
Test

ENSUREFOLLOWINGPRIORTOSTARTTHETEST:
1. MCRSHALLBECLEARED.
2. COMPLETIONOFWELDINGONPRESSUREPARTS
3. COMPLETIONOFALLNDTTOTHEACCEPTABLE
STAGE

4. TESTINGOFPTC,IFANY,TOTHEACCEPTABLE
TESTRESULTS
5. ALLDIAMENSIONALCHECKWITHINTHE
ACCEPTABLELIMIT
6. CHECKLISTSHALLBEUPDATED.

Hydro / Pneumatic
Test

ENSUREFOLLOWINGPRIORTOSTARTTHETEST:
7. HYDROTESTARRANGEMENTASPERAPPROVED
DRAWING.
8. ALLTESTEDJOINTSFREEFROMPAINT,DUST,
RUSTETC..
9.
INTERNALINSPECTIONSHALLBECARRIEDOUT.
10. ALLFASTENERSARETIGHTENEDTOREQUIRED
TORQUE.
11. PROPERVENTTOBEPROVIDEDONTOPOFTHE
VESSELS.
12. TWOPRESSUREGAUGESTOBEAVAILABLE.

Hydro / Pneumatic
Test

ENSUREFOLLOWINGPRIORTOSTARTTHETEST:
13. GAUGESRANGE:1.5TO4TIMESOFTEST
PRESSSURE(UG102)

14. LOCATEGAUGEONTOPMOSTOFTHEVESSEL.
15. ALLGAUGESSHALLBECALIBRATEDAGAINST
STANDARDDEADWEIGHTTESTERORA

[Link]
RECALIBRATEDATANYTIME.
16. TESTMEDIUMSHALLBENONHAZARDOUSLIQUID.
17. TESTPRESSURESHALLNOTBELESSTHAN1.3TIMES
OFMAWPFORHYDROTEST&1.1TIMESOFMAWP
FORPNEUMATICTEST.

Hydro / Pneumatic
Test

WATERFILLING,PRESSURISING&INSPECTION:
1. WATERSHALLBEFILLEDFROMTOPOFVESSEL.

2. INCREASETHEPRESSUREASPERAPPROVEDPROCEDURE.
3. [Link]
17CANDNOTMORETHAN48CTOREDUCERISKOF
BRITTELFRACTURE.

4. HOLDINGTIMEASPERAPPROVEDPROCEDURE.
5. ALLPRESSUREJOINTSHALLBEVISUALYINSPECTEDAT
PRESSURENOTLESSTHANTHETESTPRESSURE/1.3
PRESSURE.
6. LEAKAGEISNOTALLOWEDATTHETIMEOFREQUIRED
VISUALINSPECTION.

Hydro / Pneumatic
Test

WATERFILLING,PRESSURISING&INSPECTION:
[Link]

PARENTMETAL,DRAINTHEWATER,REPAIRTHE
LEAKANDREPEATTHETEST.

8. TIME,TEMPERATURE&PRESSURECHART
WHEREVERSPECIFIEDSHALLBEOBTAINED.

9. REDUCETHEPRESSUREFROMTHETOPOFTHE
VESSELASPERAPPROVEDPROCEDURE.
10. DRAINTHEWATERFROMTHEBOTTOMOFTHE
VESSELWITHPROPERVENTATTOP.
11. RELIEFVALVESETTO1TIMESOFTEST
PRESSUREISRECOMMENDED.

Name Plate / U
stamping
1.

DETAILOFMARKINGISADDRESSEDINUG115TOUG119

2.

TYPEOFCONSTRUCTIONUSEDFORTHEVESSELSHALLBE
INDICATEDDIRECTLYUNDERCODESYMBOL.

TYPEOFCONSTRUCTION

LETTER(S)

ARCORGASWELDED

PRESSUREWELDED

BRAZED
RESISTANCEWELDED

3.

B
RES

INADDITIONTOABOVE,WHENAVESSELISINTENDEDFOR
SPECIALSERVICEANDREQUIREMENTCOMPLYIEDWITHLETTER
LETHALSERVICE

L
UB

UNFIREDSTEAMBOILER
DIRECTFIRING

DF

Name Plate / U
stamping
4.

WHENRADIOGRAPHICORULTRASONICEXAMINATIONHAS
BEENPERFORMEDONAVESSEL,MARKINGSHALLBEAPPLIED
UNDERCODESYMBOL:

RT1 ALLPRESSURERETAININGBUTTWELDEXCEPT
CATB&CBUTTWELDSASSOCIATEDWITH
NOZZLES
ANDCOMMUNITINGCHAMBERSTHAT
NEITHEREXCEED
NPS10NOR29MMWALL
THICKNESS

RT2

COMPLETEVESSELSATISFYREQUIREMENTOF
UW11(a)(5)ANDSPOTRADIOGRAPHY
REQUIREMENTUW11(a)(5)(b)
RT3

SPOTRADOGRAPHY

RT4WHERENONEOFTHEABOVEMARKINGAREAPPLICABLE

Name Plate / U
stamping
5. BASEDONHEATTREATMENTONVESSEL,FOLLOWING
LETTERTOSYMBOLONNAMEPLATE.

IFCOMPLETEVESSELUNDERGONEPWHT

HT

IFONLYPARTOFVESSELUNDERGONEHWHT PHT

Name Plate / U
stamping
6. WHENTHEMARKINGREQUIREDBYUG116ISAPPLIED
[Link]
LEAST8MMHEIGHTOFLETTERS.

7. STAMPINGSHALLNOTBEDONEONVESSELINFOLLOWING
CONDITIONS(UG118):
A) MATERIALSHALLBELIMITEDTOP1GR1AND2

B) MINPLATETHK5MM,&MINPIPEWALLTHK4MM
C) MDMTCOLDERTHAN29C
D) MATERIALSHALLBELIMITEDTOALLUMINIUM

9. NOMODOFVESSEL

CHARACTERSIZE

89MMMAX

3MM

89TO114MM

5MM

Name Plate / U
stamping
10. NAMEPLATESHALLBEUSEDONVESSELEXCEPTWHEN
MARKINGSHALLNOTBESTAMPEDDIRECTLYONVESSEL
BYUG118.

11. CHARACTERSIZEFORNAMEPLATENOTLESSTHAN4MM.
12. NAMEPLATEMAYBEATTACHEDEITHERBYWELDING,
BRAZINGORSOLDERING.

13. NAMEPLATEMAYBEINSTALLEDONSKIRT,SUPPORT,OR
PERMANENTATTACHMENTTOVESSEL.
14. THEADDITIONNAMEPLATESHALLBEMARKED:
DUPLICATE

OTHER REQUIREMENT
1. HEATTREATMENTREQUIREMENT(UCS56)
2. CHARPYIMPACTTEST(UG84,UCS66,UCS67)
3. MATERIAL(TABLEUCS23)
4. MANUFACTURERDATAREPORT(MDR,UG120,
NONMANDATORYAPPENDIXW,FORMU1,U2)

Over view of Pressure

vessel
Set On Nozzle

ELEVATION

PROJECTION
S.F.

PROJECTION

Set Through
Nozzle / Manway

T.L. to T.L.
Hemispherical
Dend

T.L.

T.L.
2:1 Ellipsoidal
Dend

Thank
You