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WI/INSP/01/00

Effective date:
October 2004

Work Instructions-Pressure vessel


Inspection

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TUVIPL Surveyor shall verify/confirm the following requirements for


inspection/testing of pressure vessels & in addition to the specific
requirements of Project. The specific requirements of project shall be
as addressed in vessel manufacturers QAP/ITP
Referencing Document:
Applicable Specification/Approved drawing/Data Sheet/ASME SEC
VIII Division I
Supplementary tests per project specification
Approved QAP/ITP
Inspection & Tests:
Review applicable WPS/PQR in-accordance with ASME section- IX and
or to project specification.
Identify all material used in fabrication of vessel or part (UG-93)
Examine all materials before fabrication to make certain they have
the required thickness, to detect defects (UG-93-d), and that
traceability (UG-77) to the material identification (UG-93) has been
maintained.
Verify that the material used in fabrication of vessel comply with
requirement of UG-4 through UG-14, (UG-93)
Review material test certificates of all pressure containment parts
and that of parts welded to pressure parts for conformity to
applicable material specification/project specification, including
additional & supplementary tests (NACE, HIC, Inter-granular
corrosion (IGC), SSC, Hardness, Heat treatment,
Normalizing/tempering requirement specified by client/Project
specification).
Verify impact tests results have been documented when such tests
are required (UF-5, UCS-66, UHA-51, UHT-6, and ULT-5)
Prepared by: NG Prabhu
Date : Octobr, 2004
Signature

Approved by:G Chandrasekhar


Date : October, 2004
Signature:

Issued by:G Chandrasekhar


Date : October, 2004
Signature:

WI/INSP/01/00
Effective date:
October 2004

Work Instructions-Pressure vessel


Inspection

Page 2 of 5

Ensure that the fabricator obtains concurrence of client inspector


In writing prior to any repairs undertaken on materials (UG-78, UW38, UF-37, and UF-38)
Verify NDT operators are qualified in accordance with requirement of
ASME SEC V- Clause T-140, SNT-TC-1A
Examine the shell and head sections to confirm that they have been
properly formed to the specified shapes with in permissible tolerances
(UG-79 through 81, UF-27, and UF-29)
Verify that all welding procedures have been qualified (UW-28, UW47)
Verify that all welders, welding operators have been qualified (UW29, UW-48)
Examine all parts prior to joining to make certain they have been
properly fitted for welding and that the surfaces to be joined have
been cleaned and the alignment tolerances are maintained (UW-31
through 33)
Examine parts as fabrication progresses, for material marking (UG94) that defects is evident (UG-95) and the dimensional geometries
are maintained (UG-96and UF-30)
Verify required heat treatments, including PWHT are performed on
the vessel (UW-2, UW-10, UG-85, UF-31, and Appendix-10-11)
Verify records of nondestructive testing examinations performed on
the vessel or vessel parts (UW-51, UW-52, and Appendix-10-10)
Verify that material imperfections by welding were acceptably
repaired (UG-78, UW-52 (d) 2 (c) UF-37, and UF-47 c)
Verify that weld defects were acceptably repaired (UW-51 c, and UW52 c)
Prepared by: NG Prabhu
Date : Octobr, 2004
Signature

Approved by:G Chandrasekhar


Date : October, 2004
Signature:

Issued by:G Chandrasekhar


Date : October, 2004
Signature:

WI/INSP/01/00
Effective date:
October 2004

Work Instructions-Pressure vessel


Inspection

Page 3 of 5

Verify that required nondestructive examinations, impact tests, and


other tests have been performed and that the results are acceptable
(UG-84, UG-93, UW-50, and UW-52)
Make a visual inspection of vessel, to confirm that the material weld
areas of vessel and internals are free from defects, including
dimensional defects (UG-95 through UG-97)
Ensure that chloride content of water used for hydrostatic test is less
than 50 PPM or as specified in PO specification for SS exchanger.
Verify that as on test date the pressure gauges deployed for tests are
calibrated and the calibration status is valid.
Perform internal and external inspections & witness hydrostatic or
pneumatic test and carrying required inspection during such test
(UG-96, UG-97, UG-99 through UG-101 UG-116, and UW-50)
Stamp the vessel and or nameplate to the vessel (UG-116, UG-118,
and UG-119)
Inspect the vessel internal coating if any to confirm, adequate
thickness achieved and the coated surface is free from unacceptable
pinhole defects.
Examine the internals during fabrication for weld control /distortion.
Inspect the vessel internals for dimensional accuracy and for proper
fitment.
Verify that the hydro test water has been fully drained from vessel &
the equipment is dry.
Verify that the vessel painting is carried out in accordance with
Prepared by: NG Prabhu
Date : Octobr, 2004
Signature

Approved by:G Chandrasekhar


Date : October, 2004
Signature:

Issued by:G Chandrasekhar


Date : October, 2004
Signature:

WI/INSP/01/00
Effective date:
October 2004

Work Instructions-Pressure vessel


Inspection

Page 4 of 5

PO specification and required paint thickness is available. Ensure that


the painted surfaces are free from unacceptable pinhole defects.
Inspect the vessel for readiness for shipment.
Check List
1) Review applicable WPS/PQR & welder qualifications.
2) Identify materials & review MTC for pressure parts, welded
attachments & internals. Examine material surface condition for
shell, cone & heads.
3) Verify that the MTC include results of supplementary tests such
as UT/MT, impact test, HIC, IGC, SSC hardness & heat
treatment details, and conformance to NACE etc. as
required/specified on PO specification.
4) Verify NDT operators are qualified in-accordance with ASME/PO
specification.
5) Inspection during fabrication- cutting & edge preparation, Fit
up- long seam/circ. Seam, Back chip- visual/MT, weld
appearance- before/after PWHT, Forming & bending: Shellcone-heads, Heat treatment after forming: shell-cone-head,
PWHT chart review-at furnace or local.
6) NDT examination: RT-spot/full, UT-before PWHT/after PWHT,
MT before/after PWHT, PT-before/after PWHT/hydro test.
7) Dimensional/visual inspection: Shell-cone-heads, nozzles,
manholes, skirt, legs, Lifting lug, base plate, template & anchor
bolts, clips & other attachments, tray supports & other
internals.
8) Verify type & size of nozzles/manholes-nozzle size, rating,
flange type, flange facing, & nozzle neck thickness.
9) Examine out of roundness/shape of Shell/dished heads,
installation of internals for conformity to PO specification.
10) Ensure all applicable NDTs performed & results accepted before
the Equipment is released for Hydro test.

Prepared by: NG Prabhu


Date : Octobr, 2004
Signature

Approved by:G Chandrasekhar


Date : October, 2004
Signature:

Issued by:G Chandrasekhar


Date : October, 2004
Signature:

WI/INSP/01/00
Effective date:
October 2004

Work Instructions-Pressure vessel


Inspection

Page 5 of 5

11) Pressure tests: Witness hydrostatic/pneumatic test of


equipment, duration & test medium in-accordance with PO
specification.
12) Air Leak test: Nozzle reinforcement pad/sleeve liner.
13) Verify test medium condition (chloride content) for conformity
to PO specification.
14) Review pressure gauge position, calibration & numbers.
15) Review Test pressure time chart recorder calibration.
16) Review any special caution exercised: differential pressure
designed vessel, Jacketed vessel, lined vessel.
17) Review production weld test results as applicable.
18) Review specific test requirements: Hardness test on-main
seams & nozzle welds, UT/MT/Chemical analysis tests on
overlay weld.
19) Verify that the hydro test water has been drained from vessel &
the equipment is dry.
20) Review painting/coating reports.
21) Verify application of protective cover on nozzles & providing
packing/blanking for gasket seating areas.
22) Stamp equipment & issue release note.

Prepared by: NG Prabhu


Date : Octobr, 2004
Signature

Approved by:G Chandrasekhar


Date : October, 2004
Signature:

Issued by:G Chandrasekhar


Date : October, 2004
Signature: