WI/INSP/01/02 INSPECTION SERVICES

Effective date: Oct 2004 WORK INSTRUCTION – INSPECTION OF

INDIA
Page 1 of 8
PRESSURE VESSEL / PROPRIETARY PRESSURE TUV NORD GROUP
EQUIPMENT / PARTS

TUV INDIA PRIVATE LTD

INSPECTION SERVICES

WORK INSTRUCTION – INSPECTION OF PRESSURE

VESSEL / PROPRIETARY PRESSURE EQUIPMENT /
PARTS

Clause No: 3, 4(A) 1, 2, 4(B)(1), 5, 6,

7, 11, 12, 17, 20, revised, Clause 15 SANDEEP
02 Sept 2017 NATARAJAN S. AMIT NAIK
Nozzle RF pad Pneumatic Testing DESHPANDE
added
ARUNKUMAR
01 Feb 2013 -- AMIT NAIK B. RAGHUNATHAN
WAGHMARE
Rev # Date of Issue Reason for Revision Originated by Reviewed by Approved by

REVISION HISTORY

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WI/INSP/01/02 INSPECTION SERVICES
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INDIA
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PRESSURE VESSEL / PROPRIETARY PRESSURE TUV NORD GROUP
EQUIPMENT / PARTS

1.0 Purpose: To provide a guideline to the inspectors for inspection of Pressure Vessels / Proprietary Pressure
Equipment / Parts.

2.0 Scope: Inspection of Pressure Vessels / Proprietary Pressure Equipment / Parts, designed in accordance
with ASME Section VIII Division I & II, PD 5500, IS 2825 & additional requirements applicable from
approved ITP / Drawing / Project Spec. / Mfrs. Procedures / PO.

3.0 Reference Documents:

 Applicable PO / Specification / Approved drawing / Data Sheet / ASME Section VIII Division I &II,
Section V, Section IX (Applicable Edition)
 Supplementary Tests as per project specification, NACE - MR 0103, MR 0175, TM 177, and TM 184,
approved QAP/ITP/Approved Manufacturer’s Procedures.
 For Pressure Vessels designed to code IS 2825, PD 5500, Similar stages to be followed. However for
actual details the code requirements shall be referred and incorporated in the QAP. TUV Head
Technical / Level 4 Authorized person shall approve the QAP on behalf of TUV.
 End user Instructions & their requirements / specifications shall be strictly followed in the
inspection, even when the End user is not the direct client to TUV.
 When the product is a proprietary item of the vendor, the Vendor Drawing, shall contain the part
details with dimensions & all essential data including Weld details / Size & must have an approval
from the Buyer / End user / DEC.

4.0 Stages of inspection

A) Document review:
1) Verify the approval of Latest revision of Drawing with Date. Ensure that the required details of
parts are clear & essential data like, Design / Test Pressure, External pressure, Load, Fillet size,
FPW requirement, Design Temperature (Minimum & Maximum), PWHT / Heat Treatment,
Hardness (Base metal & Weld), Impact Testing, PTC requirement, Corrosion Testing requirement,
Code requirements, Tolerances are mentioned clearly in the Drawing. Be vigilant for any missing
essential data. In the event of any missing essential data get it incorporated in the Drawing by the
vendor, and a re-approval from the Buyer / End User / DEC shall be obtained.
2) Try to understand the function & criticality of the equipment & each part including Non-Pressure
part,
3) Verify approval of QAP/ITP. QAP/ITP shall be approved by client, PMC & TUV.
4) Verify approval of applicable WPS/PQR/WPQ & weld plan by client, PMC & TUV.
5) Verify availability of NDE, PWHT & other test procedures, duly approved by Client, PMC & TUV.
6) Verification of availability of approved drawings & approval code.

Note: Only approved documents shall be followed during inspection.

B) Pre-Inspection Meeting:

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PRESSURE VESSEL / PROPRIETARY PRESSURE TUV NORD GROUP
EQUIPMENT / PARTS

1) Discuss with Buyer / End user / DEC / Manufacturer to understand the Project specific
requirements, Drawing / Specification & QAP / ITP requirements & to suggest Justifiable
improvements in the inspection requirements & TPI Scope based on previous experience.
2) Discuss with Buyer / End user / DEC / Manufacturer to understand the function & criticality of
the equipment & each part including Non-Pressure part, especially for proprietary equipment.
3) Ensure addition of specific test / Inspection for the function & criticality identified.
4) Ensure preparation of test procedures for special / different items which ensure testing of the
full strength of all load bearing parts & Chambers at 1.3 / 1.5 / 1.43 times the Design Load /
Pressure.

5) MTC Review, Material identification & Stamp transfer

 Visual & dimensional examination of material with more emphasis on the thickness(Check
thickness at various locations). Look from both sides of the plate & Outer / Inner surface of the
pipe for corrosion pitting or injurious surface defects. Ask for sufficient illumination / white light
(Minimum 1000 Lux).
 Review of Mill test certificates (MTC) & correlation with marking on the material.
 Verify that the MTC includes results of supplementary tests such as Method of manufacture,
supply conditions like Vacuum degassed, Calcium treated etc. UT/MT, impact test, HIC, IGC
practices and results (mills per year in case of Practice “B” or “C”), SSC hardness & heat treatment
details, Hydro, ECT for tubular products and conformance to NACE etc. as required/specified in PO
specification.
 Verify the Nozzle neck thickness requirements and Flange rating and Flange Face requirements as
per Nozzle schedule (Do not use the BOM for verification while accepting the Nozzle thickness/
sch., flange rating and Flange face requirements as BOM may have mistaken requirements)
 Even for Non-pressure part the Original Traceability with Mill test certificates shall be ensured.
 Be alert for falsification of MTC or Marking.
 Even when TPI scope is only review of MTC, still the reported properties of the material shall be
checked carefully against PO / Specification / Drawing / ITP requirements & traceability verified.
 In case of any doubt, seek for the clarification, ask for the additional records like, Heat
Treatment Chart, NDT reports, Compliance Certificate etc.,

Note: Without MTC (original or copy) material shall not be identified by the inspector.

 In the absence of original MTC or lack of correlation between marking on material & MTC,
coupons shall be stamped for check testing as per the material specification & additional tests
required by client specifications. Client concurrence shall be obtained before stamping of
material for check testing.
 If the material is found satisfactory based on MTC review and/or check test results, stamp
transfer shall be carried out.
 Verify the transfer of correct details before transferring the TUV stamp. For Low alloy steel &
Low temperature carbon steel parts ensure that low stress stamps are used for identification
& stamp transfer for all markings as well as TUV Stamp.

In process inspection:

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PRESSURE VESSEL / PROPRIETARY PRESSURE TUV NORD GROUP
EQUIPMENT / PARTS

6) Shell rolling & long seam set up –

 Visual examination of surface for any objectionable marks.
 Dimension check – OD or ID circumference, ovality, weld edge preparation, profile check with
inside template (internal pressure) & outside template (external pressure). Inspector shall
verify the profile at pre pinching area (both sides of long seam joint). No flat spots in the shell
are acceptable.
 Verify the minimum required length & profile of the template before its use.
 Verify the weld edge preparation w.r.t the detail shown in the approved drawing & WPS.
 Verify laminations on the Weld edge Visually and or by DPT.
 Verify that the tack welds are carried out by a qualified welder and the tack welds are sound
without any cracks, craters etc. PT examination on tack weld would be essential.

7) Shell to shell/Head circumferential seam set up –

 Visual examination of surface for any objectionable marks.
 Dimension check, weld edge preparation & alignment (straightness), orientation of long
seams, verify taper transition on dissimilar thickness joints.
 Verify laminations on the Weld edge Visually and or by DPT.
 Verify that the tack welds are carried out by a qualified welder and the tack welds are sound
without any cracks, craters etc. PT examination on tack weld would be essential.
Note 1) - Visual examination on inside surface shall be carried out before set up of closing seam, if
access inside the vessel is restricted.
Note 2) – For columns, shell alignment shall be checked at 0, 90, 180 & 270 degree. The ovality of
shells shall be maintained on the lower side of the tolerance to accommodate distortion after
welding of TSR’s & other internals. Elevation and orientation of each Tray support ring (TSR) shall
be checked from the reference line. TSR to TSR pitch shall be within the acceptable limit as
specified in the client/PMC specification. The Level of all TSR’s & bolting bars shall be checked with
a green twine (line dori). The slot/hole dimensions, center to center distance between bolting bars
shall be verified.. Caution: verify the welding size, locations and length of welds of bolting bars as
per drawing. Normally not all the sides of TSR, Bolding bars etc. are welded as they are specified in
the drawing depending on the type of trays, bolding bars.

8) Inspection of Formed heads –

 Visual examination on inside & outside surface for objectionable forming marks.
 Dimension check – Diameter, Ovality, circumference, profile check with full template & height
w.r.t the approved drawing. Template shall be checked on layout and approved for the
specified profile as per drawing.
 Thickness survey with a calibrated Ultrasonic thickness gauge shall be carried out at minimum
03 axis at 120 degrees apart or suitably increased depending on the diameter of formed head,
starting from the edge (Straight flange) to the center of the head. The spacing between check
points shall be reasonably close.
 Liquid Penetrant test shall be carried out on the knuckle portion (inside & outside surface) &
the weld edge preparation. Any additional NDE required by the client specification & ITP shall
be carried out.
 Verify NDE operator’s qualification as per SNT TC 1A. The NDE consumables (Penetrant,
developer & cleaner) shall be from same approved manufacturer.

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PRESSURE VESSEL / PROPRIETARY PRESSURE TUV NORD GROUP
EQUIPMENT / PARTS

 Verify completion of heat treatment (if applicable) including simulation heat treatment &
testing of the coupon.
 No grinding shall be permitted on the internal surface of Clad Heads as it may reduce the
cladding thickness

9) Nozzle set up on shell & head –

 Visual examination for objectionable surface marks, cracked tack welds etc.
 Dimension check (orientation, elevation, Tilt & projection from reference line, bolt hole
straddling, location from Center line for Tangential nozzles, Angles with approved templates
for angular nozzles).
 Verify the center to center distance between level gauge nozzles (difference should not be
more than 1 mm from required value). Flange face shall not be tilted by more than 0.25
degree.
 Verify TUV hard stamp on neck & flange and verify the Flange size and rating as per Nozzle
schedule.
 Verify weld edge preparation as per approved drawing.
 Verify that the tack welds are carried out by a qualified welder and the tack welds are sound
without any cracks, craters etc. PT examination on tack weld would be essential.
 Verify the gasket seating surface for required finish & any visible damage. Ensure that the
gasket seating faces are protected before commencement of welding to avoid damages
 Verify the size, number of Tell-tale hole on RF pad (when RF pad is applicable)

10) Back chip Dye penetrant test of long seams, C/Seams & nozzle to shell/head joints shall be
witnessed or report shall be reviewed as specified in the approved ITP.

11) Non Destructive Examination(NDE) –

 Review of radiographs for all butt joints as per the scope mentioned in the approved
drawing/ITP.
 In case of spot radiography, the Inspector shall select the spots randomly after visual
Examination of the completed welds & verify the coverage per welder/procedure of L/Seams
& C/seams irrespective of the ‘T’ joints covered against the requirement stated in ASME
section VIII division I, UW 11(b).
 Verify the compliance in case of full radiography as per UW 11(a).
 Any additional NDE specified by the client specification, approved drawing & ITP shall be
witnessed / reviewed as specified.
 When UT is used in lieu of RT, verify that the manufacturer has an approved procedure,
witness the UT and record the indications
 Verify NDE before & after PWHT as specified.
 Pneumatic test of RF pads – Witness the pneumatic test at a pressure as specified in the
approved drawing and check the welds (inside and outside) with soap studs or review report
as specified in the approved ITP.
 Insist for NDE (PT or MPT) on temporary cleats removed area on pressure parts.

12) Final Visual before PWHT or Hydro test –

 Verify completion of all fabrication activities & carry out thorough examination of all weld
joints for surface defects, weld profile, weld fillet size of pressure parts as well as non-
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PRESSURE VESSEL / PROPRIETARY PRESSURE TUV NORD GROUP
EQUIPMENT / PARTS

pressure parts, weld undercuts, etc. Nozzle neck inside the vessel shall be rounded to 3 mm
radius minimum. Pipe to flange joints shall be flush ground from inside. Ensure Temporary
cleats removed areas on Pressure parts are thoroughly attended by means of filling, grinding,
necessary NDE carried out.
 Flatness of bolting bars to be verified after welding as they tend to bend during welding
 Ensure that all Non Conformities and concession requests have been satisfactorily closed
before releasing the equipment for PWHT or Hydro Test.

13) Dimension check – Verify location and orientation of all nozzles, piping cleats, insulation cleats,
supports (Lugs, Saddles, Legs), Lifting lugs, TSR, Bolting bars etc., completeness of the equipment
with reference to availability of all items welded to the equipment & as built dimensions before
releasing for PWHT or hydro test. Ensure that only calibrated instruments are used for
measurements. Check the skirt support Anchor Chair dimensions as per the template (Normally,
all customers insist for templates for skirt type supports of Columns and tall vessels before
commencement of fabrication and this template is used during fixing of Foundation bolts at site
one ring template is retained at manufacturer place for verification on the column / vessel)

14) Internals: Verify completeness & trial assembly of internals with equipment. For columns ensure
full welding of TSR to shell joint from top side is completed.

15) Nozzle RF Pad Pneumatic Testing :

 Verify the completion of Fillet welds of Nozzle neck to RF pad & RF pad to shell/Dish end/Cone,
 Verify the completion of weld from inside of Equipment, check for flush Grinding or fillet weld as
required by approved Drawing,
 Carry out the visual check on the welds, ensure that the welds are free from visual surface defects.
 Check the LPT of the welds from inside / outside & ensure that it is free from surface defects.
 Check for leakage if any on the related welds of Nozzle/RF pad by pneumatic test.
 Air test being sensitive testing, the pressure shall be between 1.0 Kg/cm 2 to 1.5 Kg/cm2, or the
pressure shall be as per approved drawing / approved procedure / project requirement
OR
 In the absence of approved procedure or not referenced, the inspector shall ensure a right
procedure/Method or any written communication agreed between the vendor & the purchaser.

16) Post weld heat treatment of equipment:

 Verify completion of PWHT & subsequent NDE of equipment as specified.
 Review PWHT activities w.r.t PWHT chart, no. of thermocouples, location of thermocouples &
calibration records in accordance with approved procedure.
 Verify the thermocouple attachment procedure as per Code.
 Review production test coupon results as applicable.

17) Pressure test of equipment:

 Before Hydrostatic test refer approved pressure test procedure for any additional
requirements.

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PRESSURE VESSEL / PROPRIETARY PRESSURE TUV NORD GROUP
EQUIPMENT / PARTS

 Verify that the pressure gauge range is not less than 1.5 times or more than 4 times the test
pressure (UG-102). Verify that the pressure gauge needle returns to zero after release of
pressure.
 Ensure that the pressure gauge are provided at top most point of the equipment at its test
position.
 Verify the calibration of test gauges & recording equipment.
 Verify test medium reports w.r.t chloride content for conformity to PO specification.
 Verify pressure gauge position, calibration status & quantity.
 Verify the temperature of the test medium & ambient temperature.
 Verify the position of equipment (vertical or horizontal) & ensure correction of pressure
considering the head, in case it is in horizontal position.
 Ensure that all weld joints & flange joints free of paint, grease, oil, dust.
 Ensure that service gaskets & fasteners have been used on flange joints with original blinds or
covers.
 Review any special caution exercised: differential pressure designed vessel, jacketed vessel,
lined vessel.
 Hold the equipment under specified pressure as per approved Drawing for the required
duration & check for any leakages or pressure drop. All welds, flange joints & connections
shall be inspected with the help of sufficient light. The hydro test pressure shall not exceed
the test pressure.
 At the end of the hydro test ensure that the pressure is released gradually from the topmost
connection.
 Report shall be made in the prescribed format. Report shall contain equipment name & tag
no, the start & end time of test, pressure gauge identification no & calibration status, holding
time, position of vessel (vertical or horizontal).
 Witness/review NDE post hydro test as specified.

18) Painting:
 Verify availability of approved painting procedure.
 Review painting report. Ensure details such as ambient conditions, substrate temperature,
surface profile after blasting, start time & primer application time are mentioned on the
report. Review the paint certificates w.r.t approved specification (type of Paint, Paint material)
etc..
 Verify that the hydro test water has been drained completely from vessel & the equipment is
thoroughly dried.
 Check DFT, with a calibrated DFT measuring instrument, at random locations including
underside of the equipment, supports, non-pressure parts. Inspection of painting shall be
done after complete drying of final coat.
 Verify application of protective cover on nozzles & providing packing/blanking for gasket
seating areas.
 Ensure that the painted surface is free from unacceptable pinhole defects, paint sagging, peel
off & excessive coating. Carryout peel test (Adhesion test) when required by the approved ITP

19) Nitrogen Purging of equipment:

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PRESSURE VESSEL / PROPRIETARY PRESSURE TUV NORD GROUP
EQUIPMENT / PARTS

 Verify Nitrogen (N2) filling by verification of provision of Pressure gauge, NRV etc., Check the
PG+NRV assembly by soap solution to check leakages. VCI filling (volatile corrosion inhibitors)
if required by project specification. Endorse the N2 filling report with above details supported
by photos. Check for provision of Silicagel when required by the project specification.

20) Inspection Release Note:

 Verify the correctness of hard stamping details & equipment name plate & apply TUV hard
stamp such that it appears completely.
 Review Manufacturers Record Book (MRB / Documents) and collect a soft copy for TUV office
record. Ensure that all the documents are approved in the final code prior to issue of IRN.
 Issue Inspection Release Note in the TUV standard format or client format if specified &
agreed.
 The IRN shall completely address all review & witness stages as per QAP / ITP & include
important values viz. Test Pressure, reference to the manufacturers certificate, MRB & Test
reports (No. of Pages)
 The slightest deviation or variation or missing data from the approved QAP / ITP / Drawing
shall not be accepted by the Inspector unless duly approved by the original approving
authority, although suggested by the manufacturer even for a proprietary or own design.

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