PGHU-EH-RSPDS-008304-Rev 0 - Pressure Casting Quality and Inspection (PG-PDS 18-03-04)

PG-PDS 18-03-04 Pressure Casting Quality and Inspection December 2008
Scope
This Project Design Specification (PDS) covers the minimum quality and inspection level for iron,
steel (carbon, alloy or stainless), and nickel-based alloy pressure-retaining castings used for pumps,
steam turbines, compressors, valves and pipe fittings or other equipment, when specified by the
Company.
Esso Highlands Limited Strictly Confidential – For Venture Use Only PGHU-EH-RSPDS-008304
Page 2 of 13 ©ExxonMobil Development Company Rev 0

Table of Contents
Table of Tables................................................................................................................4
1. Required References..............................................................................................5
1.1. Project Design Specifications ........................................................................5
1.2. API–American Petroleum Institute .................................................................5
1.3. ASME–American Society of Mechanical Engineers ......................................5
1.4. ASTM–American Society for Testing and Materials ......................................5
1.5. MSS–Manufacturers Standardization Society of the Valve and Fittings
Industry ..........................................................................................................5
2. General ....................................................................................................................6
3. Definitions ...............................................................................................................6
4. Materials ..................................................................................................................8
5. Examinations and Acceptance Criteria ................................................................8
6. Repairs...................................................................................................................11
Attachment: Purpose Code Definitions.....................................................................13

Table of Tables
Table 1: Casting Quality Levels....................................................................................6
Table 2: Critical Areas for Inspection ..........................................................................7
Table 3: Required Examinations and Acceptance Criteria for Valves(5) ...................8
Table 4: Required Examinations and Acceptance Criteria for Piping

Components ................................................................................................10
Table 5: Required Examinations and Acceptance Criteria for Rotating

Equipment Pressure-Retaining Components (4) .......................................11

1. Required References
This Section lists the Practices, codes, standards, specifications, and publications that shall be used
with this document. Unless otherwise specified herein, use the latest edition.
1.1. Project Design Specifications

PGHU-EH-RSPDS- PG-PDS 18-10-01 Additional Requirements for Materials
000801
1.2. API–American Petroleum Institute

API RP 941 Steels for Hydrogen Service at Elevated Temperatures and Pressures in
Petroleum Refineries and Petrochemical Plants
1.3. ASME–American Society of Mechanical Engineers

ASME B16.34 Valves - Flanged, Threaded, and Welding End
ASME B31.3 Process Piping
ASME SEC VIII D1 BPVC Section VIII - Rules for Construction of Pressure Vessels -
Division 1
1.4. ASTM–American Society for Testing and Materials

ASTM A 395/A 395M Standard Specification for Ferritic Ductile Iron Pressure-Retaining
Castings for Use at Elevated Temperatures
ASTM A 487/A 487M Standard Specification for Steel Castings Suitable for Pressure Service
ASTM A 494/A 494M Standard Specification for Castings, Nickel and Nickel Alloy
ASTM A 703/A 703M Standard Specification for Steel Castings, General Requirements, for
Pressure-Containing Parts
1.5. MSS–Manufacturers Standardization Society of the Valve

and Fittings Industry
MSS SP-53 Quality Standard for Steel Castings and Forgings for Valves, Flanges
and Fittings and Other Piping Components - Magnetic Particle
Examination Method
MSS SP-54 Quality Standard for Steel Castings for Valves, Flanges and Fittings and
Other Piping Components - Radiographic Examination Method
MSS SP-55 Quality Standard for Steel Castings for Valves, Flanges, Fittings and
Other Piping Components - Visual Method for Evaluation of Surface
Irregularities

2. General
The Owner's Engineer shall specify inspection requirements for non-ferrous castings other than
nickel-based castings.
3. Definitions
1) [I] The term Inspector, as used in this Practice, refers to the Owner's Representative.
2) Casting Quality Levels hall be assigned to the casting as defined in Table 1.
Table 1: Casting Quality Levels
Quality
Level Casting Type
I 1. All alloy steel and stainless steel castings in continuous cyclic hot hydrogen
service where the design temperature exceeds the CS curve in API RP 941.
2. All castings in hydrofluoric (HF) acid service.
3. [*] Castings in other services or applications as specified by the Owner's Engineer.
II 1. All castings in non-cyclic hot hydrogen service where the design temperature
exceeds the CS curve in API RP 941.
2. All castings in high-pressure steam and hydrocarbon (Class 1500 and higher)
service.
3. Pump castings in:
a. Hydrocarbon or boiler feedwater service where the design pressure is ≥750
psig or design temperature is ≥750°F
b. Chemical service (e.g. sulfuric acid, phenol, peroxide)
c. Low temperature or cryogenic hydrocarbon and petrochemical service where
the design temperature is ≤ –20°F
d. Service where Cr-Mo steels, CA-15, CA6NM, CN7M, stainless steel, alloy
20, and all nickel based alloys, except those covered by Quality Level I or III
are specified
4. Cast steel reciprocating compressors and reciprocating pumps pressure-retaining
castings (cylinders and cylinder heads).
5. Centrifugal and rotary compressor pressure-retaining castings.
III 1. Pump castings in amine and sour water services.
2. Carbon steel castings in high-pressure hydrogen (Class 600 and higher) service.

Quality
Level Casting Type
IV 1. Ductile iron pressure-retaining castings for reciprocating compressors and pumps

(cylinders and cylinder heads).
2. Hydrocarbon and water services not covered in Quality Levels I–III.
3. All commercial grade castings.
3) Major casting repairs are repairs to defects that:

a) Cause a casting to leak during hydrotest.
b) Result in repair cavities exceeding 20 percent of the casting wall thickness or 1 in. (25 mm),
whichever is less.
c) Result in a repair area >10 in.2 (6500 mm2).
4) [*] Critical areas are those defined by the Owner's Engineer and/or based on the results of
examination of initial casting(s), including those listed in Table 2.
Table 2: Critical Areas for Inspection
Component Critical Area
Valves 1. End flange to body transition area

2. Body transition area to the bonnet
3. Small integral nozzle/bleed connections
4. Both ends of buttwelding end valves
Pumps 1. Transition between the volute and casing flanges
2. Transition between the suction nozzle and casing
3. Transition between the discharge nozzle and casing
4. Transition between the casing and feet (pressure boundary only)
5. Junction between the casing and stuffing box
Steam Turbines 1. Nozzle block
2. Steam chest
3. Transition between the casing and nozzle
4. Transition between the casing and joint flange
Reciprocating 1. Valve pockets
Compressors
2. The bore and box packing area
and Pumps(1)
Centrifugal and 1. Transition between the nozzles and casing
Rotary
2. Transition between the casing and horizontal joint
Compressors
3. Areas with radii less than 1 in. (25.4 mm)

Component Critical Area
Other 1. Abrupt changes in casting section thickness or shape

Equipment
2. Locations where risers, gates and feeders are attached
3. Locations that may be subject to high-stress service loadings
4. Ends of buttwelding connections
5. Other areas so designated by the Owner's Engineer
Note to Table 2:
(1) Refers to cast steel reciprocating compressors only. Ductile iron reciprocating compressors
shall be inspected in accordance with Quality Level IV. The final machined valve pocket and
packing box surfaces of cylinders and heads shall be free of porosity on the sealing surfaces,
unless the supplier can demonstrate that this condition will not result in leakage around the
valve or packing.
4. Materials
1) [R] For ductile iron reciprocating compressors and pumps, all castings shall:
a) Be given a ferritizing anneal.
b) Have a microstructure containing a minimum of 90 percent of the Graphite as Type I and
Type II Graphite as defined in ASTM A 395/A 395M.
2) [R] Alloy 400 castings for use in hydrofluoric acid service shall be grade M-35-1 as defined in
ASTM A 494/A 494M except that (Si + 5 x C) shall be less than 2.5 percent.
3) [R] Castings of CA6NM shall be provided per ASTM A 487/A 487M Class B heat treatment.
5. Examinations and Acceptance Criteria

1) Mill test reports of chemical composition and mechanical properties of castings shall be submitted
to the Inspector.
2) [R] For castings requiring postweld heat treatment (except carbon steel), final radiographic
inspection shall be performed after heat treatment.
3) [R] Table 3 specifies the nondestructive examinations and acceptance criteria required for valves.
Table 3: Required Examinations and Acceptance Criteria for Valves(5)
Quality Exam Exam Frequency Acceptance

Level Type(1) (No. of Castings) Extent of Exam(6) Standards
VT All 100 percent VT-1

(4) (2)
I MT/PT All 100 percent MT-1/PT-1(4)
RT All 100 percent RT-1


Level Type(1) (No. of Castings) Extent of Exam(6) Standards

(4) (2)
MT/PT All 100 percent MT-2/PT-2(4)
II
Initial: F1 Critical areas
RT RT-2(3)
Balance: F2 (see below) (see Table 2, this Practice)
III Initial: F1 Critical areas
MT/PT(4) MT-2/PT-2(4)
IV VT All 100 percent VT-1
Frequency of F1 Inspect the first casting of each size and ANSI Class rating.
Examination:
F2 Minimum of 10 percent of the order as selected by the Inspector.
Acceptance VT-1 MSS SP-55
Standards
MT-1 ASME SEC VIII D1 MA APP 7
PT-1 ASME SEC VIII D1 MA APP 7
RT-1 ASME SEC VIII D1 MA APP 7
MT-2 ASME B16.34 Mandatory Appendix II, Section II-2.1
PT-2 ASME B16.34 Mandatory Appendix III, Section III-2.1
RT-2 ASME B16.34 Section 8 and Mandatory Appendix I, Section I-2
Notes to Table 3:
(1) Examination techniques:
VT - Visual examination per MSS SP-55.
MT, PT and RT per ASME SEC VIII D1 MA APP 7
(2) Including machined gasket surfaces and weld bevels.
(3) If a defective casting is found by radiography, two additional castings of the same material and
type shall be examined. If either of these is defective, all remaining castings of the same material
and type shall be examined.
(4) PT shall be substituted for MT for all non-magnetic alloys and low alloy nickel steels.
(5) [*] Table 3 shall cover batch type castings other than valves and piping components when
specified by the Owner's Engineer.
(6) When 100 percent inspection is specified for critical areas or for the entire casting, it shall mean
inspection of all accessible areas.
4) [R] Casting wall thickness shall be measured and dimensional checks shall be performed on all
castings. Results shall meet the requirements of the Manufacturer's approved drawings.
5) [*] [R] Table 4 specifies the nondestructive examinations and acceptance criteria required for
piping components. The Owner's Engineer may specify additional requirements not listed below.

Table 4: Required Examinations and Acceptance Criteria for Piping

Components

Level Type (1) (No. of Castings) Extent of Exam Standards

(4) (2)
MT/PT(4) All 100 percent(2) MT-3/PT-3(4)
II
Initial: F1 Critical areas
RT RT-3(3)
III Initial: F1 Critical areas
MT/PT(4) MT-3/PT-3(4)
Frequency of F1 Inspect the first casting of each size and ANSI Class rating.
Examination
F2 Min. of 10 percent of the order as selected by the Inspector.
Standards
MT-3 MSS SP-53
PT-3 MSS SP-53 Table 1
RT-3 MSS SP-54
Notes to Table 4:
MT per MSS SP-53, PT per Table 1 MSS SP-53, and RT per MSS SP-54
(3) If a defective casting is found by radiography, two additional castings of the same material
and type shall be examined. If either of these is defective, all remaining castings of the same
material and type shall be examined.
6) [R] Table 5 specifies the nondestructive examinations and acceptance criteria required for rotating
equipment components.

Table 5: Required Examinations and Acceptance Criteria for Rotating

Equipment Pressure-Retaining Components (4)

Level Type (1) (No. of Castings) Extent of Exam Standards

(3) (2)
MT/PT(3) All 100 percent(2) MT-2/PT-2(3)
II
RT All Critical areas RT-2
(see Table 2, this Practice)
III MT/PT (3)
All Critical areas MT-2/PT-2(3)
(see Table 2, this Practice)

Standards
MT-2 ASME B16.34 Mandatory Appendix II, Section II-2.1
PT-2 ASME B16.34 Mandatory Appendix III, Section III-2.1
RT-2 ASME B16.34 Mandatory Appendix I, Section I-2
Notes to Table 5:
MT, PT and RT per ASME SEC VIII D1 MA APP 7
(4) [*] Table 5 shall cover small quantity, non-batch type castings other than rotating equipment
pressure-retaining parts when specified by the Owner's Engineer.
6. Repairs
1) [A] [R] The Owner's Engineer shall approve weld repair procedures for Quality Level I, II and III
castings prior to performance of such repairs.

2) [R] Repair and re-examination of castings shall be in accordance with the applicable ASTM
standard or other standard referenced in the purchase order. Repair welds in carbon and low alloy
steel shall be postweld heat treated in accordance with the requirements of ASME SEC VIII D1 C
PT UCS or ASME B31.3. Where the requirements of the applicable standard exceed those of
ASME SEC VIII D1 C PT UCS or ASME B31.3, they shall govern. Welds shall meet the
hardness requirements in GP 18-10-01 except that the hardness of Grade CA6NM castings shall
not exceed 255 HB or Rc23.
a) [R] Repair welds in austenitic stainless steel shall be solution annealed unless otherwise
approved by the Owner's Engineer.
b) [A] The Owner's Engineer shall approve repair procedures for other materials.
3) [R] Weld repairs shall not be carried out on cast iron.
4) [R] All repair welds shall be reinspected to the same standard required for the original casting.
5) [R] Records of all major repairs shall be provided with the final equipment documentation.

Attachment: Purpose Code Definitions

Code Description
* Assigned to paragraphs that require the Owner's Engineer to provide additional information or
make a decision.
A Assigned to paragraphs that require approval from the Owner's Engineer before the work may
proceed or the design is finalized.
C Assigned to paragraphs whose primary purpose is reduced costs. Reduced cost in this context
refers to initial investment cost and does not include life cycle cost considerations. Life cycle
cost considerations are captured under reliability, maintainability, or operability purpose codes.
E Assigned to paragraphs whose primary purpose is driven by environmental considerations.
Environmental considerations typically include specifications intended to protect against
emissions/leakage to the air, water, and/or soil. Deviations from the specifications contained
in such paragraphs require formal review and approval according to local environmental
policy.
I Assigned to paragraphs that provide only clarifying information, such as Scope statements,
definitions of terms, etc.
M Assigned to paragraphs whose primary purpose is to provide for maintainability of equipment
or systems. Maintainability provisions are those that facilitate the performance of maintenance
on equipment/systems either during downtimes or during onstream operations.
O Assigned to paragraphs whose primary purpose is to assure operability of equipment or
systems. Operability is the ability of the equipment/system to perform satisfactorily even
though conditions are off-design, such as during start-ups, process swings, subcomponent
malfunction, etc.
R Assigned to paragraphs whose primary purpose is to improve or assure the reliability of
equipment or systems. Reliability is a measure of the ability of equipment/systems to operate
without malfunction or failure between planned maintenance interventions.
S Assigned to paragraphs containing specifications/guidance where the primary purpose is the
avoidance of incidents impacting personnel safety, operational safety, and the public in general
and/or involving responses to emergency situations. Any deviation from the specifications
contained in such designated paragraphs requires formal review and approval according to
local safety policy.
Personnel Safety: Refers to incident-related personnel injuries or illness, e.g., burns, cuts,
abrasions, inhalation of or exposure to dangerous substances, etc., that
could result in medical treatment, restricted work, lost-time incidents, or
fatalities.
Operational Refers to the prevention and control of process releases, fires, and/or
Safety: explosions that could result in damage to equipment, process disruption,
or personnel injury or illness.

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PG-PDS 18-03-04 Pressure Casting Quality and Inspection December 2008

Page 2 of 13 ©ExxonMobil Development Company Rev 0

5. Examinations and Acceptance Criteria ................................................................8

Attachment: Purpose Code Definitions.....................................................................13

Page 3 of 13 ©ExxonMobil Development Company Rev 0

Table 1: Casting Quality Levels....................................................................................6

Table 2: Critical Areas for Inspection ..........................................................................7

Table 3: Required Examinations and Acceptance Criteria for Valves(5) ...................8

Table 4: Required Examinations and Acceptance Criteria for Piping

Table 5: Required Examinations and Acceptance Criteria for Rotating

Page 4 of 13 ©ExxonMobil Development Company Rev 0

1.1. Project Design Specifications

1.2. API–American Petroleum Institute

1.3. ASME–American Society of Mechanical Engineers

1.4. ASTM–American Society for Testing and Materials

1.5. MSS–Manufacturers Standardization Society of the Valve

Page 5 of 13 ©ExxonMobil Development Company Rev 0

Table 1: Casting Quality Levels

Page 6 of 13 ©ExxonMobil Development Company Rev 0

IV 1. Ductile iron pressure-retaining castings for reciprocating compressors and pumps

3) Major casting repairs are repairs to defects that:

Table 2: Critical Areas for Inspection

Component Critical Area

Valves 1. End flange to body transition area

Page 7 of 13 ©ExxonMobil Development Company Rev 0

Component Critical Area

Other 1. Abrupt changes in casting section thickness or shape

5. Examinations and Acceptance Criteria

Table 3: Required Examinations and Acceptance Criteria for Valves(5)

Quality Exam Exam Frequency Acceptance

VT All 100 percent VT-1

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Quality Exam Exam Frequency Acceptance

VT All 100 percent VT-1

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Table 4: Required Examinations and Acceptance Criteria for Piping

Quality Exam Exam Frequency Acceptance

VT All 100 percent VT-1

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Table 5: Required Examinations and Acceptance Criteria for Rotating

Quality Exam Exam Frequency Acceptance

VT All 100 percent VT-1

Acceptance VT-1 MSS SP-55

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Page 12 of 13 ©ExxonMobil Development Company Rev 0

Attachment: Purpose Code Definitions

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