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Quality Control Procedures


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Collection of Quality Control Procedures

Controlled Copy

□ Uncontrolled Copy
Controlled NO.

Issuance Date Document No.

2009 6 18 HD/ASME-2009

Weifang HuoDa Pipe Fittings Manufacture Co. Itd.

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Document No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 No. HD/ASME-01 HD/ASME-02 HD/ASME-03 HD/ASME-04 HD/ASME-05 HD/ASME-06 HD/ASME-07 HD/ASME-08 HD/ASME-09 HD/ASME-10 HD/ASME-11 HD/ASME-12 HD/ASME-13 HD/ASME-14

Title Rev. Control Procedure of Documents General Material Control Procedure Material Coded Marking Procedure Welding Material Control Procedure Welder Identification Marking Procedure General Welding Repair Procedure Manufacturing and Examination Procedure Pressure Testing Procedure Radiographic Testing Procedure Liquid Penetrant Testing Procedure Written Practice Postweld Heat Treatment Procedure Nonconformity Control Procedure Calibration procedure of measuring, examination, and test equipments 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Date

July.18th ,2009 July.18th ,2009 July.18th ,2009 July.18th ,2009 July.18th ,2009 July.18th ,2009 July.18th ,2009 July.18th ,2009 July.18th ,2009 July.18th ,2009 July.18th ,2009 July.18th ,2009 July.18th ,2009 July.18th ,2009 July.18th ,2009

15

HD/ASME-15

Visual Examination Written Practice B31.1

In Accordance With ASME Code 0 July.18th ,2009

16

HD/ASME-16

Visual Examination Procedure For Power Piping

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Control Procedure of Documents

Prepared by

Date _____________

Approved by _________________Date ____________

Accepted by _________________ Date ____________

1. General 1.1 This procedure describes the responsibility and requirements for the Quality Control Manual, design documents, technology documents, working procedure’s numbering, preparation, approval, distribution, revision and maintaining.

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ASME

2. Stipulate for numbering of QC Manual. 2.1 Document number of QC Manual : HD/QM-01 HD/QM-01 2.2 The numbering of QC Manual:

Is Natural Sequence No(01 02 03···)

01 02 03···

2.3 The numbering of QC Manual is the same as shown in Controlled Manual Issuing List i.e. each Manual Holder has an applicable numbering manual.

2.4 Document numbering of exhibit form is listed on QC Manual, and the numbering has been marked on it.

A B··· 001 002··· 2.5 The preparation QC Manual. 3. Coding Regulation of ASME Quality Control Procedure ASME 3.1 Document coding of ASME Quality Control Procedure ASME HD/ASME The last two digit of sequence No. ASME system ASME Definitions of company 01 02 03··· approval distribution and revision of the QCM should be implement as chapter1 of

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3.1.2 Exhibit forms’ No. and code of other procedures of ASME conform with those of manual procedures and add A symbol in front of them. ASME 3.2 , A Preparation and approving of Procedure

3.2.1 Material control procedure and material marking procedure should be prepared by Material Engineer, Document Control Procedure, Nonconformity Control Procedure, Visual Examination Procedure For Power Piping, Measurement Inspecting equipment procedure should be prepared by QC engineer and approved by quality department manager.

3.2.2 Hydrostatic test procedure and post-welding heat treatment procedure should be prepared by the Design Engineer and approved by the Technical Manager.

3.2.3 Examination procedure should be prepared by the Design Engineer and approved by the Technical Manager. QC 3.2.4 Welding material control procedure and General Welding Repair Procedure should be prepared by Welding Engineer and approved by QC Manager. Ⅲ 3.3 Revision of control procedure is the same as the original. NDE

3.4 The distribution of control procedure 3.4.1 After control procedures were prepared and approved, they will be distributed by the quality department.

3.4.2 Distribution and reclaiming of documents should be recorded in the document distribution form. The reception department should be kept well and not copy them without permission.

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3.5 Maintenance of QC documents 3.5.1 QC documents shall be kept by the QC Engineer in file.

3.5.2 QC documents shall be available for AI to review. AI 4. The drawings, design documents and other technology documents 4.1.1 Drawing No. part sequence No. assembly drawing sequence No. B C

The first two digits are year No. and the last two digits are contract No. Category of drawing S A U

A Category of drawing: S: means Pipe products U: symbol Vessel products B Assembly Drawing sequence No. 1, 2, 3…… 1 2 3··· C part sequence No. 01, 02, 03…… 01 02 03··· 4.1.2 Design document No.

documents sequence

1 2 3···

the first two digits are year No. and the last two digits are contract No. Classification Design document classification code name as follows, AC-----pressure vessel design count book

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b

AR――pressure vessel purchasing technique condition 4.1.3 Craft document No.

docum ents sequence

1 2 3 ···

the first two digits are year No.and the last two digits are contract No Classification code name Craft document classification code name as follows, Process flow chart No.: PFC Process check list No.: PCL heat treatment card: HTI welding craft procedure: WPS joint identification card: f g welding craft evaluation record: PQR welder and weld operator skill evaluation: WPQ/WOPQ WPQ/WOPQ 4.2 The preparation and approval of the drawings design documents and technology documents. JIC PQR HTI WPS PFC PCL

4.2.1 The Design Drawing, the Calculation Sheet, the Customer Specification, the Material Purchasing List and the Material Purchasing Specification should be prepared by the craft engineer, audited by EE and approved by TECHNICAL MANAGER.

4.2.2 PCL should be prepared by the Design Engineer, reviewed by QC Engineer and approved by Technical Manager. 4.2.3 c), d), e), f), g) are prepared by Welding Engineer and approved by Design Engineer. c), d), e), f), g)

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4.3 The revision of the Drawing and Design Documents. 4.3.1 The control methods of the revision to the drawing and technology documents are as same as the originals. 4.3.2 When the drawings and design documents need to be revised, the Technician shall first write a Document Revision Notice which includes the number of the design documents or the drawings and the name, the reason and content for revision as so on. It should be approved by TECHNICAL MANAGER. If it isn’t consistent with customers’ requirements, the company shall obtain the agreement of the customer in written form.

4.4 The revision of Technology Documents 4.4.1 The revision of technology documents shall be controlled in the same manner as the original.

4.4.2 When a change does not involve hold, witness points, the TECHNICAL MANAGER can be authorized to approve some changes by signing and dating adjacent to the process of document. Any change with hold point shall be confirmed by AI and the change shall be informed the Workshop Supervisor.

4.4.3 The revision of technology documents shall be made so as to meet with the following requirements. owing to the revision of design input. the mistake of the design documents. the special requirement provided by the customer. 4.5 Concerning the revision of drawings and design documents, the DE takes the fully filled Revision Notice and marks the revision mark on the revised place. 4.6 The Issuance of Drawing, design documents and Technology Documents

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4.6.1 The drawing, design documents and technology documents shall be distributed by the Document Keeper according to the Document Issuance List.

4.6.2 When the documents are distributed or recalled, the mark shall be signed on the Documents Issuance List. 4.6.3 The drawing design documents and technology documents shall be maintained well and shall not be copied without authorization.

4.7 Retention 4.7.1 The drawings, design documents and technology documents prepared by the Design Engineer shall be kept on file for at least three years.

4.7.2 All of the technology documents shall be available for AI to review. AI

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General Material Control Procedure

Prepared by

Date

Approved by

Date

Accepted by

Date

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1. 1.1

Scope This procedure is established requirements for general material control especially for steel plates, steel

tubes and other materials including welding material during the material purchasing, receiving, marking and manufacturing.

1.2 1.2

This procedure is supplementary requirement to the QC Manual for Code items construction.

2 Material Purchasing For raw materials which used in construction of ASME Code items, Design Engineer shall prepare “Material Requisition” (MR) and “Material Purchasing Specification” (MPS) based on the design drawings. “Material

Requisition” shall specify the designation of material, grade, class and type, the specification edition of the material required, size and quantity. The “Material Purchasing Specification” shall specify the material designation, type, grade and applicable ASME Code Section Edition and Addenda, chemical and mechanical property, supplementary examination and testing required by the Code (e.g. NDT requirements, impact test, etc.,) marking requirement, type of material certificate to be submitted, etc. “Material Requisition” and “Material Purchasing Specification” shall be approved by Technical Manager before transmitted to the Purchasing Engineer for preparing Purchase Order. ASME MR MPS ASME e.g. NDT

2.1

For welding materials, Welding Engineer shall prepare “Material Requisition” and “Material Purchasing

Specification”for welding material based on the drawing and WPS. MR and MPS shall specify the welding

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material type, trade name (or AWS designation number, ASME SFA number, if applicable), size, supplementary test requirements and whether material certificate is required or not. MR and MPS shall be approved by Technical Manager before transmit to the Purchasing Engineer to prepare Purchase Order. WPS MR MPS AWS ASME SFA

MR,MPS 2.2 The material specification, qualified supplier, size, quantity, unit price, total price, delivery time, shipment and payment method, material certificate to be required and items of breach the contract should be specified clearly in the Purchase Order. The PO should be concluded after it is approved by the Purchasing Manager.

3 Material Receiving Inspections 3.1 Material Keeper should receive the goods according to the copy of the PO and the corresponding documents, such as MP ,MPS ,packing list, material certificate and invoice when the goods was sent to the JSSX by the supplier. The Packing List should clearly indicate the materials name, quantity, unit price, total price and delivery time. The material certificate should clearly specify the material specification, type, grade, class, chemistry element, mechanical property, and seal of the supplier and the signature of the supplier. The Material Keeper should confirm with signature on the packing list and receive the goods, when document is checked and the delivered goods are in accordance with the Purchase Order.

3.2 Purchasing Engineer should advice Examiner to perform receiving inspection. Examiner shall conduct material receiving inspection according to MR, MPS and PO; the “Material Receiving Examination Record” shall be prepared by Examiner after material receiving inspection.

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MR

MPS

PO

The receiving inspection shall include but not limited to the followings:

Marking and Stamping verify Quantity verification Surface condition examination Lamination and deformation check especially on the cutting edges

Dimensional check , thickness verification, shape tolerance measuring

3.3 Material Engineer should responsible to review the “Material Receiving Examination Record” and MTR after the material receiving inspection. If the result is satisfactory, the Material Engineer shall stamp the “Material Test Report Review Stamp” on the MTR. MTR MTR 3.4 If deemed necessary, the Material Engineer and Examiner shall request for chemical analysis and physical test on the in-coming material. The specimen preparation shall be fully in compliance with the requirements of ASME Section II. Charpy impact test if required, shall be subcontracted to qualified lab. and shall comply with the QC Manual requirements.

ASME

3.5

When the materials are accepted after material receiving examination, Examiner shall inform the

Material Keeper to place materials in the accepted area. The “Material Acceptance Label” shall be prepared by Examiner and attached on the material or parts. The Material Coded Mark shall be indicated on “Material Acceptance Label” according to “Material Coded Marking Procedure” (HD/ASME-03).

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(HD/ASME-03)

3.6 Material found not acceptable or rejected shall be treated as nonconformity. NCR shall be issued and treated as the requirements described in the Section 6 of QC Manual. NCR

3.7 The material receiving examination results recorded in the Material Receiving Examination Record, Mill Certificate, Inspection Report, Partial Data Report and Chemical Analysis / Physical Test Reports, if applicable shall be made available to the AI for his review and acceptance. / AI 4 Material Storage

The Material Keeper shall keep a log of material which all materials and parts are listed on it and stored in stock.

4.1 Material Keeper shall place the acceptable material in the designated area. Board of “Storage Area of ASME material” shall be placed to identify the ASME material from other materials. Material Keeper is responsible to periodically verify and maintain material records, identification markings etc. and shall refresh marking before they are obliterated. All Code material is protected from damage, loss, deterioration and separation from other material. ASME ASME

4.2 Stainless steel shall be stored separately with other material and shall not be contaminated with ferrous metals.

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4.3 The welding material for Code items shall be stored in the designated shelves of 12 in. (300 mm) away from the wall and above the floor under controlled temperature (30 C + 10 C) and humidity (less than 60%). The Material Keeper of welding material shall prevent intermingling material of different specification, brands and lots, and shall make correct marking. Welding material shall be protected from damage, loss or

deterioration. The Material Keeper shall assure that appropriate storage conditions are maintained. 12 300mm 300mm (30 C + 10 C) ( 60%) 12

4.4 The store-house of welding material shall be furnished with proper facilities for storing.

If applicable,

these facilities shall be calibrated and controlled as per the requirement of QC Manual. The material-keeper shall be responsible for receiving, storing, baking and issuing welding material, and maintaining the records. Before using, covered electrodes and the flux shall be dried according to the technical procedure, recommendation or specifications by welding material manufacturer.

5

Material Issuance

5.1 Material Keeper shall issue the material to the shop according to the “Material Delivery Card” which is prepared by Shop Supervisor in accordance with drawings and production schedule.

5.2 The Shop Supervisor shall prepare “Material Delivery Card” for welding material in according to drawings and qualified WPS to the production welders. welder according to Material Delivery Card. WPS The Material Keeper shall issue welding consumable to the

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5.3 Welding consumable used for ASME Code items shall be duly baked and stored in the specified conditions as required by the welding material manufacturer specification before issuing. ASME

5.4 Material Keeper shall indicate the using time limitation on the Material Delivery Card and advise the welder to return the welding consumable when the using time limitation of welding consumable was exceeded.

5.5 Welder shall return all welding consumable to the Material Keeper when the using time limitation of welding materials is exceeded or at the end of one shift.

5.6 All returned welding consumable shall be re-baked, stored and issued as per the original.

5.7 The re-baking times for welding consumables shall not be more than three (3) times. 3 6 Material Identification and Traceability During Fabrication

6.1 All material shall be properly identified by the Material Coded Mark in accordance with
HD/ASME-03. HD/ASME-03

6.2 When the material shall be cut to more than two pieces the material identification or material Coded mark shall be transferred on each piece of material before the cutting. The material identification or material Code mark shall be kept the material traceability during the fabrication.

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7

Nonconformity

7.1 When nonconformity was found during the fabrication process, it shall be handled as per the requirements of Section 6 of QC Manual. 6 7.2 The Examiner shall be responsible to put Nonconformity Tag on the found nonconformity parts. All fabrication work shall be stopped before disposing NCR. NCR 8 Records 8.1 All records created during the construction of pressure vessels for Code items shall be filed by the material Engineer and made available to the AI for review and acceptance. AI

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Material Coded Marking Procedure

Prepared by

Date

Approved by

Date

Accepted by

Date

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1.11 General

This procedure is a written description of the control for material Coded marking using in material identification and traceability during the pressure vessels construction according to ASME Code Section VIII, Division 1 ASME 1.2 For non-pressure parts which welded to the pressure parts, the marking transfer shall also made in the same manner as pressure parts.

2 2.1

Requirements The Material Keeper shall identify material or parts with material coded marking number after receiving inspection is completed and found acceptable.

2.2

During the fabrication process, the Shop Supervisor shall be responsible to transfer the material coded mark after lay-out and prior to cutting.

2.3

The Examiner shall be responsible for issuance, implement and supervising the correct transfer of coded marking number. A list of coded marking number shall be maintained by Examiner.

2.4

Material Coded marking number shall be indicated on the “Material Receiving Examination Record” and MTR; it can be traced back to the material heat number and/or plate number on the original MTR. MTR MTR /

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3 Consist of Material Coded Marking Number

3.1

Material Coded Marking Number will be consisted with A letter and six digits as following: A

A

is represented ASME material or parts ( without A is represented non ASME material ) A ASME ASME A ASME

where: B - represented for plate B– F - represented for head FC – represented for flange which fabricated by HD C– HD

D – represented for flange except for fabricated by HD D– HD

H-represented for welding material M- represented for valve HG –represented for tube & pipe G3.2 Examples Material Coded Marking Number: AB07001 where : 09 means that material arrived at shop in year 2009 ML – represented for bolts & nuts L-

AB09001 :

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09

2009

B means that material is plate. B 001 means serial No of material incoming shop. 001 4 4.1 Method of Marking For carbon steel and low alloy steel plate : When the plate thickness is less than 1/4 in. (6 mm), material coded marking number shall be indicated on the plate by white paint When the plate is thicker than 1/4 in. (6 mm), die stamping may be employed. or indicated on the plate by painting. 1/4 1/4 4.2 6mm 6mm

For non-ferrous plate: When the plate thickness is less than 1/2 in. (13 mm), material coded marking shall be indicated on the plate by green paint. When the plate is thicker than 1/2 in. (13 mm), die stamping may be employed. 1/2 1/2 (13 mm) (13 mm),

4.3

For stainless steel plate: green painting shall be employed.

4.4

For tube, pipe rod or bar: white painting and mark pen shall be employed on the tube and pipe when the outside diameter is less than 2 in. (50 mm). 2 in. (50 mm)

4.5

The marking character shall be of about 1/2 in. (12 mm) in height, and the stamping shall not be deeper than 0.3 mm. 1/2 in. (12 mm) 0.3 mm

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4.6

When the material specification, service conditions or customer stipulated that die-stamping on the materials is prohibited, paint, or tag shall be used to identify the material during the whole fabrication process.

5 Location of Material Coded Marking

5.1

The material coded marking shall be located on each pressure parts or components and can be plainly visible during the whole fabrication process or when the vessel is completed.

5.2

The material coded marking shall be away from the welding seam or attachment as possible.

5.3

The location of material coded marking on the plate shall be at bottom right corner and about 4 in. (100 mm) away from the edge and the welding seam. 4 in. (100 mm)

5.4

The location of material coded marking on the blank head shall be within a circle of not more than 8 in. (200 mm) from the center, others, the marking shall be located within the circle of not more than two-third (2/3) of head radius from the center of head. 8 in. (200 mm) 2/3

5.5

The location of material coded marking on the finished flanges and forging shall be on the outside of peripheral surface.

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5.6

The location of material coded marking on the nozzle neck and reinforcing plate shall be at the center as possible.

5.7

The location of material coded marking on the bolt and stud shall be on the end surface or on peripheral surface near the end , if it is available.

5.8

The location of material coded marking on the components of finished vessel shall be framed with paint for easy identification.

6

Record

6.1 Examiner shall log the material coded marking on the “Material Coded Marking Record”.

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Welding Material Control Procedure

Prepared by

Date

Approved by

Date

Accepted by

Dat ___________

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1

Scope

1.1 This procedure provides supplementary requirements to the QC Manual and “General Material Control Procedure”
HD/ASME-02

about the storage, baking, issuance and return of welding consumables used for

construction of ASME Code items. ASME
HD/ASME-02

2

Receiving Inspection of Welding Consumables

2.1 QC Engineer shall provide sufficient training and knowledge to the Material Keeper about the welding consumables control requirement in the QC Manual. The Material Keeper shall be familiar with the general requirements and specifications of welding materials.

2.2 When receiving welding consumables, the Material Keeper shall check and verify welding consumable as per “Material Requisition”. He shall check the marking of the welding consumable container in accordance with the applicable specifications. He shall also inspect the condition of packing in order to assure that no damage has been occurred.

3

Storage of Welding Consumables

3.1 Welding materials shall be stored in such the way as specified in the General Material Control Procedure.

3.2 The welding materials for Code items shall be stored in the designated shelves of 12 in. (300 mm) away from the wall and above the floor under controlled temperature (30 C + 10 C) and humidity (less than 60%). The Material Keeper shall prevent intermingling materials of different specification, brands and lots, and shall make correct marking. Welding materials shall be protected from damage, loss or deterioration. The

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Material Keeper shall assure that appropriate storage conditions are maintained. 12 ( 60%) 300mm (30 C + 10 C)

3.3 The store-house of welding materials shall be furnished with proper facilities for storing. If applicable, these facilities shall be calibrated and controlled as per the requirement of QC Manual. The Material Keeper shall be responsible for receiving, storing, baking and issuing welding materials, and maintaining the records.

3.4 The Material Keeper shall check and verify the temperature and humidity in the store-house twice a day.

4

Drying and Holding

4.1 Prior to using, electrodes and flux shall be dried in accordance with the general recommendation as specified in Table 1. 1 4.2 The dried electrodes shall be kept in the holding oven and held at 212 F to 302 F (100 C to 150 C). The dried low hydrogen electrodes shall not be exposed to atmosphere for more than 4 hours. 212 F 302 F (100 C 150 C)

4.3 After the packing has been opened, the electrodes and flux shall be put into the drying oven, the charge temperature of oven shall be limited no more than 212 F (100 C) so as to prevent the coating from breaking. The heating and cooling temperature shall not exceed the speed of 212 F to 302 F (100 C to 150 C) per hour.

212 F (100 C)

212 F

302 F (100 C

150 C)

4.4 Covered electrodes shall be placed on the shelves of drying oven with no more than five (5) layers. Fluxes are placed into the drying oven using the box and the thickness shall not be more than 4 in. (100 mm). During

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drying, welding materials shall be free from fastenings, bindings. 4 (100 mm)

4.5 The records for drying of the welding material shall be maintained by the Material Keeper, which shall include the designate specification, brand and lot, heating temperature and drying time.

4.6 The QC manager shall review the drying records and verify the drying operation periodically.

5

Issuance of Welding Consumables

5.1 The Material Keeper shall issue the welding materials in accordance with the Material Delivery Card.

5.2 The issued electrodes shall be kept in the welder quiver. The issued coiled welding wire shall be installed on reel. The issued GTAW welding wire shall be stored in plastic pipe with identification.

5.3 The Material Keeper shall advise the welder about the time limitation for the use of electrodes .Anyway the time limitation for the use of electrodes shall not exceed four (4) hours. 4 6 Return of Welding Consumables

6.1 Welders shall return the remaining welding consumables to the Material Keeper as soon as the welding operation is finished or when the time limitation for the welding material is exceeded. The Material Keeper shall place the returned welding consumables in the designated location and record the returned quantity on the Material Delivery Card.

6.2 Returned covered electrode may be reused after rebaking, but the rebaking times shall not be more than

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three (3) times.

Table 1 Recommendation for the Baking of Electrode Flux

Welding Consumable AWS Classification E7015 E308(L)-16 E309(L)-16, GB Classification E5015 , E308(L)-16, E309(L)-16, FA402-H08A(HJ431)

Baking Temperature

Baking Hours

350 C ~ 400 C 300 C ~ 350 C

Min. 1 hour Min. 1 hour

~ 250 C

Min. 2 hours

* Note: For other welding materials which are not listed in this table, the baking temperature and holding time shall be controlled according to the requirements of ASME Code Section II, Part C, welding material specifications or manufacturer recommendation. ASME , C

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Welder Identification Marking Procedure

Prepared by

Date

Approved by

Date

Accepted by

Date

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1 1.1

Scope This procedure is a supplementary requirement to the QC Manual for the welding control. It provides welder and welding operator with an identifying method for weld that he has made.

2 2.1

Welder or Welding Operator Symbol Each qualified welder or welding operator shall be assigned a unique identifying symbol by the Welding Engineer and this symbol shall be recorded in the Welder Performance Qualification Record (WPQ).

WPQ 2.2 The welder identifying symbol shall be composed of capital English letter followed by the natural number, which shall be 0.312 in. (8 mm) high. 0.312 in. (8 mm) 3 3.1 Stamping for P-No.1 Gr.Nos.1 and 2 / P-No.1 Gr.Nos.1 2

Each welder shall immediately stamp his identifying symbol adjacent to the weld that he makes in steel plates 1/4 in (6mm) and over in thickness as per the requirements specified by following paragraph except such stamping is not permitted. The welder shall control the stamping in order that the identifying symbol indented down on the surface of about 0.01~0.02 in. (0.3 ~ 0.5 mm). 1/4 in (6mm)

0.01~0.02 in. (0.3 ~ 0.5 mm) 3.2 When several welders made a weld cooperatively, each of them shall stamp or make out his identifying symbol individually in accordance with the requirements in paragraph 3.1.

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3.1

3.3

Stamp location

3.3.1 For longitudinal weld : The identifying symbol shall be stamped along the weld and shall be away from the fusion zone about 1/2 in. (13 mm). The identifying symbol shall be stamped at place of 2 in. (50 mm) from the edge of the weld end. The interval of two identifying symbol shall not be more than 3 ft. (1 meter). 1/2 in. (13 mm) 2 in. (50 mm) 3 ft. (1 )

3.3.2 For circumferential weld : The identifying symbol shall be stamped along the weld and shall be away from the fusion zone about 1/2 in. (13 mm). The interval of two identifying symbol shall not be more than 3 ft. (1 meter), and the interval shall be made uniformly in length as possible. 1/2 in. (13 mm) 3 ft. (1 )

3.3.3 For welded head: The identifying symbol shall be stamped on the convex face, and shall be parallel to the weld. The location of stamping shall be kept away form the skirt and knuckle of the head, and shall be away from the fusion zone about 1/2 in. (13 mm). The interval of two identifying symbol shall not be more than 3 ft. (1 meter) in length.

1/2 in. (13 mm) 3.3.4 For nozzle and inspection opening to vessel: The identifying symbol shall be stamped on the vessel surface as possible and shall be parallel to the weld. The location of stamping shall be away from the fusion zone about 1/2 in. (13 mm).

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1/2 in. (13 mm) 3.3.5 For nozzle to flange: The identifying symbol shall be stamped on the nozzle surface as possible and shall be parallel to the weld. The location of stamping shall be away from the fusion zone about 1/2 in. (13 mm).

1/2 in. (13 mm) 3.3.6 For non-pressure part to pressure part: The identifying symbol shall be stamped on the non-pressure surface as possible and shall be parallel to the weld. The location of stamping shall be away from the welding edge about 1/2 in. (13 mm). The interval of two identifying symbol shall not be more than 3 ft. (1 meter) in length.

2 in. (50 mm)

3 ft. (1

)

3.3.7 The welder's identifying mark shall be recorded for the condition that the stamp is prohibited.

3.3.8 For welding procedure qualification, welder qualification and test plate: The identifying symbol shall be stamped on the coupon immediately after the welding is completed. be enough. One stamping on each coupon will

4 4.1

Welder Identification Recording For welds on vessels made material except for P-No.1 Gr.1 and 2, or with the wall thickness of less than 3/16 in. (5 mm) or the minimum nominal pipe wall thickness is less than 0.154 in (3.91mm), or MDMT is cold than -20 F and non-ferrous materials with the wall thickness of less than 0.249 in. (6.32 mm), or the minimum nominal pipe thickness is less than 0.133 in (3.37 mm), or when stipulated by the customer. The welder identifying number will be prohibited to stamp on the vessel. The welder identification shall be marked by pen or paint nearby weld and welder identification shall be recorded with weld map

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specified in following paragraphs shall be employed: P-No.1 Gr.1 and 2 0.154 in (3.91mm) 0.249 in. (6.32 mm) MDMT -20 F 3/16 in. (5 mm)

0.133 in (3.37 mm)

4.2 Record.

The welding Engineer shall record the production welding details on the Welding Work

4.3

Each welder shall mark his identifying symbol adjacent to and parallel to the completed weld clearly with marking pen or paint.

5 5.1

Others Tack welds if merged into the final production weld shall also be identified in accordance with the requirements specified in above paragraphs.

5.2

In case of multiple numbers of welds on a part, such as tube sheet welds, Welding Work Record or other report forms shall be employed to identify the weld seams instead of stamping the welder identification symbol.

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General Welding Repair Procedure

Prepared by

Date

Approved by

Date

Accepted by

Date

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1

Scope

1.1 This procedure is prepared to establish repair procedure for defects on the material, welds and pressure parts of Code items which is frequently found on the material and welds. This procedure is supplementary requirement to the QC Manual.

2

Repair of Defects in Materials

2.1 When serious or unaccepted defects found on the pressure parts during the receiving inspection. Examiner shall report to QC Engineer If nonconformity exists, QC Engineer prepare NCR.

NCR 2.2 QC Engineer shall be responsible for proposing the disposition of NCR. QC Engineer shall put the number of NCR on the Process Check List (PCL). Design Engineer is responsible for proposed repair method. NCR NCR PCL

2.3 If the defects shall be repaired by welding, the qualified WPS and welder or welding operator shall be used in repair, the repair method including removing the defects and Welding Procedure Specification (WPS) shall be prepared based on the material specification, mill certificate. WPS WPS

2.4 AI shall be informed the kind and extent of defect, methods of removing defects, repair methods and intended NDT or testing before repair. All inspection and examination reports and results shall be presented to the AI to assist him to make the decision on the acceptance of the material repair. AI AI 2.5 Defective material that can not be satisfactorily repaired or repair is unacceptable to the AI, it shall be rejected.

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AI

2.6 All welding repair on the material shall be conducted to fully comply with the ASME Code requirements. After repair and found acceptable by inspection and examination, material can be used for the Code items. ASME

3

Repair of Defects in Welds

3.1 Defects such as irregular surface profiles, overlap, too much high and low shall be repaired by grinding. Defects such as lack of penetration, lack of fusion, slag inclusion, porosity, undercut, under-fill etc. were randomly found in the welds by visual check shall be repaired by welding. Defects shall be thoroughly removed before repair. The visual check shall be conducted after removing defects. Repair welding shall be performed by qualified and experienced welders according to the original WPS. Welding consumables used for repair shall be controlled as the original. Repair weld shall also be identified by stamping or recording down welder identification number. After repairing, the visual check shall be performed and the results shall be made available to the AI during his next visit.

WPS AI

AI 3.2 When defects regularly found in the welding, QC Engineer shall carry out investigation on the possible causes. NCR shall be issued and proposed dispose shall be collected from relevant departments. If deemed necessary, new WPS or re-qualification of welder shall be carried out. All repair related inspection and examination shall be indicated on the Process Check List. AI shall be informed before, during and after welding. All repair related examination and inspection results or reports and NCR shall be made available to the AI for review and acceptance.

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NCR WPS AI NRC 4 4.1 AI

Repair of Defects caused by Testing When defects occurred during the pressure testing or other operation such as assembly and pressure testing, the defects shall be repaired according to paragraph 3.0. 3.0

4.2. After repair including welding repair, visual and/or dimensional check shall be carried out to ensure that no defects existed in the welds, and possible deformation or deviation in dimensions of the repaired pressure vessel shall within tolerance of the ASME Code required. / ASME 4.3 After welding repair, the pressure testing shall be carried out on Code items according to drawing.

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Manufacturing and Examination Procedure

Prepared by

Date

Approved by

Date

Accepted by

Date

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1 1.1

Scope This procedure establishes the inspection, testing and examination requirements during the fabrication process of pressure vessels which constructed to the ASME Code Section VIII, Division 1.

ASME 1.2

ASME B31.1

The manufacturing process mentioned in this procedures including material preparation (cutting, edge preparation, machining), forming, welding and final testing, etc. The inspection mentioned in this

procedure mainly means the visual inspection and dimensional measuring check.

2 2.1

Responsibility: The QC Manager shall be responsible to train and qualify the Examiners who engaged in the manufacturing process inspection on pressure vessels, and shall control the quality.

2.2 The Examiner shall conduct inspection and examination based on the items listed in Process Check List (PCL), procedures and the applicable Code Section requirements. PCL 2.3 After inspection, Examiner shall record the results in the “Inspection and Examination Record” forms and keep them in file.

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2.4

Any unacceptable items or quality related problems found during the inspection shall be handled as nonconformity.

3 3.1 3.2

Preparation for Inspection Examiner shall have an annual vision test. Direct visual examination may be conducted when the parts can be examined at an angle not less than 30 degree. Mirrors may be used to assist examination when deemed necessary. 30

3.3

The material, part, component etc. under visual examination shall be sufficiently illuminated. Flashlight or other auxiliary lighting devices shall be employed is necessary.

3.4 In some cases, remote visual examination may have to be substituted for direct examination.

Remote

visual examination may use visual aids such as mirrors, telescopes, borescopes, fiber optics, cameras, or other suitable instruments. Such systems shall have a resolution capability at least equivalent to that obtainable by direct observation.

3.5

All the examined surfaces shall be clean. Irregular shapes covering and mixing surface defects shall be washed away.

4

Inspection during Material Cutting

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4.1

After lay-out but before cutting, the Examiner shall verify and examine the accurate transfer of Coded Mark.

Material

4.2

When plates, components, and other parts, may be cut to shape and size by oxygen or arc cutting for carbon and low alloy steel and by plasma cutting machine for austenitic stainless steel. After cutting, the edges to be welded shall be uniform and smooth and shall be free of all loose scale and slag accumulations before welding. The detrimental discoloration of material which has been molten shall be removed prior to further fabrication or use.

4.3

Ends of nozzles or manhole necks which are to remain unwelded in the completed vessel may be cut by shearing provided sufficient additional material is removed by any other method that produces a smooth finish. Exposed inside edges shall be chamfered or rounded.

4.4

The Examiner shall examine the shapes and dimensions of cut parts by steel ruler, band tape or model.

4.5 Cutting edge of being cut parts shall be examined by direct visual examination or by magnifying glass when deemed necessary in order to disclose possible lamination, shearing crackle, or other defects.

5 5.1

Forming Examination If the plates are to be rolled, the adjoining edges of longitudinal joints of cylindrical vessels shall first be

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shaped to the proper curvature by preliminary rolling or forming in order to avoid having objectionable flat spots along the completed joints.

5.2

The shell of an internal pressure vessel shall be substantially round. The difference between the maximum and minimum inside diameters at any cross section shall not exceed 1% of the nominal diameter at the cross section under consideration.

1% When the cross section passes through an opening or within 1 ID of an opening or within 1ID of the opening measured from the center of the opening, the permissible difference in inside diameters given above, may be increased by 2% of the inside diameter of the opening. 1ID 2% When the cross section passes through any other location normal to the axis of the vessel, including head to shell junctions, the difference in diameters shall not exceed 1 %. For vessels with longitudinal lap joints, the permissible difference in inside diameters may be increased by the nominal plate thickness. Roundness measurement shall be completed inside vessels, and be vertical to the rolling shaft by special gauge, instrument steel rule, band tape, caliber etc. Each shell shall be examined at least in three cross sections, two at ends and one at midst section.

5.3

The shell of a completed vessel to operate under external pressure shall not exceed the out-of-roundness limitation described in paragraph 5.2 and maximum plus-or-minus deviation from the true circle form, measured radially on the outside or inside of the vessel, shall not exceed the maximum permissible deviation obtained from Fig. UG-80.1.

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5.4

The inner surface of a torispherical , hemispherical, or ellipsoidal head shall not deviate outside of the specified shape by more than 1-1/4 % of D nor inside the specified shape by more than 5/8 % of D,

where D is the nominal inside diameter of vessel shell at the point of attachment. The knuckle radius shall not be less than that specified. The deviation shall be measured perpendicular to the specified shape and shall not be abrupt.
1-1/4% 5/8%

5.5 Hemispherical heads or any spherical portion of a torispherical or ellipsoidal head designated for external pressure shall, in addition to satisfying the requirements of paragraph 5.4, meet the tolerance specified for spheres in UG-80(b) using a value of 0.5 for L/D0.
5.4 0.5 UG-80 b L/D0

5.6

The skirt of heads shall be sufficiently true to round so that the difference between the max. and min. inside diameter shall not exceed 1 % of the normal diameter.

5.7 The marks on the cylindrical shell and heads shall be examined after formation to make sure they are clear.

6 6.1

Machining Examination Examiner shall attach material identification tag or make marking on all machined parts.

6.2

The shape, dimensions of being machined parts shall be measured by straightedge, caliper, caliber, angle square etc.

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6.3

Examining for the roughness of the being machined surfaces shall be carried out by surface roughness measuring devices.

6.4

For screw parts, examined by closing screw (ring screw gauge, screw plug gauge) etc.

7 7.1

Fabrication Process Examination Alignment of sections at edges to be butt welded shall be checked, the maximum offset is not greater than applicable amount for the weld joint category under consideration as listed in Table 1. The section thickness t is the normal thickness of the thinner section at the joint.

1

Table 1 Maximum Alignment Tolerance for Butt-weld 1 Section Thickness Joint Categories

in.

A

B C and D

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Up to 1/2,incl Over 1/2 to 3/4, incl over 3/4 to 1.5,incl over 1.5 to 2,incl

1/4t 1/8 in (3mm) 1/8 in(3mm) 1/8 in (3mm) lesser of 1/16 t or

1/4t 1/4t 3/16 in. (5mm) 1/8 t lesser of 1/8 t or 3/4in (19mm)

Over 2

3/8 in (10mm)

7.2 Any offset within the allowable tolerance provided above shall be faired at a three to one taper over the width of the finished weld or if necessary by adding additional weld metal beyond what would other wise be the edge of the weld. Such additional weld metal build up shall be subject to the requirement of following :
3 1

a) A butt welding procedure qualification in accordance with provision of ASME Section IX must be performed for the thickness of weld metal deposited, prior to production welding.
ASME IX

b) All weld metal buildup must be examined the full surface of the deposit by liquid penetrate examination to the requirements ASME Code Section VIII, Division 1.
ASME VIII 1

c) When such surface weld metal buildup is used in welded joints which require full or spot radiographic examination, the weld metal buildup shall be included in the examination. X

7.3

A tapered transitive having a length not less than three times of the offset between the adjacent surfaces of abutting section shall be provided at joints between sections that differ in thickness by more than 1/4 of the thickness of the thinner or by more then 1/8 in . 1/4 3 1/8

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7.4

Except when the joints are examined by RT for 4 in. on each side of circumferential welded intersection, vessels made up of two or more course shall have the centers of the welded longitudinal joints of adjacent course staggered or separated by a distance of at least five (5) times thickness of the thicker plate. X 4 5

7.5

All lugs, brackets, saddle type nozzles, manhole frames, reinforcement around openings, and other appurtenances shall be formed and fitted to conform reasonably to the shell surface to which they are attached when pressure parts extend over pressure retaining welds, such welds shall be ground flash for the portion of the weld to be covered.

7.6

Fabricate dimensions and shapes shall be examined by template.

7.7

The surface to be welded shall be clean and free to scale, rust, oil, grease or other deleterious foreign material. The cleaning distance from the edge of welding joint shall be at least 1 in. (25 mm) for ferrous metal and 2 in. (50 mm) for non-ferrous metals.

1 8 Welding Process Examination

25

2

50

8.1

Examiner shall examine the surface cleanness of being welded parts.

8.2

Examiner shall verify the correct WPS as specified by the drawing has been available and all welders have been qualified.
WPS

8.3

Tack weld shall be carried out by the qualified welders following the qualified WPS used for production welding. Tack weld shall be at least 1/2 in. (13mm) in length at the interval of not longer than 16 in.

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(400 mm).
WPS 16 8.4 400 2/1 13

Prior to welding, the groove surface shall be cleaned for a distance of at least 1 in. (25 mm) from the welding joint edge. The welding joint shall be preheated by either torch or electrical method to the specified temperature with a range of 3 in. (75 mm) from the welding joint. It is recommended that the welding can not be done when the temperature of base metal is lower than 0 F (-20 C). At temperatures between 32 F (0 C) and 0 F (-20 C), the surface of all areas within 3 in. (75 mm) of the point where a weld is to be started should be heated to a temperature above 60 F (15 C) before welding is started. It is recommended also that no welding be done when surface are wet. The preheated temperature shall be checked by the thermometer. 1 25 0 F( 32 F ( 60 F (15 C) 0 C) 0 F (-20 C) 3 75 3 -20 C) 75

8.5 The Shop Supervisor shall assign the experienced and qualified welders to perform welding. He shall issue qualified WPS and Material Delivery Card to the welder to receive the welding consumables. During welding, Shop Supervisor shall spot monitor the welding operation of welder on the Code Item.
WPS

8.6

Butt welded joints shall have complete penetration and full fusion. As welded surface are permitted, the surface of welds shall be sufficiently free from coarse ripples, grooves, overlaps and abrupt ridges and valleys. The reduction in thickness due to the welding process is acceptable provided all of the following conditions are met.

a) The reduction in thickness shall be not reduced the materials of the adjoining surfaces below the minimum required thickness at any point.

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b) The reduction in thickness shall be not exceeded 1/32 in.(1.0MM) or 10% of the nominal thickness of the adjoining surface, whichever is less. 1/32 in. 8.7 10%

In making fillet welds, the weld metal shall be deposited in such a way that adequate penetration into the base metal at the root of the weld is secured. The reduction on the base metal due to the welding process at the edges of the fillet weld shall meet the same requirements as for butt welds.

8.8 To assure the weld grooves are completely filled, the surface of the weld metal at any point does not fall below the surface of the adjoining base material, weld metal may be added as reinforce on each face of the weld. The thickness of the weld reinforcement on each face shall not exceed the following:

Table 2 Maximum Reinforcement for Pressure Vessel 2 Maximum Reinforcement (mm) Material thickness (mm) Less than 2.4 2.4 2.4 to 4.8, incl. Over 4.8 to 13, incl. Over 13 to 25 , incl. Over 25 to 51, incl. Over 51 to 76, incl. Over 76 to 102, incl. Over 102 to 127, incl. Over 127 Category B & C Butt Welds B C 2.4 3.2 4.0 4.8 5 6 6 6 8 (mm) Other Welds 0.8 1.6 2.4 2.4 3.2 4 6 6 8

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8.9

The reverse side of double-welded joints shall be prepared by chipping, grinding, or melting out, to secure sound metal at the base of weld metal first deposited, before applying weld metal from the reverse side.

8.10 When the shell, head and other pressure part are to be welded to a flat plate thicker than 1/2 in. to form a corner joint under the provision of UW-13(e), the weld joint preparation in the flat plate shall be examined before welding by liquid penetrate methods. After welding, both the peripheral edge of the flat plate and any remaining exposed surface of the weld joint preparation shall be reexamined by liquid penetrate methods. 1/2 in. UW-13(e)

8.1 The finished welding seam should be checked by visual examination with magnifier if deemed necessary. The welding reinforcement should be checked by welding checking tool. The fit-up of the welding joint should be inspected to guarantee the fit-up tolerance, cleaning and tack welding etc. Welder mark stamped near the weld seam shall also be inspected and verified during the inspection. Thickness reduction due to welding should be checked by thickness gauge (if required).

9 9.1

Test Plate When test plate is required by either the ASME Code, the design or customer specification, test plate shall be prepared to meet the following requirements: ASME a) The vessel impact test plate shall be formed with the same heat number as the vessel plate.

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b) For category A joints, the test plate shall be welded as an extension to the end of a production joint. For category B joints that are welded using a different welding procedure than used on category A joints, a test plate shall be welded under the production welding conditions used for the vessel, the same type of equipment and at the same locations and using the same procedures as used for the joint, and it shall be welded concurrently with the production welds or prior to the start of production welding. A B

c) For each vessel, one test plate shall be made for each welding procedure used for joints of category A and B. (unless the other requirement). A B

10

Records

10.1 All inspection and examination shall be recorded in the Inspection and Examination Record Exhibit No.A09-1 by Examiner. A09-1 10.2 Examiner shall be responsible for preparing, maintaining and distributing all inspection and examination forms which has been properly verified and approved.

10.3 All inspection and examination records shall be made available to the AI for his review and acceptance. AI

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Pressure Testing Procedure

Prepared by

Date

Approved by

Date

Accepted by

Date ___________

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1. 1.1

Scope This procedure describes the control of operation and inspection for pressure testing of Code items which are constructed in according to ASME Section VIII, Div.1 and ASME B31.1. ASME ASME B31.1

1.2

This procedure is supplementary requirement to the QC Manual.

2

Preparation before Pressure Testing

2.1

Hydrostatic pressure test shall be carried out after all fabrication works has been finished.

QC Engineer

shall verify that all required fabrication, examination, inspection and test activities have been completed, especially those inspection points established by AI have been properly closed. Reports have been completely closed if existed. , AI 2.2 Before hydrostatic pressure testing, QC Engineer shall carry out visual inspections both internally and externally with Examiner on the Code items. If such inspection is requested by AI, AI’s visual , All Nonconformity

inspection, dimensional check shall be carried out prior to the pressure test and the result shall be acceptable. AI AI

2.3

The being pressure tested Code item shall be clean and free from any oil, grease, paint and other dirties. The outside surface of the Code item shall be kept dry and clean during the period of pressure test. The

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testing equipment shall be examined to that it is tight and that all low-pressure filling lines and other appurtenances that shall not be subjected to the test pressure have been disconnected.

3 3.1

Hydrostatic Pressure Test Hydrostatic Pressure Test for Pressure Vessel

3.1.1For internal pressurized vessels, hydrostatic pressure tests shall be applied by raising the pressure gradually to the maximum allowable working pressure (MAWP) as shown on the manufacturer’s data report to be stamped on the pressure vessel and hold for a few minutes in order to verify whether there is leakage. Then the pressure shall be raised to the testing pressure which at every point in the vessel is at least equal to 1.3 times the MAWP to be marked on the vessel multiplied by the lowest ratio of the stress value S at the test temperature on the vessel to the stress value S at the design temperature. All loading that may exist during pressure test shall be considered. The testing pressure shall be indicated on the drawings. MAWP

1.3

3.1.2 After holding for 30 minutes, the testing pressure may then be reduced to the MAWP, if applicable, and this pressure shall be maintained to inspect carefully on the vessel and connections for leakage. 30 MAWP

3.2 Hydrostatic Pressure Test for Power Pipe

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3.2.1 For power pipes, hydrostatic pressure tests shall be applied by raising the pressure gradually to the design pressure and hold for a few 10 minutes in order to verify whether there is leakage. Then the pressure shall be raised to the testing pressure which at every point is at least equal to 1.5 times the design pressure. The testing pressure shall be indicated on the drawings.

1.5

3.2.2 After holding for 10 minutes, and testing pressure shall be maintained to inspect carefully on the pipe and connections for leakage. 10 3.3 Water used for hydrostatic pressure testing shall be clean and deaerated. be used with the chloride content less than 250 PPM. 250PPM 3.4 Metal temperature during hydrostatic pressure test shall be maintained at least 30 F(17 C) above the minimum design metal temperature (MDMT) or 21 C whichever is lower but need not exceed 120 F (48 C), to minimize the risk of brittle fracture. (MDMT) 120 F (48 C) 3.5 An indicating pressure gauges shall be connected directly to top of the pressure vessel, If it is impossible to connect the pressure gauge to the top of pressure vessel, the hydrostatic head on the gage shall be considered. If the indicating gage is not readily visible to the operator controlling the pressure applied, an additional indicating gage shall be provided where it will be visible to the operator throughout the during of the test. 21 C 30 F(17 C) Potable water is recommended to

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3.6 Dial pressure gages used in testing shall preferably have dials graduated over a range of about double the intended maximum test pressure, but in no case shall the range be less than 1.5 nor more than 4 times that pressure. The spacing between graduations shall be such that the inspector and the operator controlling the test shall be able to determine when the required test pressure has been applied. Digital pressure gages having a wider range of pressure readings may be used provided the readings give the same or greater degree of accuracy as obtained with dial pressure gages. All pressure gages used for hydrostatic pressure test shall be duly calibrated.

1.5

4

4 4.1

Inspection by Authorized Inspector

AI

Inspection “Hold Point” shall be established on the Process Check List ( PCL ). Before pressure test, the vessel condition shall be inspected by the AI. test and the result shall be accepted by AI. AI AI AI AI AI shall witness the whole stage of hydrostatic pressure

4.2 If during the pressure test is exceeded either intentionally or accidentally, and that the visible permanent distortion has been detected, AI shall have rights to permanently reject the pressure vessel or power pipe . AI

5

Record and Report

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5.1

The pressure test results shall be recorded in the “Pressure Test Report” by the Examiner and reviewed by QC Engineer, then present to AI for his review and acceptance. AI

5.2

Examiner, QC Engineer and AI shall sign and date on the Pressure Test Report. AI

5.3

All related inspection, test records and NDT reports shall be made available to AI for review and acceptance. NDT AI

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7 of 22

Radiographic Testing Procedure

Prepared by

Date _____________

Approved by _________________ Date ____________

Accepted by _________________

Date ____________

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1.0 1.1

Scope This procedure defines the requirements of radiographic examination of pressure vessels and other components manufactured in according to ASME Boiler and Pressure Vessel Code Section V and Section VIII division 1, latest applicable edition and addendum. Preparation and modifications to this procedure may only be made by a duly certified NDT level III. ASME V VIII

1.2

The product material and its thickness limits refer to applicable NDT instruction. NDT

2.0 2.1

Equipment and Materials Radiation Sources :

:

2.1.1 Type XXH3005 X-Ray units are used in HD XXH3005 X-Ray HD Pipe Manufacturer Model Voltage Pipe Current Focus measurement Max. thickness to be radiographic examined

KV Dandong XXH3005 170 300

mA 5

( mm) 3.0×3.0

(mm) 40

2.1.2 Other equipment may be used provided equivalent or better results are obtained.

2.1.3 The equipment manufacturer or supplier shall supply source size verification, such as technical manuals, decay curves, or written statement documenting the actual or maximum source size or focal spot.

2.2 Films

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Radiographs shall be made using industrial radiographic film. X

1.1 Intensifying Screens

: :

Lead Screens, see table as follows

Energy of Radiation Source Front Screen Thickness (mm) Back Screen thickness (mm)

80 290kv 2.4 Lead Symbol "B" B

0.03 mm

0.03 mm or 0.1 mm

A lead symbol "B" with minimum dimension of 13mm in height and 1.5mm in thickness shall be attached to the back of each film holder during exposure. B 2.5 13mm 1.5mm IQI

Image Quality Indicator ( IQI)

The wire –type IQI shall be manufactured and identified in accordance with the requirements or alternates allowed in SE-747. IQI 2.6 SE-747

Densitometer and Step Wedge Comparison Film

2.6.1 Densitometer and a step wedge comparison film shall be used to judge the film density requirements. The density of step wedge, comparison films and densitometer calibration shall by comparison with a calibrated step wedge film traceable to a National Standard.

2.6.2

Densitometers shall be calibrated by NDT level II or

personnel at least every 90 days. Periodic

calibration verification checks shall be performed at the beginning of each shift, after 8 hr of continuous use, or after change of apertures, whichever comes first.

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90 8 2.6.3

II

NDT

Step wedge comparison films shall be verified by NDT level II or

personnel by a calibrated

densitometer prior to first use, but the actual readings for each step do not have to be recorded. II NDT

2.6.4 A national standard step tablet or a step wedge calibration film, traceable to national standard step tablet and having at least 5 steps with neutral densities from at least 1.0 to 4.0 shall be used. 1.0 4.0

The step wedge calibration shall have been verified within the last year by comparison with a national standard step tablet unless, prior to first use, it was maintained in the original light-tight and waterproof sealed package as supplied by the manufacturer. Step wedge calibration films may be used without verification for one year upon opening, provided it is within the manufacturer’s stated shelf life.

3.0 Certification of Personnel

:

Personnel Performing Radiographic Examinations shall be certified in accordance with Written Practice (JSSX/ASME-11) which meets the requirement of SNT-TC-1A. (HD/ASME-11) 4.0 Time and Extent Of Examination : SNT-TC-1A

The time and extent of examination shall be as specified on the RT Instruction. RT 5.0 Technique of Radiographic Examination

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5.1 Surface Preparation 5.1.1 Surface irregularities or weld ripples on both inside (where accessible) and outside shall be removed so that such irregularities cannot mask or be confused with the image of any discontinuity. ,

5.1.2 Finished surfaces of all butt welded joints shall be flush with the base material or shall have reasonably uniform crowns, with reinforcement not to exceed the following on each face. Section , Division 1 Component.

Material thickness

Maximum Reinforcement (mm) mm Category A & B Butt Welds Other Welds

(mm) A B Less than 2.4 to 4.8, incl. Over 4.8 to 13, incl. 4.0 4.8 13 Over 13 to 25 , incl. Over 25 to 51, incl. 5.2 Film Processing 5.2.1 Manual processor shall be used to develop the films. 4.8 5 2.4 3.2 2.4 2.4 2.4 3.2 0.8 1.6

5.2.2 All radiographs shall be free from mechanical, chemical, or other blemishes which might discontinuity in

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the area of interest.

5.3 Radiographic Density 5.3.1 Density Limitation The transmitted film density through the radiographic image of adjacent to the designated wire of a wire-type IQI and the area of interest shall be 1.8 minimum for single film viewing for radiographs made with an X-ray source. For composite viewing of multiple film exposures, each film of the composite viewing of multiple film exposures, each film of the composite set shall have a minimum density of 1.3. The maximum density shall be 4.0 for either single or composite viewing. A tolerance of 0.05 in density is allowed for variations between densitometer readings. X 1.8 0.05 1.3 4.0

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5.3.2

Density Variation

If wire-type IQI are used, the density of the radiograph shall not varies -15% to + 30% of density adjacent to the designated wire of a wire-type IQI. When the film density varies more than -15% to 30% then an additional IQI shall be used for each exceptional area or areas and the radiograph retaken. When calculating the allowable variation in density, the calculation may be rounded to the nearest 0.1 within the range specified in Para.5.3.1. -15% +30% 5.3.1 5.4 Film Identification Permanent identifications on the radiograph shall not obscure the area of interest. Permanent identifications shall be parallel marked 5mm away from the weld. 5mm 0.1

Figure -1 5.4.1 Identification marks from left to right in sequence on the top half section are as follows,

JS: stands for HD JS HD

A0701 stands for product No. A0701

5.4.2 Identification marks from left to right on the bottom half section are as follows, Y, M, D stand for radiographic examined year, month and date, T stands for plate thickness, Rx special notes stand for repair weld times (Rx), (K) for increase examination percentage.

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Y

M Rx

D K

T

Rx

5.5 Location Markers 5.5.1 The position of the location markers shall be permanently marked on the surface of the part.

5.5.2 “↑” Superposition mark (the interest area mark if it is not 100% radiographed). shall be ≥15mm away from both sides of the film “↑” 5.5.3 100% 15mm

Central section center location markers, center identification shall be marked in the 1/2 of each film. (exclude 100% center radiographed or continuous films exposed one time) 1/2 100%

5.5.4 Weld symbol: A stands for longitudinal weld, B stands for circumferential weld; No. stands for the sequence number of each film. A B No.

5.5.5 Verification of coverage of the placing of the location markers shall be in accordance with Figure 1. Location markers may be placed on both the surfaces to facilitate repair locations. 1 5.6 Selection of Energy of Radiation 5.6.1 On the premise of fully penetration on the coupon, take the smaller value of kV to improve the contrast and sharpness of the film and to improve the good detection on small defects kV 5.6.2 The radiation energy employed for any radiographic technique shall achieve the density and IQI image requirements of this Article. IQI

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5.7

Geometric Unsharpness (Ug)

5.7.1 Source of radiation to film distance shall be selected to satisfactory Ug with reasonable exposure time. Ug 5.7.2 Geometric Unsharpness Limitations

Material thickness In 2 50

Maximum Ug Ug in 0.020 ≤ 0.51

Note: Material thickness is the thickness on which the IQI is based. IQI 5.7.3 Geometric unsharpness may be calculated from the following equation

Ug = F * d/ D Ug = Geometric unsharpness F = source size: the maximum projected dimension of radiating source (or effective focal spot) in the plane perpendicular to the distance D from the weld or object being radiographed. D D = Distance from source of radiation to weld or object being radiographed. (in.) D= in.

d = Distance from source side of weld or object being radiographed to the film. (Max.) d= Note: For Double Wall radiography, with double wall viewing, d shall be the outside diameter of the pipe or tube at weld diameter of the pipe or tube at weld location, plus any space between weld and film. d

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5.8

IQI

5.8.1 The radiographic technique shall be sufficiently sensitive to reveal the IQI image, the specified wire diameter and the identifying numbers.

5.8.2 IQI Selection IQI Per Table 5.8.2. 5.8.2

TABLE 5.8.2

5.8.2

Material Thickness, Wire-Type IQI Dia. IQI Dia Source Side Nominal Single-wall Mat'l Thk. Rang (mm) Wire Dia.(mm) Mat’l Thk Rang (mm) ≤6.4 >6.4-9.5 >9.5-12.7 >12.7-19.0 >19.0-25.4 >25.4-38.1 >38.1-50.8 0.20 0.25 0.33 0.41 0.51 0.64 0.81 0.16 0.20 0.25 0.33 0.41 0.51 0.64 Wire Dia.(mm) Film Side

Wire IQI Designation, Wire Dia., and Wire Identity

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IQI Set A A in. Set B B in.

Wire Diameter in. (mm) Wire Identity 0.0032 (0.08) 0.004 0.005 (0.10) (0.13) 1 2 3 4 5 6

Wire Diameter in. (mm) Wire Identity 0.010 0.013 0.016 0.020 0.025 0.032 (0.25) (0.33) (0.41) (0.51) (0.64) (0.81)

6 7 8 9 10 11

0.0063 (0.16) 0.008 0.010 (0.20) (0.25)

5.8.3 For welds with reinforcements. The thickness on which the IQI is based is the nominal single-wall thickness plus the estimated reinforcement not to exceed those permitted by Para. 5.1.2 5.8.4 (if not removed). Backing rings or strips are not to be considered as part of the weld or reinforcement

thickness in IQI selection. IQI IQI For welds without reinforcements. The thickness on which the IQI is based is the nominal single-wall thickness. Backing rings or strips are not to be considered as part of the weld or reinforcement thickness in IQI selection. IQI IQI 5.8.4 Requirements and Placement of film, IQI and marker 5.8.4.1 Film IQI 5.1.2

The type and trade mark should meet the requirements of this procedure and instruction.

The film is storage in a lightproof and sealed cassette. 5.8.4.2 Marker Marker shall be placed on the source side on the of the part being radiographed Their

locations shall be permanently marked on the surface of the part being radiographed when permitted. Only in

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the special conditions that Markers display by drawings. The Marker on the film, indicating the area of interest on parts being radiographed (effective film length, the length of important evaluation area) is acquired.

Location Markers shall be placed as follow

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(a) Source-Side Markers. (1) Flat components or longitudinal joints in cylindrical or conical components;

(2) Curved or spherical component whose concave side is toward the source and when the source-to-material distance (focus F1) is greater than the inside radius; F1

(3) Curved or spherical components whose convex side is toward the source.

(b) Film –Side Markers Location marker shall be placed on the film side when radiographing either curved or spherical components whose concave side is toward the source and when the “source-to-material” distance(focus F1) is greater than the inside radius.

F1 (c) Either Side Markers Location markers may be placed on either the source side or film side when radiographing either concave side or spherical components whose concave side is toward the source and the source-to-material F1) equals the inside radius of the component. distance (focus

F1 5.8.4.3 Placement of IQI IQI a) Source Side IQI. The IQI (s) shall be placed on the source side of the part being examined. If the wire –type IQI (s) are used, they should be put on the weld surface near the end of radiographic effective areas. The wires

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should be put across the weld and be perpendicular to the direction of the weld with the thinner wires at the outside. The condition described on the below is an exception. IQI IQI IQI

b) Film Side IQI (s). Where inaccessibility prevents hand placing the IQI (s) on the source side, it shall be placed on the film side in contact with the part being examined. Identification number (s) shall be placed adjacent to or on the IQI(s). The identification number(s) and the lead letter "F" shall not mask the area of interest. For the condition described in (1) or (2) below, the identification numbers and lead letter "F" may be placed in the area of interest. Others are as same as 5.8.4 a). IQI IQI IQI 1 2 5.8.4 a).

(1) When geometric configuration makes it impractical to place the IQI (s) as out lined in the above. IQI (2) When the weld metal is not radiographiclly similar to the base material. X c) IQI Location for Materials Other Than Welds. The IQI(s) with the IQI identification number(s), and the lead letter "F", if used, may be placed in the area of interest. IQI IQI IQI

d) Alternative Location for IQI(s)when configuration or size prevents placing the IQI(s) as described above, it may be placed on a separate block (or like part/product). IQI / 5.8.5 Number of IQI(s) IQI For components where one or more film holders are used for an exposure, at least one IQI image shall appear IQI

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on each radiograph except as outlined in (b) below. IQI b

a) If the density requirements (Para.5.3) are met by using more than one IQI, one shall be representative of the lightest area of interest and the other the darkest area of interest; the intervening densities on the radiograph shall be considered as having acceptable density. 5.3 , b) 1) For cylindrical vessels where the source is placed on the axis of the object and one or more film holders are used for a single exposure of a complete circumference, at least three IQIs shall be spaced approximately 120 deg. apart. Where sections of longitudinal welds adjoining the circumferential weld are radiographed simultaneously with the circumferential weld, an additional IQI shall be placed on each longitudinal weld at the end of each section most remote from the junction with the circumferential weld being radiographed. , , 120° , , , IQI ,

2) For cylindrical vessels where the source is placed on the axis of the object and four or more film holders are used for a single exposure of a section or the circumference, at least three IQI (s) shall be used. One IQI shall be in the approximate center of the section of the exposed and one at each end. When the section of the circumference exposed exceeds 240 deg., the rules of Para. 5.8.5 (b) apply. In each case, additional film locations may be required to establish proper IQI spacing, otherwise at least one IQI image shall appear on each radiograph. , , , 240° 5.8.5 b IQI IQI X

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5.8.6

If the IQI image does not show on any radiograph in a multiple film technique but does show in

composite viewing, interpretation shall be permitted only by composite film viewing. IQI

5.9 Radiographic Technique 5.9.1 Single-wall Technique In the single-wall technique, the radiation passes through only one wall of the weld (material), which is viewed for acceptance on radiograph, An adequate number of exposures shall be made to demonstrate that the required coverage has been obtained. X

5.9.2 Double-wall Technique When it is not practical to use a single-wall technique, one of the following double-wall techniques shall be used.

a) Single wall viewing (1) For material and for welds in components, a technique may be used in which the radiation passes through two walls and only the weld (material) on the film side wall is viewed for acceptance. An adequate number of exposures shall be made to demonstrate that the required coverage has been obtained. When complete coverage is required for circumferential welds (materials), a minimum of three exposures taken 120 deg. to each other shall be made.

120° (2) For double wall technique with single wall viewing, the IQI selected from the table 5.8.2 shall be based on nominal single wall thickness. 5.8.2 IQI

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b) Double-Wall Viewing For materials and for welds in components 89mm or less in outside diameter, a technique may be used in which the radiation passes through two walls and the weld (material) in both walls is viewed for acceptance on the same radiograph. For double-wall viewing, only a source side IQI shall be used. Care should be exercised to ensure that the required geometric unsharpness is not exceeds. If the geometric unsharpness requirements cannot be met, then single-wall viewing shall be used. 89mm IQI

1) For welds, the radiation beam may be offset from the plane of the weld at an angle sufficient to separate the images of the source side and film side portions of the areas to be interpreted. In this situation, a minimum of two exposures taken at 90 degree to each other shall be made for each joint.

2) As an alternative, the weld may be radiographed with the radiation beam positioned so that the images of both walls are superimposed. In this situation, a minimum of three exposures taken at either 60 deg. to each other shall be made for each joint.

X 3 60°

3) Additional exposures shall be made if the required radiographic coverage cannot be obtained using the minimum number of exposures indicated in b. 1), b. 2) above. b. 1), b. 2)

6.0 Evaluation of radiographs

:

6.1 Viewing facilities shall provide subdued background lighting of an intensity which will not cause troublesome reflections, shadows, or glare on the radiograph.

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Equipment used to view radiographs for interpretation shall provide a variable light source of sufficient intensity for the essential IQI designated wire to be visible for the specified density range. The viewing conditions shall be such that light from around the outer edge of the radiograph or coming through low-density portions of the radiograph does not interferes with interpretation and evaluation. IQI X

6.2 Radiographs shall be evaluated in accordance with the acceptance/rejection criteria stated in Para 7.0. 7.0 6.3 The NDT Record shall be filled in before the radiographs are submitted to the AI and customer's representative for re-inspection and acceptance. NDT AI

6.4 If a light image of the "B", appears on a darker background of the radiograph, protection from backscatter is insufficient and the radiograph shall be considered unacceptable. A dark image of the "B" on a lighter background is not cause for rejection. , “B” , , . B 1/2 1/16 , , “B”

6.5 If there is a question regarding the surface condition of the weld when interpreting a radiographic film, the film shall be compared to the actual weld surface for determination of acceptability.

7.0 Acceptance/rejection criteria 7.1 Full RT(UW-51)

/

:

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In accordance with ASME Section VIII, Div.1, Para UW-51(b) ASME UW-51(b) .

Indications shown on radiographs of welds and characterized as imperfections are unacceptable under the following conditions and shall be repaired and the repair radioghaphed to this procedure:

(a) Any indications characterized as a crack, or zone of incomplete fusion or penetration.

(b) Any other elongated indication on the radiograph which has a length greater than:

6mm (1/4 in. ) for T up 19mm (3/4 in.); 1/3 T for T from 19mm to 57mm (3/4 in. to 2 1/4 in.); 19mm (3/4 in. ) for T over 57mm (2 1/4 in. ) where T is the thickness of the weld excluding any allowable reinforcement. T 3/4 in. 19 mm , 1/4 in. 6 mm 3/4 in.≤T≤2-1/4 in. 19 mm≤T≤57 mm , 1/3T

T 2-1/4 in. 57 mm . 3/4 in 19 mm T (c) Any group of aligned inclusions that have an aggregate length greater than T in a length of 12T, except when the distance between the successive imperfections exceeds 6L where L is the length of the longest imperfection in the group. , 12t t ; 6L ,L

Rounded indications in excess of those specified by the acceptance standards detailed in the Rounded Indication Charts Attached.

7.2 Power piping RT(Para 136.4.5,B31.1)

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(A) Acceptance Standards. Welds that are shown by radiography to have any of the following types of discontinuities are unacceptable (A.1) any type of crack or zone of incomplete fusion or penetration (A.2) any other elongated indication which has a length greater than (A.2.1) 1/4in. (6.0mm) for t up to 3/4in.(19.0mm),inclusive. (A.2.2) 1/3t for t from 3/4in.(19.0mm)to 2 1/4in.(57.0mm),incl. (A2.3) 3/4in(19.0mm) for t over 2 1/4in. (57.0mm) where t is the thickness of the thinner portion of the weld NOTE: t referred to in (A.2.1),(A.2.2), and (A.2.3) above pertains to the thickness of the weld being examined; if a weld joins two members having different thickness at the weld, t is the thinner of these two thickness. (A.3) any group of indications in line that have an aggregate length greater than t in a length of 12t,except where the distance between the successive indications exceeds 6L where L is the longest indication in the group. (A.4) porosity in excess of that shown as acceptable in Appendix A-250 of Section I of the ASME Boiler and Pressure Vessel Code. (A.5) root concavity when there is an abrupt change in density, as indicated on the radiograph. 7.3 Spot RT (UW-52) See Attachment 1 8.0 Records 8.1 A drawing or sketch showing the location and identification of each weld radiographed in a vessel or component shall be prepared.

8.2 The form No. 8-4 of QC Manual shall be used to record radiographic examination result. QC No.8-4

9.0 Radiography of repairs 9.1 The complete weld need not be re-radiographed, but only the repaired area plus sufficient extra area on either side, to ensure complete coverage of the affected area.

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10.0 Typical techniques for welds

:

10.1 Recommended radiographic technique sketches for circumferential weld

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10.2

RECOMMENDED RADIOGRAPHIC TECHNIQUE SKETCHES FOR LONGITUDINAL WELD

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11.0 Attachments 11.1 Attachment 1 1

Spot examination of welded joints. 11.2 Attachment 2 2

Rt for welder examination. (Including technology qualification) RT 11.3 Appendix 1 1

In accordance with ASME Section VIII, Div.1: UW-51 Radiographic and radioscopic examination of welded joints ASME Linear indications 11.4 Appendix 2 2 UW-51

ASME Section VIII Div.1: Mandatory Appendix 4 ASME Rounded Indications Charts Acceptance Standard for Radiographically determined rounded indications in welds

11.5 Appendix 3

3

In accordance with ASME Section V: SE-94 Manual processing ASME SE-94

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Attachment 1

1

Spot Examination of Welded Joints 1.0 If it is not necessary to radiograph a welded joint for overall length, Then spot examination is performed in accordance with the procedure as provided herein.

2.0 Scope and requirements of spot examination of welded joints

2.1 One spot shall be examined on each vessel for the first 15m of weld, and then one spot for each 15m increment of weld or fraction thereof, however, for identical vessels, each with less than 15m of weld, 15m increments of weld may be represented by one spot examination. 15m 15m 15m 15m

2.2 Examine the welding of each welder or welding operator. Under conditions where two or more welders or welding operators make weld layers in a joint, or on the two sides of a double-welded butt joint, one spot may represent the work of all welders or welding operators.

2.3 Each spot examination shall be made as soon as practicable after completion of the increment of weld to be examined. The location and quantity or percent of the spot examination shall be chosen by Authorize Inspector after completion of the increment of welding to be examined, except that when the Authorized Inspector has been notified in advance and can not be present or otherwise make the selection, the HD may exercise his own judgment in selecting the spots.

AI

AI

HD

2.4 The length of the film for the spot examination shall be ≥ 150mm. Radiographic examination should be

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conducted according to the procedure. ≥ 150mm 3.0 Acceptance standards for spot radiographic examination shall as following:

(a) Welds in which indications are characterized as cracks or incomplete fusion or lack of penetration shall be unacceptable.

(b) Welds in which indications are characterized as slag inclusions or cavities shall be unacceptable, If the length of any such indication is greater than 2/3 T (where T is thickness of the weld excluding any allowable reinforcement, for butt weld joint, the thinner of plate thickness). If several indications within the above limitation exist in line, the weld shall be judged acceptable if the sum of the longest dimensions of all such indications is not more than T in a length of 6T. (or proportionately for radiographs shorter than 6T) and if the longest indications considered, are separated by at least 3L of acceptable weld metal where L is the length of longest indication. The maximum length of acceptable indications shall be 19mm. Any such indications shorter than 6mm shall be acceptable for any plate thickness. 2/3t t 6t , 3L L 19mm 6mm t t t 6t

(c) Rounded indications are not a factor in the acceptability of welds not required to be fully radiographed.

4.0 Evaluation and retest 4.1 When a spot, radiographed as required in 2.1, 2.2,2.3 above, is acceptable in accordance with 3.1,3.2 above, the entire weld increment represented by this radiograph is acceptable. 2.1 2.2 2.3 3.1 3.2

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4.2 When a spot , radiographed as required in 2.1,2.2,2.3 above has been examined and the radiograph which does not comply with the requirements of 3.1 and 3.2 above, two additional spots shall be radiographically examined in the same weld at location away from the original spot. The locations and quantity of additional spot shall be determined by the Inspector or manufacturer. 2.1 2.2 2.3 3.1 3.2

(a) If the two additional spots examined show welding which meets the minimum quality requirements of para. 3.0 (a) and (b) above , the entire weld increment represented by three radiographs is acceptable provide the defects disclosed by the frist of the three radiographs are removed and the area repaired by welding. The weld repaired area shall be radiographically examined in accordance with the foregoing requirement of attachment -1. 3.0 a b 1

( b) If either of the two additional of the two spots examined shows welding which does not comply with the minimum quality requirement of para.3 (a) and (b) above, the increment of weld represented shall be rejected. The entire rejected weld shall be removed and the joints shall be re-welded, or the entire increment of weld represented shall be completely radiographed and only defects need be corrected. 3 a b

c For re-welded joints or repairing area, spot examination shall be performed at one location in accordance with foregoing requirement of UW-52. UW-52

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Attachment 2

2 Rt For Welder Examination RT (Including Technology Qualification )

1.0 The RT for qualification examination for welders should meet the requirements of the procedure and acceptance standard of this attachment 3.0 para. RT 3.0

2.0 The single wall exposure technique, with source side IQI (s) shall be used. However, Double-wall technique, with film side IQI (s) may be used for the pipe circumferential weld which has a nominal diameter not more than 89mm. IQI 89mm 2.1 Place the IQI with source side. Incline radiograph 2 films (exposures at 90). IQI X 90 . IQI

3.0 Radiographic acceptance standard (Section IX , QW-191) Unaccepted when the radiograph exhibits any imperfections in excess of the limits specified below.

3.1 Linear indications (1) Any type of crack or zone of incomplete fusion or penetration.

(2)

any elongated slag inclusion which has a length greater than:

- 3.0mm for T (plate thickness) up to 10mm inclusive -3.0 T 10mm, 10mm

- 1/3T for T over 10mm to 57mm , inclusive -1/3T T 10mm 57mm 57mm

- 19mm for T over 57mm -19mm T 57mm

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(3)

Any group of slag inclusions in line that have an aggregate length greater than T in A length of 12T,

except when the distance between the successive imperfections exceeds 6L where L is the length of the longest imperfection in the group. 12T X 6L 3.2 Rounded indications (1) The maximum permissible dimension for rounded indications shall be 20% of T of 3.0mm whichever is L T

smaller. 3.0mm (2) 20%

For welds in material less than 3.0mm in thickness, the maximum number of acceptable rounded

indications shall not exceed 12 in 150mm length of weld. A proportionately fewer number of rounded indications proportionately fewer number of rounded indications shall be permitted in welds less than 150mm in length. 3.0mm 150mm (3) For welds in material 3.0mm or greater in thickness, the charts in attachment 3 represent the maximum 150mm 12

acceptable types of rounded indications illustrated in typically clustered, assorted, and randomly dispersed configurations. Rounded indications less than 0.8mm in maximum diameter shall not be considered in the radiographic acceptance tests of welders in these ranges of material thickness. 3.0mm 0.8mm 3 X

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Rounded Indications Charts Of Rt For Welder Examination (Including Technology Qualification) RT

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Appendix 1

1 UW – 51 Radiographic and radiographic examination of welded joints UW-51 X

(a)

All welded joints to be radiographed shall be examined in accordance with article 2 of section V except as specified below. X V 2

1 A complete set of radiographs and records, as described in T-291 and T-292 of article 2 of section V, for each vessel part shall be retained by the Manufacturer until the Manufacturer’s data Report has been signed by the Inspector V 2 T-291 T-292 X

2

The Manufacturer shall certify that personnel performing and evaluating radiographic

examinations required by this Division have been qualified and certified in accordance with their employer’s written practice. SNT-TC-1A shall be used as a guideline for employers to establish their written practice for qualification and certification of their personnel. Alternatively, the ASNT Central Certification Program (ACCP), or CP-189 may be used to fulfill the examination and demonstration requirements of SNT-TC-1A and the employer’s written practice. Provisions for training, experience, qualification, and certification of NDT personnel shall be described in the Manufacturer’s Quality Control System (see Appendix 10). X SNT-TC-1A ACCP CP-189 NDT 10 3 A written radiographic examination procedure is not required. Demonstration of density and IQI SNT-TC-1A ASNT

image requirements on production or technique radiographs shall be considered satisfactory evidence of compliance with Article 2 of Section V.

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X 2

X

IQI

V

4 The requirements of T-285 of Article 2 of Section V are to be used as a guide. Final acceptance of radiographs shall be based on the ability to see the prescribed IQI image and the specified the designated wire of a wire-type IQI. V 2 T-285 IQI (b) Indications shown on the radiographs of welds and characterized as imperfections are unacceptable under the following conditions and shall be repaired as provided as provided in UW-38, and the repair radiographed to UW-51 or, at the option of the Manufacturer, ultrasonically examined in accordance with the method described in Appendix 12 and the standards specified in this paragraph, provided the defects has been confirmed by the ultrasonic examination to the satisfaction of the Authorized Inspector prior to making the repair. For material thicknesses in excess or 1 in.(25mm),the concurrence of the user shall be obtained. This ultrasonic examination shall be noted under remarks on the Manufacturer’s Data Report Form: X UW-35 12 1 25mm X AI UW-38 X IQI

(1) any indication characterized as a crack or zone of incomplete fusion or penetration;

(2) any other elongated indication on the radiograph which has length greater than: X (a) (b) (c) 1/4 in.(6mm) for t up to 3/4in.(19mm) 1/3t for t from 3/4in.(19mm) to 2 1/4in.(57mm) 3/4in.(19mm)for t over 2 1/4in.(57mm)

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1/4 1/3t 3/4

(6mm) 3/4 (19mm)

3/4 (19mm) 2 1/4

(19mm) 2 1/4

t (57mm)t t

(57mm)

where t = the thickness of the weld excluding any allowable reinforcement. For a butt weld joining two members having different thicknesses at the weld, t is the thinner of these two thickness. If a full penetration weld includes a fillet weld, the thickness of the throat of the fillet shall be included in t. t= t (3) Any group of aligned indications that have a aggregate length greater than t in a length of 12t, except when the distance between the successive imperfections exceeds 6L where L is the length of the longest imperfection in the group; 12t X t 6L L t

(4) Rounded indications in excess of that specified by the acceptance standard give in Attachment 2 2

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Appendix

2

2 ROUNDED INDICATIONS CHARTS ACCEPTANCE STANDARD FOR RADIOGRAPHICALLY DETERMINED ROUNDED INDICATIONS IN WELDS

1.0 APPLICABILITY OF THESE STANDARDS

1.1 These standards are applicable to ferritic, austenitic and nonferrous materials.

1.2 Terminology 1.2.1 Rounded Indications. Indications with a maximum length of three times the width or less on the radiograph are defined as rounded indications. These indications may be circular, elliptical, conical or irregular in shape and may have tails. When evaluating the size of an indication, the tail shall be included. The indication maybe from any imperfection in the weld, such as porosity, slag, or tungsten. X 3

1.2.2 Aligned Indications. A sequence of four or more rounded indications shall be considered to be aligned when they touch a line parallel to the length of the weld drawn through the center of the two outer rounded indications. 4 , 1.2.3 Thickness t. t is the thickness of the weld, excluding any allowable reinforcement. For a butt weld jointing two members having different thickness at the weld, t is the thinner of these two thickness. If a full penetration weld includes a fillet weld, the thickness of the fillet weld throat shall be included in t. t t ,t 1.3 ACCEPTANCE CRITERIA 1.3.1 Image Density. Density within the image of the indication may vary and is not a criterion for acceptance : . ,t

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or rejection.

1.3.2 Relevant Indications (See Table 1 for Examples). Only those rounded indications which exceed the following dimensions shall be considered relevant. 1 t 1/8 in. (3.2 mm) 1/10t 1/64 in. (0.4 mm) 1/32 in. 0.8 mm :

1/8in. (3.2mm)≤t≤1/4 in. (6 mm) 1/4in. (6mm) t≤2 in. 51 mm t 2 in. (51 mm)

1/16 in. (1.6 mm).

1.3.3 Maximum Size of Rounded Indications (See Table 1 for Examples). The maximum permissible size of any indication shall be 1/4t, or 4mm, whichever is smaller; except that an isolated indications separated from an adjacent indications by 25 mm or more may be 1/3t, or 6 mm, whichever is less. For t greater than 50 mm the maximum permissible size of an isolated indication shall be increased to 10mm. 1 1 in. 25 mm t 2 in.(51 mm) 3/8 in.(10 mm) 1/3t 1/4t 5/32 in. 4 mm

1/4 in.(6 mm)

1.3.4 Aligned Rounded Indications. Aligned rounded indications are acceptable when the summation of the diameters of the indications is less than t in a length of 12t (see Fig.4- 1). The length of groups of aligned rounded indications and the spacing between the groups shall meet the requirements of Fig.4-2. 12t X 4.2 t 4-1 t

1.3.5 Spacing. The distance between adjacent rounded indications is not a factor in determining acceptance or rejection, except as required for isolated indications or groups of aligned indications.

1.3.6 Rounded Indications Charts. The rounded indications characterized as imperfections shall not exceed that

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shown in the charts. The charts in Figs. 4-3 through 4-6 illustrate various types of assorted, randomly dispersed and clustered rounded indications for different weld thickness greater than 3mm. These charts represent the maximum acceptable concentration limits for rounded indications. 4.3-4.6 3mm

The chart for each thickness range represents full scale 150mm radiographs, and shall not be enlarged or reduced. The distributions shown are not necessarily the patterns that may appear on the radiograph, but are typical of the concentration and size of indications permitted. 150mm X

1.3.7 Weld Thickness Less Than 3mm. For t less than 3mm the maximum number of rounded indications shall not exceed 12 in 150mm length of weld. A proportionally fewer number of indications shall be permitted in welds less than 150mm in length. 3mm 150mm 1.3.8 Clustered Indications. The illustrations for clustered indications show up to four times as many indications in a local area, as that shown in the illustrations for random indications. The length of an acceptable cluster shall not exceed the lesser of 25mm or 2t. Where more than one clusters shall not exceed 25mm in a 150mm length weld. t 3mm 150mm 12

25mm 2t

150mm

25mm

Thickness t t mm

Table 1 1 Maximum Size of Acceptable Rounded Indications (mm) mm

Maximum Size of Non-relevant Indication(

)

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mm 3 3 5 6 8 10 11 13 14 16 17 19.0- 50 1/4t 0.79 1.19 1.60 1.98 2.31 2.77 3.18 3.61 3.96 3.96 3.96 1/3t 1.07 1.60 2.11 2.64 3.18 3.71 4.78 4.80 5.33 5.84 6.35 1/10t 0.38 0.38 0.38 0.79 0.79 0.79 0.79 0.79 0.79 0.79 0.79

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Appendix 3

3 Manual Processing

1.1 Preparation—No more film should be processed than can be accommodated with a minimum separation of 12.7mm. hangers are loaded and solutions stirred before starting development. 12.7mm

1.2 Start to Development—Start the timer and place the films into the developer tank. Separate to a minimum distance of 12.7mm and agitate in two directions for about 15s. 12.7mm 15 1.3 Development—Normal development time is 5 to 8 min at 20℃ .Longer development time generally yields faster film speed and slightly more contrast. The manufacturer’s recommendation should be followed in choosing a development time. When the time is higher or lower, development time must be changed. 20℃ 5 8

1.4 Agitation—Shake the film horizontally and vertically, ideally for a few seconds each minute during development. This will help film develop evenly.

1.5 Stop Bath or Rinse—After development is complete, the film must be rinsed with vigorous agitation in clear water.

1.6 Fixing—The films must not touch one another in the fixer. Agitate the hangers vertically for about 10 s and again at the end of the first minute, to ensure uniform and rapid fixation. Keep them in the fixer until fixation is complete (that is, at least twice the clearing time) but not more than 15 min in relative fresh fixer.

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Frequent agitation will shorten the time of fixation. 10

15 1.7 Washing—The washing efficiency is a function of wash water, its temperature, and flow, and the film being washed. Generally, washing is very slow below 16℃ . When washing at temperatures above 30℃ , care should be exercised not to leave films in water too long .The films should be washed in batches without contamination from new film brought over from the fixer. If pressed for capacity, as more films are put in the wash, partially washed film should be moved in the direction of inlet. 16 ℃ 30℃

1.8 The cascade method of washing uses less water and gives batter washing for the same length of time.

1.9 Wetting Agent Dip the film for approximately 30 s in a wetting agent. This makes water drain evenly off film, which facilitates quick, even drying. 30

1.10 Drying—naturally drying.

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Liquid Penetrant Testing Procedure

Prepared by

Date _____________

Approved by _________________

Date ____________

Accepted by _________________

Date ____________

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Demonstration Certificate

I hereby certify that this procedure has been demonstrated to the satisfaction of the Authorized Inspector according to the requirements of ASME Code Section V, T-150. ASME V T-150 AI

NDT level III:________________

AI: _________________________

1.0 Scope 1.1 This procedure describes liquid penetrant examination methods for welds and evaluation of the examination results of the pressure vessels constructed to the ASME Code Section VIII, Div. 1.and Visual acceptance criteria of welds in pipe and piping components for ASME/ANSI B31.1 ASME ASME B31.1

1.2 This procedure is developed in compliance with the Article 6 - Liquid Penetrant Examination of ASME Code Section V. This procedure also meets the requirements of ASME Code Section VIII, Div. 1, and piping components for ASME/ANSI B31.1 latest Edition. ASME ASME B31.1 V 6 ASME VIII

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1.3 The liquid penetrant examination method is an effective means for detecting discontinuities which are open to the surface of nonporous metals and other materials. Typical discontinuities detectable by this method are cracks, seams, laps, cold sluts, laminations and porosity.

1.4 The NDE Level III personnel shall review the latest ASME Code Edition and Addenda and duly revise this procedure if deemed necessary. NDE ASME

1.5 This procedure shall be supplemented by the examination instruction and additional requirements which may be issued for each specified work and in which the detail parameter shall be specified.

2.0 Personnel Qualification 2.1 The liquid penetrant examination personnel for Code items shall be qualified and certified according to the Written Practice for Training, Qualification and Certification of NDT Personnel” by HD HD NDT

2.2 The NDT Level III is responsible for instructing the NDT Level II or I to perform the PT examination in accordance with this procedure or other supplementary requirements. NDT Level II is responsible for evaluating the examination results. NDE NDE 3.0 General Requirement 3.1 Written Procedure Requirements 3.1.1 Liquid penetrant examination shall be performed in accordance with a written procedure which shall as a minimum, contain the requirements listed in Table 1. The written procedure shall establish a single value, or range of valued, for each requirement. 1 NDE PT

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3.1.2 When procedure qualification is specified, a change of requirement in Table 1 identified as an essential variable from the specified value, or range of values, shall require re-qualification of the written procedure. A change of a requirement identified as a nonessential variable from the specified value, or range of values, does not require re-qualification of the written procedure. All changes of essential or nonessential variables from the value, or range of values, specified by the written procedure shall require revision of, or an addendum to, the written procedure. 1

3.2 Calibration Instrument illumination shall be calibrated at least once a year or whenever the meter has been repaired. If meter have not been in use for one year or more, calibration shall be done before being used. 1 3.3 Performance demonstration Performance demonstration, when required by the referencing Code Section, shall be documented.

3.4

Procedure demonstration

This procedure shall be certified by demonstration to the satisfaction of the AI prior toimplementation. AI Table 1 Requirements of Liquid Penetrant Examination Procedure No. Requirement Identification of and any change in type or family group of penetrant materials including developers, emulsifiers, etc.
Essential Variable Nonessential Variable Reference Paragraph

1



4.1

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2 3 4 5 6 7 8 9

Surface preparation (finishing and including type of cleaning solvent) Method of applying penetrant

cleaning, ● ● ● ● ● ● ● ● 5.2 5.4 5.5 5.6 5.6.1 5.4.3 5.6.1 5.7.2

Method of removing excess surface penetrant Method of applying developer Minimum and maximum time periods between steps and drying aids Decrease in penetrant dwell time Increase in developer dwell time ( Interpretation time) Minimum light intensity Surface temperature outside 40℉ to 125℉ (5 ℃ to 52℃ ) or as previously qualified 40℉ 125℉ ( 5 ℃ 52℃ ) Performance demonstration, when required Personnel qualification requirements Materials, shapes, or sizes to be examined and the extent of examination Post examination cleaning technique

10



5.4.3

11 12 13 14



3.4 2.0 1.3 5.8

4.0 Penetrant Materials 4.1 The penetrant materials is including all penetrants, solvents or cleaning agents, developers, etc, used in the examination process.

The liquid penetrant examination materials shall be designated, as shown in Table 2. The materials used for examination shall be the same type. Intermixing of penetrant materials from different families or different

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manufacturers is not permitted. 2

Table

2 Manufacturer Material
Cleaning Agent

Model DPT-5

Shanghai MeikdaypFlaw CO.,LTD

Penetrant

DPT-5
Developer

DPT-5

4.3 When examining nickel base alloys, austenitic or duplex stainless steels or titanium, all materials shall be analyzed individually for chlorine and fluorine content in accordance with the procedure shown in T-641 Mandatory Appendix II of ASME Code Section V. The certificate of contaminant content for all liquid penetrant materials shall be obtained from manufacturer with batch number and test results.. ASME II T-641 V

5 Examination Procedure 5.1 A color contrast (visible) with solvent removable penetrant process shall be used. Examination Flow Chart as shown here under.

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Surface Preparation

Drying

Precleaning and Dry

Development and interpretation

Penetrant Application

Evaluation and indication

Cleaning

Post Cleaning

5.2

Surface Preparation

5. 2. 1 In general, satisfactory results can usually be obtained on surfaces in the as-welded, as-rolled, or as-forged conditions. However, surface preparation by grinding or machining is necessary when surface irregularities might mask the indications of unacceptable discontinuities, or otherwise interfere with the effectiveness of the examination.

5.3 Pre-cleaning and dry 5. 3. 1 Prior to each liquid penetrant examination, the surface to be examined and all adjacent areas within at least 1 in. (25 mm) shall be dry and free of all dirt, grease, lint, scale, welding flux, weld spatter, paint, oil and other extraneous matter that could obscure surface opening or otherwise interfere with the examination. 1 25

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5. 3. 2 Typical cleaning agents which may be used are detergents, organic solvents, descaling solutions, and paint removers.

5. 3. 3 After cleaning, drying of the surface to be examined shall be accomplished by normal evaporation or with forced hot or cold air. A minimum period of 5 minutes shall be established to ensure that the cleaning

solution has evaporated prior to application of the penetrant. 5

5.4 Penetrant Application 5. 4. 1 The penetrant may be applied on the surface of work-pieces to be examined by spraying method.

5. 4. 2 The temperature of the penetrant and the surface to be examined shall not be below 40°F (5℃ ) nor above 125°F (52℃ ) throughout the examination period. This procedure shall not be used outside of this temperature range 40°F ( (52℃ ) 5. 4. 3 Penetration time is critical. The minimum dwell time is shown in Table 3. For suitable temperature, the area being examined shall remain wetted by the penetrant for the dwell time. 3 Table 3 Dwell Times (minutes)* Material Form Penetran Aluminum, Magnesium, steel and high temperature alloys Weld joint & welds Wrought material-extrusions, forgings, plate
-

5℃ )

125°F

Developer 10

6

10

10

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* For temperature range from 50℉ to 125℉ (10℃ to 52℃ ). For temperatures from 40℉ to 50℉ ((5℃ to 10℃ ) minimum penetrant dwell time shall be 2 times the value listed. 5.5 Excess Penetrant Removal and Drying

5. 5. 1 After the specified penetration time has elapsed, any penetrant remaining on the surface shall be removed, taking care to minimize removal of penetrant from discontinuities.

5. 5. 2 Excess solvent removable penetrants shall be removed by wiping with a cloth or absorbent paper, repeating the operation until most traces of penetrant have been removed. The remaining traces shall be removed by lightly wiping the surface with cloth or absorbent paper moistened with solvent. To minimize removal of penetrant from discontinuities, care shall be taken to avoid the use of excess solvent. Flushing the surface with solvent, following the application of the penetrant and prior to developing is prohibited.

5. 5. 3 For the solvent removable technique, the surfaces may be dried by normal evaporation, blotting, wiping or forced air.

5.6 Developing 5. 6. 1 he developer shall be applied as soon as possible after excess penetrant removal and drying surface. The time interval before applying developer shall be within 5 to 10 min. 5-10

5. 6. 2 With color contrast penetrants, only a wet developer shall be used. Prior to applying wet developer to the surface, the developer must be thoroughly agitated to ensure adequate dispersion of suspended particles.

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5. 6. 3 The developer shall be applied by spraying. A uniform thin coating shall be provided and the coating thickness shall be suitable.

5. 6.4 Developing time for final interpretation begins immediately, as soon as a wet developer coating is dry. The min. developing time shall be as required by Table 3 3 5.7 5.7. 1 Interpretation Final interpretation shall be made within 10 to 60 min. after the requirements of 5. 6. 4 are satisfied. 5.6.4 5.7. 2 10 60

The developing trace can be examined either by natural light or artificial light. A min. light intensity of

1000Lux is required to ensure adequate sensitivity during the examination and evaluation of indications. 1000Lux

5.7. 3 The light source, technique used, and light level verification is required to be demonstrated one time, documented, and maintained on file.

5.8 5. 8.

Post-cleaning 1 The penetrant materials shall be clearly removed away from parts after

examination. The post cleaning must be performed if remaining penetrant materials can result in corrosion by the combination with other materials during the operation.

5. 8. 2

The developer shall be cleaned as soon as possible after examination. The suitable cleaning process

shall be adopted for post cleaning such as flushing with water, mechanical cleaning, solvent soaking, etc.

6.0 Evaluation Indications

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6.1 All the indications shall be evaluated in terms of the acceptance standards of the ASME Code Section VIII Div.1 Appendix -8. ASME VIII 1 8

6.2 Discontinuities on or near the surface are indicated by bleed-out of penetrant. However, localized surface irregularities due to machining marks or other surface conditions may produce false indications.

6.3 An indication of an imperfection may be larger than the imperfection that causes it. However, the size of the indication is the basis for acceptance evaluation. Only indications with major dimensions greater than 1/16in. (1.5mm) shall be considered relevant.

1/16 6.3.1

1.5 A linear indication is one having a length greater than three times the width. 3

6.3.2 A rounded indication is one of circular or elliptical shape with the length equal to or less than three times the width. 3 6.3.3 relevant. Any questionable or doubtful indications shall be reexamined to determine whether or not they are

7.0 7.1

Acceptance Standards The following acceptance criteria shall be in accordance with the requirement of the latest edition of

ASME Section VIII. Div. 1 appendix 8.and ASME B31.1 ASME > 7.2 All surfaces to be examined shall be free of: VIII 8 ASME B31.1 <

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relevant linear indication;

relevant rounded indications greater than 3/16 in. (5 mm) 3/16 5

four or more relevant rounded indications in a line separated by 1/16 in.( 1.5mm) or less (edge to edge); 4 4 1/16 1.5

8.0 Reexamination of Repair Area. 8.1 All defects found exceed the Code allowed size shall be removed. NDT Level II personnel shall mention the found defects in the PT examination report which shall be reviewed by the NDT levelIII NDT NDT 8.2 After removing defects, it shall be repaired with the same procedures as the original. PT

8.3 Reexamination of the repaired area is required as the original.

8.4 PT report shall be presented to the AI for review and acceptance. PT AI

9.0 Examination Reports. At least the following information should be included in report.

1) 2) 3) 4)

Drawing No.; Product Number and Name of product; Material and thickness; Procedure identification and revision;

5) Date and time of examination;

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6 7) 8)

Area to be examined; Liquid penetrant type Type of each penetrant, penetrant remover, emulsifier,and developer used;

9) 10)

Map or record of indications per T691 Lighting equipment

T691

11) Examination personnel identity and qualification level; 10.0 Retention

Documentation /record for liquid penetrant examination shall be kept for a period as stipulated in section 11 of QC Manual / 11

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Written Practice

TO TRAIN, EXAMINE, QUALIFY, CERTIFY NDE PERSONNEL NDE ,

Prepared by

Date _____________

Approved by _________________

Date ____________

Accepted by _________________

Date ____________

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1 2 NDE 3 4 NDE 5 6 7 8 9 I II III III 1 2 1 2

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1. Scope 1.1 This Written Practice was developed by the HD for training, examination, qualification and certification of NDE personnel whose specific jobs require appropriate knowledge of the technical principle underlying the nondestructive examinations they perform, witness, monitor, or evaluate. HD 1.2 This Written Practice shall be prepared by the QC Manager, reviewed and approved by the NDE Level III personnel, and shall be accepted by the AI before being implemented. NDE 1.3Definitions Terms included in this document are defined as follows: AI

(1) Qualification: Demonstrated skill and knowledge, along with documented training and experience required for personnel to properly perform the duties of a specific job.

(2) Certification: Written testimony of qualification. (3) Training: An organized program developed to impart the knowledge and skills necessary for qualification.

(4) Experience: Work activities accomplished in a specific NDE method under direction of qualified supervision including the performance of the NDE method and relative activities, but not including time spent in organized training program. 2. NDE Method NDE

Qualification and certification of NDE personnel in accordance with Written Practice is applicable to Penetrant Examination and Radiographic Examination method in HD HD NDE

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3. Levels of Qualification

3.1 While in the process of being initially trained, qualified, and certified, an individual shall be considered a trainee. A trainee shall work with a certified individual. The trainee shall not independently conduct, interpret, evaluate, or report the results of any NDE test.

NDE 3.2 There are three basic levels of qualification as follows: 3.2.1 NDE Level I An NDE Level I individual shall be qualified to properly perform specific calibration, specific NDE, and specific evaluations for acceptance or rejection determinations according to written instructions and to record results. The NDE Level I shall receive the necessary instruction or supervision from a certified NDE Level II or III individual. NDE NDE1 NDE1 3.2.2 NDE Level II NDE2 NDE II 3 I NDE

An NDE Level II individual shall be qualified to set up and calibrate equipment and to interpret and evaluate results with respect to applicable code, standards, and specifications. The NDE Level II shall be thoroughly familiar with the scope and limitation of the methods for which qualified and shall exercise assigned responsibility for on-the-job training and guidance of trainees and NDE Level I personnel. The NDE Level II shall be able to organize and report the results of NDE tests. NDE II NDE2 NDE1

3.2.3 NDE Level III

NDE III

An NDE Level III individual shall be capable of, developing, qualifying, and approving procedures,

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establishing and approving techniques; interpreting codes, standards, specifications, and procedure; and designating the particular NDE methods, techniques, and procedures to be used. The NDE Level III shall be responsible for the NDE operations for which qualified and assigned and shall be capable of interpreting and evaluating results in terms of existing codes, standards, and specifications. The NDE Level III shall have sufficient practical background in applicable materials, fabrication, and product technology to establish techniques and to assist in establishing acceptance criteria where none are otherwise available. The NDE Level III shall have general familiarity with other appropriate NDE methods as demonstrated by an ASNT Level III Basic examination or other means. The NDE Level III, in the methods in which certified, shall be capable of training and examining NDE Level I and II personnel for certification in those methods.

NDE III NDE NDE III NDE NDE III

NDE III

ASNT III

NDE

NDE III

4. Examination Organization for NDE Personnel

NDE

Examination organization is consisted of QC Manager and Level III personnel (or Level III personnel certified of outside agency accepted by G.M). It is responsible for: NDE III (1) Investigating NDE personnel education, training, and experience; NDE (2) Determining examination range and questions;

(3) Evaluating examination grading;

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(4) Evaluating the personnel on the expiration of the certification for their re-certification.

(5) Organization for physical examination. 5. Education, Training, and Experience requirements for Initial Qualification

5.1 Education, Training, and Experience requirements for qualification of Level I and Level II personnel shall be in accordance with Table 5.1. I II 5.1

Table 5.1 Initial Training and Experience Levels Initial Training ( Hours )

5.1

Completion with a passing grade

Examination Level Method
High school graduate or equivalent

of at Least 2 years of engineering or science study in a University, collage, or Technical School

Experience Level (Months)

PT

I II

4 8 40 40

4 4 30 35

1 2 3 9

RT X

I II

Note: For Level II certification, the experience shall consist of time at Level I or equivalent. If a person is being qualified directly to Level II with no time at Level I, the required experience shall consist of the sum of the times required for Level I and Level II and the required training shall consist of the sum of the hours required for Level I and Level II. II I 1

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II I II

I

II

5.2 Education, Training, and Experience of Level III personnel shall be in accordance with one of the follows: III (1) Have graduated from a minimum four-year college or university curriculum with a degree in engineering and science, plus one additional year of experience beyond the level II requirements in NDE in an assignment comparable to that of an NDE Level II in the applicable test method(s).or : 4 NDE II

(2) Have completed with passing grades at least two years of engineering or science study at a university, college, or technical school plus two additional of experience beyond the level II requirements in NDE in an assignment at least comparable to that of NDE Level II in the applicable NDE method(s), or:

(3) Have four years of experience beyond the level II requirements in NDE in an assignment at least comparable to that of NDE Level II in applicable NDE method(s). NDE 6. Training Programs 6.1 Training is performed in accordance with Training Course Outline following this document and relevant technique documents. The training program shall include sufficient examinations to assure that the necessary principle and practice information of the specified test method has been comprehended. II

6.2 Training substance and class hours shall be recorded.

7. Examinations

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7.1 Vision Examination (1)Near-vision Acuity: The examination shall ensure natural or corrected near-distance acuity in at least one eye such that the applicant is capable of reading a minimum of Jaeger Number 2 letters or equivalent type and size letter at a distance of not less than 12 inches (30.5cm) on a standard Jaeger test chart. This shall be administered annually.

12

30.5cm

(2) Color Contrast Differentiation: The examination shall demonstrate the capability of distinguishing and differentiating contrast among colors or shades of gray used in the method as determined by JSSX. This should be conducted upon initial certification and at one year intervals thereafter.

(3) The examination record shall be archived in effective period of his certification.

7.2 Technical Qualifications The written examinations shall be administered without access to reference material (closed book) expect that necessary data, such as graphs, tables, specifications, procedures, and codes, may be provided.

7.2.1 For NDE Levels I & II

NDE I

II

The NDE Level III personnel shall administer and grade the examination on the NDE Level I and II personnel. NDE Level III personnel shall recommend to the QC Manager for the NDE Level I and II personnel based on their education, experience, ability and comparable qualification (such as by China Minister of Labor) etc. The QC Manager shall approve the list of candidate. NDEIII NDE I II NDE I II III NDE

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(1) General (written): The general examination shall be addressed to the basic principles of the applicable method. Number of the questions shall be shown in Table 7.2.1 (1) 7.2.1 1 Table 7.2.1(1) Number of Number of Level NDE Method I Questions NDE 1 2 PT RT 40 40 40 40 Questions Level II

(2) Specific (written): The specific examination shall address the equipment, operating procedures, and NDE techniques that the individual may encounter during specific assignments, and also cover the specifications or Codes and acceptance criteria used in HD’s NDE procedure. Number of questions is listed in Table 7.2.1 (2)

NDE HD NDE Table 7.2.1(2)
NDE Method I Questions NDE 1 2 II Questions

7.2.1(2). 7.2.1(2)
Number of Level

Number of Level

PT RT

20 20

20 20

(3) Practical: The candidate shall demonstrate familiarity with and the ability to operate the necessary NDE equipment, record and analyze the resultant information to the degree required.

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The practical examination shall be operated and tested on at least one flawed specimen or component approved by the NDE Level III. The description of the specimen, the NDE procedure, including check points, and the results of the examination shall be documented with the examination paper. At least ten different check points requiring an understanding of test variables and HD procedure requirements shall be included in this practical examination. NDE NDE3 NDE

HD Proficiency basis for each Level I and II as follows: I II

(a) For Level I, proficiency shall be demonstrated in performing the applicable NDE on one or more specimens or machine problems approved by the NDE level III and in evaluating the results to the degree of responsibility as defined by this written practice. At least ten (10) different checkpoints requiring an understanding of test variables and procedural requirements shall be included in this practical examination. I HD (b) For Level II, proficiency shall be demonstrated in selecting and performing the applicable NDE technique within the method and interpreting and evaluating the results on one or more specimens or machine problems approved by the NDE level III and in evaluating the results to the degree of responsibility as defined by this written practice. At least ten (10) different checkpoints requiring an understanding of test variables and procedural requirements shall be included in this practical examination. II 10 7.2.2 For NDE Level III NDE HD NDE III III NDE NDE 10

7.2.2.1 QC Manager shall recommend a NDE personnel as a candidate for NDE Level III qualification based on the education, experience, ability and comparable qualification and certification (such as by China Minister of Labor) etc. The NDE Level III candidate shall be approved by the G.M.

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NDE III NDE III NDE

7.2.2.2 QC Manager shall contact and arrange a qualified and certified external NDE Level III personnel to examine the JSSX NDE level III candidate. The qualification and certification of the external NDE Level III personnel shall be approved the G.M and be accepted by the AI. III AI 7.2.2.3 The NDE Level III examination shall include Basic Examination, Method Examination and Specific Examination. The composite grade shall be determined by simple averaging of the Basic Method and Specific results. QC Manager who is delegated to external qualified NDE Level III shall administer and grade of JSSX NDE Level III examinations. III NDE III NDE NDE HD III NDE III NDE

7.2.2.4 Basic Examination (Required only once when more than one method of examination is taken) The minimum number of questions should be given is as follows, where: ( 55 )

a. Fifteen (15) questions relating to understanding the SNT-TC-1A document. 15 SNT-TC-1A

b. Twenty (20) questions relating to applicable materials, fabrication and product technology. 20 c. Twenty (20) questions that are similar to published Level II questions for other appropriate NDE methods. 20 II NDE

7.2.2.5 Method Examination (for each method) 65 questions, where: 65 a) Thirty (30) questions relating to fundamentals and principles that are similar to published ASNT Level III questions for each method, and 30 ASNT

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b) Fifteen (15) questions relating to application and establishment of techniques and procedures that are similar to the published ASNT Level III questions , and 15 ASNT

c) Twenty (20) questions relating to capability for interpreting Codes, standards, and specifications relating to the method. 20 7.2.2.6 Specific Examination (for each method) Twenty (20) questions relating to specification, equipment, techniques, and procedures applicable to HD products and the methods employed and to the administration of the HD ’s written practice. 20 7.2.3 Grading A composite grade shall be determined by simple averaging of the results of all examination. A composite passing grade shall be at least 80 percent, with no individual examination having a passing grade less than 70 percent. 80% 70% 7.2.4 Re-examination Those failing to attain the required grades must wait at least 30 days or show evidence of having received additional training as determined by Level III personnel before re-examination. 30 HD HD

8. Certification 8.1 The certification for HD NDE Level III personnel shall be approved by the GM and accepted by the AI. The certification for HD NDE Level I & II personnel shall be approved by the QC Manager and accepted by the AI. HD III NDE AI AI HD I II NDE

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8.2 Condition Certified 8.2.1 Examination grading shall be in accordance with par. 7.2.3. 7.2.3 8.2.2 Education, training, and experience shall be in accordance with par.5. 5 8.2.3 Vision examination shall be in accordance with par. 7.1. 7.1 8.3 The qualification files of NDE personnel shall be maintained by NDE Level III Personnel for duration specified in HD written practice. NDE III NDE HD

The qualification files shall include the following: (1) Name of certified individual (2) Educational background and experience of certified individual

(3) Level of certification and NDE method NDE (4) Results of the vision examination for current certification period

(5) Statement indicating satisfactory completion of training in accordance with HD written practice. HD (6) Current examination copies or, practical examination records and composite grade reports.

(7) Certificate No, dates of certification and / or re-certification and the dates of assignment to NDE. / NDE

(8) Signature of the level III that verified qualifications of candidate for certificate

(9) Certification expiration date

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(10)Signature of QC Manager ( for Level I & II) or G.M ( for Level III). 1 2 3

8.4 Technical Performance Evaluation The technical performance of level I and II performed shall be evaluated and documented a half year by NDE level III. The evaluation and documentation should follow the format and guidelines described in para. 7.2.1 (3) 9.4 Re-certification 9.4.1 All Levels of NDE personnel shall be re-certified periodically in accordance with one of the following criteria: NDE (1) Evidence of continuing satisfactory performance, or

(2) Re-examination in those portions of the examinations as described above whenever deemed necessary by HD, AI or clients. HD AI 9.4.2 Maximum re-certification intervals are: (1) Level I & II ---- 3 years. I (2) Level III-------- 5 years. III II 5 3

9.4.3 NDE Personnel may be re-examined any time at the discretion of QC Manager or AI and have their certification extended or revoked. NDE AI

10. Termination 10.1 The certification for NDE personnel shall be deemed revoked when employment is terminated. NDE 10.2When the NDE personnel has not conducted the qualified NDE operation for a period of six (6) months. NDE NDE

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10.3 Whenever the performance, ability or physical condition of the NDE personnel has been questioned by the HD, AI or clients. HD AI NDE

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APPENDIX

I

1
Training Course Outline for PT Level I Personnel 1

Subject

Period – Hours A* B** 1/2 1.5 1 1

1. 2.

Introduction Liquid Penetrant Processing

1/2 1.5 1 1

3. Various Penetrant Testing Methods 4. Liquid Penetrant Testing Equipment

Total

4

4

*A **B

High school graduate equivalent Completion with passing grades of at least two years of engineering or science study at a university, college, or technical school

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APPENDIX

II

2
Training course outline for PT level II personnel 2

Subject

Period - Hours A* B**

1. Review 2. Selection of the Appropriate Penetrant Testing Method

1 2

1/2 1

3.

Inspection and Evaluation of Indications

4 1

2 1/2

4. Inspection Procedures and Standards

Total

8

4

*A **B

High school graduate equivalent Completion with passing grades of at least two years of engineering or science study at a university, college, or technical school.

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APPENDIX

III

3
Training Course Outline for RT Level I Personnel 1

Subject

Period --- Hours A* B** 5

1. Radiographic equipment operation and emergency instructions course 2. Basic radiographic physics course 3. Radiographic technique course

5

20 15

15 10

Total

40

30

*A **B

High school graduate equivalent Completion with passing grades of at least two years of engineering or science study at a university, college, or technical school.

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Weifang HuoDa Pipe Fittings

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APPENDIX

IV

4
Training course outline for RT level II personnel 2

Subject

Period - Hours A* B** 15

1. Film quality and manufacturing processes course

20

2. Radiographic evaluation and interpretation course

20

20

Total

40

35

*A **B

High school graduate equivalent Completion with passing grades of at least two years of engineering or science study at a university, college, or technical school.

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Heat Treatment Procedure

Prepared by

Date _____________

Approved by ________________ Date ____________

Accepted by _________________Date ____________

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1. General This procedure is supplemented to the “Heat Treatment Instruction ”(specific heat treatment instruction), and is applicable to the boilers and pressure vessels and parts of carbon steels (PNo1 Gr.Nos 1,2&3) fabricated according to ASME Code Sect VIII,Div1 and B31.1 ” (PNO ”( 1 2 3) ) , VIII ASME B31.1

For the other materials, the applicable procedure and condition will be added or provided. , 2. Personnel The PWHT operator shall be familiar with the general requirements of heat treatment and has been properly trained. . 3.Equipment The 4.5 4.5 14m oil PWHT furnace, Max. temp.2012 (1100 ). 4.5 4.5 14m PWHT 4. Procedures One of the following procedures may be used for the PWHT: . 4.1 If it is practicable, the vessel shall be heated as a whole in an enclosed furnace. , . , 2012 .

4.2Heating the vessel in more than one heat in furnace, provided the overlap of the heated sections of the vessels at least 5 ft. (1.5 m). When this procedure is used, the portion outside of the furnace shall be shielded so that the temperature gradient is not harmful. , 5 (1.5m), ,

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,

.

4.3.Heat of the shell sections and/or portions of the vessels to postweld heat treat longitudinal

joints or complicated welded details before joining to make the completed vessels. When the vessel is required to be PWHT, and it is not practicable to PWHT the completed vessel as a whole or in two or more heats as provided in 4.2 above, any circumferential joints not previously PWHT may be thereafter locally PWHT by heating such joins by any appropriate means that will assure required uniformity. As a minimum, the soak band shall contain the weld, heat affected zone, and a portion of base metal adjacent to the weld being heat treated. The minimum width of this volume is the widest width of weld plus T or 2in (50mm), whichever is less, on each side or end of the weld. The portion outside the heating device shall be protected so that the temperature gradient is not harmful. This procedure may also be used to PWHT portions of new vessels after repairs. , , , 4.2 . T , . 2 (51mm) . , . , ,

4.4 Heating the vessel internally by any appropriate means and with adequate indicating and recording temperature devices to aid in the control and maintenance of a uniform distribution of temperature in the vessel wall. Previous to this operation, the vessel should be fully enclosed with insulating material, or the permanent insulation may be installed provided it is suitable for the required temperature. In this procedure the internal pressure should be kept as low as practicable, but shall not exceed 50% of the maximum allowable working pressure at the highest metal temperature expected during the PWHT period. , , , 50% , , .

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4.5 Heating a circumferential band containing nozzles or other welded attachments that required PWHT in such a manner that the entire band shall be brought up uniformly to the required temperature and held for the specified time. The circumferential band shall extend around the entire vessel, shall include the nozzle or welded attachment. As a minimum, the soak band shall contain the weld, heat affected zone, and portion of base metal adjacent to the weld being heat treatment. The minimum width of this volume is the widest width of

weld plus T or 2in (50mm), whichever is less, on each side or end of the weld. The portion of the vessel outside of the circumferential band shall be protected so that the temperature gradient is not harmful. , , , 4.6 Heating a circumferential joints of the pipe or tubing by any appropriate means using a soak band that extends around the entire circumference. The minimum width of this volume is the widest width of weld plus T or 2in (50mm), whichever is less, on each side or end of the weld. The portion of the soak band shall be protected so that the temperature gradient is not harmful. , . , t 2 , (50mm), .

5.Operation The operator shall perform the PWHT in accordance with those requirement as specified following:

5.1The temperature of the furnace shall not exceed 800 placed in it. , 5.2 Above 800 800 the rate of heating shall be not more than

at the time the Vessel or the part is

divided by the maximum metal thickness of the shell or head plate in inches (25mm), but in no case more than400 /hr. During the heating period there shall not be a greater variation in (138 within any 15 feet

temperature throughout the portion of the vessel being heated than 250

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(4.6meter) interval of length. 800

5.3 The vessel or vessel part constructed of materials which belong to P-No1GrNos1,2,3 shall be held at or above the temperature specified in Table 1or 2 for the period of time specified in the Table. PNo1GrNos1,2,3 . , 1 2

TABLE 1

1

PWHT REQUIREMENTS FOR CARBON AND LOW ALLOY STEELS

Normal Holding Temp. Material ( )minimum

Minimum Holding Time at Normal Temp. For Nominal Thickness

Over 2 inch (50MM) Up to 2 in (50MM) P-No1 Gr.Nos 1 2 3 P-No1 1 2 3 1 1100 (595 1 hr/in. (1 hr/25mm) 15 min minimum / (1 15 2 (25mm) 15 (50mm) ,2 1 2 hr plus 15 min for each additional inch (25mm) over 2 inch ( 50mm)

/25mm)

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TABLE 2

2

ALTERNATIVE PWHT REQUIREMENTS FOR CARBON AND LOW ALLOY STEELS

Decease in Temp. below Minimum Specified temp.

Minimum Holding Time [Note(1)] at decreased Temperature. Hr ( 1)

50(28 100(56 150(83 200(111

) ) ) )

2 4 10(note2) 10( 20(note2) 20( 2) 2)

Note:

(1) Minimum holding time for 1 inch (25mm) thickness or less. Add 15minutes

per inch of thickness for thickness greater than 1 inch.(25mm) 1. 1 (25mm) 15 . , 1 (25mm) , 1

(2) These lower PWHT temperature permitted only for P-No.1 Gr.Nos.1 and 2materials. During the holding period, there shall not be a difference greater than 150 83 between the highest and lowest temperature

throughout the portion of the vessel being heated, except where the range of further limited by the “Heat Treatment Instruction ”. PNo , , 1 2 . “ ” 150 83

5.4 During the heating and holding period, the furnace atmosphere shall be so controlled as to avoid excessive oxidation of the surface of the vessel. The furnace shall be of such design as to prevent direct impingement of the flame on the vessel.

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5.5Above 800

cooling shall be done in a closed furnace at a rate not greater than 500 /hr (280 )

divided by the maximum metal thickness of the shell or the head plate in inches, but in no case more than 500 /hr. (280 From 800 (425 the vessel may be cooled in still air. The rates of heating and cooling need not be In all cases consideration of closed chamber and complex structure may indicated

less than 100 /hr.(56

reduced rates of heating and cooling to avoid structural damage due to excessive thermal gradients. 800 425

(425

5.6 The temperature recorder and thermocouples shall be in the effective calibration period. The thermocouples shall directly touch the vessel at the bottom, center and the top of the charge, or in other zones of possible

temperature variation so that the temperature indicated shall be true temperature for all vessels or parts in those zones. , , 5.7The thermocouple should be fastened to the attachment plate (with thread hole) by bolts. The attachment plate should be welded to workpiece. The welding shall be performed using the qualified WPS by the qualified welder. , , WPS

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5.8 The Examiner shall verify identification number of the heat treated items, heat treatment requirements and furnace name including No. & recorder No. on the Heat Treatment Record attached to the time---temperature chart. ,

6 Examination 6.1 PWHT shall be done before the hydrostatic test and after any welded repairs except as permitted by the Code. , 6.2 The Examiner shall collect the Heat Treatment Record and time temperature chart.

6.3 The QC Engineer shall review all records related to the heat treatment to verify that conditions of heat treatment meet the requirements of the procedure, the customer’s specification, certificates of materials and applicable WPS.

WPS

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Nonconformity Control Procedure

Prepared by _________________ Approved by ____________ Accepted by _________________

Date _________________ Date _________________ Date _________________

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1. General 1.1 This procedure is prepared according to the requirements of ASME Code and the QCM chapter 6. ASME 6

1.2 This procedure is applied to the control of the nonconforming items such as products, materials, documents and actions, etc. from designing to finishing fabrication.

2. Duty 2.1 The personnel responsibility shall be implemented in accordance with the QCM chapter 6. The personnel of various
responsibilities and the disposition personnel involved in the nonconformity shall sign on the Nonconformity Report and applicable documents according to the procedure.

6 2.2 Any person who finds a nonconformity shall notify the QA personnel. QC Office Chief shall investigate and evaluate the
condition according to QA Supervisor’s requirements to determine whether or not the nonconformity exists. If it exists, QC Office Chief shall fill in the Nonconformity Report (Exhibit 6-1) to report the condition to QA Supervisor, and at the same notify the QA personnel to mark the nonconformity and stop producing the product.

2.3 The QA office chief shall be responsible to call the technical personnel, QA personnel , workshop relevant personal, the
foreign trade office and relevant offices and departments to convene the meeting to study and resolve the disposition of the nonconformity and designate a person concerned such as Purchaser, Calibration Engineer, Technology Engineer , etc. to document the disposition means on the NCR.

NCR 2.4 When the disposition means of the nonconformity has been decided as “Reject”, QC Office Chief shall distribute the copy of NCR including the disposition means to the Technology Engineer, the Exam. Engineer,
workshop relevant personal, the foreign trade office, and at the same time the Exam Engineer shall attach “REJECT”

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to the nonconformity item . NCR 2.5 When the disposition means of the nonconformity has been approved as “Use As Is”, the QC Office Chief shall distribute the Cope of NCR including disposition means to the Technology Engineer, the Exam. Engineer, workshop relevant personal, the foreign trade office, and the same time the Examination Engineer shall take off the label from the item for continuing the process. NCR

2.6 When the disposition means of the nonconformity has been approved as “REPAIR”, QC Office Chief shall distribute the original NCR to the Technic Office, and at the same time shall attach “REPAIR” label to mark the item. NCR

2.6.1 The Technology Engineer of the Technic Office shall prepare repairing technology and Check Off List according to the disposition means of NCR. NCR 2.6.2 The Document keeper of Technical Office shall hand carry all of the COL documents for repairing to the

QA Supervisor . The QA Associate Super visor shall submit them to AI for acceptance and to appoint the inspection point. AI AI 2.6.3 The Document keeper in the Technic Office shall copy all of the repairing technology documents accepted by AI according to“ Documents Issuance List ”and distribute to concerned Division .The original documents shall be hand to the QC Office Chief in file. AI

2.6.4 During the repairing process, the Exam. Engineer shall control the repair work and write down the

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corresponding record after finishing repairing, the record or report shall be attached to the Nonconformity Report and hand carry to QA Supervisor for approval and to AI for acceptance, then the Exam. Engineer shall take the “Repair” Label to turn to the continue process.

AI

2.6.5 The QC Office Chief shall be responsible to control the original document of Nonconformity Report of “Use as Is”, “Repair”, and technology documents, inspection record and maintain them in file.

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Calibration procedure of measuring, examination, and test equipments

Prepared by _________________ Approved by _________________ Accepted by _________________

Date _________________ Date _________________ Date _________________

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