PROJECT

TRAINING
MANUFACTURING ,INSPECTION & DESIGNING OF
PRESSURE VESSEL AND PARTS AS PER ASME 2015
SECTION 8
 ASME CODE

THIS INTERNATIONAL CODE OR STANDARD WAS DEVELOPED

UNDER PROCEDURES ACCREDITED AS MEETING THE
CRITERIA FOR AMERICAN NATIONAL STANDARDS AND IT IS
AN AMERICAN NATIONAL STANDARD . THE STANDARDS
COMMITTEE THAT APPROVED THE CODE OR STANDARD WAS
BALANCED TO ASSURE THAT INDIVIDUALS FROM
COMPETENT AND CONCERNED INTERESTS HAVE HAD AN
OPPORTUNITY TO PARTICIPATE . THE PROPOSED CODE OR
STANDARD WAS MADE AVAILABLE FOR PUBLIC REVIEW AND
COMMENT THAT PROVIDES AN OPPORTUNITY FOR
ADDITIONAL PUBLIC INPUT FROM INDUSTRY , ACADEMIA ,
REGULATORY AGENCIES AND THE PUBLIC-AT -LARGE
 WHAT IS CODE ?

A CODE IS A DOCUMENT THAT SETS RULES FOR DESIGN OF

A NEW DEVELOPMENT . IT IS A TOOL THAT CAN BE USED IN
THE DESIGN AND PLANNING PROCESS BUT GOES FURTHER
AND IS MORE REGULATORY THAT OTHER FORMS OF
GUIDANCE COMMONLY USED IN THE PLANNING SYSTEM
OVER RECENT DECADES .
 WHAT IS SPECIFICATION ?

A SPECIFICATION IS A DETAILED DOCUMENT PROVIDING INFORMATION

ABOUT THE BORN OF A PROJECT TO SET CRITERIA THE DEVELOPERS WILL
NEED TO MEET.
ITS USE IS CALLED FOR WHERE A STRUCTURE OR PRODUCT HAS TO BE
SPECIALLY MADE TO MEET A NEED .FOR EXAMPLE THE DESIGN
SPECIFICATION MUST INCLUDE ALL NECESSARY DRAWINGS , DIMENSIONS ,
ENVIRONMENTAL FACTORY ,ERGONOMIC FACTORS ,AESTHETIC FACTORS ,
COST , MAINTENANCE THAT WILL BE NEEDED , QUALITY ,SAFETY ,
DOCUMENTATION AND DESCRIPTION.
IT ALSO TELLS SPECIFIC EXAMPLES OF HOW THE DESIGN OF THE PROJECT
SHOULD BE EXECUTED ,HELPING OTHERS WORK PROPERLY
 WHAT IS STANDARD ?
A SET OF TECHNICAL DEFINITIONS , INSTRUCTIONS ,RULES
,GUIDELINES ,OR CHARACTERISTICS SET FORTH TO PROVIDE
CONSISTENT AND COMPARABLE RESULTS ,INCLUDING :
1. ITEMS MANUFACTURED UNIFORMLY ,PROVIDING FOR
INTERCHANGEABILITY
2. TESTS AND ANALYSES CONDUCTED RELIABLY , MINIMIZING THE
UNCERTAINTY OF THE RESULTS
3. FACILITIES DESIGNED AND CONSTRUCTED FOR SAFE
OPERATION
BY CUSTOMS SOME STANDARDS ARE CALLED CODES.
STANDARDS NOT HAVING THE FORCE OF LAW ARE CONSIDERED
VOLUNTARY AND SERVE AS GUIDELINES . ASME PUBLISHES
STANDARDS AND CERTIFIES USERS OF STANDARDS TO ENSURE
THAT THEY ARE CAPABLE OF MANUFACTURING PRODUCTS THAT
MEET THOSE STANDARDS
 COUNCIL ON
STANDARDS &
CERTIFICATION
Board on Board on pressure
standardization technology codes and
and testing standards

Board on nuclear Energy and

Board on strategic environmental Boards on safety
codes and
initiatives standards advisory codes and standards
standards
boards

Board on codes and Board on new

standard operations development Board on hearing and Board on conformity
appeals assessment
 LIST OF SECTIONS

SUBSECTION A SUBSECTON B SUBSECTION C

• REQUIREMENTS FOR 1. REQUIREMENT FOR PRESSURE

PRESSURE VESSELS VESSEL CONSTRUCTED OF

FABRICATED BY • CARBON AND LOW ALLOY

• GENERAL STEELS (UCS)
WELDING (UW)
REQUIREMENTS FOR • NON FERROUS MATERIALS
REQUIREMENT FOR
• (UNF)
ALL METHODS OF PRESSURE VESSELS • HIGH ALLOY STEEL (UHA)
CONSTRUCTION & ALL FABRICATED BY FORGING
• MATERIAL WITH CORROSION
MATERIALS (UF) RESISTANT INTEGRAL
CLADDING , WELD METAL OVER
(UG) REQUIREMENT FOR
• CLADDING OR WITH APPLIED
PRESSURE VESSELS LINING (UCL)
FABRICATED BY BRAZING • FERRITE STEEL WITH TENSILE
PROPERTIES ENHANCED BY
(UB)
HEAT TREATMENT (UHT)
1. RULES FOR SHELL AND TUBE
HEAT EXCHANGERS (UHX)
FABRICATION DEPARTMENT

FABRICATION IS THE BUILDING OF METAL STRUCTURE BY CUTTING, BENDING &

ASSEMBLY PROCESSES.IT IS A VALUE ADDED PROCESS THAT INVOLVES THE
CONSTRUCTION OF MACHINES & STRUCTURES FROM VARIOUS RAW MATERIALS
.METAL FABRICATION JOBS USUALLY START FROM SHOP DRAWINGS INCLUDING
PRECISE MEASUREMENT THEN MOVE T FABRICATION STAGE & FINALLY TO
INSTALLATION OF FINAL PROJECT.
WELDING DEPARTMENT

 SMAW – SHIELDED METAL ARC WELDING

 SAW - SUBMERGED ARC WELDIING
 GMAW (MIG) - GAS METAL ARC WELDING
 FCAW - FLUX COREDARC WELDING
 GTAW (TIG) - GAS TUNGESTON ARC WELDING
 PAW - PLASMA ARC WELDING
 ESW - ELECTRO SLAG WELDING
 EGW - ELECTRO GAS WELDING
 RW - RESISTANCE WELDING
 FW - FLASH WELDING
 OFW - OXY FUEL GAS WELDING
 DFW - DIFFUSION WELDING
 FRW - FRICTION WELDING
 EBD - ELECTRON BEAM WELDING
 LBW - LASER BEAM WELDING
WELDING PROCEDURE
SPECIFICATION
WELDING PROCEDURE SPECIFICATION (WPS)
AWPS IS A WRITTEN QUALIFIED WELDING PROCEDURE
PREPARED TO PROVIDE DIRECTION FOR MAKING PRODUCTION
WELDS TO CODE REQUIREMENTS. THE WPS OR OTHER
DOCUMENTS MAY BE USED TO PRO-VIDE DIRECTION TO THE
WELDER OR WELDING OPERATOR TO ASSURE COMPLIANCE
WITH THE CODE REQUIREMENTS.
CONTENTS OF THE WPS
THE COMPLETED WPS SHALL DE-SCRIBE ALL OF THE
ESSENTIAL, NONESSENTIAL, AND, WHEN REQUIRED,
SUPPLEMENTARY ESSENTIAL VARIABLES FOR EACH WELDING
PROCESS USED IN THE WPS. THESE VARIABLES ARE LISTED
FOR EACH PROCESS IN QW-250 AND ARE DEFINED IN ARTICLE
IV, WELDING DATA.
THE WPS SHALL REFERENCE THE SUPPORTING PROCEDURE
QUALIFICATION RECORD(S) (PQR) DESCRIBED IN QW-200.2.
THE ORGANIZATION MAY INCLUDE ANY OTHER INFORMATION
IN THE WPS THAT MAY BE HELPFUL IN MAKING A CODE
WELDMENT.
PROCEDURE
QUALIFICATION RECORD
PROCEDURE QUALIFICATION RECORD (PQR).
THE PQR IS A RECORD OF VARIABLES RECORDED DURING THE WELDING OF THE TEST COUPONS. IT ALSO
CONTAINS THE TEST RESULTS OF THE TESTED SPECIMENS. RECORDED VARIABLES NORMALLY FALL
WITHIN A SMALL RANGE OF THE ACTUAL VARIABLES THAT WILL BE USED IN PRODUCTION WELDING.

CONTENTS OF THE PQR.

THE COMPLETED PQR SHALL DOCUMENT ALL ESSENTIAL AND, WHEN REQUIRED, SUPPLEMENTARY ESSENTIAL
VARIABLES OF QW-250 FOR EACH WELDING PROCESS USED DURING THE WELDING OF THE TEST COUPON.
NONESSENTIAL OR OTHER VARIABLES USED DURING THE WELDING OF THE TEST COUPON MAY BE RECORDED
AT THE ORGANIZATION'S OPTION. ALL VARIABLES, IF RECORDED, SHALL BE THE ACTUAL VARIABLES
(INCLUDING RANGES) USED DURING THE WELDING OF THE TEST COUPON. IF VARIABLES ARE NOT MONITORED
DURING WELDING, THEY SHALL NOT BE RECORDED. IT IS NOT INTENDED THAT THE FULL RANGE OR THE
EXTREME OF A GIVEN RANGE OF VARIABLES TO BE USED IN PRODUCTION BE USED DURING QUALIFICATION
UNLESS REQUIRED DUE TO A SPECIFIC ESSENTIAL OR, WHEN REQUIRED, SUPPLEMENTARY ESSENTIAL
VARIABLE.
WELDER PERFORMANCE
QUALIFICATION
WPQ TALKS ABOUT QUALIFICATION BASED ON REQUIREMENTS OF ASME CODE
SECTION 9.THE WPQ RECORD INDICATES THE ABILITY OF THE WELDER OR WELDING
OPERATOR TO DEPOSIT “SOUND” WELD METAL.
EACH MANUFACTURER OR CONTRACTER SHALL MAINTAIN A RECORD OF THE RESULT
OBTAINED IN WELDING PROCEDUREAND WELDER PERFORMANCE QUALIFICATION .AS
MINIMUM ANY WELDING PERFORMANCE QUALFICATION RECORD SHOULD INDICATE
THE ESSENTIAL VARIABLES,THE RANGE OF QUALIFIED VARIABLES SUCH AS
MATERIAL ,PIPE DIAMETER , THICKNESS,POSITION.
THE RECORD SHOULD ALSO INDICATE THE RESULT OF MECHANICAL OR NON
DESTRUCTIVE TESTING RESULT
 ELCTRODE
 
FUNCTION OF FLUX IN WELDING: 
– STABILIZES ARC
FLUX COATING ON ELECTRODE – PREVENTS CONTAMINATION OF WELD
METAL
 
– CLEANS THE WELD FROM UNWANTED
– SODIUM CHLORIDE IMPURITIES

– POTASSIUM CHLORIDE – INCREASES FLUIDITY OF MOLTEN METAL

– GENERATES INERT GAS SHIELDING
– TITANIUM DIOXIDE WHILE METAL TRANSFERS
– SODIUM SILICATE – FORMS SLAG AFTER MELTING & COVERS
WELD
– FERROSILICON
– ALLOWS DEPOSITED METAL TO COOL
– IRON POWDER SLOWLY
– INTRODUCES ALLOYING ELEMENTS IN
– ALLOYING ELEMENTS THE WELD
– BINDING MATERIAL – INCREASES DEPOSITION EFFICIENCY
– MINIMIZES THE SPATTER GENERATION
– HELPS IN EVEN & UNIFORM BEAD FINISH
 ELECTRODE SIZES &
RECOMMENDED CURRENT
 
 
 
BAKING IS DONE TO REMOVE THE MOISTURE (H2O) FROM COATING TO AVOID POSSIBLE
CRACKING OF WELD

 Baking Requirements For Flux

 
 Spread the loose Flux in a Tray Of baking Oven
 Identify The Tray With The Quality/Grade Of Flux
 Bake Tray in an Oven Between 300° C to 350° C
 Baking Time 2Hrs to 3 Hrs
 Reduce the temperature to 100 ° C to 150 ° C
 Hold the Flux at this temperature till use

 Why Baking Flux?

 
 To remove the moisture (H2O)
 To avoid possible cracking of weld due to H2
 
 HOW DOES MOIST FLUX GENERATE CRACK WITHIN WELD?
 
 MOIST FLUX INTRODUCE ATOMIC HYDROGEN AT HIGH TEMPERATURE IN WELD
 ON COOLING, ATOMIC HYDROGEN TRY TO FORM MOLECULES
 THE REACTION RESULTS IN STRESSES AND FINE CRACKS
 CRACKS OCCUR WITHIN HARDENED METAL - HAZ
 KNOWN AS “HYDROGEN EMBRITTLEMENT” OR “UNDER BEAD CRACK” OR DELAYED
CRACK
 
 REUSE OF FLUX
 
• FLUX MAY BE REUSED PROVIDED
- WELD NOT HIGHLY CRITICAL IN IMPACT / CHEMISTRY
- REUSE LIMITED TO MAXIMUM TWICE
- ALL SLAG PARTICLES ARE SIEVED & REMOVED
- REBAKED IF NOT REMAINED IN HOT
- MINIMUM 50% FRESH FLUX WELL MIXED
- CUSTOMER SPEC. DOESN'T PROHIBIT THE SAME
EXAMPLE:
E 7018
E = ELECTRODE
70 = UTS IN 1000 PSI (60/70/80/90/100/ 110)
1 = POSITION (1= ALL, 2= 1G, 1F & 2F, 3= 1G & 1F)
8 = TYPE OF COATING (0,1,2,3,5,6,8)
 
(18)= TYPE OF COATING- LOW HYDROGEN
POTASSIUM, IRON POWDER.
TYPE OF CURRENT -AC OR DC
 SUBMERGED ARC WELDING

FABRICATION

SUBMERGED ARC WELDING IS A COMMON ARC WELDING PROCESS.THE PROCESS REQUIRES A

CONTINUOSLY FED CONSUMABLE SOLID OR TUBULAR ELECTRODE.THE MOLTEN WELD AND THE ARC
ZONE ARE PROTECTED FROM ATMOSPHERIC CONTAMINATION BY BEING SUBMERGED UNDER A
BLANKET OF GRANULAR FUSIBLE FLUX
 FUSION WELDING PROCESS
 AUTOMATIC / SEMI AUTOMATIC
 ARC BETWEEN CONSUMABLE ELECTRODE AND WORK
 ARC COVERED UNDER GRANULAR FLUX
 WIRE / ELECTRODE CONTINUOUSLY FED TO WELD POOL
 WIRE / ARC UNDER FLUX MOVES ALONG THE GROOVE
 WIRE, BM & FLUX CLOSE TO ARC MELT UNDER FLUX
 ON COOLING WELD METAL SOLIDIFIES
 MOLTEN FLUX FORMS THICK SLAG COATING ON WELD
 Hopper

Flux Power Source

Wire +
+ –
Slag
Flux Weld
Base Metal
••••••••••••••••
••• Arc
FUSIBLE FLUX CONSISTS OF
 LIME SILICA
 MAGNESIUM OXIDE
 CALCIUM FLUORIDE

WHEN THE MOLTEN FLUX BECOMES CONDUCTIVE AND PROVIDES A CURRENT PATH BETWEEN
THE ELECTRODE AND THE WORK.THIS THICK LAYER OF FLUX COMPLETELY COVERS THE
MOLTEN METAL THUS PREVENTING SPATTER AND SPARKS AS WELL AS SUPPRESSING THE
INTENSE ULTRAVIOLET RADIATION AND FUMES THAT ARE PART OF SMAW( SHIELDED METAL ARC
WELDING)

THE PROCESS IS NORMALLY LIMITED TO THE FLAT OR HORIZONTAL FILLET WELD POSITIONS

 SINGLE OR MULTIPLE ELECTRODE WIRE VARIATIONS OF THE PROCESS EXIST

 SAW STRIP-CLADDING UTILIZES A FLAT STRIP ELECTRODE
 DC OR AC CAN BE USED
FEATURES:-
 WELDING HEAD
IT FEEDS FLUX AND FILLER METAL TO THE WELDING JOINT.ELECTRODE GETS ENERGIZED
HERE

 FLUX HOPPER
IT STORES THE FLUX AND CONTROLS THE RATE OF FLUX DEPOSITION ON WELDING JOINTS

 FLUX
 THE GRANULATED FLUX SHIELDS AND THUS PROTECTS MOLTE WELD FROM ATMOSPHERIC
CONTAMINATION
 FLUX CLEANS WELD METAL AND ALSO MODIFY ITS CHEMICAL COMPOSITION
 THE FLUX IS GRANULATED TO A DEFINITE SIZE.IT MAY BE BONDED ,FUSED OR MECHANICALLY
FUSED TYPE
 FLUX MAY CONSIST OF FLURIDES OF CALCIUM AND OXIDES OF
CALCIUM,MAGNESIUM,SILICON,ALUMINIUM & MAGANESE
 ALLOYING ELEMENTS CAN BE ADDED AS PER REQUIREMENT

 ELECTRODE
SAW FILLER MATERIAL USUALLY IDS A STANDARD WIRE AS WELL AS OTHER SPECIAL
FORMS.NORMALLY HAS A THICKNESS OF 1.6 MM .TWISTED WIRE CAN BE USED TO GIVE THE
ARC AN OSCILLATION MOVEMENT.THISA HELPS FUSE THE TOE OF WELD TO BASE METAL

 DIAMETERS MAY BE 1.6 , 2.0 ,2.4 ,3.4 ,4.0 ,4.8 ,6.4

 ADVANTAGES
• HIGH DEPOSITION RATES
• DEEP WELD PENETRATIONS
• SOUND WELLS ARE READILY MADE
• HIGH SPEED WELDING
• MINIMAL WELDING FUME
• NO EDGE PREPARATION IS NECESSARY
• WELDS PRODUCED ARE SOUND ,
UNIFORM ,DUCTILE , CORROSION
RESISTANT
• SINGLE PASS WELDS CAN BE MADE
• NO CHANCE OF SPATTER OF WELD
• 50% - 90% OF FLUX IS RECOVERABLE
,RECYCLED AND REUSED
LI M I T A T I O N S
• LIMITED TO FERROFOR PROPER ROOT
PEUS BASED ALLOY
• LIMITED TO 1F ,1G ,& 2F POSITIONS
• LIMITED TO LONG STRAIGHT SEAMS OR
ROTATED PIPES OR VESSELS
• TROUBLESOME FLUX HANDLING
SYSTEM
• REQUIRES INTERPASS AND POST WELD
SLAG REMOVAL
• BACKING STRIPS FOR PROPER ROOT
PENETRATION
• LIMITED TO HIGH THICKNESS
MATERIALS
 SHIELDED METAL ARC
WELDING

FABRICATION

SMAW IS ALSO KNOWN AS MANUAL METAL ARC WELDING ,FLUX SHIELDING ARC WELDING ,STICK
WELDING THAT USES A CONSUMABLE ELECTRODE COVERED WITH A FLUX TO LAY THE WELD
 A Fusion Welding Process – Semi Automatic
 Arc Between Consumable Electrode &Work
 Arc Generated by Electric Energy From a Rectifier /
Thyrester / Inverter
 Filler Metal As Electrode Continuously fed From
Layer Wound Spool.
 Filler Wire Driven to Arc By Wire Feeder through
Welding Torch
 Arc & Molten Pool Shielded by Inert Gas through
Torch / Nozzle
AN ELECTRIC CURRENT IN THE FORM OF EITHER AC OR DC FROM A WELDING POWER SUPPLY
IS USED TO FORM AN ELECTRIC ARC BETWEEN THE ELECTRODE AND METALS TO BE JOINED.
THE WORKPIECE AND THE ELECTRODE MELT FORMING A POOL OF MOLTEN METAL THAT
COOLS TO FORM A JOINT, AS THE WELD IS LAYED THE FLUX COATING OF THE ELECTRODE
DISINTEGRATES GIVING OF VAPOURS THAT SERVE AS SHIELDING GAS ND PROVIDING A
LAYER OF SLAG BOTH OF WHICH PROTECT THE WELD AREA FROM ATMOSPHERIC
CONTAMINATION
BEACAUSE OF VERSALITY OF PROCESS AND THE SIMPLICITY OF ITS EQUIPMENT AND
OPERATION AND THE SIMPLICITY OF ITS EQUIPMENT AND OPERATION SMAW IS ONE OF THE
WORLD FIRST AND POPULAR WELDING PROCESS

 THE MOST QUALITY PROBLEMS ASSOCIATED WITH SMAW INCLUDE WELD SPATTER ,
POROSITY ,POOR FUSION ,SHALLOW PENETRATION AND CRACKING
 OFTEN USED TO WELD CARBON STEEL ,LOW AND HIGH ALLOY STEEL ,CAST IRON AND
DUCTILE IRON
 CAN BE USED ON NICKLE AND COPPER AND THEIR ALLOYS AND IN RARE CASES ON
ALUMINUM
 THICKNESS RARELY DROP BELOW 1.5 mm
 POWER SUPPLY
 CONSTANT CURRENT OUTPUT
 IT CONSISTS OF A STEP DOWN TRANSFORMER
 FOR DIRECT CURRENT MODELS A RECTIFIER
 ELECTRICAL GENERATORS AND ALTERNATORS ARE FREQUENTLY USED AS PORTABLE
WELDING POWER SUPPLIES

 ELECTRODE
 ELECTRODE IS COATED IN A METAL MIXTURE CALLED FLUX

ELCTRODES ARE DIVIDED INTO 3 GROUPS

 FAST FILL ELECTRODES
 FAST FREEZE ELECTRODES
 FILL FREEZE OF FAST FOLLOW ELECTRODES
COATING CONSISTS OF RUTILE,CALCIUM FLUORIDE ,CELLULOSE & IRON POWDER

COMMON ELECTRODE
 E6010
 E7024
 E6012
 E6013
THE ELECTRODES EMPLOYED ARE COATED HEAVILY IN FLUX AND ARE TYPICALLY 71CM IN
LENGTH AND 6.35 MM THICK
 DEFECTS OF GMAW

1. Porosity 2. Spatters
3. Lack Of Fusion 4. Under Cut
5. Over Lap 6. Slag
7. Crack 8. Lack Of Penetration
9. Burn Through 10. Convex Bead
11. Unstable Arc 12. Wire Stubbing
 GAS TUNGESTON ARC
WELDING

FABRICATION

TIG IS AN ARC WELDING PROCES THAT USES A NON CONSUMABLE TUNGESTON ELECTRODE TO
PRODUCE THE WELD.THE ELECTRODE AND WELD AREA IS PROTECTED FROM OXIDATIONOR OTHER
ATMOSPHERIC CONTAMINATION BY INERT SHIELDING GAS ARGON AND HELIUM.
GTAW IS MOST COMMONLY USED TO WELD THIN SECTIONS OF STAINLESS STEEL AND NON
FERROUS METALS SUCH AS ALUMINIUM,MAGNESIUM AND COPPER ALLOYS.

THE PROCESS GRANTS STRONGER , HIGHER QUALITY WELDS .HOWEVER GTAW IS

COMPARATIVELY MORE COMPLEX AND DIFFICULT TO MASTER AND SLOWER THAN OTHER
WELDING TECHNIQUES.

GTAW NORMALLY REQUIRES TWO HANDS SINCE MOST APPLICATIONS REQUIRE THAT THE
WELDER MANUALY FEED A FILLER METAL INTO WELD AREA MAINTAING A SHORT ARC
LENGTH WHILE PREVENTING CONTACT BETWEEN THE ELECTRODE AND THE WORKPIECE.

TO STRIKE THE WELDING ARC A HIGH FREQUENCY GENERATOR PROVIDES AN ELECTRIC

SPARK.THIS SPARK IS CONDUCTIVE PATH FOR THE WELDING CURRENT THROUGH THE
SHGIELDING GAS AND ALLOWS THE ARC TO BE INITIATED WHILE THE ELECTRODE AND
THE WORKPIECE ARE SEPARATED TYPICALLY ABOUT 1.5-3 MM APART.

GTAW FOR WELDING THIN WORKPIECES ESPECIALLY NONFERRUS METALS.USED

EXTENSIVELY IN THE MANUFACTURE OF SPACE VECHILES ,SMALL DIAMETER ,THIN WALL
TUBING ,ROOT OR FIRST PASS WELDS FOR PIPINGOF VARIOUS SIZES
 Pressure Regulator
Flow Meter

Tungsten Rod
Argon Gas In
Cooling Water In Solenoid
Valve Argon Cylinder

HF Unit &
Welding Cable & Cooling Water Cooling
Water In Tube System
Cooling Water Out
Argon Shielding
High Frequency
Connection
Work

Pedal Switch Power Source – +

WELDING TORCH
 DESIGNED FOR EITHER AUTOMATIC OR MANUAL OPERATION AND ARE EQIPPPED WITH
COOLING SYSTEMS
 AIR COOLING SYSTEMS ARE MOST OFTEM USED FOR LOW CURRENT OPERATIONS UP TO 200
A
 WATER COOLING FOR HIGH CURRENT WELDING UP TO 600 A
 INTERNAL METAL PARTS ARE MADE OF HARD ALLOYS OF COPPER OR BRASS
 NOZZLE IS NORMALLY MADE OF ALUMINA OR A CERAMIC MATERIAL BUT FUSED QUARTZ A
HIGH PURITY GLASS

POWER SUPPLY
 DIRECT CURRENT WITH A NEGATIVE CHARGED ELECTRODE (DCEN) IS OFTEN EMPLOYED
WHEN WELDING STEELS , NICKLE ,TITANIUM
 DIRECT CURRENT WITH A POSITIVE CHARGED ELECTRIODE (DCEP) IS LESS USED & IS USED
PRIMARILY FOR SHALLOW WELDS

 TUNGESTEN HAS HIGHEST MELTING TEMP 3422*C

 DIA VARY BETWEEN 0.5 & 6.4 mm
 LENGTH RANGE FROM 75 TO 610 mm
 Cap with collet For Torch Handle Cooling Water Outlet
Holding Tungsten
Argon Gas Inlet

Cooling Water Inlet Tube with cable

Ceramic Cup

Tungsten Rod Argon Shielding Gas

Base Metal
Earthing Cable Arc
GTAW ELECTRODES

 CERIUM OXIDE
 LANTHANUM OXIDE
 THORIUM OXIDE
 ZIRCONIUM OXIDE

SHIELDNG GAS
 ARGON- HELIUM MIXTURES ARE FREQUENTLY USED
 MIXTURES ARE MADE PRIMARLY HELIM 75% OR HIGHER AND A BALANCE OF ARGON
 ARGON -HYGROGEN IS USED IN MECHANIZED WELDING OF LIGHT GAUGE STAINLESS
STEEL
 NITROGEN CAN SOMETIMES BE ADDED TO ARGON TO HELP STABILIZE THE AUSTENITE
STAINLESS STEEL AND PENETRATION WHEN WHEN WELDING COPPER

MATERIALS
 ALUMINIUM AND MAGNESIUM
 STEELS ( CARBON AND STAINLESS)
 DISSIMILAR METALS
Cylinder Valve

Flow Meter

Flow Regulator

Pressure Regulator

Connection To Torch

Argon Cylinder
 DEFECTS
1. Cracks 2. Lack Of Fusion
3. Porosity 4. Undercut
5.Lack Of Penetration 6. Excess Penetration

7.Overlap 8. Suck Back

9. Under Flush 10. Burn Through
11. Tungsten Inclusion 11.Stray Arcing
 NON DESTRUCTIVE
TESTING DEPARTMENT
NON DESTRUCTIVE TESTING IS A WIDE GROUP OF ANALYSIS
TECHNIQUES USED IN ENGINEERING TO EVALUTE THE
PROPERTIES OF A MATERIAL,COMPONENT OR A SYSTEM
WITHOUT CAUSING DAMAGE.
NDT DOES NOT PERMANENTLY ALTER THE ARTICLE BEING
INSPECTED IT IS HIGHLY VALUABLE TECHNIQUE THAT CAN
SAVE BOTH MONEY AND TIME IN PRODUCT EVALUATION-
TROUBLESHOOTING & RESEARCH
NON DESTRUCTIVE
TESTING

 LIQUID PENETRATE EXAMINATION

 MAGNETIC PARTICLE EXAMINATION
 RADIOGRAPHY EXAMINATION
 ULTRA SONIC EXAMINATION
 ULTRA SONIC THICKNESS MEASUREMENT
 LIQUID PENETRATION
EXAMINATION PROCEDURE

NDE METHOD TECHNIQUE

DYE PENETRANT INSPECTION ALSO CALLED LIQUID PENETRANT INSPECTION IS USED TO

LOCATE SURFACE BREAKING DEFECTSBIN ALL NON POROUS MATERIALS.IT IS USED TO
DETECT CASTING , FORGING, & WELDING SURFACE DEFECTS SUCH AS HAIRLINE CRACKS,
SURFACE POROSITY , LEAKS IN NEW PRODUCTS AND FATIQUE CRACKS ON IN SERVICE
COMPONENT
Penetrant solution is applied to the surface of a pre-cleaned
component. The liquid is pulled into surface breaking defects by
capillary action. Excess penetrant material is carefully cleaned
from the surface. A developer is applied to pull the trapped
penetrant back to the surface where it is spread out and forms an
indication. These indication are much easier to see than the actual
defects. And Visual inspection is the final step in the process. The
penetrant used is often loaded with a fluorescent dye and the
inspection is done under UV light to increase test sensitivity.
 
ADVANTAGE:
 LARGE SURFACE AREAS OR LARGE VOLUMES OF PARTS/MATERIALS
CAN BE INSPECTED RAPIDLY AND AT LOW COST.
 PARTS WITH COMPLEX GEOMETRY ARE ROUTINELY INSPECTED.
 INDICATIONS ARE PRODUCED DIRECTLY ON THE SURFACE OF THE
PART PROVIDING A VISUAL IMAGE OF THE DISCONTINUITY.
 EQUIPMENT INVESTMENT IS MINIMAL.
 
 
 
DISADVANTAGE:
 DETECTS ONLY SURFACE BREAKING DEFECTS.
 SURFACE PREPARATION IS CRITICAL AS CONTAMINANTS CAN MASK
DETECTS.
 REQUIRES A RELATIVELY SMOOTH AND NONPOROUS SURFACE.
 POST CLEANING IS NECESSARY TO REMOVE CHEMICALS.
 REQUIRES MULTIPLE OPERATIONS UNDER CONTROLLED
CONDITIONS.
 CHEMICAL HANDLING PRECAUTIONS ARE NECESSARY (TOXICITY,
FIRE, WASTE).
• PENETRANT MATERIALS

 PENETRANT,DEVELOPER & CLEANER SHALL BE OF SAME BRAND MANUFACTURER

 MAGNAFLUX MATERIAL IS APPROVED FOR USE
 FOR NICKLE BASED ALLOYS PENETRANT MUST NOT CONTENT SULPHUR ABOVE 1% BY
WEIGHT
 FOR AUSTENITIC OR DUPLUX STAINLESS STEELS AND TITANIUM ALLOYS THE
PENETRANT MUST NT CONTAIN CHLORINE &FLUORINE ABOVE 1%

• SURFACE PREPARATION &

CLEANING

 PRIOR TO THE EXAMINATION THE SURFACE WITHIN 25MM MUST BE SHOULD BE

CLEANED ,DRIED AND FREE FROM DIRT,GREEASE,LINT,SCALE,WELDING
FLUX,WELD SPATTER,PAINT ,OIL

 SATISFACTORY RESULTS MAY BE OBTAINED WHEN THE SURFACE IS

WELDED,GROUNDED,ROLLED, GRINDED CONDITION

• DRYING AFTER PREPARATION

 SHALL BE ACCOMPLISHED BY NORMAL EVAPOURATION
 A MINIMUM TIME PERIOD OF 2 MINUTES AND MAXIMUM OF 10 MIN
SHALL BE ALLOWED FOR DRYING
• SURFACE TEMPERATURE
 PART TO BE PROCESSED SHALL NOT BE BELOW 10*C OR ABOVE 52*C
THROUGHOUT EXAMINATION PERIOD

• CALIBRATION

 LIGHT METERS SHALL BE CALIBRATED AT LEAST ONCE A YEAR OR

WHERNEVER THE METER HAS BEEN REPAIRED

• EXAMINATION

 THE PENETRANT SHALL BE APPLIED BY SPRAYING

 THE DWELL TIME SHALL BE 10 MIN & NOT EXCEED 30 MIN
 PENETRANT REMAINING ON THE SURFACE SHALL BE REMOVED BY WIPING WITH CLEAN
,DRY,LINT FREE CLOTH
 THE CLOTH MUST BE MOISTED BY SOLVENT
 FLUSHING OR FLOODING THE SURFACE WITH SOLVENT IS PROHIBITED
 DRYING TIME SHALL BE MAX 2 MIN
 DEVELOPER (NON AQUEOUS) SHALL BE APPLIED AS SOON AS POSSIBLE AFTER PENETRANT
REMOVAL(MAX 10 min)
 • INTERPRETATION

 INTERPRETATIO SHALL BE MADE NOT LESS THAN 10 min NOR MORE THAN 60 min
AFTER THE WET DEVELOPER IS DRY
 DEVELOPER FORM A REASONABLE UNIFORM WHITE COATING
 SURFACE DISCONTINUITIES ARE INDICATED BY BLEED OUT OF THE PENETRANT
WHCH IS DEEP RED THAT STAINS THE DEVELOPER
 IGHT PINK INDICATE EXCESSUVE CLEANING

• LIGHT INTENSITY

 A MIN LIGHT INTENSITY SHALL BE 1000 LUX

 A HAND LAMP OF 220V/100 WATT INCANDESCENT BULB OR WHITE LIGHT
WITHOUT REFLECTOR, WHEN HELD AT A DISTANCE OF 250mm WLL GIVE A MIN
1000 LUX WITHIN A DIA 250 mm DIRECTLY BELOW THE BULB CENTRE

• EVALUATION
 BROAD ARES OF PIGMENTATION ARE UNACCEPTABLE AND SUCH
AREAS SHALL BE CLEANED & REEXAMINED
 ONLY INDICATIONS WITH MAJOR DIMENSIONS GREATER THAN 1.5 mm
SHALL BE CONSIDERED RELEVANT
  D E FE C T R E M O V A L A N D R E P A I R

 UN ACEPTABLE IMPERFECTION SHALL BE REPAIRED AND REXAMINED

 EXCAVATED AREA SHALL BE MERGED WITH SURROUNDING SURFACE SO AS
TO AVOID SHARP NOTCHES ,CREVICES OR GRINDING
 WHEN THE DEPTH OF REPAIR IS LESS THAN THE RADIOGRAPHIC
SENSITIVITY REQUIRED , RADIOGRAPHY MAY BE OMITTED

 TEST SHALL BE CONDUCTED IN WELL VENTILATED AREA

MAGNETIC PARTICLE
EXAMINATION PROCEDURE

NDE METHOD TECHNIQUE

 WET CONTINEOUS COLOUR CONTRAST MAGNETIC PARTICLE EXAMINATION USING AC

ELECTROMAGNETIC YOKE MAGNETIZATION TECHNIQUE
 WET CONTINEOUS COLOUR COTRAST MAGNETIC PARTICLE EXAMINATION USING PERMANENT
MAGNETIC YOKE MAGNETIZATION TECHNIQUE
THERE ARE SEVERAL METHODS OF MAGNETIC PARTICLE TESTING (ASTM E 709 OR IS
10543 AND IS 12147). ALL THESE METHODS ARE USED TO DETECT VARIOUS KINDS OF
FLAWS IN FERROMAGNETIC COMPONENTS SUCH AS WELDING'S, CASTINGS AND
FORGINGS OF IRON AND STEEL. THE COMPONENT TO BE INSPECTED FOR FLAWS IS
MAGNETIZED (FIG. 4.1) AND THE INSPECTION MEDIUM IS APPLIED TO THE COMPONENT,
OR MAGNETIZATION OF THE COMPONENT AND APPLICATION OF INSPECTION MEDIUM
CAN BE DONE SIMULTANEOUSLY. IN THE DRY METHOD OF INSPECTION, A SPECIAL
FINE FERROMAGNETIC POWDER IS APPLIED ON THE SURFACE BY MEANS OF A HAND
SHAKER, VIBRATING SCREEN OR BY ANY OTHER SUITABLE METHOD SO THAT THE
POWDER UNIFORMLY DISTRIBUTES ON THE SURFACE OF THE COMPONENT (IS 10543).
IN THE WET METHOD OF INSPECTION, A LIQUID CONTAINING FINE FERROMAGNETIC
PARTICLES SUSPENDED IN SOME CARRIER SUCH AS KEROSENE OR PETROLEUM OIL IS
APPLIED BY SOME SUITABLE METHOD SUCH AS DIPPING, SPRAYING OR BURSTING.
TEST MATERIALS:
• MATERIALS WILL BE IN READY MIX AEROSOL CONTANERS

MATERIAL BRAND MANUFACTURE GROUP

BLACK INK MAGNAVIS MAGNAFLUX 11K25K

WHITE PAINT MAGNAVIS MAGNAFLUX 11K04K

SURFACE CONDITION AND PREPARATION:

• SATISFACTORY RESULT WHEN SURFACE OF COMPONENT IS ROLLED,WELDED,FORGED
• ALL AREAS WITH IN AT 25mm SHALL BE DRY ANF FREE OF ALL DIRT,GREASE,LINT,SCALE,WELDING
FLUX OR SLAG,SPATTER,PAINNT,OIL
• CLEANING MAY BE ACCOMPLISHED BY DETERGENT,ORGANIC SOLVENTS,DE SCALING
SOLUTIONS.PAINT REMVERS,SAND OR GRIT BLASTING
QC OF TEST EQUIPMENT:
 THE EQUIPMENT SHALL BE CHECKED FOR ADEQUANCY OF MAGNETIC STRENGTH BY
SETTING THE POLE SPACING TO THE REQUIRED MAXIMUM AND VERIFY LIFTING OF 4.5 KG
STEEL FOR AC ELECTROAGNETIC YOKE

EXAMINATION:
 TEST SURFACE SHALLBE MAGNETIZED USING YOKE
 FIELD INDICATOR TO CHECK ADEQUANCY OF MAGNETIC FIELD
 PIE TYPE or BURMAH CASTROL TYPE FLUX INDICATOR
 BC STRIPS
 THE MAGNETIC FIELD 0.72 TESLA WILL BE SATISFACTORY IF ALL 3 LINES ARE VISIBLE ON
BC STRIP OR THE LINES ON PIE GAUGE PERPENDICULAR TO FLUX DIRECTION
 MAGNETIC INK SHALL BE APLIED TO TEST AREA BY UNIFORM SPRAYING, WHEN THE
CURRENT IS ON
 YOKE LEGS SHOULD BE POSITIONED ON EITHER SIDE OFWELDAXIS.SPACING USED DURING
THE LIFTING POWER TEST AND THE MIN SPACING SHOULD NOT BE LESS THAN 75mm &
200mm
 MIN 10% OVERLAP ON EACH PROGRESSIVE AREA TESTED
CONTRAST ENHANCEMENT:
• A UNIFORM THIN SPRAY OF WHITE PAINT IS APPLIED BEFORE START OF
MAGNETIZING AND ALLOWED TO HAVE NORMAL EVAPOURATION IN A UNIFORM
WHITE BAGROUND
• COAING SHOULD BE APPLIED ONLY ON UNCOATED SURFACE ONLY IN AMOUNTS
SUFFICIENT TO ENHANCE PARTICLE CONTRAST

TEST TEMPERATURE:
THE TEMP OF TEST SURFACE & MAGNETIC INK SHALL NT EXCEED 57 DEGREES

VIEWING CONDITION
• A MIN LIGHT INTENSITY OF 1000 LUX IS REQUIRED ON THE SURFACE TO BE
EXAMINED
• A WHITE LIGHT WITH A FOCUSINGCURVATURE HOOD WITH A 100 WATT BULB
PLACED AT A DISTANCE MAX 1 METER FROM THE SURFACE WILL FULFILL THE
REQUIREMENT
• AREA OF EXAMINATION CAN BE VIEWED UNDER MAGNIFICATION USING LENSES ( AT
5X MAGNIFICATION)
INTERPRETATION OF INDICATION :
• EVALUATION OF INDIACTION WILL BE DURING THE PERIOD WHEN THE MAGNETICLINK
IS APPLIED AND THE CURRENT IS ON
• INDICATION WILL BE REVEALED BY RETENTION OF MAGNETIC PARTICLES
• RELEVENT INDICATIOS ARE THOSE INDICATIONS WHICH HAVE ANY DIMENSION
GREATER THAN (1.5 mm)
 LINEAR INDICATION > 3 TIMES THE WIDTH
 ROUNDED INDICTION < 3 TIMES THE WIDTH

EVALUATION FOR ACCEPATANCE :

ALLRELEVANT SHALL BE REORDED AS A MINIMUM AND INTERPRETED AGAINT THE
RELEVANT ACEPTANCE CRITERIA

FINAL CLEANING:
CLEANING MAY BE ACCOMPLISED USING DETERGENT , ORGANIC SOLVENT, DESCALING
SOLUTIONS, PAINT REMOVERS ,VAPOUR DEGREASING,SND OR GRIT BLASTING ,OR
ULTRASONIC CLEANING METHODS

DEMAGNITIZING:
 PRIOR TO TESTING IF MATERAIL CONTAINS STRONG REMNANT MAGNETIC FIELDS
FROM SOME PREVIOUS OPERATION OR INSPECTION
 RADIOGRAPHY

NDE METHOD TECHNIQUE

THE EQUIPMENT USED BY JSPL IS GAMMA RAY REMOTE HANDLING CAMERA WITH
CONTAINING IRIDIUM 192 AND COBALT 60 SOURCE RADIOACTIVE ISOTOPE / 300 KV
DIRECTIONA X RAY MACHINE.
INDUSTRIAL RADIOGRAPHIC FILM AGFA-D4 / KODAK MX125 AND AGFA –D7 / KODAK MX 400
ARE USED
X—RAY OR RAY RADIOGRAPHY

THIS IS USED FOR DETECTING DEFECTS IN COMPONENTS MANUFACTURED BY CASTING,

WELDING, FORGING, ETC.
HERE, THE COMPONENT TO BE EXAMINED IS EXPOSED TO RADIATIONS OF SHORT WAVE
LENGTH SUCH AS X—RAYS OF WAVE LENGTH 0.2 TO 5 A' OR Y—RAYS OF STILL SHORTER
WAVE LENGTHS FROM A SUITABLE SOURCE SUCH AS AN X—RAY TUBE OR COBALT 60
(ASTM E 94 OR IS 2595). THESE RADIATIONS PENETRATE THROUGH THE COMPONENT
AND WHILE DOING SO, THEY ARE ABSORBED BY THE MATERIAL. THE PENETRATING
ABILITY OF THESE RADIATIONS DEPEND ON THEIR WAVE LENGTH AND THE ABSORBING
POWER OF THE MATERIAL. WHEN THESE RAYS PASS THROUGH A MATERIAL OF NON
UNIFORM STRUCTURE CONTAINING DEFECTS SUCH AS CAVITIES OR CRACKS OR
REGIONS OF VARIABLE DENSITY, THE RAYS PASSING THROUGH A LESS DENSE REGION
OF THE OBJECT ARE ABSORBED TO A SMALLER EXTENT THAN THE RAYS PASSING
THROUGH THE ADJACENT SOUND MATERIAL. THE AMOUNT OF RADIATION EMERGING
FROM THE OPPOSITE SIDE OF THE MATERIAL CAN BE RECORDED AND FROM THE
OBSERVED VARIATION, DEFECTS CAN BE DETECTED. THE RECORDING IS USUALLY DONE
BY PLACING A FILM SENSITIVE TO RADIATIONS IN A CASSETTE AT THE END OF THE
OBJECT. AFTER DEVELOPMENT OF THE FILM, IT SHOWS A PICTURE OF LIGHT AND DARK
AREAS, THE LATTER REPRESENTING THE REGIONS OF THE MATERIAL OF LOW DENSITY
SUCH AS HOLES, POROSITY, CRACKS, ETC. THIS FILM IS CALLED AN EXOGRAPH WHEN
PRODUCED BY X—RAYS AND GAMMA—GRAPH WHEN PRODUCE(] BY Y—RAYS AND BOTH
OF THEM ARE CALLED RADIOGRAPHS. THE GENERAL PRINCIPLE INVOLVED IN THE
PRODUCTION OF RADIOGRAPH BY THE USE OF X—RAYS OR Y—RAYS
GAMMA RAY RADIOGRAPHY
THIS TECHNIQUE OF DETECTING THE DEFECTS IN THE COMPONENTS IS VERY MUCH
SIMILAR TO THAT OF X—RAY RADIOGRAPHY. IN THIS METHOD, Y—RAYS WHICH ARE
PRODUCED BY RADIOACTIVE DECAY OF RADIUM AND ITS SALTS OR ISOTOPE STICH AS
COBALT 60 ARE USED. THE APPARATUS NECESSARY FOR Y—RAY RADIOGRAPHY IS
SIMPLE. MOST OF THE COBALT-60 ISOTOPES ARE CYLINDRICAL WITH DIMENSIONS OF
ABOUT 3 MIN IN DIAMETER AND 3 TO 6 MM IN LENGTH SEALED IN AN
APPROPRIATE CONTAINER OR CAPSULE.
GAMMA RAY RADIOGRAPHY HAS SEVERAL ADVANTAGES OVER X—RAY RADIOGRAPHY AS
BELOW :
(I) Y—RAYS HAVE SHORTER WAVE LENGTHS THAN X—RAYS AND HENCE THEIR
PENETRATION POWER IS MORE. DUE TO THIS, IT IS POSSIBLE TO TEST LARGE SIZED
COMPONENTS WHICH MAY NOT BE POSSIBLE BY X—RAYS.
(II) THE SCATTERING OF Y—RAYS IS LESS AS COMPARED TO X—RAYS AND HENCE THE
COMPONENTS OF NON UNIFORM SECTION SIZES CAN BE SATISFACTORILY TESTED BY THE
USE OF Y—RAYS THAN X RAYS. HOWEVER, X—RAYS GIVE A BETTER RESULT FOR
COMPONENTS OF UNIFORM THICKNESS.
(III) Y—RAY TECHNIQUE CAN BE EMPLOYED TO INSPECT MANY COMPONENTS AT THE
SAME TIME, AS SHOWN IN FIG. 4.10. THIS IS POSSIBLE BECAUSE THE Y—RAYS ARE
EMITTED IN ALL THE(I DIRECTIONS FROM THE SOURCE SUCH AS COBALT 60 CAPSULE.
HOWEVER, X—RAY TECHNIQUE CAN(IBE USED TO EXAMINE ONLY ONE COMPONENT AT
ANY ONE TIME.
F I LM Q U A L IT Y

• FILM PROCESSSING- IN ACCORDANCE WITH ASTM SE-999 OR SE-94

• FILM HANDLING-EMULSIONS OR OTHER MARKSMUST NOT BE DAMAGED BY FINGERPRINTS OR
OTHER MARKS
• QUALITY- ALL RADIOGRAPHS SHALL BE FREE OF THE FOLLOWING DEFECTS
 MECHANICAL DAMAGE
 CHEMICAL DAMAGE
 RADIOGRAPHIC DEFECTS
 INTERPRETATION
 VIEWING CONDITIONS
 DENSITOMETER
 SURFACE CONDITION
WELD TO BE EXAMINED SHALL BE FREE OF IRREGULARITIES SUCH AS WELD RIPPLES,
SPATTER, GRINDING OR CHIPPING MARKS OR OTHER IRREGULARITIES

 SCATTERED RADIATION
IT MAY CAUSE REDUCTION IN FILM QUALITY.THUS A LEAD SYMBOL “B” OF MIN SIZE 0.5 H x
1/16 THK SHALL BE ATTACHED TO THE BACK OF THE FILM CASSETTE IF THE WHITE SYMBOL
“B” IS EVIDENT THAT ADEQUATE PRECAUTIONS SHOULD BE TAKEN BY SHIELDING THE
CASSETTE WITH LEAD SHEETS.DARK SYMBOL “B” IMAGE SHALL BE DISREGARDED AS LONG AS
THE IMAGE DOES NOT MASK ANY INDICATION OF WELD IMPERFECTION

 RADIOGRAPHIC FILM VIEWING & LOCATION MARKERS

LOCATION MARKERS SHALL BE PLACED ON THE PART AND NOT ON THE EXPOSURE HOLDER
OR CASSETTE.PLACEMENT OF LOCATIONS MARKERS SHALL BE AS PER THE FOLLOWING

 SIDE WALL VIEWING

 SOURCE SIDE MARKERS
 FILM SIDE MARKERS
 EITHER SIDE MARKERS
 DOUBLE WALL VIEWEING

A SINGLE WALL EXPOSURE TECHNIQUE SHALL BE USED WHENEVER PRACTICAL.WHEN IT IS

NOT POSSIBLE TO USE SINGLE WALL TECHNIQUE A DOUBLE WALL TECHNIQUE SHALL BE
USED.HOWEVER ADEQUATE NO OF EXPOSURES SHALL BE MADE
METHOD:-
 PROCEDURE QUALIFICATION AND APPROVAL
 IDENTIFICATION OF RADIOGRAPHS
 MANUFACTURE SYMBOL / NAME
 DRAWING NO. / NAME
 PIPE SIZE
 WELD NO / SEAM NO
 ELDERS NO
 JOB NO
 DATE OF RADIOGRAPHY
 REPAIR REFERENCE
 LOCATON MARKER
 PENETRAMETER NO (IQI)

LEAD LOCATION MARKERS SHALL BE USED WITH APPROXIMATE HEIGHT OF 6 mm & 1.5 mm
THICK
a) OVER 88.9mm O/D to 508 O/D = EVERY 50 mm
b) OVER 508mm O/D = EVERY 100mm
THE FILM DENSITY IS THE DEGREE OF BLACKENING AND SHALL BE CHECKED USING A
CALIBRATED.THE DENSITY SHALL BE 1.8 TO 4.0 FOR SINGLE VIEWING FOR RADIOGRAPHS
MADE WITH X RAY & 2.0 TO 4.0 MADE WITH GAMMA RAY
PLACEMENT OF PENETRAMETRE:-

1. SHALL BE PLACEDON SOURCE SIDE OF PART BEING EXAMINED

2. WHEN CONFIGURATIONOR SIZE PREVENTS PLACINNG THE PANATRAMETER ON THE PART
OF WELD,THE PENETRAMETER MAY BE PLACED O A SEPARATE BLOCK
3. SEPARATE BLOCKS SHALL BE MADE OF THE SAME OR RADIOGRAPHICALL SIMILAR
MATERIALS
4. THERE IS NO RESTRICTION ON BLOCK THICKNESS
o THE PENETRAMENTER ON THE SOURCE SIDE OF SEPARATE BLOCK SHALL BE PLACED NO
CLOSE TO THE FILM THAN THE SOURCE SIDE OF PART BEING RADOGRAPHED
o THE SEPARATE BLOCK DIMENSIONS SHALL BE PLACED AS CLOSE AS POSSIBLE TO PART
BEING RADIOGRAPHED
o THE BLOCK DIMENSIONS SHALL EXCEED THE PENETRAMETER DIMENSIONS SUCH THAT
THE OUTLINE OF AT LEAST 3 SIDES OF PENETRAMETER IMAGE SHALL BE VISIBLE ON HE
RADIOGRAPH
o FILM SIDE PENETRAMETER- WHERE INACCESSIBILITY PREVENTS HAND PLACING.IT
SHOULD BE PLACED IN CONTACT WITH THE PART EING EXAMINE
 ULTRASONIC EXMANATION
PROCEDURE

NDE METHOD TECHNIQUE

THE PULSE ECHO TYPE INSTRUMENTS IS BEING USED AT JSPL. PETI SHALL BE CAPABLE OF
OPERATION AT FREQUENCY OVER THE RANGE OF AT LEAST 1Mhz TO 5Mhz.& SHALL BE EQUIPED
WITH A STEPPEED GAIN CONTROL IN UITS OF 2.0 DB OR LESS
THE EQUIPMENT SHALL HAVE FACILITIES TO WORK WITH BOTH COMBINED AND SEPARATE
TRANSMITTER/RECEIVER PROBES
 THE PRINCIPLE OF ULTRASONIC TESTING INVOLVES A MEASURE OF THE TIME REQUIRED
BY ULTRASONIC VIBRATIONS TO PENETRATE THE MATERIAL OF INTEREST, REFLECT
FROM THE OPPOSITE SIDE OR FROM AN INTERNAL DISCONTINUITY AND RETURN TO THE
POINT WHERE THE WAVES WERE FIRST INTRODUCED. THE BEHAVIOR OF WAVES THROUGH
SUCH A CYCLE OF TRAVEL WITH REGARD TO TIME IS APPROPRIATELY RECORDED ON A
CATHODE—RAY OSCILLOSCOPE (CRO) SCREEN. BY VISUAL OBSERVATION OF THIS WAVE
PATTERN ON CRO SCREEN, PRESENCE OF DEFECTS AND THEIR LOCATION CAN BE DETECTED.
ULTRASONIC TESTING IS A VERY FAST METHOD OF TESTING FOR DEFECTS BECAUSE THE
TIME OF TRAVEL OF ULTRASONIC WAVES IS OF THE ORDER OF MICROSECONDS FOR THE
USUAL SIZE OF THE COMPONENT. IT IS ALSO A VERY SENSITIVE METHOD AND REVEALS VERY
FINE FLAWS AND DISCONTINUITIES.
THERE ARE TWO TYPES OF ULTRASONIC
INSPECTION METHODS. THESE ARE
(I) PULSE—ECHO METHOD (IS 9664)
(II) TRANSMISSION METHOD (IS 4225).
IN THE PULSE ECHO METHOD, A PULSE GENERATOR PRODUCES ULTRASONIC WAVES AND
THESE WAVES ARE PASSED INTO THE COMPONENT THROUGH A QUARTZ TRANSDUCER
CRYSTAL (FIG. 4.4). FOR A BETTER CONTACT OF THE TRANSDUCER WITH THE METAL
SURFACE, COUPLENT LIKE THIN OIL OR GLYCERIN IS USED. AS SOON AS THE WAVE COMES
ACROSS A DISCONTINUITY, IT GETS REFLECTED BACK. THIS IS INDICATED AS A PATTERN OR
"PIP" ON THE OSCILLOSCOPE SCREEN. THE WAVE REFLECTED BY THE SURFACE OF THE TEST
PIECE AND THE WAVE REFLECTED BY THE OPPOSITE SIDE OF THE TEST PIECE ARE ALSO
INDICATED AS "PIPS" ON OSCILLOSCOPE SCREEN, DEFINING THE TIME OF INITIAL PULSE AND
THE REFLECTED PULSE FROM THE OPPOSITE SIDE. IF THERE IS A FLAW IN THE SPECIMEN, A
SMALLER PIP WILL BE SEEN BETWEEN THE TWO I.E. ONE FROM TOP AND THE OTHER FROM
BOTTOM (FIG. 4.5). SINCE THE DISTANCE BETWEEN THE PIPS ON THE OSCILLOSCOPE SCREEN
REPRESENT ELAPSED TIME OF THE REFLECTED PULSE, THE DISTANCE TO A FLAW CAN BE
ACCURATELY MEASURED
THE THROUGH-TRANSMISSION METHOD USES A TRANSDUCER ON EACH
SIDE OR ENDS OF THE TEST PIECE (FIG. 4.6). THE SIGNAL PULSE
ENTERS THE MATERIAL FROM ONE TRANSDUCER, TRAVELS THROUGH
THE MATERIAL AND IS RECEIVED BY THE OTHER TRANSDUCER. THIS IS
TRANSLATED INTO ANOTHER SIGNAL AND IS SHOWN ON AN
OSCILLOSCOPE. IF NO FLAWS ARE PRESENT, A CLEAR STRONG SIGNAL
WILL BE SEEN ON THE OSCILLOSCOPE ; BUT IF THE MATERIAL
CONTAINS FLAWS, A WEAKER OR DISTORTED SIGNAL WILL BE SEEN.
o THE RECOMMENDED MODELS INCLUDE USM-35X AND AS-414
o SEARCH UNIS SHALL BE EITHER SINGLE CRYSTAL OR TWIN CRYSTALL TYPES.THE
NOMINAL FREQUENCIES SHALL BE FROM 1Mhz to 5Mhz
o LONGITUDINAL SHEAR WAVES AT ANGLES 45,60,& 70
o NOMINAL CROSS SECTION SIZES OF NORMAL PROBES SHALL BE BETWEEN 10mm TO
25mm
o THE CROSS SECTIONAL SIZES OF ANGLES PROBES SHALL BE 8x9mm TO 20mm TO 22mm

COUPLANT;-
LIQUIDS OR PASTES TO ELEMENT THE AIR GAP BETWEEN THE TRANSDUCER AND THE TEST
SURFACE EX,POLYCEL IN WATER , LIQUID SOAP ,SODIUM CMC OR ANY OTHER SUITABLE
COUPLANT MEDIUM GLYCERIN ,LIGHT MACHINE OIL ORGREASE MAY ALSO BE USED

SYSTEM CALIBRATION:-

• ANGLE BEAM CALIBRATION

• DISTANCE AMPLITUDE CORRECTION (DAC) CURVES
• CALIBRATION CORRECTIONFOR PERPENDICULAR REFLECTOR AT OPPOSITE SURFACE
• STRAIGHT BEAM CALIBRATION
• DISTANCE AMPLITUDE CORRECTION
EXAMINATION:-
 EACH PASS OF SEARCH UNIT SHALL OVERLAP A MIN 10% OF ACTIVE TRANSDUCER (PIEZO
ELECTRIC MATERIAL)
 EACH PASS OF SEARCH UNIT AY OVERLAP A DIMENSION LESS THAN THE MINIMUM
BEAMNSION
 THE PULSE REPETION RATE SHALL BE SMALL ENOUGH TO ASSURE THAT A SIGNAL FROM A
REFLECTOR LOCATED AT MAX DISTANCE IN EAMINATION VOLUME WIL ARRIVE BACK BEFORE
THE NEXT PULSE
 THE RATE OF SEARCH UNIT MOVEMENT (SCANNING SPEED) SHALL NOT EXCEED 152 mm/s

THE SCANNING SENSITIVITY LEVEL SHALL BE SET A MN OF 6dB HIGHER THAN THE REFERENCE
LEVEL GAIN
THE TEMPERATURE DIFFERENCE BETWEEN THE TEST SURFACE AND THAT OF TH CALIBRATION
BLOCK SHALL BE LESS THAN 25*F
WELD JOINTS SHALL BE SCANNED WITH AN ANGLE BEAM SEARCH UNIT IN BOTH PARALLEL AND
TRANSVERSE DIRECTION TO WELD AXIAS
ASTRAIGHT BEAM EXAMNATION SHALL BE PERFORMED ON THE VOLUME OF BASE MATERIAL
SIZING OF INDICATIONS:
• ALL INDICATIONS CONSIDERED TO BE RECORDABLE SHALL BE SIZED FOR THEIR LENGTH
EXTENSION BY 6dB DROP METHOD

FINAL CLEANING:
AFTER COMPLETION OF EXAMINATION , COUPLANTS SHALL BE CLEANED BY WATER
COPLANTS SUCH AS GLYCERIN /OI GREASE SHALL BE CLEANED UTILIZING SUITABLE SOLENT
REMOVER.SUCH AGENTS SHALL NOT PRODUCE ANY DETRIMENTAL EFFECT TO THE TEST
COMPONET
 PRESSURE VESSEL

INTRODUCTION

A PRESSURE VESSSEL IS A CONTAINER DESIGNED TO HOLD GASES OR

LIQUIDS AT A PRESSURE SUBSTANTIALLY DIFFERENT FROM THE AMBIENT
PRESSURE
 PRE HEATING

WHAT IS PREHEATING?
 
 
 HEATING THE BASE METAL ALONG THE WELD JOINT TO A
PREDETERMINED MINIMUM TEMPERATURE IMMEDIATELY
BEFORE STARTING THE WELD.
 HEATING BY OXY FUEL FLAME OR ELECTRIC RESISTANT COIL
 HEATING FROM OPPOSITE SIDE OF WELDING WHEREVER
POSSIBLE
 TEMPERATURE CAN BE VERIFIED BY THERMO CHALKS PRIOR
TO STARTING THE WELD
WHY PREHEATING?
 
 PREHEATING ELIMINATES POSSIBLE CRACKING OF WELDS AND HAZ AND REDUCES
SHRINKAGES
 APPLICABLE TO
 -HARDEN ABLE LOW ALLOY STEELS OF ALL THICKNESS
 -CARBON STEELS OF THICKNESS ABOVE 25 MM.
 -RESTRAINED WELDS OF ALL THICKNESS
 PREHEATING TEMPERATURE VARY FROM 75°C TO 200°C DEPENDING ON HARDENABILITY
OF MATERIAL, THICKNESS & JOINT RESTRAIN

 
HOW DOES PREHEATING ELIMINATE CRACK?
 
 PREHEATING PROMOTES SLOW COOLING OF WELD AND HAZ
 SLOW COOLING SOFTENS OR PREVENTS HARDENING OF WELD AND HAZ
 SOFT MATERIAL NOT PRONE TO CRACK EVEN IN RESTRAINED CONDITION
 POST HEATING

WHAT IS POST HEATING?

 
 
 RAISING THE PRE HEATING TEMPERATURE OF THE WELD JOINT TO A
PREDETERMINED TEMPERATURE RANGE (250° C TO 350° C) FOR A MINIMUM
PERIOD OF TIME (3 HRS) BEFORE THE WELD COOLS DOWN TO ROOM
TEMPERATURE.
 POST HEATING PERFORMED WHEN WELDING IS COMPLETED OR TERMINATED
ANY TIME IN BETWEEN.
 HEATING BY OXY FUEL FLAME OR ELECTRIC RESISTANT COIL
 HEATING FROM OPPOSITE SIDE OF WELDING WHEREVER POSSIBLE
 TEMPERATURE VERIFIED BY THERMO CHALKS DURING THE PERIOD
WHY POST HEATING?
 
 POST HEATING ELIMINATES POSSIBLE DELAYED CRACKING OF WELD AND HAZ
 APPLICABLE TO
 -THICKER HARDENABLE LOW ALLOY STEELS
 -RESTRAINED HARDENABLE WELDS OF ALL THICKNESS
 POST HEATING TEMPERATURE AND DURATION DEPENDS ON HARDENABILITY OF MATERIAL,
THICKNESS & JOINT RESTRAIN
 
 
HOW DOES POST HEATING ELIMINATE CRACK?
 
 
 SAW INTRODUCES HYDROGEN IN WELD METAL
 ENTRAPPED HYDROGEN IN WELD METAL INDUCES DELAYED CRACKS UNLESS REMOVED
BEFORE COOLING TO ROOM TEMPERATURE
 RETAINING THE WELD AT A HIGHER TEMPERATURE FOR A LONGER DURATION ALLOWS THE
HYDROGEN TO COME OUT OF WELD
CLASSIFICATIONS BASED ON

 FUNCTION
 STORAGE TANK , PROCESS VESEEL ,HEAT EXCHANGER

 GEOMETRY
 CYCLINDRICAL , SPHERICAL ,CONICAL , NON-CIRCULAR , HORIZONTAL
/ VERTICAL

 CONSTRUCTION
 MONOWALL , MULTIWALL ,FORGED ,CAST

 SERVICE
 CRYOGENIC , STEAM , LETHAL ,VACUUM , FIRED / UNFIRED
,STATIONARY / MOBILE
PARTS OF PRESSURE VESSEL

 DISH END ( BLANK DIAMETER , PETAL SIZE , NOMINAL THICKNESS )

• TYPES(SPHERICAL , CONICAL , ELLIPTICAL ,TORISPHERICAL )

 SHELL
• CLADDING OF SHELL AND NOZZLE

 NOZZLE ( FORGED , FABRICATED )

 TRAY SUPPORT RINGS , BOLTINGN , BARS , DOWN-COMER
 NOZZLE REINFORCEMENT PADS
 EXTERNAL ATTACHMENT ( LADDER , PIPE CHEATS )
 LUGS ( FOR EARTHING , LIFTING , TAILING)
 SADDLE SUPPORT / SKIRT SUPPORT
 PIPE OR MANWAY DAVIT
 LADDER RUNGS
 INTERNALS ( DIMNISHER , VORTEX BREAKEE , DEFLECTOR etc. )
 NAME PLATE & ASME STAMPS
SUPPORT FOR VESSEL

 SUPPORTS ARE REQUIRED FOR THE INSTALLATION OF THE VESSEL

ON THE FOUNDATION

 TYPE OF SUPPORTS

 LEG TYPE SUPPORT

 SKIRT TYPE SUPPORT ( CYCLINDRICAL / CONICAL )- USING AD
MARKBLATTER
 BRACKET TYPE SUPPORT
 SADDLE SUPPORT – THIS SUPPORT DESIGN USING ZICK ANALYSIS
DETAILS OF SKIRT
 HEAD / END CLOSURES

HEAAD IS THE PART WHICH CLOSES THE END OPENINGS OF THE

CYLINDER SHELL

TYPES OF HEADS:
 BOLTED BLING FLANGE
 CONICAL HEAD
 ELLIPTICAL HEAD
 TORICONICAL HEAD
 TORISPHERICAL HEAD
NOZZLE /CONNECTIONS

 NOZZLES ARE THE OPENINGS PROVIDED IN THE SHELL / HEAD

FOR CONNECTING THE EXTERNAL PIPING WITH VESSEL.
 NOZZLES CONSISTS OF NOZZLE NECK, FLANGE & RF PAD

TYPES OF THE NOZZLES / CONNECTIONS :

 PIPE NECK WITH FLANGE CONNECTION
 FORGED NECK WITH FLANGE CONNECTION
 STUB END CONNECTION
 NOZZLE NECK TO BE DESIGNED AS PER ASME SEC VIII DIV I
CL. UG-45
 RF PAD FOR THE NOZZLE TO BE DESIGNED AS PER ASME SEC
VIII DIV I CL. UG-36
 NON STD. FLANGE TO BE DESIGNED AS PER ASME SEC VIII
DIV I, APPX-2 & STD FLANGE TO BE SELECTED AS PER UG-
44/ASME B16.5
NOZZLE DETAILS
DETAILS OF MANHOLE
SUPPORT CLEATS
NAME PLATE DETAIL
 TESTING
 ALL BUTT JOINTS TO BE RT / UT / MPT / DP TESTED AS PER ASME CODE
REQUIREMENT
 ALL CORNER JOINTS e.g. NOZZLE TO SHELL JOINT SHALL BE MPT / DP
TESTED
 ALL FILLET WELDS SHALL BE DP TESTED
 ACCEPTANCE CRITERIA FOR NDT REQUIREMENT FOR WELD JOINT
 FOR R.T ----- APPENDIX IV - ASME SEC. VIII DIV.1
 FOR M.P.T ------ APPENDIX VI
 FOR D.P.T ------ APPENDIX VIII
 FOR U.T --------- APPENDIX XII
 EQUIPMENT TEST

 HYDROTEST -- 1.3 x DESIGN PRESSURE (UG - 99)

 PNEUMATIC TEST --- 1.1 x DESIGN PRESSURE (UG - 100)

 OFFICIAL STAMP FOR CODED VESSELS

 ‘U’ STAMPS --- ASME SEC. VIII DIV.1

 ‘UV’ STAMPS --- FOR PRESSURE RELIEF VALVE
 HYDROTEST
TO ENSURE THE INTEGRITY OF THE VESSEL AND
SYSTEM OPERATION UNDER PRESSURE.

RECOMMENDED FOR PRESSURE VESSEL OPERATING

UNDER PRESSURE
ENSURES THE STRENGTH OF WELD JOINTS &
MATERIALS
ENSURES NOZZLE-FLANGE JOINT
TEST THE STRENGTH OF THE PRESSURE VESSEL AT
1.5 TIMES THE DESIGNED PRESSURE
ENSURES SAFE & RELIABLE PERFORMANCE DURING
THE OPERATIONAL LIFE
REQUIREMENTS OF MATERIALS ,
TOOLS & EQUIPMENTS

TEST MEDIUM
• WATER WITH ‘X’ PPM AS FREELY AVAILABLE
• (PARTS PER MILLION---CHLORINE IMPURITIES)

• ‘X’ ---- 25 PPM OR LESS FOR SS VESSEL

• ‘X’ ---- 80 PPM OR LESS FOR CS VESSEL

• CHLORINE PARTICLES AFFECT THE ANTICORROSIVE PROPERTIES OF

VESSEL
REQUIREMENTS OF MATERIALS ,
TOOLS & EQUIPMENTS-(CONTD.)

WOODEN SADDLES (SOFT WOOD)

• TO SUPPORT THE VESSEL & AVOID ANY DEFORMATION OR DENT
AT CONTACT SURFACES
• CONTACT ANGLE---120 DEGREES

Vessel

0
120

Wooden saddle
REQUIREMENTS OF MATERIALS , TOOLS
& EQUIPMENTS-(CONTD.)

THERMOCOL SHEETS

• 20--30 MM THICKNESS
• USED AS A SOFT PACKING BETWEEN VESSEL & SADDLE

COVER FLANGES

 NOZZLES WHICH HAVE ORIGINAL BLIND FLANGES TO BE

BLANKED BY THOSE FLANGES
 OTHER NOZZLES TO BE BLANKED AS PER SPECIFIED DRAWING
 REQUIREMENTS OF MATERIALS , TOOLS
& EQUIPMENTS-(CONTD.)

PIPE FITTING

• HIGH PRESSURE (5000 TO 10000 PSI)

• REQUIRED SIZES (BSP,NPT) TO BE USED FOR INLET & OUTLET EQUIPMENT, VALVES,
GAUGES CONNECTIONS

HIGH TENSILE FASTNERS

 TO BE USED AS SPECIFIED IN THE DRAWING

GASKETS

 TO BE USED JOB GASKET UNLESS OTHERWISE SPECIFIED

PUMP ACCESSORIES
• SQUARE BAR

• SHUT OFF VALVE

• COUPLER

• FLOW
DIRECTION
REQUIREMENTS OF MATERIALS , TOOLS
& EQUIPMENTS-(CONTD.)

PRESSURE GAUGES

• USE MINIMUM TWO CALIBRATED PRESSURE GAUGES

• RANGE--- MIN. 1.5 TIMES THE TEST PRESSURE MAX. 4 TIMES
THE TEST PRESSURE
• EXAMPLE: FOR TEST PRESSURE OF 60 KG/CM 2 RANGE SHOULD BE
0-100 KG/CM2
(OR) 0-240 KG/CM2
• SQUARE BAR

• SHUT OFF
VALVE

• COUPLER

• PRESSURE
GAUGE
REQUIREMENTS OF MATERIALS , TOOLS
& EQUIPMENTS-(CONTD.)

WATERPUMP & HOSE ASSEMBLIES

• SUBMERSSIBLE OR ANY OTHER PUMP IS USED FOR

FILLING THE VESSEL
• CONNECTED THROUGH FLEXIBLE HOSE PIPES TO TANK
& VESSEL
REQUIREMENTS OF MATERIALS , TOOLS
& EQUIPMENTS-(CONTD.)

HYDROTEST PUMP
• REQUIRED FOR PRESSURIZING THE VESSEL TO THE TEST PRESSURE
• COMPRISES OF
A HIGH PRESSURE PUMP
B NON-RETURN VALVE
C RELIEF VALVES
D ATTACHMENTS LIKE HOSES, COUPLERS
• PRESSURE
GAUGE

• SUBMISSILE
PUMP

• OUTLET
HOSE
REQUIREMENTS OF MATERIALS , TOOLS
& EQUIPMENTS-(CONTD.)

TORQUE WRENCH, GUN & STUD TENSIONER

• ALL THE OPENINGS MUST BE CLOSED WITH
BLIND FLANGES
• TIGHTENING TO BE ENSURED AT DESIRED
TORQUE BY TORQUING WRENCH, TORQUING GUN
OR STUD TENSIONER
TYPES OF HYDROTEST PUMP

• HIGH DISCHARGE LOW PRESSURE

PRESSURE RANGE : UP TO 100 KG/SQ.CM(g)
QTY. : 02

• LOW DISCHARGE HIGH PRESSURE

PRESSURE RANGE : UP TO 400 KG/SQ.CM(g)
QTY. : 06
HYDROTEST PUMP
DETAILS
(HIGH PRESSURE, LOW DISCHARGE)

• INLET HOSE
• TANK

• TROLLEY

• OUTLET HOSE
 SEQUENCE OF OPERATIONS

SADDLE ARRANGEMENT

• REQUIRED NO. OF SADDLES AS MENTIONED ON

DRG. TO BE PLACED AT THE DISTANCES
• PUT THERMOCOL SHEETS ON SADDLES BEFORE
KEEPING THE VESSEL
SEQUENCE OF OPERATIONS
(CONTD.)

ORIENTATION

• LONGSEAM, CIRCSEAM REMAIN EXPOSED FOR

VISUAL INSPECTION & NOT COVERED UNDER
SADDLE
• INLET NOZZLE FOR WATER IS AT THE TOP &
DRAIN OUT AT THE BOTTOM OF VESSEL
SEQUENCE OF OPERATIONS
(CONTD.)

AIR LOCK REMOVAL

• ADEQUATE ARRANGEMENT TO BE MADE FOR

VENTING THE AIR, TRAPPED INSIDE THE VESSEL
• FOUR DIFFERENT CASES TO BE STUDIED
TIGHTENING SEQUENCE

1
8 5

4 Bitmap Image

6 7
2
PRESSURE VALVE SETTING

• VALVE SETTING
FOR REQUIRED
PRESSURE
GUIDELINES FOR
HYDROTEST
• PUMP SHAFT SHOULD ROTATE CLOCK WISE LOOKING
FROM SHAFT SIDE

• ENSURE BYPASS LINE IS OPEN.

• ENSURE THAT BYPASS LINE SHOULD NOT CONNECT TO

THE PUMP SUCTION LINE.
(IF DISCHARGE LINE IS SHUT OFF, BYPASS WATER IS
DIVERTED TO THE PUMP SUCTION & AS A RESULT THERE
IS A RAPID RISE IN TEMPERATURE , WHICH CAUSES
DAMAGE TO PISTON PLUNGER PACKING)
• CONNECT PUMP OUTLET TO VESSEL INLET THROUGH
STANDARD HOSE PIPE, WITH PROPER VALVE
CONNECTIONS, SQUARE BAR, COUPLERS, ETC.

• ENSURE THE PRESSURE REGULATOR VALVE , FOOT

VALVE , SHOULD BE IN UNLOADING POSITION.

• ENSURE THE PRESSURE GAUGE CALIBRATION

VALIDITY

• ENSURE WATER TANK OR SUCTION LINE SHOULD BE

FREE FROM ANY FOREIGN MATERIAL
OPERATING PROCEDURES
• START HYDROTEST PUMP

• ENSURE 100% REMOVAL OF ENTRAPPED AIR

( MONITOR THE TANK INTO WHICH THE OUTLET HOSE
PIPE IS DIPPED. AS SOON AS BUBBLES STOP SHOWING
UP, CLOSE OUTLET VALVE)

• MONITOR PRESSURE GAUGE PROVIDED AT OUTLET.

OPERATING PROCEDURES
(CONTD.)
• AS SOON AS PRESSURE REACHES 50% OF THE TEST
PRESSURE , WAIT FOR 10 MINUTES

• INCREASE PRESSURE BY 10% IN STAGES TILL THE

TEST PRESSURE IS ACHIEVED

• OBSERVE PRESSURE DROP

( BY MARKING LINE ON PRESSURE GAUGES)
• HOLD THE HYDROTEST PRESSURE FOR SPECIFIC
TIME AS MENTIONED IN DRAWING

• CARRY OUT THOROUGH VISUAL INSPECTION OF

ALL JOINTS & CONNECTIONS
(IF ANY LEAKAGE IS NOTICED, MARK THE POINT.
THE VESSEL IS TO BE DEPRESSURIZED AND THEN
NECESSARY REPAIRS ARE TO BE CARRIED OUT.
AGAIN THE TEST PROCEDURE IS TO BE
REPEATED)
 DOs & DON’Ts
• ENSURE PRESSURE GAUGE READABILITY

• WORKING, DESIGN & TEST PRESSURE TO BE

DISPLAYED NEAR THE VESSEL

• ENSURE ALL GASKET SURFACES ARE FREE

FROM DENT & SCRATCHES BEFORE BLANKING

• DO NOT APPLY PAINT, OIL, GREASE ON WELD

JOINTS

• DO NOT WELD ON JOB BLIND FLANGE

 DESIGN CALCULATIONS OF PRESSURE VESSEL

ASME SECTION 8 DIV 1 , 2015

DESIGN INVOLVES PARAMETERS SUCH AS MAXIMUM SAFE OPERATION PRESSURE AND TEMPERATURE ,
SAFETY FACTOR ,CORROSION ALLOWANCE ,AND MINIMUM DESIGN TEMPERATURE
 MADE BY:-
THANKS
 AAYUSH PANDEY

 VIVEK PRAKASH SAHU

7th SEM

BE-MECHANICAL UNDER THE GUIDANCE OF

SSGI(FET) ,DURG
1. MR.PALLAV SHUKLA - DGM QA&QC
2. MR.V.SRINIVAS RAO-Manger