NDE PROCEDURES FOR SHOP FABRICATED EQUIPMENTS

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Prepared by: Prashant Malve

Contents I 1.0 2.0 3.0 4.0 5.0 II 1.0 2.0 3.0 4.0 5.0 6.0 Radiographic Testing Procedure Purpose Scope Reference Documents Procedure Evaluation Dye Penetrant Testing Procedure Purpose Scope Reference Documents Equipment/Material Procedure Evaluation

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Prepared by: Prashant Malve

RADIOGRAPHIC TESTING PROCEDURE

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PURPOSE This procedure covers the requirements for conducting Radiographic Examination of welds for Tanks for ISPRL, Padur project by using radiographic testing method by X-ray. SCOPE 2.1. CAUSTIC (TAG NO. XXXX) & SULPHURIC ACID (TAG NO. XXXX) BULK LYE STORAGE TANKS (DESIGNED AS PER API 650) 100% T joints & 10% Long Seam & Circumferential Seam shall be tested by radiography. 2.2. DOSING TANKS (TAG NO. XXXX) (DESIGNED AS PER GOOD ENGINEERING PRACTICE) Spot radiography shall be done one on Long Seam & one on Circumferential Seam of each tank.

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REFERENCE DOCUMENTS This procedure has been developed and prepared in accordance with the following documents as reference. 3.1. ASME Section V Nondestructive Examination 3.2. ASTM E94 Standard Recommended Practice for Radiographic Testing. 3.3. ASTM E1032 Radiographic Examination of Weldments 3.4. API 650 Storage Tanks 3.5. Project Standard Specification for Storage Tanks 3.6. QA Plan / Inspection Test Plan PROCEDURE Radiographic inspection personnel shall be qualified as per applicable code. To ensure sufficient overlapping, location markers shall be used. They are to appear as radiographic image on the film. It shall be placed on the part close to the area of interest - not on the exposure holder/cassette. Their locations shall be marked on the surface of the part being radiographed, in a manner permitting the area of interest traceable to its location on the part for the required retention period of the radiograph and provide evidence on the radiograph, that the required coverage of the region being examined, has been obtained. As an alternative a measuring tape, with lead figures may be used testing circumferential welds.

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5.0.

EVALUATION 5.1. VIEWING REQUIREMENT Dimmed lighting, rather than total darkness, is preferable in the viewing room. The brightness of surroundings shall be less than the brightness of the light passing the radiograph. Room illumination must be arranged so that there is no reflection from the surface of the film under examination. All films shall be interpreted in the dry condition. High Intensity illuminators shall be provided for viewing the radiographs. 5.2. GENERAL REQUIREMENT Prior to start of production Radiography a procedure radiograph shall be reviewed and approved by client. 5.3. ACCEPTANCE CRITERIA The acceptance criteria shall meet any one of the respective code and as per the approved QA Plan / Inspection Test Plan, Project Standard Specification for Storage Tanks, API 650 whichever is applicable

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DYE PENETRANT TESTING PROCEDURE

1.0.

PURPOSE This procedure define application, extent & requirements to detect discontinuities that are open to the surface by the non destructive method of Dye / Liquid Penetrant Test of equipment built according to code API 650 and Good Engineering Practice. SCOPE 2.1. Prefabricated / Fabricated structures of Oily & Chemical Sludge Thickener Mechanism (Tag No. XXXX) LP Test shall be carried out randomly as per TPIAs instruction 2.2. Puddle Flanges for RCC tanks (All Tags) LP Test shall be carried out randomly as per TPIAs instruction DOSING TANKS (TAG NO. XXXX) (DESIGNED AS PER GOOD ENGINEERING PRACTICE) LP Test shall be carried out randomly as per TPIAs instruction, where Radiography Test shall not be done.

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2.3.

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REFERENCE DOCUMENTS This procedure has been developed and prepared in accordance with the following documents as reference. 3.1. ASME Section V Nondestructive Examination 3.2. API 650 Storage Tanks 3.3. Project Standard Specification for Storage Tanks 3.4. QA Plan / Inspection Test Plan EQUIPMENT / MATERIAL 4.1. 4.2. 4.3. 4.4. Solvent Cleaner Penetrant / Remover Developer Lint Free Cloth or equivalent

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5.0.

PROCEDURE The Dye Penetrant Examination shall be conducted by Visible Contrast Dye Penetrant Solvent removal method. 5.1. SURFACE PREPARATION 5.1.1. The surface to be examined and adjacent area within at least 25 mm of the surface to be tested shall be dry and free of dirt, grease, lint, scale, welding flux, oil or any other extraneous matter that could obscure surface opening or interfere with test. 5.1.2. The surface to be examined shall be ground at least 25mm base material besides the weld joint if irregularities that Mask the indication of defects. CLEANING & DYING 5.2.1. The surface shall be cleaned with lint free cloth soaked with cleaner. After cleaning the surface to be tested can be accomplished for drying process by normal evaporation for volatile solvents. PENETRANT APPLICATION 5.3.1. The temperature of the surface to be examined shall be within the range of 100 C to 520 C. 5.3.2. The penetrant shall be applied on the surface to be tested after drying by means of spraying or brushing. 5.3.3. The penetrant shall be applied such that the entire part of area under inspection is completely covered with penetrant. 5.3.4. The soak time for penetrant shall be in accordance with code and penetrant. During this time the penetrant shall not be allowed to become dry. If long penetration time is required, fresh penetrant shall be regularly applied to the surface to ensure that the surface is wet at all time. 5.3.5. On completion of penetration time the excess penetrant shall be wiped from the surface by using clean and dry paper or cloth dampened with cleaner. Solvent shall not be applied directly to the surface, since, it may wash out or dilute penetrant in discontinuities. DEVELPOING 5.4.1. The developer shall be applied to the surface immediately after the surface penetrant removal process is completed. The developer is to be shaken well before application to ensure that particles in suspension are dispersed. The developer shall be applied by spray with pressurized cans so as to form a mist, thin white coating on the surface which must be allowed to completely dry. 5.4.2. Developer soak time shall not be less than 7 minutes. Inspection shall be done within 30 minutes of developer application. Soak time shall be in accordance with code and Developer.

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5.4.

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EVALUATION 6.1. INTERPRETATION 6.1.1. The examination is performed in minimum light intensity of 1000 Lux to ensure adequate sensitivity during the examination & interpretation of indications. All indications shall be considered as discontinuities until investigated, upon investigation such indications shall be recognized as weld or material related and relevant, therefore subject to interpretation in accordance with ASME SEC. VIII, Appendix-8, Para 8-3 to 8-5 with regard to

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6.2.

accept / reject criteria. Only indications with major dimensions greater than 1.6mm shall be considered relevant. 6.1.1.1. A linear indication is one having a length greater than three times the width. 6.1.1.2. A rounded indication is one circular or elliptical shape with a length equal to or less than three times its width. ACCEPTANCE All surfaces to be examined shall be free of: 6.2.1. Relevant linear indications 6.2.2. Relevant rounded indications greater than 5.0mm 6.2.3. Four or more relevant rounded indications in a line separated by 1.6mm or less.

Prepared by: Prashant Malve