PRESSURE CASTING INSPECTION

OCTOBER 1993

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EGE 00-B-20 1993

TABLE OF CONTENTS 1. 2. 3. 4. 5. Scope References Casting Quality Levels General Requirements Casting Inspection Requirements 5.1 Pump Casings and Impellers 5.2 Steam Turbines 5.3 Ductile Iron Reciprocating Compressor/Pump Cylinders and Cylinder Heads 5.4 Cast Steel Reciprocating Compressor/Pump Cylinders and Cylinder Heads 5.5 Centrifugal/Rotary Compressors 5.6 Valve Bodies 5.7 Furnace Return Bends and Fittings that are Statically Cast 6. Techniques and Acceptance Criteria 6.1 Radiographic Inspection 6.2 Ultrasonic Inspection 6.3 Magnetic Particle Inspection 6.4 Liquid Penetrant Inspection 6.5 Visual Inspection 6.6 Thickness Checks 6.7 Dimensional Checks 7. Repairs 7.1 General 7.2 Welding 7.3 Weld Inspection 8. Heat Treatment 9. Hydrostatic Tests Appendix - Data Required from Bidder

1. SCOPE This Guide covers the basic requirements for the inspection of pressure-retaining castings used for components of pumps, steam turbines, compressors, and piping. 2. REFERENCES The following publications form a part of this Guide. The references cited with dates in this Guide were used in its development. For all references which have been superseded, revised, and/or corrected, the user of this Guide is obligated to determine if the latest versions of the cited references have any impact on the content of this Guide or its use. MTC (Guide Sponsor) should be consulted if there are any concerns or questions.
Mobil Engineering Guides EGE 00-B-21 EGE 00-B-22 EGE 16-B-40 (1993) (1991) (1989) Pressure-Containing Equipment Welding and Weld Inspection Pressure Equipment Impact Test Requirements Piping Fabrication, Erection, Inspection, and Testing

API (American Petroleum Institute) Standards

MOBIL ENGINEERING GUIDE EGE 00-B-20 1993

Std 611 Std 612 Std 618 (1988) (1987) (1986)
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General Purpose Steam Turbines for Refinery Service Special Purpose Steam Turbines for Refinery Services Reciprocating Compressors for General Refinery Services

ASME (American Society of Mechanical Engineers) Publications Boiler and Pressure Vessel Code: (1992 ) Section III, Rules for Construction of Nuclear Power Plant Components (1992) Section V, Nondestructive Examination (1992) Section VIII, Pressure Vessels, Division 1 B16.34 B31.3 (1988) (1990) Valves Flanged, Threaded, and Welding End Chemical Plant and Petroleum Refinery Piping

ASNT (American Society for Nondestructive Testing) Publications Personnel Qualifications and Certification SNT-TC-1A (1988) Recommended Practice ASTM (American Society for Testing and Materials) Standards A395 A609 A703 A802 E94 E114 E125 E142 E155 E165 E186 E272 E280 E310 E446 E543 E709 (1988) (1991) (1991) (1989) (1991) (1990) (1985) (1992) (1991) (1992) (1991) (1991) (1991) (1991) (1991) (1992) (1991) Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated Temperatures Standard Practice for Castings, Carbon, Low-Alloy, and Martensitic Stainless Steel (Ultrasonic Examination) General Requirements Applicable to Steel Castings for Pressure-Containing Parts Steel Castings, Textures and Discontinuities, Evaluating and Specifying, by Visual Examination Radiographic Testing Ultrasonic Pulse-Echo Straight-Beam Examination by the Contact Method Magnetic Particle Indications on Ferrous Castings Controlling Quality of Radiographic Testing Inspection of Aluminum and Magnesium Castings Liquid Penetrant Inspection Examination Heavy-Walled (2 in. to 4 1/2 in.) Steel Castings High-Strength Copper-Base and Nickel-Copper Alloy Castings Heavy-Walled (4 1/2 in. to 12 in.) Steel Castings Tin Bronze Castings Steel Castings up to 2 in. in Thickness Evaluating Agencies That Perform Nondestructive Testing Magnetic Particle Examination

MSS (Manufacturers Standardization Society - Valve and Fittings Industry) Publications SP-53 SP-55 (1985) (1985) Quality Standard for Steel Castings and Forgings for Valves, Flanges and Fittings and Other Piping Components (Magnetic Particle Examination Method) Quality Standard for Steel Castings for Valves, Flanges and Fittings and Other Piping Components (Visual Method)

3. CASTING QUALITY LEVELS 3.1 Casting quality is a designation that indicates the desired quality level and the extent of inspection. A quality level shall be assigned to the casting by Mobil and noted on the equipment data sheet. The casting quality level designations are based upon service requirements and are defined below:

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Quality Level I This designation is intended primarily for castings that contain hydrofluoric (HF) 3.1.1 acid. The inspection requirements for each casting are:
Visual 100 % Radiography 100 % Magnetic Particle 100 % Thickness Check Paragraph 6.6 Dimensional Check Paragraph 6.7

3.1.2 Quality Level II This designation is for castings in high-pressure steam or in high-pressure hydrogen, hydrocarbon, or petrochemical service at elevated temperature. The temperature and pressure limitations that constitute Quality Level II depend upon the specific item of equipment. Refer to Section 5 of this Guide for additional information. This quality grade is also applicable to castings in continuous cyclic service. The inspection requirements are:
Visual 100 % Radiography 100 % Critical Areas Magnetic Particle 100 % Thickness Check Paragraph 6.6 Dimensional Check Paragraph 6.7

3.1.3 Quality Level III This designation is applicable to castings in medium- and low-temperature hydrogen, hydrocarbon, petrochemical, steam, or general refinery service. The temperature and pressure limitations that constitute Quality Level IlI depend upon the specific item of equipment. Refer to Section 5 of this Guide for additional information. The inspection requirements are:
Visual 100 % Radiography Magnetic Particle 100 % Critical Areas Thickness Check Paragraph 6.6 Dimensional Check Paragraph 6.7

3.1.4 Quality Level IV This designation is for commercial grade castings in water and hydrocarbon (nonhydrogen sulfide bearing) services. The inspection criteria are:
Visual 100 % Radiography Magnetic Particle Thickness Check Paragraph 6.6 Dimensional Check Paragraph 6.7

3.2

Critical Areas These areas are defined as: (a) (b) (c) Those locations where abrupt changes in casting section thickness or shape occur. Those locations where risers, gates, and feeders are attached to the casting. Any other location that may be subject to high-stress loading during service.

Additional critical areas for specific equipment are defined in Section 5 of this Guide. 3.3 When 100 percent inspection is specified for critical areas or for the entire casting, it shall mean inspection of all accessible surfaces. For radiographic (RT) and ultrasonic (UT) techniques, inspection shall be performed to the maximum extent possible.

MOBIL ENGINEERING GUIDE EGE 00-B-20 1993 4. GENERAL REQUIREMENTS 4.1 The provisions of this Guide, together with the relevant ASTM material specifications and applicable codes, shall be used to supplement the requirements contained in the project specification. 4.2 All castings shall be purchased from foundries that have demonstrated experience, facilities, and a quality assurance program to ensure the production of consistently sound castings of the required design quality. 4.3 When Mobil requests a meeting with the equipment vendor to discuss castings, the following documentation shall be made available: Casting drawings. Shop melting and pouring practices. Quality assurance manual. Welding and heat treating procedures. A summary of experience with the material and pattern to be cast.
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The vendor shall be represented by personnel who possess technical and commercial expertise in casting technology. 4.4 The equipment vendor shall furnish procedures for all welding repair, heating treating, nondestructive examination and inspection to the purchaser's inspector. These procedures shall have been previously approved by the purchaser and shall include all details of welding, heat treating, and inspections (radiographic, ultrasonic, magnetic particle, liquid penetrant, and visual). 4.5 For Quality Levels I, II and III, mechanical testing shall be performed on prolongations of representative size or on samples taken from keel blocks. Samples shall receive the same heat treatment as the casting (normalizing, quenching, tempering, etc.). For Quality Levels I and II only, a coupon that represents each heat of cast material shall be provided to the purchaser for referee purposes. The coupon shall be provided after heat treatment. 4.6 For weldable materials, the heat-treated test samples shall be given a simulated heat treatment to represent the postweld heat treatment (PWHT) required as a result of repairs. Simulated PWHT holding time shall be at least 80 percent of the total PWHT time that is anticipated during fabrication. This requirement applies to Quality Levels I, II and III only. 4.7 The following documentation is required for Quality Level I, II, and III castings: Casting weld repair maps for major repairs. Casting inspection reports. Approved welding, heat treatment, and nondestructive testing procedures. Certified Material Test Report (CMTR) for each heat of material. The CMTR shall contain: Chemical analysis of the material.

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Mechanical test data (including hardness and impact testing when required by the purchase order, EGE 00-B-22, or the applicable materials specification). Applied heat treatment cycle and furnace charts. 4.8 For Quality Levels I, II, and III castings, all major defects as defined in Paragraph 7.1.2 and subsequent repairs shall be documented on defect charts/weld repair maps. This documentation shall: (a) (b) (c) (d) Specify defect sizes (including depth). Show defect location in the castings. The NDE methods used to detect the defects. Indicate the procedure utilized to make the repairs.

An estimate of the amount of weld metal, expressed as a percentage of total casting weight, shall be provided. 5. CASTING INSPECTION REQUIREMENTS 5.1 5.1.1 Pump Casings and Impellers Castings for hydrofluoric acid service shall be inspected in accordance with Quality Level I.

5.1.2 The inspection of pressure-retaining castings made from carbon steel or 300 Series austenitic stainless steel shall be based upon the Quality Levels contained in Table 1. 5.1.3 Quality Level II inspection is required for pressure-retaining castings that are made from the following materials: Cr-Mo, CA-15, CA6NM, CN7M, Monel or nickel-base alloy (such as cast Inconel, Hastelloy, and other proprietary alloys).

Exception: Quality Level I examination shall be applied to all hydrofluoric acid service castings.
NOTE: The increased inspection is warranted because the materials are more sensitive to cracking during repair.

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TABLE 1 SERVICE AND CASTING QUALITY LEVEL

Pressure Service Hydrocarbon, petrochemical, or boiler feedwater (BFW) Corrosive chemicals (sulfuric acid, phenol or peroxide) Hydrocarbon, petrochemical or BFW Amine; sour water; hydrocarbons that contain wet hydrogen sulfide; and petrochemical streams kPa(g) psig

Temperature C F Quality Level II II III III [Apply Quality Level II if pressure is kPa(g) (

$ 6225
< 6225 < 6225

$ 900
< 900 < 900

$ 177

$ 350

$ 900 psig)]
IV

$ 6225

Hydrocarbon, petrochemical, water, condensate or noncorrosive chemicals

< 6225

< 900

< 177

< 350

5.1.4 Impellers and other nonpressure-retaining parts shall be inspected in accordance with Quality Level IV. 5.1.5 5.2 Critical areas for pump casings are defined as: The transition between the volute and casing flanges. The transition between the suction nozzle and casing. The transition between the discharge nozzle and casing. The transition between the casing and feet. The junction where the casing meets the stuffing box. Steam Turbines

5.2.1 Cr-Mo and carbon steel castings for special-purpose steam turbines, as defined in API 612, shall be inspected in accordance with Quality Level II requirements. This also includes the valve body of the tripand-throttle valve. 5.2.2 Gray or ductile iron castings for special-purpose steam turbines and castings for general-purpose steam turbines, as defined in API 611, shall be inspected in accordance with Quality Level III requirements.

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5.2.3 5.3

Critical areas of turbine casings are defined as: Nozzle block. Steam chest. The transition between the casing and the nozzle. The transition between the casing and the joint flange. Ductile Iron Reciprocating Compressor/Pump Cylinders and Cylinder Heads

5.3.1 Ductile iron castings shall be inspected in accordance with Quality Level IV. Acceptance criteria shall be per MSS SP-55. The castings shall be free from cracks, hot tears, and adhering sand or scale. 5.3.2 All castings shall be given a ferritizing anneal. The casting microstructure shall contain a minimum of 90 percent of Type I and Type II graphite as defined in ASTM A395, to ensure that the required mechanical properties, including API 618 toughness criteria, are met. 5.3.3 The machined valve pocket and packing box surfaces of compressor cylinders and heads shall be visually (VT) examined after final machining. The presence of porosity on sealing surfaces shall be cause for rejection, unless the supplier can demonstrate that this condition will not result in leakage around the valve or packing. 5.3.4 Mobil reserves the right to evaluate and approve the suspect areas for service if any one of the following occurs: 5.4 5.4.1 5.4.2 5.5 5.5.1 5.5.2 The VT examination is inconclusive. Disputes arise concerning interpretation. Linear indications are found on the casting surfaces. Cast Steel Reciprocating Compressor/Pump Cylinders and Cylinder Heads Pressure-retaining castings shall be inspected in accordance with Quality Level II. Critical areas of the casing shall be defined as: Valve pockets. The bore and box packing area. Centrifugal/Rotary Compressors Pressure-retaining castings shall be inspected in accordance with Quality Level II. Ductile iron diaphragms shall be inspected in accordance with Quality Level IV.

MOBIL ENGINEERING GUIDE EGE 00-B-20 1993 5.5.3 5.6 Critical areas shall be defined as: The transition between the nozzles and casing. The transition between the casing and horizontal joint. Areas with radii less than 25.4 mm (1 in.). Valve Bodies
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5.6.1 Valves in hydrofluoric acid service shall be inspected in accordance with Quality Level I. For valve size less than or equal to NPS 8 (NPS = nominal pipe size, in inches), each sand casting shall be inspected by maximum feasible volume radiography (as described in ASME Section III, Paragraph NB-2575.2). For valve size greater than NPS 10, 100 percent of the critical areas shall be RT inspected. Critical areas shall be as defined in ASME/ANSI B16.34. Refer to "HF Acid Service Valves Specification Requirements," dated December 23, 1992. 5.6.2 For valves with pressure ratings of Class 1500 or higher, castings are to be inspected in accordance with the requirements of Quality Level II. 5.6.3 For all other valve castings, inspection shall be in accordance with the project specification and requisition. 5.7 Statically Cast Furnace Return Bends and Fittings

5.7.1 Return bends and other pressure-retaining fittings that are cast in any of the following materials shall be inspected in accordance with Quality Level II: (a) (b) (c) Cr-Mo. Austenitic stainless steel (such as CF8M, CF8C, etc.). Nickel-base alloys (including proprietary alloys).

5.7.2 Prior to welding statically cast Cr-Mo fittings and return bends to tubes, the weld bevels for each joint shall be magnetic particle inspected. Weld bevels shall be free from cracks and hot tears. The photographs contained in ASTM E-125 shall be used to judge the acceptability of other weld bevel defects. The extent of defects such as linear indications, inclusions, shrinkage and porosity shall not exceed Severity Level 1, as defined in ASTM E-125. 5.7.3 Prior to welding statically cast austenitic stainless steel or nickel-base alloy return bends to tubes, the weld bevels for each joint shall be liquid penetrant inspected. Weld bevels shall be free from cracks and hot tears. The photographs contained in ASTM E125 shall be used as a reference to judge the acceptability of other weld bevel defects. The extent of defects such as linear indications, inclusions, shrinkage, and porosity shall not exceed Severity Level 1. 5.7.4 Return bends and other pressure-retaining fittings cast in carbon steel material shall be inspected in accordance with Quality Level III. Prior to welding, weld bevels shall be inspected as prescribed in Paragraph 5.7.2 of this Guide.

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6. TECHNIQUES AND ACCEPTANCE CRITERIA 6.1 Radiographic Inspection

6.1.1 Radiography shall be in accordance with the ASME Boiler and Pressure Vessel Code (Section V, Article 3), ASTM E94, and ASTM E142. Personnel who interpret NDE results shall possess ASNT Level II or III qualification. All inspection personnel shall be qualified in accordance with ASNT requirements. The manufacturer shall provide access to the radiographic facilities to allow the purchasers inspector to check the filming setup on production castings. Evidence of incorrect radiographic techniques will result in rejection of all radiographs, including those previously accepted. 6.1.2 For steel castings, radiographs shall comply with the requirements of ASTM E446, E186, or E280 depending upon casting thickness. Acceptance standards concerning discontinuities and severity level shall be in accordance with Table 3 of this Guide. For aluminum, copper and nickel-copper alloys, and bronze materials radiographs shall comply with the requirements of ASTM E155, E272 (acceptance level No. 2 for codes A, Ba, Bb), and E310 (acceptance level No. 2 for codes A and B), respectively. Unacceptable defects shall be removed to the extent that the remaining material meets the above acceptance criteria. 6.1.3 When required by the job specification, weld ends of steel castings shall be radiographed. Acceptance criteria for radiography shall be in accordance with ASTM E446, Class 1, for defect designations A, B, and C for a distance of 50 mm (2 in.) on either side of the weld bevels. It should be noted that this requirement is in addition to those contained in Paragraph 6.1.2 of this Guide. 6.1.4 Radiographic film shall be in accordance with ASTM E94, Type 1 or 2. Only lead intensifying screens of 0.125 mm or 0.250 mm (0.005 in. or 0.010 in.) thickness shall be used. Radiographs shall be dry for final acceptance interpretation. 6.1.5 Single-film viewing shall be used, and the film density shall be 1.8 to 4.0 for an X-ray source and 2.0 to 4.0 for a gamma-ray source. In those instances where variable wall thickness makes single-film viewing impractical, double-film viewing may be used with the approval of the purchasers inspector. The maximum film density shall be 4.0 for the double-film combination, with a minimum density of 1.3 for each film. 6.1.6 Use of penetrameters other than those specified in the ASME Code (Section VIII, Div. 1) shall require purchaser approval. 6.1.7 Image quality indicators shall be clearly identified, and the source side indicator sensitivity shall be equal to or better than 2-2T. 6.1.8 Radiographic films that have been accepted by the purchasers inspector shall be processed, handled, and stored by the supplier so that they are available for a minimum period of five years. The manufacturer shall demonstrate to the satisfaction of the purchasers inspector the adequacy of the film processing. The maximum residual thiosulfate ion level allowance shall be "3" on an appropriate estimator strip (Kodak Hypo or equal).

MOBIL ENGINEERING GUIDE EGE 00-B-20 1993 6.2 Ultrasonic Inspection

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6.2.1 Ultrasonic inspection of castings shall be performed in accordance with the requirements of the ASME Code (Section V, Article 5), ASTM A609, ASTM E114, and the applicable fabrication code. Personnel who interpret NDE results shall possess ASNT Level II or III qualification. All inspection personnel shall be qualified in accordance with ASNT requirements. The following defects are unacceptable: (a) For castings in ASME/ANSI B31.3 piping systems, defects that exceed 5 percent of the wall thickness. (b) For all other castings, imperfections which result in indications exceeding 20 percent of the straight-beam back reflection. Indications which reduce the height of the back reflection by more than 30 percent during a 50 mm (2 in.) total movement of the transducer in any direction are also unacceptable. 6.2.2 All unacceptable defects shall be removed.

6.2.3 For Quality Level I or II castings, the reference blocks shall be made from production material that is in the same heat treatment condition and has the same surface finish and wall thickness as the production castings that are to be inspected. For other castings, the requirements of the ASME Code (Section V) shall apply. 6.2.4 The ultrasonic inspection procedure shall be qualified by a procedure qualification test that is witnessed by the purchasers inspector. The test piece that is used shall be available for reference during all production inspection operations. 6.2.5 When inspection is difficult for special reasons (geometry, varying thickness, etc.), reference test blocks shall be prepared which are representative of the production configuration. The purchasers inspector shall approve the test blocks prior to the calibration of the equipment. 6.2.6 Ultrasonic (UT) inspection techniques may be used in lieu of radiography (RT) only when approved by the purchaser. 6.3 Magnetic Particle Inspection

6.3.1 Magnetic particle inspection of castings shall be performed in accordance with the ASME Code (Section V, Article 7) and ASTM E709. Wet or dry methods may be used. Personnel who interpret NDE results shall possess ASNT Level II or III qualification. All inspection personnel shall be qualified in accordance with ASNT requirements. Castings shall meet the criteria listed below: (a) Castings for ASME/ANSI B31.3 piping systems shall not contain cracks or hot tears. Acceptance shall be in accordance with MSS SP-53, except that the length of linear indications shall not exceed 7.5 mm (0.3 in.) regardless of the material thickness. The reference photographs in ASTM E125 shall be used to determine the acceptability of indications. (b) For all other castings, the acceptability of defects shall be based on a comparison with the photographs contained in ASTM E125. The degree of severity for each type of defect shall not exceed the criteria contained in Table 2.

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TABLE 2 MAGNETIC PARTICLE EXAMINATION ACCEPTANCE CRITERIA

ASTM Type I II III IV V VI

Defect Linear Discontinuities Shrinkage Inclusions Chills and Chaplets Porosity Welds

Maximum Severity Level 1 2 2 1 1 1

6.3.2 Inspection shall be performed using coils, prod or yoke equipment. Permanent magnets or yokes shall be used on air-hardening steel. Prods shall be equipped with switches on the handles for activating the magnetizing current. Arcing shall be avoided. Any arc strikes that occur shall be removed by grinding. Magnetic particle field indicating pie gages shall be used during inspections to confirm the adequacy of the magnetic field. 6.3.3 The lift strengths of AC electromagnetic yokes and DC yokes shall be 4.5 kg (10 lb) and 18 kg (40 lb), respectively, at the maximum pole spacing. 6.3.4 In lieu of magnetic particle (MT) inspection, liquid penetrant (PT) inspection techniques shall be used on nonferrous materials. For ferrous materials, PT inspection may be substituted for MT only when approved by the Purchaser. 6.4 Liquid Penetrant Inspection

6.4.1 Liquid penetrant inspection of castings shall be performed in accordance with the requirements of the ASME Code (Section V, Article 6) and ASTM E165. Personnel who interpret NDE results shall possess ASNT Level II or III qualification. All inspection personnel shall be qualified in accordance with ASNT requirements. Castings shall meet the following criteria. (a) Castings for ASME/ANSI B31.3 piping systems shall not contain cracks or hot tears. Acceptance criteria shall conform to the requirements contained in Table 1 of MSS SP-53, except that the length of linear indications shall not exceed 7.5 mm (0.3 in.) regardless of material thickness. The reference photographs in ASTM E125 should be used as a reference for surface flaws. (b) In all other castings, indications shall be removed if they are: (1) Cracks and hot tears.

(2) Linear indications more than 6 mm (0.25 in.) long for wall thicknesses up to 19 mm (0.75 in.) inclusive; more than one-third of the wall thickness in length for wall thicknesses over 19 mm to 57 mm (0.75 in. to 2.25 in.); and more than 19 mm (0.75 in.) long for wall thicknesses greater than 57 mm (2.25 in.). Aligned imperfections separated from one another by a distance equal to or greater than the length of the longer imperfection are acceptable if individual imperfections do not exceed the lengths stated. Linear indications are those having a length greater than three times the width.

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TABLE 3 RADIOGRAPHIC ACCEPTANCE STANDARDS FOR CASTINGS Designation or Category

Discontinuity Type

Severity Level

ASTM E446, thickness up to 51 mm (2 in.)

Cracks Gas porosity Sand and slag inclusions Internal shrinkage Hot tears Unfused chaplets Internal chills D A B C E F G None permitted Class 2 acceptable Class 2 acceptable Class 2 permitted None permitted None permitted None Permitted

ASTM E186, thickness 51 mm to 114 mm (2 in. to 4 1/2 in.)

Cracks Gas porosity Sand and slag inclusions Shrinkage: Type 1 linear shrinkage Type 2 dendritic shrinkage Type 3 spongy shrinkage Hot tears Inserts: Type 1 Type 2 D A B C C C E F F None permitted Class 2 acceptable Class 2 acceptable Class 1 acceptable Class 2 acceptable Class 2 acceptable None permitted None permitted None permitted

ASTM E280, thickness 114 mm to 305 mm (4 1/2 in. to 12 in.)

Cracks Gas porosity Sand and slag inclusions Shrinkage Type 1 Type 2 Type 3 Hot tears Inserts: Type 1 Type 2 D A B C C C E F F None permitted Class 2 acceptable Class 2 acceptable Class 2 acceptable Class 2 acceptable Class 2 acceptable None permitted None permitted None permitted

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(3) Any group of more than six linear indications (other than cracks and hot tears) in any rectangular area of 38 mm x 152 mm (1.5 in. x 6.0 in.) or less, or in any circular area having a diameter of 89 mm (3.5 in.) or less. These areas shall be in the most unfavorable location relative to the indications being evaluated. (4) Nonlinear indications having any dimension which exceeds 2.4 mm (0.094 in.). Nonlinear indications are those having a length less than three times the width. 6.4.2 Penetrating, cleaning, and developing solutions that have a combined total residual sulfur and halogen content of one percent or greater by weight shall not be used. 6.5 Visual Inspection

Visual inspection shall be performed in accordance with the requirements of the ASME Code (Section V, Article 9), MSS SP-55 and ASTM A802. Mirrors, boroscopes, cameras, etc., shall be used as required to maximize the extent of inspection. Personnel who interpret NDE results shall possess ASNT Level II or III qualification. All inspection personnel shall be qualified in accordance with ASNT requirements. A802 and MSS SP-55 shall apply to all materials, including nonferrous grades. Visual inspection procedures shall be submitted for the purchasers review. 6.6 Thickness Check

6.6.1 The suitability and accuracy of the tools and instruments that are used for casting thickness determination shall be demonstrated to the satisfaction of the purchasers inspector. 6.6.2 Local areas of valve body castings that have thicknesses less than the minimum wall thickness shown on the approved vendors drawings shall meet the applicable requirements of ASME/ANSI B16.34; however, if more stringent requirements of other codes specified in the purchase order apply (for example, API valve standards), such requirements shall be met. 6.6.3 Casting wall thickness shall be in accordance with the equipment vendors approved drawings. Wall thickness less than the minimum requirements shall be reported to the purchaser, together with the proposed remedial action. The vendor shall not implement any proposed plan of action without the prior approval of the purchaser. 6.7 Dimensional Check

6.7.1 The suitability and accuracy of the tools and instruments that are used for the dimensional check shall be demonstrated to the satisfaction of the purchasers inspector. 6.7.2 Casting dimensions shall conform to the vendors approved drawings. Dimensions that do not conform to the drawings shall be reported to the purchaser, together with the proposed resolution. The vendor shall not implement any proposed plan of action without the prior approval of the purchaser. 7. REPAIRS 7.1 General

7.1.1 For Quality Levels I, II, and III, all casting repair procedures shall be approved by the purchaser prior to performing any repairs.

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7.1.2 Major repairs to castings made in accordance with approved procedures do not require prior purchaser approval, except when the estimated weight/volume of weld metal needed to perform all of the repairs exceeds 5 percent of the total casting weight. Defects that result in major casting repairs are: (a) Those that cause the casting to leak during hydrostatic or pneumatic testing.

(b) Those that result in repair cavities that exceed 20 percent of the casting wall thickness or 25 mm (1 in.), whichever is less. (c) Those that result in a repair area that exceeds 6500 mm (10 in. ).
2 2

All other defects are considered to be minor, but may require repair. Minor defects need not be documented on defect charts. 7.1.3 Defect charts/weld maps shall be prepared for major repairs and submitted to the purchaser for information prior to the start of repairs. The charts shall be in accordance with Paragraph 4.8 of this Guide. 7.1.4 Repairs performed by peening, impregnating, or the use of fillers are not acceptable on pressureretaining castings. Mechanical type of repairs such as plugging, helicoils, metal stitching or shoulder bolts shall be subject to purchaser approval. Full details of the procedures shall be provided when such approvals are requested. 7.1.5 Weld repairs need not be considered when a surface discontinuity can be eliminated by removing less than 5 percent of the casting thickness. Excavated areas shall be blended smoothly into the surrounding surfaces. Sharp contours and abrupt transitions in dimensions shall be avoided. Transitions in dimensions shall exhibit a taper of at least 3:1. After removal of defects, the minimum design wall thickness shall remain. 7.2 7.2.1 Welding Weld repairs to cast iron shall not be allowed.

7.2.2 Welding of components for ASME/ANSI B31.3 piping systems shall conform to the requirements of EGE 16-B-40. All other repair welding (including procedure and welder qualifications) shall conform to the requirements of EGE 00-B-21. 7.2.3 Welding procedure qualification test coupons shall be given a simulated postweld heat treatment (PWHT) when such heat treatment is required for the materials being welded. The minimum holding time at temperature shall be at least 80 percent of the total anticipated PWHT time. Charpy impact testing of welded test plates shall be performed when required by EGE 00-B-21 or EGE 00-B-22 or the relevant codes. A hardness survey shall be made 1.6 mm (0.063 in.) below the top and bottom surfaces of the weld and shall include base metal, heat-affected zones, and weld deposit. Hardness values shall not be greater than 225 HB when converted to Brinell (for Grade CA6NM, hardness shall not exceed 255 HB). Indenter diameter shall not exceed 1.6 mm (0.063 in.). 7.2.4 When the casting requires preheat prior to welding, the same preheat temperature shall be applied prior to thermal gouging. After gouging, all dross and heat-affected material shall be removed by grinding. 7.2.5 The manufacturer shall maintain a filler metal control program to ensure that fluxes, covered electrodes, and wires are not contaminated by moisture or other deleterious substances. A filler metal control procedure shall be submitted to Mobil for approval prior to welding.

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7.3

Weld Inspection

7.3.1 Excavations shall be subject to visual and magnetic particle inspection (or liquid penetrant inspection for nonmagnetic material) to ensure that unacceptable defects are removed prior to repair welding or blending. Excavations for repair welding shall meet the criteria contained in ASTM A703, Supplementary Requirement S10. 7.3.2 At a minimum, all casting repair welds shall be nondestructively inspected using the same nondestructive testing methods that were employed to inspect the casting. For defects that result in through-wall repairs or repairs that extend into the minimum wall thickness, radiography of the repair weld is required for Quality Level I and II castings. This applies regardless of the method used to detect the defects. For castings requiring postweld heat treatment, final radiographic or ultrasonic inspection shall be performed after PWHT. In addition, all repairs shall be visually and magnetic particle inspected subsequent to PWHT (liquid penetrant inspection may be used if the casting is of nonmagnetic material). Adjacent areas of cast material and other weld repairs that were previously inspected may be reinspected if the purchasers inspector considers that such areas may have been adversely affected by subsequent welding or heat treatment. 7.3.3 Weld examination procedures and acceptance standards shall be in accordance with Table 4 and the requirements of EGE 00-B-21 or EGE 16-B-40 as applicable. Casting defects revealed by weld repair inspections shall be evaluated using the casting acceptance criteria specified herein. If casting defects are considered by the purchasers inspector to be detrimental to the proposed welding, such defects shall be removed. Weld repair areas shall be adequately marked to ensure that the weld and casting boundaries are identified during inspection. 7.3.4 Accessible major repair welds and heat affected zones in ferritic materials shall be checked for hardness after any heat treatment. Hardness values shall not exceed 225 HB (for Grade CA6NM, hardness values shall not exceed 255 HB). If ball-type equipment is used for hardness measurements, the maximum diameter of the indentor shall be 1.6 mm (0.063 in.). An Equotip instrument is acceptable for use on materials thicker than 13 mm (0.50 in.), provided a surface smoothness of 2 microns is obtained. This can be achieved with a smooth mill file.

TABLE 4 WELD EXAMINATION PROCEDURES AND ACCEPTABLE STANDARDS Method Radiography Specification or Standard Table 3 of this Guide EGE 16-B-40 (piping components only). Paragraph 6.3 of this Guide EGE 16-B-40 (piping components only). ASME Section VIII, Div. 1, Appendix 7 EGE 16-B-40 (piping components only). ASME Section VIII, Div. 1, Appendix 7 EGE 16-B-40 (piping components only).

Magnetic particle

Liquid penetrant

Ultrasonic

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7.3.5 Straight-beam ultrasonic inspection of weld repairs shall be supplemented by the use of angle probes to ensure the adequacy of the welds. The procedure shall be approved by Mobil and the adequacy of the technique shall be approved by the purchasers inspector. 8. HEAT TREATMENT 8.1 Postweld heat treatment cycles shall be in accordance with EGE 00-B-21 or EGE 16-B-40 as applicable. All PWHT procedures shall be approved by the purchaser. Heating and cooling rates, holding times, and furnace temperature tolerances shall be in accordance with the applicable fabrication codes. Recording charts of all heat treatment cycles shall be provided, and recording instruments and furnace thermocouples shall be properly calibrated. 8.2 The maximum accumulated postweld heat treatment holding time, including reheat treatments, shall not exceed the total anticipated PWHT time (Paragraphs 4.6 and 7.2.3). The depth of the weld shall be used to determine minimum soaking time. 8.3 Local postweld heat treatment is not acceptable unless prior approval is obtained from the purchaser and the PWHT procedure has been approved by Mobil. 9. HYDROSTATIC TESTS 9.1 When required by the purchaser, each casting shall be hydrostatically tested to the maximum test pressure required by the applicable code or as specified in the requisition, whichever is greater. 9.2 The test pressure shall be maintained for an adequate time to detect small seepage-type leaks, but not less than that required by the applicable code. The test water supply source shall be isolated from the component being tested during the test period. 9.3 When ferritic, martensitic, or duplex alloy castings are being hydrostatically tested, the fluid temperature shall be maintained at a level sufficient to prevent brittle fracture. 9.4 After a casting is filled with test fluid, the temperature of the casting shall be allowed to equalize prior to application of test pressure. 9.5 Metal temperature of Quality I, II, and III ferritic, martensitic, or duplex alloy castings shall be recorded over the period of the test. 9.6 The chloride content of the test water shall not exceed 50 ppm when austenitic stainless steel components are being tested. 9.7 Upon completion of hydrostatic testing, the casting shall be drained. Special precautions shall be taken to remove all water from low-points and deadleg areas.

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EGE 00-B-20 1993

APPENDIX DATA REQUIRED FROM BIDDER Applicable to Quality I and II Castings A-1. 1. 2. Suppliers shall include the following information in their bids: Equipment which is to be used for steel melting and refining, including furnace types and capacities. Equipment and personnel that are available for the performance of metallurgical examinations (including metallograph), determination of casting chemical composition, and mechanical testing. A summary of the equipment and personnel qualifications shall be included. The organization of the quality control, quality assurance, and shop departments and their specific responsibilities. A summary of personnel qualifications shall be included. Any deviations from the purchasers requirements and the reasons for them. Deviations shall only be considered for special reasons, not on the basis of the manufacturers standard practice. Available radiography, ultrasonic, magnetic particle, and thickness determination equipment. Facilities available for welding repair. A summary of the equipment and personnel qualifications shall be included. Fabrication and inspection schedule, including hold and purchasers witness points. Note: Purchasers final inspection shall take place after postweld heat treatment. It is the vendors responsibility to ensure that adequate inspections (for example, radiography, ultrasonic, magnetic particle, and thickness examinations) are carried out prior to PWHT and the purchasers final inspection.

3.

4.

5. 6. 7.

If any of the above activities are to be subcontracted, the bidder shall identify the proposed subcontractor and provide full details as outlined above. The bidder shall confirm that the execution and evaluation of all nondestructive testing will meet the requirements of ASTM E543.