Practical Guide to Pressure Vessel Manufacturing Sunil PullarcotPractical Guide to Pressure Vessel ManufacturingQaeNe OND 14. 15. 16. 18. 19. 20. 21. 22. . Probabilistic Engineering Design: Principles and Applications, James N. 24, 25. MECHANICAL ENGINEERING A Series of Textbooks and Reference Books Founding Editor L. L. Faulkner Columbus Division, Battelle Memorial Institute and Department of Mechanical Engineering The Ohio State University Columbus, Ohio . Spring Designer's Handbook, Harold Carlson .. Computer-Aided Graphics and Design, Daniel L. Ryan . Lubrication Fundamentals, J. George Wills . Solar Engineering for Domestic Buildings, William A. Himmelman . Applied Engineering Mechanics: Statics and Dynamics, G. Boothroyd and C. Poli . Centrifugal Pump Clinic, \gor J. Karassik .. Computer-Aided Kinetics for Machine Design, Daniel L. Ryan . Plastics Products Design Handbook, Part A: Materials and Components; Part B: Processes and Design for Processes, edited by Edward Miller |. Turbomachinery: Basic Theory and Applications, Earl Logan, Jr. 10. 11, 12. 13. Vibrations of Shells and Plates, Wemer Soedel Flat and Corrugated Diaphragm Design Handbook, Mario Di Giovanni Practical Stress Analysis in Engineering Design, Alexander Blake ‘An Introduction to the Design and Behavior of Bolted Joints, John H. Bickford Optimal Engineering Design: Principles and Applications, James N. Siddall Spring Manufacturing Handbook, Harold Carlson Industrial Noise Control: Fundamentals and Applications, edited by Lewis H. Bell .. Gears and Their Vibration: A Basic Approach to Understanding Gear Noise, J. Derek Smith Chains for Power Transmission and Material Handling: Design and Appli- cations Handbook, American Chain Association Corrosion and Corrosion Protection Handbook, edited by Philip A. Schweitzer Gear Drive Systems: Design and Application, Peter Lynwander Controlling In-Plant Airbore Contaminants: Systems Design and Cal- culations, John D. Constance CAD/CAM Systems Planning and Implementation, Charles S. Knox Siddall Traction Drives: Selection and Application, Frederick W. Heilich IIl_ and Eugene E. Shube Finite Element Methods: An Introduction, Ronald L. Huston and Chris E. Passerello26. 27. 28. |. Practical Seal Design, edited by Leonard J. Martini 30. 31. 32. 33. 37. 38. 39. 40. 41. 42. 43. 49. ). Clutches and Brakes: Design and Selection, William C. Orthwein 51. 52. 53. . How to Integrate CAD/CAM Systems: Management and Technology, William 55. Mechanical Fastening of Plastics: An Engineering Handbook, Brayton Lincoln, Kenneth J. Gomes, and James F. Braden Lubrication in Practice: Second Eadition, edited by W. S. Robertson Principles of Automated Drafting, Daniel L. Ryan Engineering Documentation for CAD/CAM Applications, Charles S. Knox Design Dimensioning with Computer Graphics Applications, Jerome C. Lange Mechanism Analysis: Simplified Graphical and Analytical Techniques, Lyndon O, Barton CAD/CAM Systems: Justification, Implementation, Productivity Measurement, Edward J. Preston, George W. Crawford, and Mark E. Coticchia . Steam Plant Calculations Manual, V. Ganapathy 35. 36. Design Assurance for Engineers and Managers, John A. Burgess Heat Transfer Fluids and Systems for Process and Energy Applications, Jasbir Singh Potential Flows: Computer Graphic Solutions, Robert H. Kirchhoff Computer-Aided Graphics and Design: Second Edition, Daniel L. Ryan Electronically Controlled Proportional Valves: Selection and Application, Michael J. Tonyan, edited by Tobi Goldoftas Pressure Gauge Handbook, AMETEK, U.S. Gauge Division, edited by Philip W. Hartand Fabric Filtration for Combustion Sources: Fundamentals and Basic Tech- nology, R. P. Donovan Design of Mechanical Joints, Alexander Blake CAD/CAM Dictionary, Edward J. Preston, George W. Crawford, and Mark E. Coticchia . Machinery Adhesives for Locking, Retaining, and Sealing, Girard S. Haviland 45. }.. Shaft Alignment Handbook, John Piotrowski 47. Couplings and Joints: Design, Selection, and Application, Jon R. Mancuso BASIC Programs for Steam Plant Engineers: Boilers, Combustion, Fluid Flow, and Heat Transfer, V. Ganapathy .. Solving Mechanical Design Problems with Computer Graphics, Jerome C. Lange Plastics Gearing: Selection and Application, Clifford E. Adams Transducers in Mechanical and Electronic Design, Harry L. Trietley Metallurgical Applications of Shock-Wave and High-Strain-Rate Phenom- ena, edited by Lawrence E. Murr, Karl P. Staudhammer, and Marc A. Meyers Magnesium Products Design, Robert S. Busk D. Engelke Cam Design and Manufacture: Second Edition; with cam design software for the IBM PC and compatibles, disk included, Preben W. Jensen . Solid-State AC Motor Controls: Selection and Application, Syivester Campbell 57. . Belt Selection and Application for Engineers, edited by Wallace D. Erickson 59. . Organizing Data for CIM Applications, Charles S. Knox, with contributions Fundamentals of Robotics, David D. Ardayfio Developing Three-Dimensional CAD Software with the IBM PC, C. Stan Wei by Thomas C. Boos, Ross S. Culverhouse, and Paul F. Muchnicki61. 62. 63. 65. 66. 67. 69. 70. 71. . Pressure Sensors: Selection and Application, Duane Tandeske 73. 74, 75. 76. 77. 78. 79. 80. 81. 82. 83. 86. 87. 88. 89. 90. 91. Computer-Aided Simulation in Railway Dynamics, by Rao V. Dukkipati and Joseph R. Amyot Fiber-Reinforced Composites: Materials, Manufacturing, and Design, P. K. Mallick Photoelectric Sensors and Controls: Selection and Application, Scott M. Juds . Finite Element Analysis with Personal Computers, Edward R. Champion, Jr., and J. Michael Ensminger Ultrasonics: Fundamentals, Technology, Applications: Second Edition, Revised and Expanded, Dale Ensminger Applied Finite Element Modeling: Practical Problem Solving for Engineers, Jeffrey M. Steele Measurement and Instrumentation in Engineering: Principles and Basic Laboratory Experiments, Francis S. Tse and Ivan E. Morse . Centrifugal Pump Clinic: Second Edition, Revised and Expanded, Igor J. Karassik Practical Stress Analysis in Engineering Design: Second Edition, Revised and Expanded, Alexander Blake An Introduction to the Design and Behavior of Bolted Joints: Second Edition, Revised and Expanded, John H. Bickford High Vacuum Technology: A Practical Guide, Marsbed H. Hablanian Zinc Handbook: Properties, Processing, and Use in Design, Frank Porter Thermal Fatigue of Metals, Andrzej Weronski and Tadeusz Hejwowski Classical and Modem Mechanisms for Engineers and Inventors, Preben W. Jensen Handbook of Electronic Package Design, edited by Michael Pecht Shock-Wave and High-Strain-Rate Phenomena in Materials, edited by Marc A. Meyers, Lawrence E. Murr, and Karl P, Staudhammer Industrial Refrigeration: Principles, Design and Applications, P. C. Koelet Applied Combustion, Eugene L. Keating Engine Oils and Automotive Lubrication, edited by Wilfried J. Bartz Mechanism Analysis: Simplified and Graphical Techniques, Second Eadition, Revised and Expanded, Lyndon O. Barton Fundamental Fluid Mechanics for the Practicing Engineer, James W. Murdock Fiber-Reinforced Composites: Materials, Manufacturing, and Design, Second Edition, Revised and Expanded, P. K. Mallick . Numerical Methods for Engineering Applications, Edward R. Champion, Jr. 85. Turbomachinery: Basic Theory and Applications, Second Edition, Revised and Expanded, Earl Logan, Jr. Vibrations of Shells and Plates: Second Edition, Revised and Expanded, Wemer Soedel Steam Plant Calculations Manual: Second Edition, Revised and Ex panded, V. Ganapathy Industrial Noise Control: Fundamentals and Applications, Second Edition, Revised and Expanded, Lewis H. Bell and Douglas H. Bell Finite Elements: Their Design and Performance, Richard H. MacNeal Mechanical Properties of Polymers and Composites: Second Edition, Re- vised and Expanded, Lawrence E. Nielsen and Robert F. Landel Mechanical Wear Prediction and Prevention, Raymond G. Bayer92. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102. 103. 104. 105. 106. 107. 108. 109. 110. 111. 112. 113. 114, 115. 116. 117. 118. 119. 120. 121. 122. 123. 124. 125. 126. Mechanical Power Transmission Components, edited by David W. South and Jon R. Mancuso Handbook of Turbomachinery, edited by Earl Logan, Jr. Engineering Documentation Control Practices and Procedures, Ray E. Monahan Refractory Linings Thermomechanical Design and Applications, Charles A Schacht Geometric Dimensioning and Tolerancing: Applications and Techniques for Use in Design, Manufacturing, and Inspection, James D. Meadows An Introduction to the Design and Behavior of Bolted Joints: Third Edition, Revised and Expanded, John H. Bickford Shaft Alignment Handbook: Second Edition, Revised and Expanded, John Piotrowski Computer-Aided Design of Polymer-Matrix Composite Structures, edited by Suong Van Hoa Friction Science and Technology, Peter J. Blau Introduction to Plastics and Composites: Mechanical Properties and Engi- neering Applications, Edward Miller Practical Fracture Mechanics in Design, Alexander Blake Pump Characteristics and Applications, Michael W. Volk Optical Principles and Technology for Engineers, James E. Stewart Optimizing the Shape of Mechanical Elements and Structures, A. A. Seireg and Jorge Rodriguez Kinematics and Dynamics of Machinery, Vladimir Stejskal and Michael ValaSek Shaft Seals for Dynamic Applications, Les Horve Reliability-Based Mechanical Design, edited by Thomas A. Cruse Mechanical Fastening, Joining, and Assembly, James A. Speck Turbomachinery Fluid Dynamics and Heat Transfer, edited by Chunill Hah High-Vacuum Technology: A Practical Guide, Second Edition, Revised and Expanded, Marsbed H. Hablanian Geometric Dimensioning and Tolerancing: Workbook and Answerbook, James D. Meadows. Handbook of Materials Selection for Engineering Applications, edited by G. T. Murray Handbook of Thermoplastic Piping System Design, Thomas Sixsmith and Reinhard Hanselka Practical Guide to Finite Elements: A Solid Mechanics Approach, Steven M. Lepi Applied Computational Fluid Dynamics, edited by Vijay K. Garg Fluid Sealing Technology, Heinz K. Muller and Beard S. Nau Friction and Lubrication in Mechanical Design, A. A. Seireg Influence Functions and Matrices, Yuri A. Melnikov Mechanical Analysis of Electronic Packaging Systems, Stephen A. McKeown, Couplings and Joints: Design, Selection, and Application, Second Edition, Revised and Expanded, Jon R. Mancuso Thermodynamics: Processes and Applications, Earl Logan, Jr. Gear Noise and Vibration, J. Derek Smith Practical Fluid Mechanics for Engineering Applications, John J. Bloomer Handbook of Hydraulic Fluid Technology, edited by George E. Totten Heat Exchanger Design Handbook, T. Kuppan127. 128. 129. 130. 131. 132. 133. 134. 135. 136. 137. 138. 139. 140. 141. Designing for Product Sound Quality, Richard H. Lyon Probability Applications in Mechanical Design, Franklin E. Fisher and Joy R. Fisher Nickel Alloys, edited by Ulrich Heubner Rotating Machinery Vibration: Problem Analysis and Troubleshooting, Maurice L. Adams, Jr. Formulas for Dynamic Analysis, Ronald L. Huston and C. Q. Liu Handbook of Machinery Dynamics, Lynn L. Faulkner and Earl Logan, Jr. Rapid Prototyping Technology: Selection and Application, Kenneth G. Cooper Reciprocating Machinery Dynamics: Design and Analysis, Abdulla S. Rangwala Maintenance Excellence: Optimizing Equipment Life-Cycle Decisions, edited by John D. Campbell and Andrew K. S. Jardine Practical Guide to Industrial Boiler Systems, Ralph L. Vandagriff Lubrication Fundamentals: Second Edition, Revised and Expanded, D. M. Pirro and A. A. Wessol ‘Mechanical Life Cycle Handbook: Good Environmental Design and Manu- facturing, edited by Mahendra S. Hundal Micromachining of Engineering Materials, edited by Joseph McGeough Control Strategies for Dynamic Systems: Design and Implementation, John H. Lumkes, Jr. Practical Guide to Pressure Vessel Manufacturing, Sunil Pullarcot Additional Volumes in Preparation Diesel Engine Engineering: Dynamics, Design, and Control, Andrei Makartchouk Reliability Verification, Testing, and Analysis in Engineering Design, Gary S. Wasserman Nondestructive Evaluation, edited by Peter J. Shull and Michael Ehrlich Bearing Design in Machinery, Avraham Harnoy Handbook of Machine Tool Analysis, loan D. Marinescu, Constantin Ispas, and Dan Boboc implementing Concurrent Engineering in Small Companies, Susan Carlson Skalak Mechanical Properties of Engineering Materials, Wole Soboyejo Mechanical Engineering Software Spring Design with an IBM PC, Al Dietrich Mechanical Design Failure Analysis: With Failure Analysis System Software for the IBM PC, David G. UllmanPractical Guide to Pressure Vessel Manufacturing Sunil Pullarcot FACT Engineering and Design Organisation Kerala, India MaRcet MarceL Dexxer, INC. New York + Baset DEKKERISBN: 0-8247-0740-0 This book is printed on acid-free paper. Headquarters Marcel Dekker, Inc. 270 Madison Avenue, New York, NY 10016 tel: 212-696-9000; fax: 212-685-4540, Eastern Hemisphere Distribution Marcel Dekker AG Hutgasse 4, Postfach 812, CH-400] Basel, Switzerland tel: 41-61-261-8482; fax: 41-61-261-8896 World Wide Web hup://www.dekker.com The publisher offers discounts on this book when ordered in bulk quantities. For more information, write to Special Sales/Professional Marketing at the headquarters address above. Copyright © 2002 by Marcel Dekker, Inc. All Rights Reserved. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and re- cording, or by any information storage and retrieval system, without permission in writing from the publisher. Current printing (Last digit): 10987654321 PRINTED IN THE UNITED STATES OF AMERICAPreface ‘Twenty years ago, after completing my degree in mechanical engineering, I began my career in a pressure vessel fabrication company. Because I was a newcomer to the industry, I sought areliable reference explaining fabrication and the correspond- ing procedures of quality assurance and control (QAC). I came across books such as Pressure Vessel Design Manual, by Den- nis R. Moss, and Pressure Vessel Handbook, by Eugene F. Megyesy, but these were confined to aspects of design. The ASME code and the other national codes were the only docu- ments available for reference. The ASME code provided all the expected specifications but failed to suggest the means of achieving compliance with such specifications—perhaps because it was intended for engi- iiiiv Preface neers with an insight into the underlying logic of the code. Thus, my efforts to understand the code led only to further confusion. This book summarizes my efforts, over 20 years, to bridge the gap between code specifications and the procedures neces- sary to comply with them. It can be considered a guide to and clarification of the ASME code—encompassing fabrication, in- spection, testing, and documentation. Because the book offers wide coverage of fabrication (from organization setup to final testing and documentation), it also promotes uniformity in manufacturing, inspection, testing, and documentation. Chapters 1 through 10, which are based on my experience in QAC and heavy fabrication, are dedicated to practical as- pects of fabrication, beginning with organizational require- ments and leading up to the final documentation of the vessel. Chapters 11 to 16 describe procedures that are essential for conducting various inspections and tests. Chapter 17 ad- dresses welding procedure specifications, the procedure quali- fication record, and welder qualification tests. Chapters 18 and 19 detail a typical quality plan and an inspection and test plan, which is also included in QAC documentation. Chapter 20 provides recommended tolerances for vessels; such toler- ances, which vary only slightly between most consultants, are usually not given in the code. Chapter 21 consists of excerpts from ASME Section VIII Div(1) (1998 edition), which is fre- quently referred to during manufacture. Because the code is continually updated to incorporate the latest available data, users of this book are encouraged to refer to these sections from the latest editions of the code as they become available. The book is written based on the requirements of ASME Section VIII Div(1). Other sections of the ASME code, such as V and IX, are also referred to for the full coverage. Even though the book is based only on ASME codes, it could be ex- tended to other codes for pressure vessels, because the rela- tionship between fabrication and nondestructive testing (NDT) is the same regardless of the code used. I would like to acknowledge the assistance and coopera-Preface . v tion I have received from the learned surveyors of Lloyd’s Reg- ister, ABS Industrial Verification, Det Norske Veritas, and Hartford Steam Boiler. The continued interaction I have had with these third-party inspection agencies has been a tremen- dous help in giving this book its present shape. Similarly, the technical and moral support extended to me by my colleagues at FACT Engineering and Design Organisation (FEDO) has played a vital role in my completion of this work. Sunil PullarcotContents Preface Part I ea Pp ey Fabrication Introduction Organization Manufacture of Components Manufacture of Vessel Nondestructive Testing Pad Air and Preliminary Hydrostatic Testing ii 29 67 141 147 viiviii 10. Part II 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Index Postweld Heat Treatment Hydrostatic Testing Post-Hydrostatic Test Cleaning Documentation Procedures Radiographic Testing Procedure for Pressure Vessels Ultrasonic Testing for Pressure Vessels Magnetic Particle Testing for Pressure Vessels Liquid Penetrant Testing for Pressure Vessels Furnace Postweld Heat Treatment for Pressure Vessels Hydrostatic Testing of Pressure Vessels Quality Assurance and Control in Welding Quality Plan Inspection and Test Plan Standard Tolerances for Pressure Vessels ASME Exhibits Contents 153 159 169 173 187 209 237 249 257 265 271 291 297 301 305 343Practical Guide to Pressure Vessel Manufacturing{ Introduction 1 GENERAL Pressure vessels are manufactured all over the world under various international standards. These standards do specify the requirements to be met during the manufacture of pres- sure vessels; however, the means used to meet these require- ments are not specified in any of these standards. In the fol- lowing chapters, a detailed methodology to check each essential parameter specified in the relevant standards is es- tablished. Even though the attempt is made based on ASME Section VIII Div (1), the same methodology could also be ex- tended to pressure vessels manufactured under different stan- dards. The only difference would be in the acceptability norms that obviously could be gathered from the applicable standard. 12 Chapter 1 2 PRESSURE VESSEL A vessel used for the containment of pressure (either internal or external) is a pressure vessel. Pressure vessels can be of any shape. However, the most complicated one, as envisaged in ASME Section VIII Div (1), is shown in Figure 1.1. 3° STANDARDS The most commonly used standard in the manufacture of pres- sure vessels in India is ASME Section VIII Div (1) even though there is another Indian standard for unfired pressure vessels. The standards that are commonly used in India for the manu- facture of pressure vessels are the following. 1, ASME Section VIII Div (1): Rules for Construction of Unfired Pressure Vessels 2. ASME Section VIII Div (2): Alternative Rules for Construction of Unfired Pressure Vessels 3. ASME Section VIII Div (3): Alternative Rules for Construction of High Pressure Vessels 4. IS 2825: Indian Standard code for Unfired Pressure Vessels 5. BS 5500: Specification for Unfired Fusion Welded Pressure Vessels 6. Chapter J of Rules and Regulations for the Construc- tion and Classification of Steel Ships by Lloyds Regis- ter of Shipping 7. AD Merkblater Technical Rules for Pressure Vessels 4 METHODOLOGY The basic information for designing pressure vessels, being a part of the process plant, should be formulated by the process engineering group and contain such criteria as shown in Figure 1.2. This is known as the design data sheet (DDS).Introduction |_ Nozzle NI €N 21ZZ0N HN 21ZZON fe—{_eN21220N 5 10 avaH m0 ‘TTaHS NOD £0 20 'TT4HS avaH ‘0 "T1aHS 10 11a HS Tans |__| SN 1ZZON TW 10quR OO Figure 1.1 Typical pressure vessel.4 Chapter 1 1 Customer/Client 2 Customer Order No. 3 Shop Order No. 4 Design Drawing 5 Specifications 6 Vessel Name 7 Equipment No. '$ Design Code & Addenda ‘9 Design Pressure Internal External 10 Design Temperature 11 Operating Pressure Internal External 12 Operating Temperature 13 Vessel Diameter 14 Volume 15 Contents & Specific Gravity 16 Service 17 Design Liquid Level 18 Maximum Allowable Working Pressure 19 Test Pressure Shop Field 20 Heat Treatment 21 Joint Efficiency 22 Corrosion Allowance Shell Heads ‘Nozzles Boot 23 Materials — Shell Heads ‘Nozzles Flanges Bolting Supports 24 Flange Ratings 25 Weights Fabricated Operating Empty Test 26 Notes /Remarks Figure 1.2 Design data sheet. Additional conditions that are to be considered during design, manufacture, and testing, along with technical/commercial conditions of delivery, will be furnished in a document called the technical procurement specifications (TPS), which is part of the purchase order (PO). Based on the design data sheet and other technical condi-Introduction 5 tions, the design department of the fabricator performs the design calculations as per the applicable code, and a detailed fabrication drawing is prepared. This in turn is sent to the client, consultant, third party inspection agency, statutory au- thority, etc., for their scrutiny and approval. After the approval of the design and drawings by various agencies (primarily the client or consultant), the planning de- partment of the fabricator generates material requisitions to the procurement department. The material requisition is just a translation of all the relevant data given in the drawing as well as in the TPS in a form that can be understood by the vendor for that particular item. The purchase department floats enquiry for materials to reputed vendors who are already registered with the fabrica- tor. The department is primarily responsible for obtaining ma- terials of required quality at the lowest price and within the stipulated time frame. The responsibility of the department ceases only when the material is received at stores and ac- cepted by the quality assurance and control (QAC) depart- ment. On receipt of the material, the planning department is- sues a work order to the production department with authori- zation to draw materials from stores along with certified-for- fabrication drawings and a detailed delivery schedule for the work. N4 Figure 1.3 Sketch of two views of pressure vessel.6 Chapter 1 The production department in turn works out its micro- level planning based on availability of manpower and ma- chines to meet the deadlines committed to the client. The microlevel planning of the QAC department is car- ried out in such a way that it shall not conflict with the overall production schedule nor the microplanning of production. With the concerted efforts of all the mentioned depart- ments, as well as the other service departments like stores, maintenance, personnel, finance, etc., the targets for cost, time, and quality can be met. If these targets are achieved, it paves way for prosperity of the organization.2 Organization 1 THE NEED AND ROLE OF ORGANIZATION In order to achieve the required level of quality in production, all the departments mentioned in Chapter 1 must function in a concerted and organized manner with the ultimate aim of better and consistent overall quality for the product. This in turn calls for a strong and well-defined organization well in- terlaced between departments so that all departments func- tion as a team with a single corporate objective, rather than focus on the best performance of any individual department. The product quality shall in no case be lower than that desired by the client in the specifications. At the same time it need8 Chapter 2 not be of extremely high quality, in which case the product cost would also be very high. The organization shall be capable of delivering the products of optimal quality at the lowest cost. Therefore, repairs and reworks shall be avoided to the extent. possible as they inevitably turn out to be very expensive in terms of both money and time. With this objective in mind, this chapter describes a successful organizational model based on the author’s experience in the field. 2 ORGANIZATION CHART A typical organization chart for a medium scale pressure ves- sel manufacturing setup is shown in Figure 2.1. The positions shown in the organization chart can be broadly classified into three levels. The level consisting of the General Manager (GM) and the Deputy General Managers (DGMs) is called the top management; they make the policy and strategic decisions. The middle management level con- sists of Managers and Assistant Managers, who make deci- sions on day-to-day affairs. They are also expected to brief the top management with an abridged version of all decisions and the results of same for information management to be utilized for future policy decisions. Interdepartmental coordination is another major area of concern for middle managers, and they must communicate the goals set by top management to facilli- tate implementation by the junior managers of the company. The junior managers include engineers and supervisors. The engineers mostly carry out the theoretical and analytical part of the work, whereas the supervisors are expected to provide the labor management. Out of the positions described, engineers shall man all engineering and procurement disciplines, whereas the officers and staff in the finance, personnel, and stores departments may be from the nontechnical side. Depending on the turnover of the company and amount of work, additional posts can be generated as needed. In theOrganization Wo exams Susoui: (couusiueyy)n0u/90g epee fre orp 2400 (ourainoorg).28euew ssy (wonnparg s=Beuey flung), qomoy souenssy Ken \a8u6)5 cue) paau wo Buypuadap au uo panusine “qaeyp uoTezTuRsIQ TZ aans1y Gouna) (uawo (oan v i 1” a fos soupy (e812) aay10 Chapter 2 interest of the organization, it is better to have all key person- nel from every department on a permanent basis, and the ju- nior staff required can be hired on a contract basis depending on need. 3 DEPARTMENT FUNCTIONS AND RESPONSIBILITIES 3.1 Commercial Department The commercial department is responsible for bagging orders for the firm by constantly keeping in touch with probable and potential clients. Its scope of work is vast and a few of the salient responsibilities are as follows: 1. Keep the company in the approved vendor list of all prospective clients as well as renowned consultants. 2. Obtain tender documents and make a competitive of- fer, attending to technical discussions and clarifica- tions along with concerned engineers from the re- quired departments; follow up on offers; and bag orders. (In order to prepare estimates, preliminary designing may be done by the design department and may be discussed with other departments to confirm on all practicalities of the job in formal pretender meetings.) 3. Enter into formal contracts with clients and consul- tants as needed to obtain orders. 4, Transfer purchase order (PO) and other documents pertaining to the contract to the concerned depart- ments and explain to them the basis of estimation in a postorder meeting. 5. Keep track of changes in the environment and direct company in equipping itself for meeting new chal- lenges as well as to keep the company always in the forefront.Organization "1 6. Promote the company in all appropriate potential av- enues. 7. Prepare and monitor the schedules for improvements and developmental activities as well as diversifica- tion plans. 3.2 Design and Drawing Department The first step in the manufacture of pressure vessel is the de- sign of the vessel based on the design data sheet as well as the other technical conditions stipulated in the technical pro- curement specifications (TPS). For this reason, the depart- ment must go through all the technical conditions while car- trying out the design. As all the subsequent activities are based on this fabrication drawing, all practical aspects of production must be considered. Some of the major responsibilities of the department are 1. Carry out the design as per applicable codes and cli- ent specifications; prepare fabrication drawings; sub- mit design calculations and fabrication drawings for the approval of the client, third party, consultant, and statutory authority to obtain their approvals as needed. 2. Issue the prepared drawings to all the concerned de- partments to obtain feedback as to the method of fab- rication and sequence of fabrication and incorporate such changes in the drawing as desired by the depart- ments and obtain approvals for the changes effected. 3. Issue the certified-for-fabrication drawings to various departments to start the work. 4. Maintain reference standards like codes, etc., for the design and fabrication and keep abreast with the lat- est design and drawing trends. 5. Obtain as-built dimensions from concerned depart- ments and prepare as-built drawings. 6. Issue solutions to fabrication problems and for mate-12 Chapter 2 rial problems and suggest alternative materials and methods when needed. 3.3 Planning Department This department is the backbone of the production even though they are not directly involved in the production func- tion. A few major responsibilities of the department are as fol- lows: 1. Keep track of all materials in hand and plan the most effective and economical use of same. 2. Generate material requisitions to procurement de- partment for raw materials other than that available in the stores, highlighting the required delivery date. The format suggested for this purpose is shown in Figure 2.2. 3. Issue technical recommendations on offers obtained by the procurement department and keep track of same up to their delivery to stores. 4, Issue work order and material authorization for shops to draw materials and to start with the actual execution of the job. The suggested formats are shown in Figures 2.3 and 2.4. 5. Schedule the shop loading based on machine and manpower availability considering all other aspects of economy. 6. Identify and monitor critical path activities and keep management posted on schedules, targets, and tasks. 7. Schedule necessary discussions with clients includ- ing progress reporting. 8. Coordinate with other departments in overcoming problems. 9. Conduct periodic review meetings with concerned de- partments and chart out appropriate action plans as needed.Organization 13 EMBLEM MATERIAL REQUISITION Onder No. MRNo. Purchaser: Date Description Delivery date ‘The following items may be procurred for the above referred project as per the delivery schedule. Applicable SLNo. Description Specification | Quantity | Unit | Due Date (Note: - As far as possible, one request may be used for one type of material only) Manager Planning Routing: - Asst. Manager Procurement Co: Manager (Production) ‘Manager (QAC) O/C 1: Master File OIC 2: Job File Figure 2.2 Format for material requisition.14 Chapter 2 EMBLEM WORK ORDER Order No. Purchaser Description Drawing Numbers ‘The production is hereby requested to manufacture —number(s) of pressure vessels/ columns/ as per the above drawings with the salient features as below. 1__| Wessel Identification Number(s) 2 [Design & Manufacturing Code 3__| Approximate Diameter & Length 4 3 Design Pressure & Temperature Test Pressure [6] Heat Treatment T__| Joint Efficiency 8 [ NDT requirements ‘| Material of Construction 10 | Inspection Agency _ 11 | Cleaning & Painting — 12__[ As Built Documents Manager Planning Routing: - Manager Production ‘Ce: Manager (QAC) Officer (Stores) O/C 1: Master File OC 2: Job File Figure 2.3 Format for work order.Organization 15 EMBLEM MATERIAL AUTHORIZATION Order No. ‘Authorization No. Purchaser, Date Description ‘Work Order Ref. ‘The production is hereby authorized to draw the following materials received at stores as per the references indicated against each for the above referred work order. The scrap material against this project should be returned to stores on completion of the work with material reconciliation statement. POERR SLNo. Description Quantity Unit Details Manager Planning Routing: - ‘Manager Production Co: Manager (QAC) Officer (Stores) O/C 1: Master File OIC 2: Job File Figure 2.4 Format for material authorization:16 Chapter 2 3.4 Procurement Department The basic function of this department is to procure materials as specified in the requisition of the planning department, within the allocated budget and time. A few major functions of the department are 1. Maintain an up-to-date approved vendor list on all raw materials, consumables, and spares for the heavy machinery in the shops. 2. Obtain enquiries within the time frame specified by the planning department as per the technical pro- curement specifications and at the lowest cost. 3. Place orders with reliable parties and expedite them to ensure timely receipt at stores. 4, Collect the documents pertaining to supply and for- ward them to the concerned departments for further action. 5. Constantly upgrade and revise vendors list based on previous interactions with these parties as well as on reliable information from various sources. 3.5 Stores All raw materials received and accepted will be under the cus- tody of stores. They are expected to issue the same to produc- tion based on authorization from the planning department. Listed here are a few of their salient functions: 1. Receive and store materials at the incoming stores area earmarked for the purpose. 2. Offer materials to the quality assurance and control department (QAC) for the inspection of same through intimation of material receipt (a sample format is given in Figure 2.5). 3. Take all accepted materials to the stock and store them properly. The intimation of the materials shallOrganization 7 EMBLEM INTIMATION OF MATERIAL RECIEPT Purchase Date Order No. Vendor Date of Receipt DETAILS OF ITEMS RECEIVED SIN. Tag No. Description Location: Store Keeper in Charge: Status of MTC: Received/ not received Officer (Stores): Routing:- Manager (QC&A) Ce: Manager (Purchase) O/C 1 Master File Manager (Planning) O/C2 PO File Manager (Production) Figure 2.5 Intimation of material receipt.18 Chapter 2 be given to the planning department for further ac- tion. 4. Issue materials to users based on authorization from the planning department (for raw materials only). 3.6 Quality Assurance and Control Department Even though the quality assurance and control department is a service department to production, it has a higher responsi- bility to the client by virtue of its function. Therefore the de- partment enjoys more autonomy than others and shall be manned by well-qualified personnel with a high degree of in- tegrity. Listed here are some of their important responsibili- ties: 1. Carry out the inspection of all incoming raw materi- als at stores based on PO terms and applicable codes as specified in the PO and maintain records to that effect. 2. Prepare and obtain approval for all quality assurance/quality control procedures, including the quality assurance plan (QAP), inspection and test plan (ITP), welding procedure specifications (WPS), procedure qualification records (PQRs), and the welder’s qualification test (WQT), as well as nonde- structive testing (NDT), postweld heat treatment (PWHT), and final hydrostatic testing (HT) proce- dures. All are based on requirements of applicable codes and contracted specifications. 3. Carry out stagewise inspection during manufacture and maintain records. 4. Carry out NDT and DT as required at various stages, reporting on unacceptable defects; review rectification of defects previously detected through rigorous follow-ups with production; and maintain records to this effect.Organization 19 5. 10. 11. Prepare NDT summary, weld summary, etc., along with weld maps and consolidation of same to check the completeness of NDT. Witness various tests carried out during the process of manufacture and prepare documents. Coordinate with third party/client/consultant for witnessing the hold points/stages as laid out in the QAP and prepare documentation of same. Issue manufacturer’s certificates for the vessels in the required format. Prepare manufacturer’s data report (MDR) and sub- mit it to client after approval by third party/ consultant/client as required. Supply information to the design department for the preparation of as-built drawings. Perform quality auditing and reporting to top man- agement on overall quality level of various depart- ments directly involved in the making of the vessel, namely, design and drawing, planning, procure- ment, stores, production, and QAC departments. 3.7 Production Department The physical transformation of raw materials to a pressure vessel is the function of the department, even though a lot of effort by other departments also goes into it prior to the start of manufacture. Listed here are some of the main functions of the production section: Production of shells, dished ends, cones, subassem- blies as per engineering drawings, code practices, and the schedule of the planning department. Feed back to planning on daily production status, problems, remedial measures, catch-up plans, etc. Offer materials or products to QAC at various stages of fabrication for inspection.20 9. 10. 11. Chapter 2 Return balance materials to stores with proper iden- tification and certification by the inspection depart- ment or agency concerned. Perform the physical conduct of tests other than NDT/DT as per approved procedures and the in- structions of QAC. Keep up valid calibration certificates for all the mea- suring instruments. Use proper procedures for the manufacture of com- ponents based on the process to be used. Perform PWHT as per the approved procedure and in consultation with QAC on placement of thermo- couples and on alterations to the cycle. Perform the physical conduct of the hydrostatic test and the post—hydro test cleaning of the vessel. Clean and paint the vessel as per the PO. Pack the equipment for shipment to site as per PO. 3.8 Maintenance Department Improving the availability of machines required for produc- tion is the main function of this department. A few other re- sponsibilities as noted are also usually entrusted to them: 1. Keep all the machines in good order using proper pre- ventive maintenance and scheduled shutdowns with- out affecting production. Prepare material requisition for spares and consum- ables for the smooth operation of all the equipment including welding machines, grinders, etc., apart from heavy equipment. Maintain all company vehicles for the transport of goods for production. 3.9 Personnel Department All personnel matters are to be tackled by this department, including the following:Organization 21 1. Recruitment, training, maintenance of personal rec- ords, renewal of contracts, sanction of increments, fixation of pay, etc. Welfare measures for employees. Office administration matters including housekeep- ing, postage, and other office facilities management. 3.10 Finance Department Anything related to finance should be in the scope of the fi- nance department’s work, including poe Resources planning and allocation of funds for differ- ent jobs based on profitability. Accounting and its regularization and ratification with all statutory agencies. Payroll for all employees. Payment to all outside agencies on accounts of pur- chase of materials and services. 4 MASTER DOCUMENT FLOW DIAGRAM The flow of documents between departments is shown in Fig- ure 2.6, which depicts only the salient documents. 5 INPUTS AND OUTPUTS OF DEPARTMENTS The important inputs and outputs of the departments de- scribed in Section 3 are summarized in Table 1. Inputs and outputs are categorized in two main groups—namely, one to outside agencies and one to other departments within the or- ganization.Organization 23 Table 1 Inputs and Outputs Inputs Outputs Outside the Inside the Outside the Inside the organization organization organization organization Commercial Department Enquiry Preliminary de- sign Order Details for esti- mation Comments on sched- Suggestion for ules and reports development activities Budgetary prices for cost esti- mation Fabrication details for cost esti- mation Minutes of review meetings Design and Drawing Department Approval for design NIT for prelimi- and drawing nary design PO and technical specifications Problems during fabrication Dimensions for as- built drawings Minutes of review meetings Planning Department Comments on sched- NIT and other doc- ules and reports uments Call for review PO and technical meetings specifications Material receipts Design and draw- and documents ings for fabrica- tion Registration with clients Offer Clarification and negotiation Promotion Design and draw- ings for ap- proval Final as-built drawings Schedules and progress reports Minutes of review meetings Dispatch docu- ments for com- pleted vessel Intimation of or- der receipt. PO and technical specifications Schedules for de- velopment work Preliminary de- sign for esti- mation Design and draw- ings for fabrica- tion Solutions to fabri- cation problems Fabrication details for cost esti- mation Schedules and progress reports Material requisi tion for raw ma- terials24 Chapter 2 Table 1 (Continued) Inputs Outputs: Outside the Inside the Outside the Inside the organization organization organization organization Planning Department Credentials of ven- dors for evalua- tion Materials status including new receipts Progress reports on materials and work Manpower and ma- chine availabi- lity Inspection report, of raw materials Dispatch docu- ments for com- pleted vessel Procurement Department Credentials of ven- Recommendation dors for evalua- of vendors for in- tion clusion Offers from vendors for raw materials Material requisi- tion for raw ma- terials ‘Technical recom- mendation on of- fers ‘Acceptance or re- jection of items Clarifications on enquiries Dispatch documents and certificates Receipt of materials at stores Request for pur- chase of spares Minutes of review meetings ‘Technical recom- mendation on of- fers Materials request authorization Invoices against the delivery Periodic review of progress and plans Dispatch docu- ments for com- pleted vessel Recommendation of vendors for in- clusion Credentials of ven- dors for evalua- tion Offers with com- parison state- ment Dispatch docu- ments and cer- Notice for vendor qualification Intimation of qua- lification Enquiry to vendor for raw mate- rials tificates Clarifications on PO and other con- enquiries ditions of de- livery Dispatch docu- ments and cer- tificate PO and other con- ditions of de- livery Acceptance or re- Jection of itemsOrganization 2 Inputs Outputs Outside the Inside the Outside the Inside the organization organization organization organization Stores Receipt of materials at stores Dispatch documents and certificates PO and other con- ditions of de- livery Dispatch docu- ments and cer- tificates Material inspec- tion reports Material request authorization Minutes of review meetings Return of rejected materials Quality Assurance and Control Department Approved QAP, ITP, WPS, PQR, and WQT records Approved NDT, PWHT, and HT procedures Certificate of inspee- tion from third party (TP) PO and technical specifications Design and draw- ings for fabrica- tion Schedules and progress reports Materials inspee- tion call from stores Stagewise inspec- tion call from shop NDT requisition from shops as re- quired PWHT charts and reports Dimensions for as- built drawings Minutes of review meetings QAP, ITP, WPS, PQR, and WQT records NDT, PWHT, and HT procedures Stagewise inspec- tion call to TP MDR with as-built drawing Inspection call to Qac Issue of materials as per authori- zation WPS/PQR results PQR/WAQT re- quirements Approved QAP, ITP, WPS, PQR, and WQT ree- ords Approved NDT, PWHT, and HT procedures Materials inspee- tion reports Stagewise inspec- tion reports NDT reports with interpretation Pad air test re- ports Endorsed PWHT charts and re- ports26 Chapter 2 Table 1 (Continued) Inputs Outputs Outside the Inside the Outside the Inside the organization organization organization organization Quality Assurance and Control Department Production Department PO and technical specifications Design and draw- ings for fabrica- tion Schedules and progress reports Material request authorization Advance notice on maintenance schedule Restrictions on machines Minutes of review meetings Maintenance Department Receipt of spares Schedule of ma- chine loading Actions for mainte- nance contract Hydraulic test re- ports signed by TP Dimensions for as- built drawings Cleaning and painting reports MDR with as-built drawing Quality audit re- port and ana- lysis Material request authorization Stagewise inspec- tion eall to QAC NDT requisition as required in code Request to witness pad air test Request for PWHT verifi- cation Request to witness hydrostatic test Dimensions for as- built drawings Dispatch docu- ments for com- pleted vessel Advance notice on maintenance scheduleOrganization 27 Inputs Outputs Outside the Inside the Outside the Inside the organization organization organization organization Maintenance Department Maintenance con- _Intimation of tracts for special breakdowns equipment Personnel Department Liaison with statu- Manpower re- tory authorities quirement Training need for skilled workers Employee records (personal and technical) Finance Department Audited financial results Cashflow require- ments Invoices and re- ceipts for pay- ment Restrictions on machines Request for pur- chase of spares Consumables for machines Renewal of con- tracts as re- quired Granting of inere- ments and pro- motions Liaison with statu- tory authorities Audited financial results Salary statement of employees Payment to pur- chase of materi- als and services3 Manufacture of Components 1 GENERAL Pressure vessels consist of various components (as shown in Figure 3.1); based on the shape, various methodologies are adopted for manufacture. These methods must be strictly in accordance with the provisions of the prevailing code. The methods described here are in line with the requirements of ASME Section VIII Div (1) and hence shall meet almost all the requirements of other codes for pressure vessel manufacture. 2 COMPONENTS The different components that are normally encountered in the manufacture of a pressure vessel are 29Chapter 3 30 Nozzle NI } £N 9[220N YN 21220N, Cc + ‘TN 1ZZ0N, so 10 GVaH au | TNO? co | wo TIaHS ‘0 ‘T1aHs 10 T1aHs ‘T1aHs | ——_| SN 2[220N, ¢- apoyueN Cc) Figure 3.1 Typical pressure vessel.Manufacture of Components 31 Heads or dished ends Shell (body of the vessel) Cones or reducers Attachments like nozzles, manholes, saddle supports, skirt supports, leg supports, trunnions, lifting lugs, platform and ladder supports, etc. Bor 3 PRIORITY IN MANUFACTURE ‘The manufacture of heads and cones is considered to be more difficult than that of shells due to the difficulty in controlling the dimensions of these two items. (Whereas the dimensions of shell sections, for example, can be controlled precisely.) For this reason, if the vessel has dished ends or cones, they should be made first (of course, within the code tolerances) and shells are made later to suit these heads and cones. 4 MANUFACTURING PROCESSES The basic manufacturing process adopted for the fabrication of the vessel is forming. Forming is the process by which the size or shape of the part is changed by application of force that produces stresses in the part which are greater than the yield strength and less than the fracture strength. Depending on the temperature during fabrication, it is categorized as hot, warm, or cold forming. It is called hot work- ing when the temperature is above the recrystallization tem- perature of the material, warm working if the temperature is sufficiently above room temperature but below recrystalliza- tion temperature, and cold working when the temperature is very much below recrystallization temperature, for example, at room temperature. The manufacturing processes that fall under the forming operation specifically used in pressure vessel manufacturing are pressing, spinning, and bending.32 Chapter 3 4.1 Pressing Pressing is the process usually adopted when the size of the part to be made is comparatively small. Domes and pipe caps are usually made using this process mostly at room tempera- ture. In this process, the plate is gradually pressed to the re- quired shape by local pressing, covering the entire area of the blank progressively. The thickness of the plate, the radius of curvature to be made, the material used, the machine capac- ity, and the availability of the right die for the shape are the limiting factors to decide on the process of manufacture. As formation is effected in stages, it is comparatively a slow pro- cess, and the shapes thus produced can have local deforma- tions and hence the process calls for thorough inspection. In the case of cold pressing, due to the effect of work hardening, the chances for surface cracks on the outer surface is very high and hence calls for liquid penetrant testing (LPT) during ex- amination of the surface of the component. It may even be nec- essary to carry out a heat treatment in between the cold form- ing in cases where the effects due to work hardening are severe. This is decided based on the calculated extreme fiber elongation expected in the component when it is cold formed. In hot pressing, utmost care shall be taken to see that the heating, the maintenance of heat during the process, and the subsequent cooling shall be strictly as per the procedure, as they have great bearing on the grain structure of the material. The temperature, heating/cooling rate, etc., are decided based on the material specification of the component as well as the amount of forming required, as specified in the applicable code. 4.2 Spinning This process is used for making a variety of dished ends, namely, torispherical, 2:1 ellipsoidal, toriconical, and hemi- spherical. The specific advantages with this process are that the dished ends are made without the use of dies and it is the fastest process for the manufacture of dished ends.Manutacture of Components 33 Initially a hole of about 20 mm diameter is made, prefera- bly by drilling, at the center of the blank, and the crown por- tion of the dish is formed using local pressing. Later it is loaded onto the spinning machine; then while spinning the partially formed blank, using adjustable guide rollers, the fi- nal shape is given. The movement of the guide roller shall be from the crown area progressing toward the straight flange through the knuckle area. As the blank is continuously spin- ning, the surface of the dished end shall be free from local de- formations. However, there could be spinning lines all along the formed surface, especially at the knuckle portion, being the area under maximum deformation. In this case also, based on the thickness of the blank, ma- chine capacity etc., the process is carried out either cold or hot. In case of hot spinning, precautions are to be taken as for hot pressing mentioned in Section 4.1. 4.3 Bending This process is conventionally called rolling even though it is not rolling. Rolling is a process where a thickness reduction to a plate takes place, whereas in bending only a curvature is given to the plate and no thickness reduction is expected. The usual practice of bending is by passing the plate through either a three- or a five-roll plate bending machine of adequate capacity to bend the plate to the required diameter. The most commonly used bending machine in fabrication in- dustry is the three-roll plate bending machine. A schematic diagram of a three-roll plate bending machine is shown in Fig- ure 3.2. Prior to passing the complete length of the plate through the rollers, both edges of the plate are pressed to the required radius. This is called prepinging and is achieved by pressing the two power/drive rollers against the top idle roller and thereby bending the plate edge. Once both the edges are pressed to the correct radius, the complete length of the plate is passed through the rollers to impart curvature in steps. If the diameter is large and the34 Chapter 3 PARTIALLY BENT SHELL PLATE POWER or PINGE ROLLER, Figure 3.2 Schematic diagram of plate bending. thickness is comparatively less (say up to 10 mm), then the curvature can be given in one pass. Whereas if the thickness is high and the diameter is small, the full bending is to be carried out in stages. The profile of the plate is checked after bending using a template of required dimensions as highlighted in subsequent chapters of this book. 5 MANUFACTURE 5.1 General The manufacture referred to here pertains to individual com- ponents that form a pressure vessel. Even though this is dealt with in detail in this chapter, a few aspects are repeated again in Chapter 4 for the sake of completeness and in order to better appreciate the importance of the sequence of manufacture.Manufacture of Components 35 5.2 Material Identification For the manufacture of any component, the first step is to identify the material to be used for the job. For this the mate- rial test certificate of the intended material is essential. As all the raw materials have undergone incoming inspection at stores, it is presumed that detailed scrutiny was done at that point in time. However, verification as to the material specifi- cation and heat numbers stamped on the plate has to be car- ried out with respect to that given in the certificate and the specification in the drawing. If a few pressure parts are to be marked on the plate, say, dished end, cone, etc., then the iden- tification on the plate has to be transferred to all the small components as shown in the diagram. Sufficiently large scrap plates shall also be identified in the same way, along with the personal stamp of the inspector responsible for the work. A certificate to this effect also shall be made, preferably with sketches for future reference. The form to be used for this is shown in Figure 3.3; Figure 3.4 indicates the actual work. The mentioned identification shall be carried out for each and every pressure part of the vessel and, as far as possible, the material identification stamping shall be on the outside of the vessel so that they can be verified at any point of time in case of uninsulated vessels. The stamping on the vessel shall be carried out using low stress stamps. Hard punching shall be avoided. When stamping is done on components like dished ends, care shall be taken to see that the stamping is made on the crown portion where the deformation is minimal. Likewise, in the case of subassemblies that are subjected to cold work after identification, the stamping shall be on an area which is sub- ject to minimal cold work. 5.3 Heads 5.3.1 Flat Ends Flat ends are usually made by forging. In that case it is a bought out item and is to be subjected to raw material inspec- tion at the receiving end.36 Chapter 3 EMBLEM CERTIFICATE OF MATERIAL IDENTIFICATION AND TRANSFER OF IDENTIFICATION ‘Order No. Sheet of. Purchaser ‘Attachment to Certificate No Description Date Drawing No Part No(s). Marked ‘Original Identification Found Identification Transferred with Drawing No & Part No SKETCH OF PLATE Number of scrap pieces identified (with approx. size & shape) Material Marked by Material Identified by Figure 3.3 Certificate of material identification and transfer of identification.37 Manufacture of Components ‘uoBoyryuEpr jo Jejsuesy pue Suryseul ayelq p'g ONT ‘96m aumyny s0y uopod aourieg, pua POUSIP 404 UBL xpooon NH SEY LN 0LuD SIs VS ° vooroN HU soon on 810) axpo000 NH SEP LN OLYD Sts VS yo woudop.og AN OLUD SIS VS xxpo00x NH SEY38 Chapter 3 Semi-Ellipsoidal Dished Ends. This is the most com- monly used type of dished end in the pressure vessel industry. The inside depth of the dished end excluding the height of the straight face is one-half the inside radius of the dish and hence is called 2:1 ellipsoidal. Dished ends are manufactured by cold or hot pressing and in a combination process of pressing and spinning. Dished ends of comparatively smaller size and lower thickness, diam- eter up to around 700 mm with thickness over 10 mm, are made by either cold pressing or hot pressing, whereas all larger size dished ends are made by the combination process of both pressing and subsequent spinning. Hemispherical Dished Ends. Dished ends of this cate- gory are also produced in the same way as that of 2:1 ellipsoi- dal heads. It has already been mentioned that for spinning the dished end, a hole of approximately 20 to 30 mm in diameter has to be provided at the center of the blank for holding during spinning. In case any nozzles are to be attached at the center of the dished end, the opening is enlarged to fit the nozzle. If not, the hole has to be plugged, either by welding alone or by welding in a plug whose thickness will match the thickness of the dish at that place. In both cases, the hole is enlarged slightly to a maximum diameter of 60 mm as specified in UW 34 (see Chapter 21, Section 1 of this volume) and then plugged using matching material with the V groove as shown in Figure 3.5. A single V toward the inside of the dish is preferred when the thickness is below 16 mm. For larger thickness, an un- equal V of *s ¢ and 's ¢ with the major V from inside is best suited from the distortion point of view. Torispherical Dished Ends. This shape is also similar to that of 2:1 ellipsoidal. However, there is a difference in consid- eration at the design stage based on the L/r ratio which is not in the purview of this write up. As far as the manufacture is concerned, the methodology is one and the same as that of ei- ther hemispherical or 2:1 ellipsoidal heads.Manufacture of Components 39 Toi eit LSS “ aarp Ae san wees ‘a (-3)2/3mm_ bn < Se, Joint Design for Plate Abovel6mam, Figure 3.5 Spin hole plugging details.40 Chapter 3 5.4 Shells 5.4.1 Shells Made from Single Plate If the length of the plate is sufficient to accommodate the full circumference of the shell, this is the preferred condition be- cause the shell will have only one longitudinal seam. The plate is first cut to the required length and breadth and later on all four sides; a bevel is prepared as in the drawing. The square cutting and the bevel preparation is carried out by oxyacety- lene flame for carbon steel plates and by plasma-are process for stainless and high alloy steels. The cut edges are then ground back to sound metal at least by 1 to 1.5 mm so that all the adversely affected material in the cut zone is removed. This will help in preventing the oxidized metal from going into the weld pool, thereby making the weld incompatible to the base metal. The dressed edges are then examined for defects like laminations and irregularity on the bevel due to incorrect cutting parameters. If laminations are found, they must be investigated in detail per applicable specifications. In the case of irregular cut edges, the irregularities shall be removed by buttering and subsequent dressing. However, the buttering shall be done only on a clean surface that is free from the re- mains of the oxyacetylene/plasma arc cutting. The plate is then prepinged at both ends first and then completely bent to the required diameter in a plate bending machine. Depending on the amount of curvature needed, the plate is passed through the roller a number of times, to achieve the curvature in stages so that any elongation to the plate will be negligible. The various parameters of the shell section, like the diameter, profile, out of roundness, etc., are checked and if found satis- factory, the shell is taken for longitudinal seam fit up. 5.4.2 Shells Made from Multiple Plates If the length of plate is not sufficient for making the shell, two or more plates are joined together to obtain the required shell length. This joining is done in plate-to-plate fashion. As thereManufacture of Components 4 is a possibility for the squareness to be lost while joining, the plate shall be checked for squareness after the full shell length is marked on the joined plate, and if needed, correction by trimming is performed. The plate shall be bent only after completing the weld from both sides. The reinforcement shall be ground off to the parent metal level to facilitate the smooth bending of the plate in the machine. In case the seams are to be radiographed, it is to be done after bending. 5.5 Cones or Reducers Cones are produced by two methods. When the bevel angle is comparatively small and the diameter is comparatively large, it can be made in a plate bending machine by independently adjusting the pressure rollers at both ends of the bending ma- chine. This work needs expert operators compared to shell bending. In some cases, the cone has to be made in one piece. This depends mainly on the available plate size, machine ca- pacity, etc. When the thickness of the cone is larger and the diameter is smaller, cones are made by pressing. The pressing is carried out using matching male and female dies either in full length or in pieces depending on the machine capacity. In both meth- ods, the manufacture of eccentric cones is much more difficult than concentric cones and hence they are made in two halves, provided the machine capacity permits. 6 MEASUREMENT OF DIMENSIONS 6.1 Flat Ends 6.1.1 Dimensions to Be Checked. The main dimensions that are to be checked are the diameter and thickness of the flat head. Being a flat surface, obviously the flatness also has to be checked. Apart from these, there is nothing else to be checked for a flat head.42 Chapter 3 6.1.2 Methodology Depending on the size of the head, the diameter of the head can be measured by a standard steel measuring tape and is to be taken at least at 0, 45, 90, and 135° (in four directions). The straightness can be checked using a straight edge and feeler gauge combination for diameters below 1000 mm. Be- yond this dimension, the use of a straight edge is not recom- mended due to unavailability of large straight edges. In that case the use of a stretched piano wire and taper gauge combi- nation as described herein is preferred. The piano wire has to be stretched over the surface of the flat head over standard blocks of known dimensions. Check the taper gauge reading between the stretched piano wire and the flat head at fixed intervals. The deviation in reading from the standard block thickness is the out-of-straightness. In addition to this, the thickness at various locations has to be checked by using a micrometer at accessible locations as well as by using a cali- brated ultrasonic thickness gauge. The dimensions mentioned shall be recorded in the dimension report that accompanies the head. Figure 3.6 depicts the methodology. 6.2 Dished Ends 6.2.1 Dimensions to Be Checked The following dimensions shall be recorded, as shown in Fig- ure 3.7. 1. Actual inside diameter at a minimum of four loca- tions. 2. Outside circumference at straight flange (SF) and thickness at SF from at least 12 locations. 3. Depth of dish (inside) excluding SF and SF. 4. Thickness reading at 100-mm spacing along four lines radiating from the center of the head to SF at 0, 90, 180, and 270° marked on the outside surface at SF using an ultrasonic thickness gauge (UTG).Manufacture of Components 43 10mm Standard Block ‘Stretched Piano Wire Figure 3.6 Dimensional check of flat heads. Whenever a UTG is used for measuring the thick- ness, the readings shall be furnished in the format depicted in Figure 3.8. 6.2.2 Methodology Upon manufacture of a dished end as required in the specifi- cation, the inside diameter (ID) at four directions shall be re- corded using a measuring tape. Similarly, the outside circum- ference at the straight face also shall be recorded. The thickness at SF at various locations can be taken accurately using a micrometer. This can also be taken using the UTG44 Chapter 3 Grid Lines for Thickness Measurement Figure 3.7 Dimensional check of dished ends.Manufacture of Components EMBLEM ULTRASONIC THICKNESS GAUGING REPORT Order No. ‘Sheet of. Purchaser ‘Attachment to Certificate No Description Date Drawing No(s) Test Equipment Calibration Blocks “Test Method Couplant Probe Material under Test ‘Measuring accuracy Surface Condition. SLNo. | Identification Thickness (mm) Remarks TI 72. T3, T(av) Figure 3.8 Ultrasonic thickness gauging report.46 Chapter 3 Figure 3.9 Overcrowning of dished ends. (Note: The overcrowning should be checked in at least four directions and the maximum value recorded.) but wherever possible, it is recommended to use a micrometer, which is very simple in operation. The overcrowning as well as the out-of-profile is checked by the use of a template (made per the design) and a taper gauge. Figure 3.9 may be referred to for details. 6.3 Shells 6.3.1 Dimensions to Be Recorded The following dimensions shall be recorded without fail: 1. Outside circumference at both ends as well as at the center of the shell 2. Inside or outside diameter (OD) at four angles on ei- ther side of the shell 3. Straightness of the shell through center lines at 0, 90, 180, and 270°C 4. Length of shell at four center lines 6.3.2 Methodology Bend the shell and tack weld the longitudinal seam as re- quired. In cases of thin shells with large diameter, provide spi-Manufacture of Components 47 ders (at least four numbers) to maintain the circularity. Mea- sure the circumference at both the edges and at the center of the shell by tightly stretching a steel measuring tape. The ID at four angles should be taken using steel tape after providing the stiffeners at both ends as shown in Figure 3.10. Cireumference to be checked along these Straightness to be checked along these lines Figure 3.10 Dimensional check of shells.48 Chapter 3 Straightness of the shell is to be measured and recorded using a stretched piano wire over standard machined blocks of 10- or 20-mm thickness using a taper gauge. The length of the shell at four locations over the circum- ference is to be measured and recorded using steel measuring tape. The profile of the shell should be examined over the entire area, either inside or outside, using the template as specified in UG 29.2. The deviation from the designed profile shall be measured by inserting a taper gauge between the template and the shell. The templates can be either inside or outside, as shown in Figure 3.11A and B. 6.4 Cones or Reducers 6.4.1 Concentric Dimensions. The following dimensions shall be measured: Outside circumference at both the ends Inside or outside diameter at both ends Slant height of the cone at four diametrically opposite points 4. Straightness of the cone in cases of larger slant height or when circumferencial seams are unavoidable 5. Thickness at random points 6. Profile at both ends 7. Concentricity eye Methodology. Bend the cone and tack weld the longitu- dinal seams and put it on rotators so that it can be turned freely. Measure the outside circumference at both ends at the locations shown in Figure 3.12 in the farthest point possible by stretching the steel tape very tightly to the shell and main- taining the position of the tape exactly in one plane. Due to the configurational deviation at the edges due to edge preparation, there could be a little mismatch in the measured circumfer-Manufacture of Components 49 (A) ‘Chord (8) Figure 3.11 Templates: (A) inside; (B) outside. ence based on (ID + 2t) x. However, this will be negligible com- pared to the fabrication tolerance provided in the code. Also measure the ID or OD at both ends at four angles, as done in the case of shells. The thickness of the cone can be taken at the edges using a micrometer. If there is no noticeable thickness reduction, then it need not be recorded. Otherwise it is to be plotted along four lines connecting the four center lines at both ends. 6.4.2 Eccentric Dimensions. The following dimensions shall be measured: 1. Outside circumference at both the ends 2. Inside or outside diameter at both endsChapter 3 Measure outside circumference here Figure 3.12 Dimensional check of cones.Manufacture of Components 51 3. Slant height of the cone 4, Straightness of the cone in cases of larger slant height or when circumferencial seams are unavoid- able 5. Thickness at random points 6. Profile at both ends 7. Eccentricity Methodology. Same as for concentric cones and re- ducers. 7 INSPECTION 7.1 Dished Ends 1. Dimensions discussed in Sections 6.1.1 and 6.2.1 and subsequently recorded in the related certificate must be physically counterchecked in cases of bought-out items. 2. Profile of the dished end all around shall be checked using a template, and local deformations need to be quantified, including overcrowning. 3. If edge preparation is mentioned in the order, the LPT of the prepared edge shall be carried out. 4. Visual inspection of the surface (especially the out- side) and LPT of the crown, knuckle radius portion, and the SF is to be carried out without fail. Thickness as recorded may be counterchecked. When dished ends are seam welded prior to forming, reports to all the specified tests (destructive and non- destructive) are to be verified for compliance. The tol- erance for the formed end shall be per UG 81 of ASME Section VIII Div (1) (see Chapter 21, Section 2 of this volume). oo 7.2 Shells 1. All dimensions mentioned in Section 6.3.1 must be verified.52 Chapter 3 2. Edge preparation must be inspected for its compli- ance to that specified in the drawing, such as the V configuration, angle of bevel, root face, root gap, and the uniformity of these aspects throughout the length of the seam. Check the profile with a template whose cord sub- tends an angle of at least 20° at the center. When the vessel is expected to take external pressure, the max- imum plus or minus deviation from the true circular form measured radially on the outside or inside cir- cumference shall not exceed the maximum value of e obtained from UG 80.1 (see Chapter 21, Section 3). Use e = 1.0¢ ore = 0.2t, respectively, for points falling above and below the curves. The templates used for such measurement shall have dimensions as per UG 29.2 (see Chapter 21, Section 4). This has to be car- ried out throughout the circumference as well as the length of the shell. For example, consider the case of a pressure ves- sel of tan to tan length 8000 mm, 2000 mm outside diameter, and thickness 20 mm. OD/t = 2000/20 = 100, and L/OD = 8000/2000 = 4. This corresponds to an approximate value of e = 0.75t = 0.75 X 20 = 15 mm. Similarly, for the size of the template, for OD/ t = 100 and L/OD = 4, the arc length of the tem- plate = 0.300 OD = 0.300 x 2000 = 600 mm. Check the difference between the maximum and min- imum ID and ensure this is less than 1% of the ID. When the cross-section passes through an opening or within one ID of the opening, the limit may be in- creased by 2% of ID of the opening, i.e., tolerance = 1% of ID of the vessel + 2% of the ID of the opening. For vessels with longitudinal lap joints, the permissi- ble tolerance may be increased by the nominal thick- ness of the plate. Check the outside circumference and ensure that the same is within +0.25% of the calculated outside cir-Manufacture of Components 53 cumference based on the actual thickness of the plate used. (This tolerance is taken from BS 5500, as there is no mention about it in ASME.) However, this limit is applicable only for the first component of the vessel, as the individual shells are expected to match each other. This restriction on tolerance due to other speci- fications is explained with the help of an example. The tolerance for alignment of shells is given in UW 33 of ASME Section VIII Div (1) (see Chapter 21, Section 5). According to this, for a shell thickness of 10 mm (for category A, B, C, and D welds), the permit- ted mismatch between the shells is 4 ¢ = 2.5 mm. Assume the worst case, where there is 2.5 mm mis- match all around the circumference. In that case, the second shell can be larger or smaller in circumference by 5x = 15.70 mm. In other words, to meet the align- ment tolerance of the code, the maximum variation in circumference between shells is only +15.70 mm. Because of this restriction, the maximum circumfer- ential tolerance of +0.25% can only be availed by the manufacturer who makes the first component; usu- ally it will be for the dish. For the very same reason, it is recommended to begin work on shells only after the receipt of the dished ends. 7.3. Cones or Reducers 1 2. All dimensions as delineated in Section 6.4 shall be verified. Apart from these, the concentricity/eccentricity of the cone must be checked as follows: Step 1. Make a level base plate and draw the OD at the big end and the ID at the small end per the design on the base plate. Step 2. Put gusset plates all around the small end OD and place the cone inside exactly. Step 3. Drop plumb from the OD at the big end from54 Chapter 3 at least eight different points, namely, 0, 45, 90, 135, 180, 225, 270, and 315° after level- ing the big end using a spirit level. The plumb should coincide with the OD already marked on the base plate. If not, measure the maximum deviation from the designed shape and it should be well within that spec- ified in the code. Step 4. Check the entire outside surface of the cone for any local deformations or pressmarks. If seen, these shall be removed by grinding, and LPT may be carried out to rule out sur- face defects. Step 5. Check both top and bottom of the cone using templates of the required diameter for com- pliance. Deviation, if any, shall be recorded and must be within the tolerances specified as in the case of shells. 7.4. Acceptance Norms For all shapes, objectionable flat areas are to be avoided. For shells under internal pressure, the shell shall be substantially round. Further, the difference between maximum and mini- mum ID shall be as mentioned in Section 7.2. 8 DESTRUCTIVE AND NONDESTRUCTIVE TESTING REQUIREMENTS 8.1 General Destructive and nondestructive testing (DT and NDT) re- quirements are framed based on the code requirements and also on the basis of specific requirements for the project. Usu- ally this will be consolidated in the drawing by the design de- partment as well as by the planning department in their work order released to the production. For carrying out the DT/Manufacture of Components 55 NDT, the relevant sections of ASME Sections VIII and V are to be followed as needed and must be closely monitored by the QAC department. 8.2 Destructive Testing The usual destructive testing envisaged by the code is impact testing. As far as this book is concerned, we will focus on the methodology of these tests. A minimum of three tests shall be performed and the average value may be considered for accep- tance. These tests are to be carried out on specimens taken from weld, heat-affected zone (HAZ), and base metal. The tem- perature at which the test shall be carried out shall be given in the drawing and a suitable bath may used to generate the required temperature. Up to —50°C, dry ice is very effective. As there is no positive record of these tests, it shall be done in the presence of the concerned engineer or the third party inspector as needed. As far as possible, the test may be carried out using stan- dard specimens of 10 mm X 10 mm cross-section. Smaller specimens may be used only when the thickness of the welded part is below 10 mm. The acceptance of these test results shall be as described in UG 84. In the case of alloy steel materials, the applicable section is UHA 51. 8.3 Nondestructive Testing The most commonly deployed method of NDT in manufacture of pressure vessel is radiographic testing (RT); the rest of the methods put together form only a minor segment of total NDT. There are only three categories of NDT requirement, namely, full, spot, and nil. This decision basically depends on the ser- vice, thickness, and joint efficiency used in the design. There- fore, by the time the drawing is prepared and accepted, the category will be decided. For implementation procedures, refer to UW 11, UW 50, UW 51, and UW 52 (see Chapter 21, Sec- tions 6-9).56 Chapter 3 The gist of the stated clauses is as follows: 1. For full RT, all butt welds in shell and head have to be fully radiographed. 2. Circumferential seam welds on nozzles below 10 in. need not be radiographed if the thickness of the noz- zle is less than 1 in. 3. For spot RT, one spot on each vessel is tested for each 50-ft increment of the weld or fraction thereof. For nozzles the very same condition for full radiography shall apply. 4. The acceptance criteria for all radiographs shall be per UW 51 and UW 582 for linear defects and Appen- dix 4 for rounded indications [Appendix 4 of ASME Section VIII Div (1) (see Chapter 21, Section 10)]. From the applicable specification UW 11, ultrasonic examina- tion carried out in accordance with UW 53, (see Chapter 21, Section 11) may be substituted for radiography for the final closure seam of a pressure vessel if the construction of the ves- sel does not permit interpretable radiographs. The technique adopted shall be in accordance with Appendix 12 of ASME Sec- tion VIII Div (1) (see Chapter 21, Section 12). For acceptance criteria also, the same section shall be referred to. For other NDT methods like MPT and LPT, the applica- ble sections are UG 93 and UHT 57 respectively. For both these NDT methods, the basic requirements on methodology evaluation and acceptance shall be per Appendices 6 and 8 of ASME Section VIII Div (1), respectively (see Chapter 21, Sections 13 and 14). 8.4 Records For all DT, reports must be generated and countersigned by all the parties who witness the test. If required by the client, the DT will consist of all weld tensile, transverse tensile, and bend tests; charpy or izod impact hardness test; and macro-Manufacture of Components 57 EMBLEM MECHANICAL TEST REPORT Order No, Sheet of Purchaser Attachment to: Certificate No. Description | ‘Quantity, Drawing No(s) Date 1 _ Reduced Section Tensile Test ‘Specimen | Dimensions | Area | Gauge UTS YP __|Elongation| Remarks No. | (Lx B)mm | (mm) vena (kg/mm?) | (kg/mm?) | (%) mm) 2 All Weld Metal Tensile Test ‘Specimen | Dimension | Area | Gauge UTS ‘YP No. | (diameter) | (mm’) | Length | (kg/mm?) | (kg/mm?) mm (mm) [Elongation] Remarks (%) 3 Guided Face Bend Test ‘Specimen No. | Thickness of Sample (t) Former Radius Remarks mm 4 Guided Root Bend Test Specimen No. | Thickness of Sample (t) Former Radius ‘Remarks mm Figure 3.13 Mechanical test report.58 Chapter 3 5 Guided Side Bend Test ‘Specimen No. | Thickness of Sample (1) | Former Radius Remarks mm 6 Nick Break Test Specimen No. Type of Nick ‘Specimen Thickness Remarks (nm) 7 Impact Test Specimen | Type of Notch ] Size (mm) | Test Temperature | Impact value | Remarks No. eC) ky -m) 8 Hardness Test Specimen No. Hardness Value Hardness Value Hardness Value (Brinnel) (Rockwell) (Vickers) 9 Macro Test ‘Specimen No. ‘Type of Etchant ‘Observation: Figure 3.13 Continued examination. In almost all the cases the requirement will be only for impact testing at a low temperature. A typical format for this purpose is given in Figure 3.13. Similarly every RT taken under a particular technique is to be recorded in a report form (Figures 3.14 and 3.15) along with the findings. These will be reviewed by a qualified andManufacture of Components 59 EMBLEM RADIOGRAPHIC EXAMINATION REPORT Order No. Sheet of Purchaser ‘Attachment 10 Certificate No Description Date Drawing No(s) Type of Joint Surface condition Stage of Test Extent of Test Material Thickness X-Ray Gamma Ray Film KY, Isotope. 19h mA ‘Strength 1QI Placement Exposure Exposure Lead Screen: Front Time Time Back ‘SED SED Density Focal Source Sensitivity Spot Size SKETCH Figure 3.14 Radiographic examination report.60 Chapter 3 EMBLEM RADIOGRAPHIC EXAMINATION REPORT- ANNEXURE ‘Attachment to Certificate No. Sheet of ‘SLNo. Identification Date Film Size ‘Observation Remarks Figure 3.15 Annexure to radiographic examination report.Manufacture of Components 61 EMBLEM ULTRASONIC EXAMINATION REPORT Order No. Sheet of Purchaser Attachment to Certificate No Description Date Drawing No(s) Material Probe (1) Thickness Probe (2) Surface Condition Couplant Direction of Test Basic Calibration Block Extent of Test Reference Hole T [Dia Test method Reference Level 80% FSH | dB | +6dB Test Equipment Test range t SKETCH Figure 3.16 Ultrasonic examination report.62 Chapter 3 EMBLEM ULTRASONIC EXAMINATION REPORT- ANNEXURE [Attachment to Certificate No. ‘Sheet of. ‘Scanning | Indications | Direction | Reading | Stand | Beam | Type of | Remarks surface of | Interval | off | Path | defect SUNo|%Amp | Measure- | (mm) | (mm) | (mm) ment Figure 3.17 Annexure to ultrasonic examination report.Manufacture of Components EMBLEM MAGNETIC PARTICLE EXAMINATION REPORT ‘Order No. ‘Sheet of, Purchaser ‘Attachment to Certificate No ‘Description. Date ‘Drawing No(s) Equipment ‘Surface under ‘Magnetizing Process Examination ‘Magnetizing Current ‘Surface Preparation Technique ‘Magnetic Particle Direction of Field ‘De-magnetizatic Field Strength 'SLNo. | Location Length of Defect | Remarks SKETCH Figure 3.18 Magnetic particle examination report.64 Chapter 3 EMBLEM LIQUID PENETRANT EXAMINATION REPORT Order No. Sheet of Purchaser Attachment to Certificate No_ Description Date Drawing No(s) Code Description of Surface Temperature of Surface Surface Condition Pre-Cleaning Penetrant Penetrant Application Dwell Time Cleaner Removal of Penetrant Developer Developer Application Developing Time Results Post-cleaning ‘Remarks Figure 3.19 Liquid penetrant examination report.Manufacture of Components 65 trained person according to the acceptance criteria, which again will be recorded in the report and will form a part of the final QAC documentation pertaining to the vessel. As mentioned in the case of RT, every other nondestruc- tive test (namely, UT, MPT, and LPT) shall be recorded prop- erly for future reference. These reports shall contain all sa- lient aspects of the technique used in the NDT so that in future if this is repeated under the same parameters, the results can be compared, especially in the case of UT. The formats devel- oped for this purpose are found in Figures 3.16 and 3.17 for UT, Figure 3.18 for MPT, and Figure 3.19 for LPT.4 Manufacture of Vessel 1 GENERAL In this chapter, the topics are arranged according to the se- quence of manufacture of a pressure vessel under the follow- ing assumptions. 1. The dished ends and cones are bought from outside with the material supplied by the vendor under proper certification. 2. All plates and piping materials, including but not limited to pipes, elbows, flanges, studs/bolts and nuts, gaskets, etc., are bought-out items from reputed vendors with proper certification. 6768 Chapter 4 2 RAW MATERIALS INSPECTION 2.1 General All raw materials for the manufacture of a pressure vessel are ordered from reputed vendors, and the supply shall be accom- panied by proper certification. Upon receipt of the material at the stores, the quality assurance and control (QAC) depart- ment will be informed through their intimation note, as in Fig- ure 4.1. In the meantime, the procurement department will forward the relevant documents pertaining to the received item to QAC to facilitate the inspection with a copy of the inti- mation marked to the planning department for information processing. Until inspection is carried out, the raw materials are kept in the incoming material inspection bay of the stores for all materials other than plates and pipes, which are stored separately in the open yard attached to the stores. Those items having undergone inspection will have either a green, yellow, or red sticker or tag with the initials of the inspection engineer and the date of inspection as shown in Fig- ure 4.2. Green indicates accepted material, yellow is for items under hold, and red marks rejected items. Items under hold need clarifications from other depart- ments as to their acceptability, when a discrepancy in supply is observed. This is intimated to the concerned department (planning/procurement/design) in detail by an inspection note, as in Figure 4.3. The matter is to be resolved by the con- cerned department(s), and if the item is to be accepted QAC should be notified. Until such time, the item will be under hold in an area designated for the purpose. All accepted materials will have a green sticker implying that they meet all the requirements mentioned in the pur- chase order (PO) as well as the applicable codes and items- supplied tally with the certificates furnished by the vendor. Those items that do not meet the PO or code require- ments shall be rejected and are given a red sticker. The rea- sons for the rejection are given in the inspection note to beManufacture of Vessel EMBLEM INTIMATION OF MATERIAL RECIEPT 69 Purchase Order No. Date Vendor Date of Receipt DETAILS OF ITEMS RECEIVED SLNo. Tag No. Description Location: Store Keeper in Charge: Status of MTC: Received! not received Signature of Stores Officer: Routing:- Manager (QAC) Ce: Asst. Manager(Purchase) O/C 1 Master File ‘Manager(Planning) O'C2 POFile Manager(Production) Figure 4.1 Intimation of material receipt.70 Chapter 4 DATE REPORT REFERENCE cEPTED « AC © Figure 4.2 Stamps: (A) accepted; (B) hold; (C) rejected.Manufacture of Vessel 71 EMBLEM STORES INSPECTION REPORT Purchase Date Ofder No. Vendor Date of Inspection DETAILS OF ITEMS INSPECTED ‘SINo. Tag No. Description Remarks In case the items are on hold, please indicate the clarifications needed: In case the items are rejected, please indicate the reasons: Signature of Inspection Engineer Routing:- Asst. Manager (Purchase) Ce: Manager (Planning) Manager (Design & Drawing) Manager (Production) Figure 4.3 Stores inspection report. O/C 1 Master File OIC2 PO File72 Chapter 4 communicated to the vendor by the procurement department, and at the same time the material will be returned to the ven- dor by the stores department. The procurement department in the meantime must initiate alternative procurement action on a priority basis. 2.2 Dished Ends Each dish shall be identified against its certificate. A sample certificate for dished end is enclosed as Figure 4.4. Later, the outside circumference, inside diameter (ID) at four locations, thickness at straight flange (SF), and inside depth are mea- sured and cross-checked with the measurements given in the certificate. Further, the heat number and identifications certi- fied by the third party inspector at the manufacturer’s end are also verified. If these are all in order, the physical verification part of inspection is over. The certificate is then verified for material specification, types of tests, heat treatment, etc. When all these parameters are verified per the PO and appli- cable codes, the item is accepted. 2.3 Plates/Pipes Measure the possible physical dimensions, especially the thickness. Correlate the identification found on these items with the certificate furnished. If these are in order, the certifi- cate is verified against code and PO requirements. If these are also in order, the items can be accepted. Sample certificates for plates and pipes are shown in Figures 4.5 and 4.6, respec- tively. 2.4 Pipe Fittings/Flanges Record all possible dimensions and verify against those given in the applicable standards. Cross-check the identification found on the items to that given in the certificate. Verify cer-