asme joint review (leason learnt)

Lesson learntFrom Joint reviews

Presented by

Gurunathan

Authorized Inspector Supervisor

Saudi Arabia, DH

09-26-13

22

Deficiencies• QC System

• Implementation

Note: some of the opinions expressed here are my personnel views, feed back/criticism are welcome.

33

QC system deficiency• Code books and Inspection Contract.

Team leader

-QC system review checklist requires that the demonstration item shall

be based on the latest code edition and addenda. It was found that the

company did not have any required code books, it was not possible to

evaluate the company QC system and it’s implementation.(UG-117 and

PG-105)

-Re-review

44

Common QC system deficiency• Inconsistent of use of titles

• Delegation of duties (if qualified)

• Electronic control of manuals

• Always keep a relationship between drawings and design, P.O and

Technical details.

• Contract or Individual welders.

• Welding supervision responsibilities.

• Certification of NDE procedures and approval of Written practice.

• Requirements of field compliance and field organization chart. (A,PP)

• Distribution of Data report for boilers a copy for AIA.

55

QC S deficiency cont..• Visual and color examination requirement

( Note: J1 (Cp-189) annually and color (recertification) and J2 and

color annually (code))

• Input to subcontractors

(e.g. PWHT temperature range UG-11)

• NDE level III responsibilities and qualification. (UW-54)

• Hold point signed without date.

66

Implementation Deficiency• Design and Drawing control

• Material control

• Examination and Inspection

• Welding control

• Non-Destructive Examination

• Heat treatment

• Calibration

• Misc..

77

Implementation deficiencyTeam leader

- For Section VIII Div.2 the company presented document demonstration

on a 8mm thick vessel. The required knowledge and understanding of

the division 2 related to special material, inspection and design

requirements could not be completely verified on this vessel.

- Presented a new calculation.

88

ID Design UDS• User Design specification

Team leader

-Certified UDS did not indicate design life of the vessel and did not

include sufficient data to enable screening for fatigue analysis as required

by 5.5.2 of code. UDS only indicated that fatigue is not required.

99

ID Design Cont.. • ASME Sec VIII Div. II section 2.2.2.1(f)

ASME Sec VIII Div. II section 4.1.1.4

1010

ID Design Cont.. Team leader

-MDMT was specified as 38 degree c not taking consideration the

requirements of UG-20(b).Impact test exemption were not correctly

identified on the drawings

-MDMT was corrected to 6 degree c and closed

1111

ID Design PART 6 and UG-79• Head forming

Team leader

- The forming strain for heads (double curved circumferential products)

was not correctly calculated

1212

ID Design cont..Team leader

-For tori spherical head of 14mm thickness nominal of 12mm minimum, the

fiber elongation exceeded 5% limits requiring heat treatment as per UCS-

79 are not correctly addressed.

1313

ID Design cont..Team leader

- Min. thickness specified for the head on the drawing (26.3mm) was less

than the min. thickness required in the skirt portion of the head

(26.6mm).Skirt portion on the head is to be calculated as shell.

- Actual thickness measured and closed.

Team leader

- The head to shell joint was designed with minimum thickness of head

being 11.2mm on the skirt portion while the shell thickness was 10mm.

The nominal thickness on head being 12.7mm. The joint design did not

meet the requirement of UW-13(b)(3).

- To provide proper 1:3 transition on the head to shell, the C.A was

reduced on head to modify the min. head thickness.

1414

ID Design Cont..• Team leader

-Single sided welded head to shell seams were considered as Type 1 weld

without the requirement of UW-35 examination on inside surface.

Interpretation: VIII-1-10-33

Subject: Part UW, Table UW-12 - Joint Efficiency

Date Issued: December 2, 2010

Question: Is it permitted by the rules of ASME Section VIII,

Division 1,Table UW-12 for a Type 1 weld joint to be

assigned a joint efficiency from Table UW-12 when

visual examination of the interior surface of the

weld is not performed?

Reply: Yes, provided the requirements in UW-35 and UW-

37(d) are met.

1515

ID Design Cont..Team leader

- The location of the threaded connections specified as inspection

openings do not afford and equal view of the interior.

- Drawing revised

1616


- Requirements of 122.1.4 & PG-58.3.6 for blow-off piping were not

included in the drawing and design. Number of stop valves did not meet

the requirements, and the calculated design pressure was wrong.

1717


- Design calculations for B16.11 threaded couplings and standard caps B16.9 did not meet the requirements of UG-44. Further the ¾” class 3000 couplings failed to meet the requirements of UG-45 with the specified C.A.

- Calculation Revised


Subject: Section VIII, Division 1; UG-11 and UG-45

Date Issued: February 22, 1984

Question: Are threaded couplings welded directly to a pressure vessel to be designed per ANSI B16.11 as stated in UG-11, footnote 5, Section VIII, Division 1, thus disregarding the requirements of UG-45 for nozzle neck thicknesses, since no neck exists?

Reply: Yes.

1818


-The forged nozzles did not have the proper radius as specified on the

drawing and Table 4.2.10 detail 8. The item were accepted and released for

fabrication.

- Repair by machining.

1919

ID Design Cont..

2020

ID MaterialTeam leader

-SA 105 nozzle forgings were considered as fine grain material for impact

test exemptions as curve c without meeting fine grain practice

requirements as per general note d(2) of table 3.18. on further investigation

it was found that if these forgings are considered as curve “B” materials,

impact test requirements cannot be exempted.

- Revise the technical doc. Or do a chemical analysis (spectro)

Difference between the fine austenitic grain size as per (SA 20) and the

grain size reporting on forgings.

2121


- Shell plate material SA 387 Gr.11 MT Q LTV were received and accepted

with normalizing + accelerated cooling and tempering condition, but the

MTC is not meeting the testing requirement of SA-20 for the specified

heat-treated condition

- Interpretation: II-A-10-07

Subject: Number of test coupon for tension test as per SA 20

Date Issued: Feb.7, 2011

Question: Are plates that are accelerated cooled from the austenitizing

temperature considered to be quenched and therefore subject to the test

rules described in the second sentence of SA-20 Para. 11.1.1?

Reply: Yes.

2222

ID MaterialTeam Leader

- The plate material certificate contains the ASTM designation does not

specify the year of edition

Interpretation: II-A-04-15

Subject: Certification Requirements for SA-105 Section II, Part A

Date Issued: March 15, 2006

Question: When material for Code construction is supplied to an ASTM

specification that is included in the list of Acceptable ASTM Editions in

Section II, Part A, must the certification requirements include the

specification year date and acceptable revision letter?

Reply: Yes.

Does the manufacturer able to certify the material to the latest edition.

2323


-While inspecting vessel it was found that one of the nozzle flanges was

found damaged during fabrication. Damage occurred due to welding of

temporary supports on flanges.

- Weld repair performed as per SA-105 requirements that requires PWHT

after repair.

Team leader

- SA 105 Para 7.4 requires that when more than one forging are produced

a min. of two forgings shall be hardness tested. This requirement was

not complied for some of the SA-105 flanges used on the vessel (MTC)

- Additional hardness tested.

2424

ID Examination and InspectionTeam leader

- Vessel of SA-312 TP304 & SA-182 F304 material was certified for 4504

kPa @ 70 degree C and was hydro tested at 5855kPa. The test pressure

did not meet the UG-99 requirements as the stress ration for material at

test temperature and design temperature was not taken into

consideration.

- The vessel was designed for calculated MAWP that was stamped on the

vessel. While calculating hydro test pressure, stress ratio was wrongly

taken as 1.0. Existing vessel name plate shall be removed and new

name plates attached.

2525


- While reviewing the data reports and records of the recently completed

vessels for the stamped MAWP 200.3psi, the vessel was hydro tested at

247.7psi. It was observed that the hydro test pressure of the vessel did

not meet the code requirements. The drawings and calculations also

indicated incorrect test pressure.

- Existing vessel name plate shall be removed and new name plates

attached.

2626


- The vessel required external pressure as an applicable UG-22

loading condition. Heads (2:1 ellipsoidal) were procured and

accepted without the verification for external pressure as

required by UG-81(b)

- A template prepared and verified.

2727


- During welding demonstration the gas flow specified in customary unit

“CPM” on the WPS, actual flow meter indicated “LPM” metric. No

conversion factor known by the welding/QC personnel.

- During the weld demonstration it was observed that the ampere meter

on the welding machine was not working and the welder could not

demonstrate the ampere range as specified in WPS.

2828

ID WeldingTeam Leader:

-Undersize fillet welds for nozzle to shell/head and for reinforcement pad

to shell. The fillet size were calculated based on corroded thickness(as

shown in app-l), however UW-16(b) defines thickness for shell and nozzle

to be considered as nominal for determining weld sizes.

2929

ID welding Cont.. UW-16

3030

ID welding Cont.. UW-16Interpretation: VIII-1-89-272

Subject: Section VIII, Division 1 (1989 Edition, 1989 Addenda), UW-16(b)

Date Issued: January 22, 1991

File: BC90-792

Question: Are the symbols defined in UW-16(b) to be applied in the corroded condition?

Reply: Yes. See UG-16(e).


Subject: Section VIII, Division 1 (1989 Edition, 1990 Add); UG-37(a) and UW-16(b)

Date Issued: June 3, 1992

File: BC91-303

Question: Does the nomenclature for t and tn in UG-37(a) and UW-16(b), and tn in Appendix 2 of Section VIII, Division 1 represent the same dimension as defined in Appendix 3 for nominal thickness?

Reply: Yes, except when a corrosion allowance is specified, then all dimensional symbols used in design formulas are in the corroded condition.

3131

ID welding Cont.. UW-16Interpretation: VIII-1-01-01

Subject: Section VIII, Division 1 (1998 Edition, 1999 Addenda); UW-16(b) and

Fig. UW-16.1

Date Issued: July 21, 2000

File: BC00-388

Question: For a nozzle made of pipe, may the pipe under tolerance be

subtracted from the nominal wall thickness for the evaluation of tc

in

Fig. UW -16.1 of Section VIII, Division 1?

Reply: No.

3232

ID welding Cont.. UW-16Team leader

-Tolerance for fillet welds were not specified on drawings.


Subject: Section VIII, Division 1 (1992 Edition, 1992 Addenda); UW-35(d)

Date Issued: October 20, 1993

File: BC93-604

Question: Do the reinforcement requirements of UW-35(d) in Section VIII,

Division 1 apply to weld joints other than longitudinal and

circumferential butt joints, e.g., fillet welds of nozzles and

couplings?

Reply: No.

3333

ID welding Cont.. Team Leader

- WPS used to weld 14.3mm thick ¾” diameter forged nozzle to end cover

of 39.7mm thick did not meet the base metal thickness requirement of

QW-451. WPS used was qualified for a max. thickness of 11.1 mm.

(but remember the QW-202.4 for P.no.8, P.no.43 provisions)

- Alternate WPS provided and weld plan revised.

3434

ID welding Cont.. Team Leader

- Welder used to weld the ¾” diameter nozzle (set-on type connection)

was not qualified for the diameter.

- Welder used for welding ½” coupling welded to pipe using GTAW and

SMAW was not qualified for the pipe diameter for the welding process.

- Welders re-qualified.

3535

ID NDETeam leader

- WP as per ASNT CP-189: 2006.

CP-189 clause 9.2.1 requires that the certification records include the level, method and technique covered.

- Certification record corrected.

- NDE subcontractor WP that was based on SNT-TC-1A:2001 & 2006 required technical evaluation of level I & II to be carried out at least every year. This was however not evident for the NDE personnel used for performing and evaluating NDE.

- NDE personnel shall be given practical examination for evaluating their technical performance.

3636

ID NDE Cont..Team leader

- Location of the location markers that were appearing as radiography

image on the film were not permanently marked on the surface of the

shell for the spot radiographed head to shell weld.

- The location were marked on the head.

3737

ID NDE Cont..• The NDE and Heat Treatment subcontractors reports and procedure

used on recently completed work were not certified for by the company

as required by 2.3.7

• NDE and HT reports and procedure were certified.

3838

ID Heat Treatment

3939

ID Heat Treatment

4040

ID Heat Treatment

4141

ID CalibrationTeam leader

- MT yoke calibration records did not specify the pole spacing at which

the lifting power check was performed. Further the procedure allowed

yoke to work at 110-220V range but failed to lift the required weight at

110V.

- The lifting power was rechecked at the max. pole spacing, procedure

revised.

4242

ID Calibration Cont..Team leader

- Step wedge calibration film for the calibration of densitometer did not

meet the requirements of T-262.1(a). It was found being used without

verification beyond one year of opening.

- Recalibrate densitometer using alternate step wedge film if found out

calibration check the density of all the films shot after this.

Team leader

- Calibration without technical details.

- Calibration report acceptance by manufacturer.

4343

Misc...• It was observed that the number of vessels are dispatched to the user

with code required marking/name plate but the manufacturer’s data

reports are not certified. The reason given for not signing the data

reports was that the documentation and records for these vessels have

not been completed. Some of the vessels was found having outstanding

non conformity report related to material.

• NCR open.

4444

Queries?

Thank you

asme joint review (leason learnt)

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