PHT FILTER VESSEL SPECIFICATION … FILTER VESSEL SPECIFICATION REQUIREMENTS ... occurring during filter assembly/filer element due to ... indications in which the …

PHT FILTER VESSEL SPECIFICATION REQUIREMENTS

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1. Fabrication shall be done as per ASME section VIII Div.-1 and welding as per ASME

section-IX.

2. Applicable ASME code for vessel is boiler and pressure vessel code Section-III and

classification Class-C.

3. The PHT filter vessel is to be fabricated as per the following specifications.

a. M1&2_33215_1252_DD

b. DRG NO MAPS/PPED/01006/2001/SK/R2

c. SPECIFIACTION SHEET NO : PP-E-122

d. VESSEL SPECIFICATION SHEET NO : PP-E-527 ( Refer page no: 27)

4. The material for fabrication should be as per the bill of materials given in the drawing.

NOTE: Material SA516 Gr.60/Gr.70 shall be used wherever IS-2002 grade-2A is

indicated in the drawing.

5. The inspection procedures shall be as per the attached annexure A.

6. Inner surface of the vessel shall be sand blasted and thoroughly cleaned, painted and got

approved before placing elements and final joint. Fixing of filter element to backing strip

should be got approved from QA, MAPS.

7. Outside surface of the vessel sand blasted sprayed with primer coat of red oxide, Zinc

chrome primer to IS-2074 and finished by synthetic enamel spraying quality of gray

colour.

8. Inlet and outlet pipes must be sealed with metallic caps at top in order to prevent

moisture, so that at the time of actual use of filter it can be easily removed without

damaging the groove provided for victaulic coupling.

9. Filter assembly shall be tested at 150 psig for a period at 10 minutes and then assembly to

be kept submerged in water for any sign of air bubble, no bubble of air are permitted.

Alternately a soap solutions test may be used with above air pressure. Painting of vessels

should be done only after this test.

10. Inside vessel must be dried with hot air before sealing at opening to avoid moisture.

Opening should be sealed properly.


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11. Tentative QA plan is given in annexure -B based on which various inspection stages shall

be carried out. However supplier shall submit actual QA plan on par with tentative QA

plan and get it approved before commencement of fabrication.

12. Welding procedure qualification, welder performance qualification shall be approved by

NPCIL QA.

13. The welding consumables and DPT Consumables shall be as per the NPCIL approved

brands as given in attachment .

14. The filter element will be issued as free issue material. The supplier has to handle the

filter elements carefully while assembling with the vessel, in case of any damage

occurring during filter assembly/filer element due to handling , the filter element cost

will be deducted from the supplier.

15. After fabricating one number of filter assembly as per above procedure and QA plan , and

same to be dispatched by the supplier to MAPS site in order to check the performance of

the filter. Only after getting approval from the purchaser, the supplier can proceed

for bulk fabrication and supply. The transportation cost for the supply of sample filter

assembly may be included in the quotation.

16. Only after the inspection clearance the items shall be dispatched .All the records,

inspection documents, and shipping release shall accompany the supply.

17. While fabrication and assembly it shall be ensured that no other foreign materials inside

the vessel. Extreme care shall be taken against foreign material intrusion. Same shall be

witnessed by the NPCIL QA before giving closing joint of the vessel. All open ends of

the filter inlet and outlet ends shall be covered with suitable caps.

18. The first sample vessel assembly shall be supplied within the period of three months from

the date of issue of purchase order .Remaining filter assemblies shall be supplied within

eight months from the date of clearance /Approval for the performance of the sample

vessel from MAPS

19. The total list of attachments is indicated below.

a. M1&2_33215_1252_DD A1

b. DRG NO MAPS/PPED/01006/2001/SK/R2

c. SPECIFIACTION SHEET NO : PP-E-122

d. Primary system vessel specification PP-E-527


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e. Inspection procedures ( Annexure-A)

f. Tentative QA plan ( Annexure-B)

g. NPCIL approved welding electrodes and filler materials.

h. NPCIL approved DPT materials

N.SURESH ENGINEER SO/F

Page 1 of 5 NUCLEAR POWER CORPORATION OF INDIA LIMITED

(A Government of India Enterprise) Madras Atomic Power Station.

Kalpakkam – 603 102.

TENTATIVE QUALITY ASSURANCE PROCEDURES FOR PHT FILTER VESSELS

MODEL QUALITY ASSURANCE PLAN

NAME 0F THE EQUIPMENT: PHT FILTER VESSEL LEGEND: IR – INTERNAL REPORT W – WITNESS R - REVIEW CLIENT : NPCIL, MAPS

INSPECTION REMARKS SNO ITEM

DESCRIPTION TYPE OF CHECK

QUANTUM OF CHECK

REF. DOC ACCEPTED

FORMAT OF

RECORD SUPPLIER NPC

(1) (2) (3) (4) (5) (6) (7) (8) (9) 01 MATERIAL IDENTIFICATION

(Pipes and Plates) Visual, Dimensional, mechanical & chemical properties & U.T for flaw

100% Approved Drg. MIL/LAB/ TC Reports

W W

02 WELDING QUALIFICATIONS

PROCEDURE WITNESSING 100% ASME SEC.IX Approved Drawing

WPS & PQR W W

PERFORMANCE WITNESSING 100% ASME SEC.IX PQR W W





INSPECTION REMARKS SNO ITEM DESCRIPTION

TYPE OF CHECK

QUANTUM OF CHECK

REF. DOC ACCEPTED

FORMAT OF

RECORD SUPPLIER NPC

(1) (2) (3) (4) (5) (6) (7) (8) (9) Approved Drawing

03 SHELL ‘L’ seams Fit-up Visual &

Dimensional 100% Approved Drg IR W R

‘L’ Seams Root Visual & DPT 100% ASME Section III & V

IR W W

‘L’ Seams Final Weld

Visual DPT 100% ASME Section III & V

IR W W

RT 100% ASME Section III & V

IR W R

04 TOP & BOTTOM DISH

After Forming Stress Relieving 100% Approved procedure

IR W W

Visual & Dimensional

100% Approved Drg. IR W W

DPT – Inside and Outside Knuckle

100 % ASME Sec.III & V

IR W W

05 Support Legs






TYPE OF CHECK

QUANTUM OF CHECK

REF. DOC ACCEPTED

FORMAT OF

RECORD SUPPLIER NPC

(1) (2) (3) (4) (5) (6) (7) (8) (9) Fabrication

Fit-ups Visual & Dimensional

100% Approved Drg. IR W R

Final weld to dished end

Visual & Dimensional


06 Vessel Inside painting

Surface cleaning Visual 100% IR W R Painting Visual

Thickness shall be measured

100% IR W W

07 FILTER ELEMENT Visual

inspection 100% Approved Drg. IR W W

Assembling with filer vessel


Checking the tightness of the filter element with the vessel at the sealing area







TYPE OF CHECK

QUANTUM OF CHECK

REF. DOC ACCEPTED

FORMAT OF

RECORD SUPPLIER NPC

(1) (2) (3) (4) (5) (6) (7) (8) (9) 08 Top & Bottom Dish

to shell Weld

Fit up Visual & dimensional


Root DPT 100% ASME Section III & V

IR W W

Final Weld DPT 100% ASME Section III & V

IR W W


IR W R

9 Inlet & Outlet Pipe Spools

Fit up Visual & dimensional


Root DPT 100% ASME Section III & V

IR W W

Final Weld DPT 100% ASME Section III & V

IR W W


IR R R

10 Pneumatic test Witnessing 100% Approved IR W W






TYPE OF CHECK

QUANTUM OF CHECK

REF. DOC ACCEPTED

FORMAT OF

RECORD SUPPLIER NPC

(1) (2) (3) (4) (5) (6) (7) (8) (9) procedure

11 Outside Painting Surface cleaning Visual 100% IR W R Final painting Visual

Thickness shall be measured

100% As per specification in Tender Document

IR W W

Page 1 of 9NUCLEAR POWER CORPORATION OF INDIA LIMITED



INSPECTION PROCEDURES AND TENTATIVE QUALITY ASSURANCE PLAN FOR PHT FILTER VESSELS

MODEL PROCEDURE FOR LIQUID PENETRANT EXAMINATION 1.0 SCOPE

This procedure covers the method for carrying out the Liquid Penetrant Examination and is used for detecting the presence of discontinuities open to the surface and complies with ASME Section-V, Section III, Division-1 NB for disposable type Ion exchanger.

2.0 AREA OF COVERAGE

WELDING

Weld and about ½” on either side of the weld.

DISHED END

Inside and outside of knuckle and about 1” either side of knuckle. 3.0 APPROVED METHOD AND MATERIAL

The penetrant shall be colour contrast, solvent removable type and developer shall be wet, non-aqueous. The penetrant and developer shall be compatible and from the same manufacturer.

4.0 SURFACE PREPARATION

Surface to be inspected shall be cleaned and free from oil, grease, sand, loose rust or scale, welding flux and spatter. Sand blasting is strictly prohibited prior to the examination.

5.0 LIGHTING CONDITION

The test shall take place in an area well lighted (Lighting of 100 ft candle is recommended). 6.0 PROCEDURE

6.1 Penetrant application

The penetrant shall be applied by brushing. The surface temperature of the part shall be between 60oF and 125oF.

6.2 Penetrant Removal

Excess penetrant shall be removed by wiping with a lint free cloth or absorbent paper, repeating the operation until most traces of penetrant have been removed. The remaining traces shall be removed by lightly wiping the surface with cloth or absorbent paper moistened with solvent. To minimize removal of penetrant from discontinuities, care shall be taken to avoid the use of excess solvent.

6.3 Developer Application

Developer shall be applied by spraying as soon as possible after the penetrant removal.





6.4 Examination

Examination shall be carried out after allowing a development period of 7 minutes.

6.5 Post cleaning

After completion of examination, traces of penetrant and developer shall be cleaned thoroughly by using wiping cloth.

7.0 EVALUATION OF INDICATIONS

7.1 Mechanical discontinuities at the surface are revealed by bleeding out of the penetrant. Any indication, which is believed to be non-relevant, shall be re-examined to verify whether or not actual defects are present. Surface conditioning may precede the re-examination. Non-relevant indications and broad areas of pigmentation which would mask defects are unacceptable.

7.2 Relevant indications are indications, which result from imperfections. Linear indications are indications in which the length is more than three times of the width. Rounded indications are indications which are circular or elliptical with the length equal to or less than three times of the width:

8.0 ACCEPTANCE STANDARDS a. WELD

8.1 Only imperfections producing indications with major dimensions greater than 1/16 inch,

shall be considered relevant imperfections. 8.2 Imperfections producing the following indications are unacceptable. 8.2.1 Any cracks or linear indications. 8.2.2 Rounded indications with dimensions greater than 3/16 inch. 8.2.3 Four or more rounded indications in a line separated by 1/16 inch or less edge to edge. 8.2.4 Ten or more rounded indications in any 6 sq. inch of surface with the major dimension of

this area not to exceed 6 inch with the area taken in the most unfavorable location relative to the indications being evaluated.

b. DISHED END

Any crack or linear indication is unacceptable. 9.0 PERSONNEL CERTIFICATION

Personnel performing the examination and determining the acceptance or rejection shall be certified to minimum Level-I.

10.0 DOCUMENTS

10.1 Liquid Penetrant Examination report shall be prepared.





MODEL PROCEDURE FOR RADIOGRAPHIC EXAMINATION

1.0 SCOPE

This procedure describes the method of Radiographic Examination on butt welds in steel and complies with ASME Section-V, Section-III Division-I NB for disposable Ion exchanger.

2.0 TECHNIQUES

The following technique shall be used for the Radiography of welds.

2.1 Single wall Single Image 2.2 Single wall Single Image (Panoramic) 3.0 SURFACE PREPARATION 3.1 The surface of the welds shall be sufficiently free from coarse ripples, grooves, overlaps and

abrupt ridges and valleys. 3.2 The height of the reinforcement on each face of the weld shall not exceed 2.4mm.

4.0 IDENTIFICATION SYSTEM

The following identification marks shall appear in each film as Radiographic Image: a. Job No. b. Seam No. c. Welder’s No. d. Date e. Manufacturer’s Symbol

5.0 EXTENT

100% of long seam and circumstantial seam, in pressure boundary area.

6.0 LOCATION MARKERS 6.1 The placement of location markers shall be as follows: Single Wall Single Image - Source side Single Wall Single Image (Panoramic) - Either side 7.0 RADIATION SOURCE 7.1 X-Ray Radiation, is recommended 7.2 Iridium 192 may however be used, provided the proposed technique shall be demonstrated

to the satisfaction of Inspection Authority.

8.0 FILM 8.1 Afga D4 type Film/Agfa D7 type film





8.2 Lead Screen of Thick 0.1mm front and 0.15 mm back shall be used. 9.0 SCATTERED RADIATION 9.1 Effect of scattered radiation shall be reduced by using lead screen and backing lead sheets.

To check back scattered radiation ‘B’ letter dimension of 13mm height and 1.6mm thick shall be attached to the back of the film cassettes.

10.0 SFD shall be chosen; so that the geometrical unsharpness does not exceed the following

value.

Material Thick (Inch) Ug. Max. (Inch) Under 2 0.020

11.0 PENETRAMETER

11.1 ASME Standard Penetrameter shall be used as follows:

Source Side Film Side Single Wall

Material Thick Range in inches

Designation Essential Hole Designation Essential Hole

Upto 0.25 5 4T 5 4T Over ¼ - 3/8 7 4T 7 4T Over 3/8 – ½ 10 4T 10 4T Over ½ - 5/8 12 4T 12 4T Over 5/8 – ¾ 15 4T 12 4T

11.2 One penetrameter shall be used for each Radiography. 11.3 In case of panoramic exposure, minimum three penetrameter of 120o apart shall be used. 12.0 DENSITY

The density of the radiograph shall be between 2 and 4 with variation within –15% to +30% from the density through the body of the penetrameter to the area of interest.

13.0 SENSITIVITY 13.1 The essential hole visible on radiograph shall be 4T. 14.0 PROCESSING OF FILMS 14.1 Developing : 5 minutes at 68 ± 2oF with intermittent agitation. 14.2 Stop Bath : 1 minute at 68 ± 2oF with no agitation. Drain back 10 seconds.





14.3 Fixing : 7 minutes at 68 ± 2oF. Drain back 10 seconds. 14.4 Washing : Minimum of 15 minutes in running water. Rate of flow of water must be

sufficient to replace the water in washing tank at least 4 times in every hour.

14.5 Drying immerse in wetting agent for 30 seconds, then hang films in drying cabinet. 15.0 EVALUATION

Prior to the presentation of the radiographs to the External Inspector, all the radiographs shall be interpreted by a Level-II certified person. The results of evaluation shall be recorded on the report.

16.0 ACCEPTANCE STANDARD 16.1 Indications shown on the Radiographs of welds and Characterized as imperfections are

unacceptable under the following conditions. 16.2 Any indication characterized as a crack or Zone of incomplete fusion or penetration. 16.3 Any other elongated indication which has a length greater than

¼ in for t up to ¾ inch inclusive. 1/3 t for t from ¾ to 2-1/4 in. inclusive.

16.4 Any group of aligned indications having an aggregate length greater than t in a length of 12t,

unless the minimum distance between successive indication exceeds 6L, in which case, the aggregate length is unlimited L being the length of the largest indication. Rounded indications in excess of that shown as acceptable in Appendix-VI of ASME Section III-Division-1-Appendices.

16.5 Internal root weld conditions are acceptable when the density change as indicated in the

radiograph is not abrupt; elongated indications on the radiograph at either edge of such condition shall be unacceptable as provided in 16.3.





MODEL PROCEDURE FOR HYDRO STATIC TESTING

1.0 SCOPE

This procedure describe the method for hydro-static pressure testing on Pressure Vessel for disposable type Ion exchanger to ascertain leak free base metal and welded joints and integrity of vessel.

2.0 APPLICABLE CODES

ASME Boiler & Pressure vessel code section III Division-1 NB.

3.0 CLEANING

All welded joints shall thoroughly be cleaned and to be exposed for examination during test.

4.0 PROVISION OF VENT

Vent points shall be provided at the highest point of the vessel through one of the nozzle to purge out air from vessel.

5.0 PRESSURE GAUGE

Minimum two pressure gauges shall be provided one at the highest point of the vessel and the other at the pressurizing point near the operator. Pressure gauges shall be used in the range of 1-1/2 to 4 times of test pressure and shall be calibrated condition prior to test.

6.0 TEST PRESSURE

The test medium (water) shall be pressurized to 30 kg/cm2g. Prior to pressurization of the test medium, the vent valve shall be kept open to purge out air completely.

7.0 HOLDING TIME EXAMINATION

The hydro-static test pressure shall be maintained for a minimum of 10 minutes prior to conducting the examination to ascertain the integrity of vessel. After elapse of holding time, the examination shall be conducted for any leak at base metal and welded joints. No leak is permitted.

8.0 TERMINATION OF TEST

Test shall be terminated, drained after vent valve opening and dried the vessel completely after completion of examination.





9.0 PRE-CAUTION

Pre-caution shall be taken to avoid excessive pressure due to thermal expansion of test medium when the vessel is exposed to sunlight during hydro static examination.





PAINTING PROCEDURE 1.0 SURFACE PREPARATION 1.1 Prior to cleaning, any loose rust shall be removed with power tools, or with use of wire

brush. 1.2 Remove grease oil and other contaminants, preferably using degreasing solvent approved by

purchaser (Bison make is one of the approved solvents) 1.3 Surface to be inspected by water drop wetting method to ensure normal of grease and oil

etc., after cleaning. 1.4 The surface should be cleaned and dried before application of primer. 2.0 PRIMARY COAT 2.1 Immediately after surface preparation, Ethyl silicate based inorganic zinc silicate primer

approved by purchaser shall be sprayed. Paints given in specification only shall be used.

Airless spray or brushing is acceptable, Air spray is not permitted since adhesiveness is poor.

2.2 Details of approved primer a. Hemplel’s Galvosile – 1570 zinc silicate/ zinc dust b. Hempel’s Galvosile – 1570 Zinc silicate liquid c. Thinner for zinc silicate Galvosil – 1570

2.3 Dry film thickness of paint : 150 micron minimum 2.4 Minimum interval between two coats : 24 hours. 3.0 FINISH COAT 3.1 After primary coat, a finish coat of epoxy paint (approved by Purchaser) shall be applied by

spraying or brushing. Twenty four hours should lapse between the second coat of primer and first coat of paint.

3.2

Details of approved Paint a. Amerlock – 400 (Ameron) Component – A b. Amerlock – 400 Component-b c. Thinner Amerlock-65





3.3 Dry film thickness of paint including primary coat : 250 micron minimum 3.4 Minimum interval between two coats : 24 hours. 4.0 A mock-up plate is to be painted to demonstrate the dry film thickness as per the

specifications before taking the vessel painting. 5.0 Paint dry film thickness

Primary coat : 150 micron minimum Finish coat : 100 micron minimum Total : 250 micron minimum

NOTE: Sequence of Welding: Top dished end and shall be welded finally after inside epoxy coating of shell and dish. Sequence of Painting: Top dish and shell circumferential weld inner area shall be painted finally; method of painting shall be submitted to NPCIL for approval.

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PHT FILTER VESSEL SPECIFICATION … FILTER VESSEL SPECIFICATION REQUIREMENTS ... occurring during filter assembly/filer element due to ... indications in which the …

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