PRESSURE VESSEL FABRICATION &

INSPECTION

POYYARA

L&T - HED POWAI & HZW - PRODUCTS

Pressure Vessels
Reactors
Towers
Columns
Heat Exchangers
Shell & Tube
Spiral
Plate
Submarines
POYYARA

L&T - HED POWAI & HZW - CUSTOMERS

Fertilizer Industries
Chemical Industries
Petrochemical Industries
Steel Plant Industries
Indian Navy
Nuclear Power Corporation
Indian Space Research Organization

POYYARA

DESIGN & CONSTRUCTION CODE

ASME
Sec VIII Div I, II, III
Sec III

Sec I
TEMA

CUSTOMER
SPECIFICATION

IBR
PD (BS) 5500
AD Merkblatt
POYYARA

MATERIAL FOR CONSTRUCTION

CS
LAS
C. Mn, C. Mo, Cr. Mo, Cr. Mo. V, Ni. Cr.Mo, Ni Steel
Stainless Steel.
Austenitic, Ferritic, Martensitic, Duplex
NF Metals & Alloys
Al, Cu, Brass, Bronze, Monel, Cupronickel, Inconel,
Titanium
POYYARA

MATERIAL PRODUCT FORM

Plate
Forging
Pipe
Tube
Casting

POYYARA

RAW MATERIAL IDENTIFICATION

Material Quality, Thick. & Size -- Drawing
Verify HT No., Plate No. & Isp. ID -- Material
& TC
Verify Properties Reported in TC ASME
Sec.II. Part A / B + ARM + Simulation HT
Verify NDT (UT) Requirement
Look For Pitting, Surface Damage / Defect on
Both Sides
POYYARA

PROCEDURE FOR MARKING, CUTTING AND

CHECKING OF SHELL PLATE

SA 516 GR 70
24357
9262 / 3

K1

SHELL PLATE

No Hard Punching on
ROLLING DIR.

K2

1) FM Below 6 mm thick
2) NFM Below 12 mm thick

L
TOLERANCE
L & W - + 1 mm / M, Max. + 3 mm.
K1 - K2 = + 1 mm / M,

Max. + 5 mm

IDENTIFICATION MARKING
TO ROLLING DIRECTION.
L - NOMINAL CIRCUMFERENCE = MEAN DIA. X
= 3.1415926535897932384626433832792...

POYYARA

LOADING OF PLATES FOR ROLLING

Gas Cut Edges Free From Serrations
All Corners Along the Edge Rounded Off
Plate Loaded on M/c With ID Up side.
Identification Marking On Bottom Side
Rollers Across The Plate Length
Edge Breaking Allowance Provided For Plates Above
75 mm Thick.

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CHECKING SHELL PROFILE, OVALITY

AND CIRCUMFERENCE
ACTUAL THK.

ID max - ID min = 0.5 % (1%)

of Nominal ID

ID

Allowed gap
Pick

in / out
< 152

M
TE
P

D/
4

4
D/

PEAK OUT

TE
M
P

I/D CHECK IN HORIZONTAL

PLANE

PEAK IN

POYYARA

0.8 MM
< 305

1.2 MM
< 457 1.6 MM
< 610
2.4
MM
<
914
3.2 MM
< 1219
4.0 MM
< 1524
4.8
MM
<
1905
5.6 MM
< 2133
6.4 MM
< 2438
6.4 MM
< 2743

PROFILE CHECK BY TEMPLATE

Peak Out

D/4 Template

D/4 Template

Matching Profile
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Peak In

MAXIMUM OFF SET IN BUTT WELD

Joint Thickness . t
13 mm & Below
Over 13 mm to 19 mm
Over 19 mm to 38 mm
Over 38 mm to 51 mm
Over 51 mm

Long Seam
1/4th t
3.2 mm
3.2 mm
3.2 mm

Circ. Seam

1/4th t
1/4th t
4.8 mm
1/8th t
th
1/8
t. Max.
th
1/16 t. Max. 10 mm
19mm

Aim For Half Of The Permissible Off Set At Set Up Stage

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REINFORCEMENT LIMIT ON BUTT WELDS- UW 35

Material Thickness
Below 2.4 mm
2.4 to 4.8 mm incl
Over 4.8 to 13 mm incl
Over 13 to 25 mm incl
Over 25 to 51 mm incl
Over 51 to 76 mm
Over 76 to 127 mm
Over 127 mm

Max. Reinforcement
Long Seam
Circ. Seam
0.8 mm
2.4 mm
1.6 mm
3.2
2.4 mm
4 mm
2.4 mm
4.8 mm
3.2 mm
5 mm
4 mm
6mm
6 mm
6 mm
8 mm
8 mm
POYYARA

INSPECTION OF ROLLED / CYLINDRICAL

SECTIONS
Shape

Checking Method

Profile

Template

Ovality (Out Of Roundness)

Diameter Measurement

Circularity

Swing Arm Method

Straightness

Stretching Twine
POYYARA

INSPECTION OF ROLLED / FORMED CONICAL

SECTIONS
Shape

Checking Method

Profile At Open Ends

Template

Ovality ( Out of Roundness)

Diameter Measurement

Circularity
Concentricity

Swing Arm Method

Leveling & Plumbing

POYYARA

PROFILE VERIFICATION OF SHELL SECTIONS

UNDER EXTERNAL PRESSURE
Ovality Check 0.5 (1 % Code Requirement)
Template Check UG 80 (b)
Chord Length of Template = 2 Times the Arc Length
Obtained From UG 29.2 (Based on OD, Thickness &
Length)
Vessel Length as Given in UG 28 & 28.1
Gap Permissible With the Template to be Obtained
from UG 80.1
Hemispherical D/Es & Spherical Portion of Other D/Es,
Template Check using L/D = 0.5
POYYARA

CONCENTRICITY CHECK OF CONES

0

Plumb
270
90

Water
Level
180

POYYARA

CIRCULARITY CHECKING- SWING ARM METHOD

PENCIL
SECTION

SPIDER

GRAPH
PAPER

ROLLER

SWING ARM

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DERIVATION OF OUT OF CIRCULARITY

1.Measure the Area Encircled by the Curve From Graph
2.Calculate the Mean Diameter From The Area.
D = 4A /
3.Mark Three Circles On A Transparent Paper
Circle With Mean Diameter D Derived
Circle With Mean Dia. D (Tolerance in % D)
Circle With Mean Dia. D + (Tolerance in % D)
4. SUPERIMPOSE THE CIRCLES IN TRANSPARENT PAPER ON
CURVE OPTAINED ON GRAPH & DEMONSTRATE THAT THE
CURVE IS WITHIN THE OUTER & INNER CIRCLES.

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CIRCULARITY CHECK BY TAPE OR TELESCOPIC

GAUGE
1. FIND THE GEOMETRIC CENTRE OF THE SHELL-COURSE BY
CROSSING 4 TWINES DIA , MARK THE CENTRE OF POLYGON
POLYGON
TWINES
SHELL

2. MEASURE THE RADIUS AT 48 LOCATIONS (R1 TO R48)

3. CALCULATE AVERAGE RADIUS = R1+R2++R48 / 48

POYYARA

CIRCULARITY CHECK BY TAPE OR TELESCOPIC

GAUGE

FIND THE MAXIMUM & MINIMUM RADIUS

CHECK THEY ARE WITHIN PEMISIBLE PERCENTAGE

VARIATION

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INSPECTION OF DISHED ENDS

TYPE OF DISHED ENDS

Hemispherical
Ellipsoidal
Torispherical

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INSPECTION OF DISHED ENDS

TYPE OF CONSTRUCTION

Pressed From Single Blank

- Without Any Weld Seam
- With One Long Seam
- With More Than One Long
Seam
Crown & Petal Construction
- Single Tyre
- Multi POYYARA
Tyre

INSPECTION OF DISHED ENDS

FORMING TEMPERATURE

Cold Formed At Room Temperature

Hot Formed At NR Temperature
Cold Formed With Intermediate NR
Cold Formed with Intermediate SR
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INSPECTION OF DISHED ENDS

FORMING METHOD

Single Pressing Using A pair of Die &

Punch
Progressive Forming By Repeated Point
Pressing
Progressive Forming For Crown Profile
By point pressing & Knuckle Radius By
Spinning
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INSPECTION OF DISHED ENDS

IDENTIFICATION MARKING

D/E No.
Project No.
Mtl. Specification
Heat No. & Plate No.
LOCATION OF MARKING

Appx. th Radius of Single Disc Blank & Crown Disc

Appx. At the Centre Of Blanks For Petals
POYYARA

INSPECTION OF DISHED ENDS

LIFTING LUGS ON BLANKS & PETALS

Provide Integral Lugs on Blanks & Petals For Handling.
D/E BLANK
CUT EDGE GROUND SMOOTH
CORNERS ROUNDED OFF
MARKING

LUG INTEGRAL
PART OF BKANK

POYYARA

CENTRE

INSPECTION OF FORMED DISHED ENDS

Applicable For Single Piece & Crown + Petal Construction

1 Circumference At Trimming line (Acceptance as per
Tolerance Chart)
2

Knuckle Profile With 2D Full Size Template ( No Gap

At Center End Gap max. 2mm

Height From Tan line (+ Half of 1 D/E , Half Of

5/8 D/E )

Thickness At Crown, Knuckle & Edge ( Above

Minimum Specified In Drg.

Ovality On Open End ( Of 1% Of D/E )

POYYARA

INSPECTION OF FORMED DISHED ENDS

Applicable For Single Piece & Crown + Petal Construction

6

Check - Profile, Tan Line & Trimming Line With Full

Size 2D Template. (Template radius Open End, Crown
& Knuckle - Less be 20 mm.) Template Shall Have
Markings Of Tan Line, Trimming Line & Crown Centre.
Deviation Permitted Half of 1 D/E in Plus & Half Of
D/E in Minus; No Abrupt Change In Profile.
(Template To Be Verified On Lay Out)

Water Level 3 Points at 120 Apart On Trimming Line &

Check Crown Center By A Plumb. ( Deviation 5 mm per
Meter Length Of D/E Max. 20mm.( Not Applicable To
Hemispherical D/E)
POYYARA

INSPECTION OF FORMED DISHED ENDS

Applicable For Single Piece & Crown + Petal Construction

8

Check Straight Face ( Tan Line To Trimming Line )

With A Straight Edge of 1 Foot Scale. Minimum As
Specified In Drawing. ( Not Applicable To Hemispherical
D/E)

9 All Press Marks On Out Side & Inside Shall Be Smoothly

Ground / Merged.
10 PT Check Out Side Surface No Linier Indication
Permitted
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INSPECTION OF FORMED DISHED ENDS

Applicable For Single Piece & Crown + Petal Construction

11 If Hot Formed, Check For MTC With Simulation Heat
Treatment. ( Not Applicable To Cold Formed D/E)
12 Blanks With Weld Joints Shall Be PT Checked &
Radiographed Before & After Forming.

POYYARA

INSPECTION OF FORMED DISHED ENDS

Applicable For Only Crown + Petal Construction

1. Each Formed Petal Segment Shall Be Checked By A 3D
Template From Inside. Profile Of Template Ribs To Be
Verified. Maximum Gap Permissible At Any Location At
The Rate Of 3mm / Mtr. Length Of Petal With Maximum
Of 6mm.
2. Crown Segment Shall Be Checked By 2D Template. Gap
Permissible 3mm / Mtr. Blank Dia.

POYYARA

INSPECTION OF FORMED DISHED ENDS

Applicable For Only Crown + Petal Construction

3. Checks After Assembly
Off Set Half Of Permissible As Per Code.
Root Gap ( 1mm , + 2mm )
Root Face ( 1mm )
Serrations If Any On W E P, To Be Ground Smooth
No Temporary Tacks On Groove
No Defects On Tacks With External Cleats
Petals To Be Numbered With D/E No.
Match Marks On Adjacent Petals
POYYARA

APPLICATION OF ERROR ON CALIBRATETAPE D

TAPE
ERROR
+VE ERROR TAPE

STD TAPE
- VE ERROR TAPE

25005

WITH USER

25000

WITH QA

24995

WITH USER
ERROR CORRECTION

TYPE OF
ERROR

OPERATION
MARKING

MEASURING

(ADD ERROR)

(SUBTRACT ERROR)

+ VE

X + (+Y)

X -- (+Y)

-- VE

X + (--Y)

X -- (--Y)

NOTE :1. USE CALIBRATED TAPES ONLY

2. DO NOT USE TAPE HAVING ERROR MORE THEN +1 mm FOR
CRITICAL JOBS.

POYYARA

ORIENTATION MARKING ON CYLINDRICAL SHELLS

1. ROLLED SHELLS WITH ONE OR MORE LONG SEAMS

2. FORGED SHELLS WITHOUT ANY WELD SEAM

POYYARA

ORIENTATION MARKING ON ROLLED SHELLS

Shell With Weld Seam

90 Orientation line
90

Long Seam Weld

90

Weld Center line 155

POYYARA

ORIENTATION MARKING ON ROLLED SHELLS

Shell With Long Seam
0

90

270
155

180

POYYARA

ORIENTATION MARKING ON FORGED SHELLS

Shell Horizontal, Without Weld Seam

Manometer

Line Marked by Optical

Level

Water
Tube

270

180

90

POYYARA

ORIENTATION MARKING ON FORGED SHELLS

Shell Vertical Without Seam
90 &270
0

180

270

180

90
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ALIGNMENT CHECK

1. AXIS ALIGNMENT

2. SURFACE ALIGNMENT

POYYARA

AXIS ALIGNMENT CHECK

X

90

E
D

180

C
B

Z2

Z1

270

PLAN

PLUMB BOBS

POYYARA

FRONT VIEW

AXIS ALIGNMENT CHECK

MEASURE PERPENDICULAR DISTANCE BETWEEN PLUMB LINE AND
HORIZONTAL TWINE & TABULATE READINGS AS SHOWN BELOW.

LOCATIONS

TWINE TO PLUMB DIST.

HALF DIFF ( Z1- Z2 / 2 ) MM

Z1 AT 0
Z2 AT 180

OF READING
A
B
C
D
E
F

POYYARA

AXIS ALIGNMENT CHECK

REPEAT THIS EXERCISE FOR 90 / 270 ORIENTATIONS

BY ROTATING THE SHELL ASSEMBLY.
LOCATIONS
270

TWINE TO PLUMB DIST. HALF DIFF ( Z1-Z2 / 2 ) MM

ENTER DIM.
Z1 AT 90
Z2 AT
OF READING

ABCDE & F

POYYARA

AXIS ALIGNMENT CHECK

PLOT THE POINTS ON A GRAPH PAPER WITH SUITABLE SCALE
DRAW A BEST FIT LINE TO PASS THROUGH ALL POINTS
THE MAXIMUM DISTANCE MEASURED FROM THE LINE IS THE MAXIMUM OUT OF
ALIGNMENT
FIND OUT MAX. OUT OF ALIGNMENT IN BOTH THE PLANES & NOTE AS
( A ) 0 - 180 DEG. = ____________
( B ) 90 - 270 DEG. = ______________

+3

+3

+2

+2

+1

+1

00

00

-1

-2
-3

-1

-2
0 - 180 DEG.

-3
POYYARA

90 - 270 DEG.

SURFACE ALIGNMENT CHECK

Y0
Y1

A(END)
B

Y2
Y3

X0
X1

X2
C

X3

Y4

X4

Y5

X5
D

Y6
Y0

X6
E (END)

X0

STAND
X0.
X6

Y0.
Y6

POYYARA

SURFACE ALIGNMENT CHECK

LEVEL THE SHELL ORIENTATIONS ( 0 - 180 , 90-270 ) VERTICALLY / HORIZONTALLY
DROP A PAIR OF PLUMBS NEAR EACH CIRC.SEAM AND ON ENDS
PUT TWINES HORIZONTALLY ON BOTH SIDES OF SHELL.
MAINTAIN EQUAL DISTANCE AT BOTH ENDS OF THE SECTIONS BETWEEN HORIZONTAL
TWINES & PLUMB.
MEASURE PERPENDICULAR DISTANCE BETWEEN OTHER PLUMBS AND HORIZONTAL TWINES
AND RECORD THE READINGS IN THE TABLE BELOW.
ROTATE THE JOB 90 AND REPEAT THE ABOVE MEASUREMENTS AT THE OTHER TWO
ORIENTATIONS AND RECORD THEM.
SURFACE MISALIGNMENT = MAXIMUM READING - MINIMUM READING.

SEAM NO

ORIENTATION
0

A ( END )
B
C
D
E ( END )

90

X0
X1
X2
X3
X4
X5
X6
X0

POYYARA

180
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y0

270

SURFACE ALIGNMENT OF SECTIONS WITH

DIFFERENT SHELL THICKNESS
Y1

A(END)

X1

THK T1
Y2

X2
B

X1 = X8 + ( T2-T1 )
IN CASES OF X2,X3,X4, ALIGNMENT IS
DIFFERENCE OF THAT W.R.T X1
IN CASES OF X5,X6,X7, ALIGNMENT
IS DIFFERENCE OF THAT W.R.T X8

Y3

X3

PLUMB BOBS
Y4

X4

Y5

X5

Y6

X6

THK T2
D

Y7

Y8

X7

E(END)

X8

SKETCH - 2
POYYARA

SURFACE ALIGNMENT OF SECTIONS WITH

DIFFERENT SHELL THICKNESS
THE DIMENSION SETTING AT ENDS ( X0 ) ARE DECIDED TAKING IN TO
CONSIDERATION OF SHELL COURSE THICKNESSES ( REFER SKETCH 2 )
FOR REST SAME PROCEDURE IS TO BE ADOPTED.

NOTE:
THE SHELL OVALITY / SHAPE SHALL BE CONTROLLED WITHIN THE LIMIT IN
ORDER TO GET BETTER ALIGNMENT.

POYYARA

TOLERANCES ON CIRC. OF SHELLS,

DENDS , CONES & BELLOWS
THE REQUIRED CIRCUMFERENCE SHALL BE COMPUTED BY THE
FOLLOWING METHOD.
REQUIRED CIRCUMFERENCE = ( ID + 2T )
WHERE,

I.D = INSIDE DIA. AS SPECIFIED IN DRAWINGS

T = ACTUAL THICKNESS MEASURED AT ENDS
PIE = VALUE OBTAINED FROM CALCULATOR

MEASURE THE ACTUAL CIRCUMFERENCE ON THE JOB.

ONLY CALIBRATED TAPES SHOULD BE USED FOR THE PURPOSE OF
MEASUREMENT.
COMPARE THESE TWO VALUES OF CIRCUMFERENCE AND CHECK THE
ACCEPTABILITY BASED ON BELOW GIVEN TOLERANCE CHART.

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TOLERANCE ON CIRCUMFERENCE
TOLERANCE ON CIRCUMFERENCE
COMPONENTS

THICKNESS OF COMPONENTS IN MM

REMARKS

UP TO 8

9 TO 18

19 TO 50

ABOVE 50

ROLLED SHELLS AT
L/S SET-UP STAGE

(+) 5
(-) 2

(+) 7
(-) 4

(+) 10
(-) 7

(+) 12
(-) 9

CIRCUM. TO BE CHECKED AT
3 LOCATIONS, 2 ENDS AND AT
CENTRE

PRESSED / FORMED
DEND, CONE &
EXPANSION BELLOW
AFTER COMPLETING
WELD JOINT IF ANY

(+ / - ) 5

(+ / - ) 8

(+ / - ) 10

(+ / - )15

IF COMPONENT IS IN SET-UP
STAGE WITHOUT WELDING
PER JOINT 3MM SHRINKAGE
SHALL BE ADDED TO BASIC
CIRCUMFERENCE.

(-0 / +10)** (-0 / +15)** (-0 / + 18)**

(-0 / + 25)**

NOTES:
THE ABOVE LIMITS ARE APPLICABLE ONLY IF NO OTHERS STRINGENT TOLERANCE IS SPECIFIED.
** THIS TOLERANCE IS APPLICABLE ONLY WHEN ABUTTING SHELLS HAS HIGHER THICKNESS
WITH OUTSIDE TAPER AND INSIDE FLUSH.

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REFERENCE LINE MARKING PROCEDURE

1 OPTICAL METHOD

2 PIN METHOD

DECIDING FACTORS
1 DIAMETER OF SHELL
2. THICKNESS OF SHELL
3. TOLERANCE ON TSR.
THE CHART BELOW RECOMMENDS THE METHOD (PIN OR OPTICS ) TO BE FOLLOWED FOR
MARKING THE REFERENCE LINE ON TOWERS WITH INTERNALS AS TSR
SHELL DIA
**TOLERANCE ON

UP TO 3500

3500-4500

>4500

>3

<,= 3

>3

<, = 3

>3

<, = 3

THICKNESS <, = 25

THICKNESS > 25

TSR LEVEL WITHIN

- P DENOTES PIN METHOD OF MARKING

- O DENOTE S OPTICAL METHOD OF MARKING / MARKING ON MACHINE BED WITH SHELL
AXIS VERTICAL.
- ** TOLERANCE ON TSR WITHIN 3 mm MEANS THAT THE SPECIFIED TOLERANCE IS + 1.5 mm
- ALL DIMENSIONS ARE IN mm

POYYARA

REFERENCE LINE MARKING / CHECKING

WITH OPTICAL INSTRUMENTS.
PLACE THE SHELL WITH THE AXIS VERTICAL.
THE BOTTOM EDGE OF THE SHELL SHALL BE AT LEAST 1 MT ABOVE THE GROUND
LEVEL.
SHELL OVALITY TO BE CORRECTED WITHIN 0.25 % OF I/D AT BOTH THE ENDS USING
SPIDERS.
THE ALIGNMENT OF THE SHELL SHALL BE WITHIN 2 MM. THIS IS TO BE ASCERTAINED
BY DROPPING PLUMBS AT FOUR ORIENTATIONS 90 DEG. APART.
THE MARKING / CHECKING SHALL BE DONE ON SHELL O/D AS WELL AS I/D BY
KEEPING THE PARAGON LEVEL OUTSIDE THE SHELL AS SHOWN BELOW

REF.LINE

LINE OF SIGHT

GROUND LEVEL

POYYARA

PARAGON LEVEL

PROCEDURE FOR REFERENCE LINE

MARKING BY PIN
METHOD
KEEP THE SHELL HORIZONTAL ON A PAIR OF TANK ROTATERS.
CORRECT THE OVALITY TO 0.25 % BOTH ENDS.
SPIDERS SHALL BE RIGID ENOUGH TO PREVENT BUCKLING.
TACK WELD A PIN OF 10 DIA AT THE CENTRE OF THE SPIDER.
THE PIN SHALL HAVE A MACHINED V GROOVE FOR THE PLUMB.
DROP A PLUMB ALONG THE GROOVE OF THE PIN.
THE PLUMB IS TO BE SUSPENDED IN AN OIL BATH.

POYYARA

PROCEDURE FOR REFERENCE LINE

MARKING BY PIN
METHOD
DIVIDE THE CIRCUMFERENCE OF SHALL APPROX. 250 mm
APART ON I/D AND O/D AS SHOWN IN SKETCH.
PUNCH MARK A CONSTANT DISTANCE FROM THE PLUMB ON I/D
AND ON O/D
JOIN THE PUNCH MARKS BY A FLEXIBLE STEEL RULE.
MINIMUM 3 POINTS ARE TO BE COVERED IN ONE SETTING OF
SCALE
ROTATE THE SHELL IN BOTH DIRECTIONS AND CONFIRM THE
REFERENCE LINE MARKED ON I/D & O/D.
WRITE THE REFERENCE LINE ELEVATION FROM I/S & O/S
WITH PAINT.

POYYARA

PROCEDURE FOR REFERENCE LINE

MARKING BY PIN METHOD
4
SPIDER
3

SPIDER

REF.LINE
1
3

POINTS e.g 1,2,3,4) 250 mm

APART

CONST.DIST
APPROX.1000

TANK ROTATERS
OIL BATH

POYYARA

PROCEDURE FOR MEASURING DCBB

DIMENSIONS
CHECK OVALITY OF SECTION AT FOLLOWING PLACES
a) OPEN END.
b) 100 mm ON BOTH SIDE OF THE CIRCS. SEAMS.
c) MIDDLE OF EACH SHELL COURSE.
( OVALITY SHALL BE WITHIN 0.5 % OF THE NOMINAL DIAMETER. )

INDIVIDUAL DCBB DIMENSIONS TO BE CONFORMED BEFORE S/U .

a) DCBB WIDTH, HEIGHT & THICKNESS.
b) HOLE DIA. & NO. OF HOLES.
c) HOLE TO EDGES DISTANCES.
d) HOLE TO HOLE DISTANCES.
e) DCBB ANGLE ( IF APPLICABLE)
CHECK AND CONFORM TSR DIMENSIONS ARE WITHIN TOLERANCE.

POYYARA

PROCEDURE FOR MEASURING DCBB

DIMENSIONS

CHECK THE FILLET SIZE OF DCBB # SHELL & DCBB # TSR

CHECK THE NDT OF DCBB # SHELL & DCBB # TSR

CHECK THE CLEAN CORNER / NO WELD AREAS AS PER DRAWING

CHECK ALL DRAWING DIMENSION OF DCBB AS SHOWN IN THE

SKETCH.

CHECK THE STRAIGHTNESS OF DCBB WITH 300mm LONG SCALE

( IT SHALL BE WITHIN 1mm. )

CHECK THE ALIGNMENT OF DCBB WITH FISHING TWINE AS

PER SKETCH.

POYYARA

DCBB MEASUREMENT PROCEDURE

ALIGNMENT WITH FISHING T WINE

DCBB

TANK ROTATOR

POYYARA

PROCEDURE FOR MEASURING TSR

DIMENSIONS

TAN LINE / REFERENCE SHELL BE CONFIRMED BY INSPECTION.

VERIFY TAN LINE / REFERENCE LINE ELEVATION.

CLEAR WELD VISUAL INSPECTION OF TSR # SHELL WELD.

CHECK FILLET SIZE OF TSR # SHELL JOINT AS PER DRAWING.

CLEAR NDT OF TSR # SHELL SEAM..

BUTT WELDS, IF ANY ON TSR SHALL BE GROUND FLUSH.

ANY DAMAGE ON TOP SURFACE OF TSR IS NOTICED, SAME SHALL BE WELD

REPAIRED & FLUSH GROUND.

CHECK THE TSR ELEVATION FROM TAN LINE / REFERENCE LINE

USE ONLY CALIBRATED TAPE AND FIXTURE WITH SPRING BALANCE TO

MEASURE

POYYARA

PROCEDURE FOR MEASURING TSR

DIMENSIONS

MEASURE THE TSR ELEVATION AT FOLLOWING PLACES

a) MINIMUM TWO READINGS PER T.S.R. SEGMENT OF LENGTH < ONE
METER
b) FOR T.S.R. MORE THAN ONE METER MEASURE NEAR BOTH ENDS &
EVERY ONE METER FROM OPEN END. ( i.e. ONE PASS, TWO PASS, OR
FOUR PASS TRAY )

CHECK THE FLATNESS OF TSR - (MAX. - MIN. READING IN ELEVATION IS THE

TSR FLATNESS )

CHECK THE PITCH BETWEEN THE ADJACENT TSR

CHECK THE PERPENDICULARITY OF TSR

CHECK THE STRAIGHTNESS WITH 300 mm LONG SCALE AND IT SHALL BE

WITHIN 1mm

POYYARA

PROCEDURE FOR MEASURING TSR

DIMENSIONS
TSR

MEASURING LOCATION
(BOTTOM)

REF. LINE

5 KG PULL

FIXTURE

MEASURING TAPE

POYYARA

TANK ROTATOR

PROCEDURE FOR MEASURING TSR

DIMENSIONS

FLATNESS / LEVEL OF TSR

TRISQUARE

PITCH

TSR

POYYARA

PERPENDICULARITY

STRADDLING OF RADIAL NOZZLES ON DENDS

HYPOTHETICAL DATA FOR NOZZLE :

NOZZLE INCLINED AT AN ANGLE OF 45 DEG. TO THE CENTRE LINE OF THE

VESSEL ( SEE SKETCH-1 )

ORIENTATION OF NOZZLE 315 DEGREES. (SEE SKETCH - 2 )

FLANGE FACE

90

90
B

45

180

0
315

180
A
270

270
SKETCH 1

SKETCH 2

POYYARA

SKETCH 3

STRADDLING OF RADIAL NOZZLES ON DENDS

PROCEDURE :

MEASURE FOUR FOUR QUADRANTS OF THE FLANGE FACE ALSO MARK THE
ORIENTATION LINES i.e. 0-90-180-270 ON THE FLANGE FACE.

CHECK THE CENTRE-LINE MARKING OF THE DENDS

CALCULATE THE VALUE OF CIRCUMFERENTIAL DISTANCE FOR 45 DEG.(i.e. 315-270

DEG.) BASED ON FLANGE OUTSIDE CIRCUMFERENCE.

MARK POINT A ON FLANGE FACE AT A DISTANCE EQUAL TO CALCULATED

CIRCUMFERENTIAL DISTANCE. (IN POINT NO.3, ABOVE) IN COUNTERCLOCKWISE DIRECTION FROM 270 DEG. (SEE SKETCH 3 )

SIMILARLY MARK POINT B IN COUNTER-CLOCKWISE DIRECTION FROM 90

DEGREES.

JOIN POINTS A AND B BY A STRAIGHT LINE.

MATCH THIS LINE SO OBTAINED (LINE A-B) WITH THE ORIENTATION LINE OF 315
DEGREES MARKED ON THE DEND.

POYYARA

HYDROTEST
ENSURE FOLLOWING PRIOR TO WATER FILLING

1. COMPLETION OF WELDING ON PRESSURE PARTS

2. COMPLETION OF ALL NDT TO THE ACCEPTABLE STAGE
3. CLEARANCE OF ALL PENDING NCR / DCR, IF ANY.
4. FINAL CLEARANCE OF MATERIAL CLEARED PROVISIONALLY
5. TESTING OF P TC / MTC, IF ANY, TO THE ACCEPTABLE TEST
RESULTS
6. ALL DIAMENSIONAL CHECK WITHIN THE ACCEPTABLE LIMIT

POYYARA

HYDROTEST
ENSURE FOLLOWING PRIOR TO WATER FILLING

7 VESSEL IS KEPT ON HYDRO TEST SADDLES IN THE

SPECIFIED ORIENTATION AS PER THE DRG. ISSUED BY
DESIGN DEPT.
8 ALL LONG SEAMS & CIRC. SEAMS ARE MADE VISIBLE
FOR INSPECTION.
9 IF JOB IS PRIMER COATED, ALL PRESSURE WELD
JOINTS ARE CLEANED FREE FROM PAINT.
10 GASKETS & GASKET SEATINGS ARE CHECKED FOR
ANY DAMAGE

POYYARA

HYDROTEST
ENSURE FOLLOWING PRIOR TO WATER FILLING

11 INSIDE SURFACE IS CLEANED

12 AIR VENDING ARRANGEMENTS ARE DONE INSIDE
WHEREVER REQUIRD
13 JOB HARDWARES & GASKETS SHOWN IN DRAWING
ARE ASSEMBLED EXCEPT HARDWARES SPECIFIED
FOR HYDROTEST.
14 ALL FASTENERS ARE TIGHTENED TO REQUIRED
TORQUE
15 ALL OPENINGS ARE CLOSSED EXCEPT TOP ONE FOR
FILLING WATER.
POYYARA

HYDROTEST
ENSURE FOLLOWING PRIOR TO WATER FILLING

16 ARRANGEMENT FOR PRESSURISING SHALL BE

THROUGH ONE OF THE NOZZLES FROM BOTTOM
17 SQUARE BAR ARRANGEMENTS ON INLET AND OUT LET
CONNECTIONS.
18 ARROW FOR DIRECTION OF WATER FLOW ON
FITTINGS TO BE VERIFIED & CONFIRMED
19 TWO PRESSURE GAUGES OR ONE PRESSURE GAUGE
AND ONE TRANSDUCER TO BE MADE AVAILABLE.
20 GRADUATIONS ON GAUGES - TWICE THE TEST
PRESSURE ( 1.5 TO 4 TIMES THE TEST PRESSURE).
POYYARA

HYDROTEST
ENSURE FOLLOWING PRIOR TO WATER FILLING

21 GAUGES & TRANSDUCERS SHALL BE CALIBRATED

WITH CALIBRATION STICKER
22 PPM REQUIREMENT OF TEST WATER SHALL BE
VERIFIED AND CONFIRMED.
23 HYDROTEST PUMP (HIGH PRESSURE LOW
DISCHARGE OR LOW PRESSURE - HIGH DISCHARGE
SHALL BE MADE AVAILABLE
24 HIGH DISCHARGE PUMPS SHALL NOT BE USED FOR
VESSELS WITH VOLUM BELOW 10 CUB.MTR

POYYARA

HYDROTEST
WATER FILLING, PRESSURISING & INSPECTION

1. WATER SHALL BE FILLED FROM TOP NOZZLE AND

CLOSSED WITH TEST BLANK.
2. TEST BLANK SHALL BE WITH NIPPLE, SQUARE BAR,
PRESSURE GAUGE AND PIPE CONNECTION FOR
VENDING.
3. INLET VALVE SHALL REMAIN CLOSSED TILL WATER
FILLING
4. AFTER BLANKING THE TOP NOZZLE WITH GAUGE AND
VEND PIPE, WATER SHALL BE PUMPED FROM BOTTOM

POYYARA

HYDROTEST
WATER FILLING, PRESSURISING & INSPECTION

5. VEND PIPE SHALL BE KEPT OPEN IN A BUCKET FULL

OF WATER TO OBSERVE AIR BUBLES.
6. VENDING SHALL BE CONTINUED TILL THE AIR BUBLES
IN THE BUCKET IS DISAPEARED.
7. CLOSE THE OUT LET VALVE ON TOP & CONNECT THE
GAUGE TO LINE PRESSURE.
8. ISOLATE THE GAUGE AT THE BOTTOM FROM LINE
PRESSURE AND PUMP THE WATER IN.
9. RAISE THE PRESSURE TILL 50% OF TEST PRESSURE.

POYYARA

HYDROTEST
WATER FILLING, PRESSURISING & INSPECTION

10. OPEN THE INLET GAUGE TO PRESSURE LINE AND

VERIFY THE PRESSURE ON BOTH GAUGES.
11. INCRESE THE PRESSURE IN INCREMENTS OF 10%
OF TEST PRESSURE
12. STOP PUMPING FOR 5 MINUTES AFTER EACH
INCREMENT OF 10% OF RISE IN PRESSURE.
13. ISOLATE THE INLET PRESSURE GAUGE WHEN PUMP
IN OPERATION.

POYYARA

HYDROTEST
WATER FILLING, PRESSURISING & INSPECTION

14. CONNECT THE INLET PRESSURE GAUGE TO LINE

PRESSURE WHEN PUMP IS STOPED FOR PRESSURE
VERIFICATION
15. WHEN TEST PRESSURE IS REACHED, STOP
PUMPING, CONNECT INLET GAUGE TO PRESSURE
LINE AND HOLD FOR 30 MIN (AS SPECIFIED IN SPEC)
AND OBSERVE THE VESSEL FROM DISTANCE.

POYYARA

HYDROTEST
WATER FILLING, PRESSURISING & INSPECTION

16. REDUCE THE TEST PRESSURE TO ABOVE DESIGN

PRESSURE AND INSPECT ALL CONNECTIONS FOR
LEAKAGE
17. IF ANY LEAKAGE IS OBSERVED THROUGH GASKET
CONNECTION, REPEAT THE TEST AFTER
DEPRESSURISE THE VESSEL & TIGHTEN THE
STUDS / NUTS.
18. IF ANY LEAKGE IS OBSERVED FROM WELD OR
PARENT METAL, DRAIN THE WATER, REPAIR THE
LEAK AND REPEAT THE TEST
19. TIME, TEMPERATURE & PRESSURE CHART
WHEREVER SPECIFIED SHALL BE OBTAINED
POYYARA

HYDROTEST
IMPORTANT SAFETY POINTS IN HYDROTEST

DRAIN THE VESSEL ONLY WHEN TOP OUT LET IS

KEPT OPEN

USE MINIMUM 2 GAUGES FOR ANY HYDROTEST

NEVER USE HIGH DISCHARGE PUMPS FOR

TESTING LOW VOLUM VESSELS. ( VOLUM LESS
THAN 10 M3).

NEVER PRESSURISE ANY VESSEL ABOVE TEST

PRESSURE

POYYARA

Thank You