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245
IS 804
ASME section-IX
IS 813
IS 814
Covered Electrodes for manual metal arc welding of carbon and carbon
manganese steel- Specification.
IS 816
Code of practice for use of metal arc welding for general construction in
mild steel
IS 5206
IS 6419
Welding rods and bare electrodes for gas shielded arc welding of
structural steels- specification
IS 9604
IS 9595
IS 13007
Tungsten electrodes for inert gas shielded arc welding and for plasma
cutting and welding
IS 2811
IS 3664
IS 822
IS 3658
IS 13805
ASTM A262
IS 2062
IS 1079
ASTM A240
IS 6911
ASTM A 479
Standard specification for stainless steel bars and shapes used in boilers
and other pressure vessels.
3. Technical Parameters
Approximate capacity
Quantity required
Material of fabrication
DM water
4. Material of Construction
S.S. structural steel shall be of SAIL / Tata / Jindal / Reputed equiv. make.
The tanks, their openings, mounting framework and other accessories shall be fabricated out
of material as per Sch B.
All S.S. Plates should conform to the following points:
a) Plates shall be passivated.
b) Surface finish 2D as per ASME Section II SA 480.
c) Chemical composition and mechanical properties as per ASME Section II .
d) All the plates used shall be fairly straight, flat and free from surface and internal defects
such as pitting laminations, cracks etc.
5. Fabrication procedure
Cutting:
Parts may be cut to shape and size by mechanical means such as machining shearing,
grinding to produce a smooth finish surface. Exposed edges (inside and outside) shall be
rounded to a radius of at least 3mm.
Forming shell section and head:
All the parts for shell section shall be trimmed to the required shape by any process that will
not unduly impair the physical properties of the material.
If the plates are to be rolled the adjoining edges of longitudinal joints of cylindrical tank
shall first be shaped to the proper curvature by preliminary rolling or forming in order to
avoid objectionable flat spots along the completed joints.
6.
Welding procedure
All stainless steel welding shall be made by tungsten inert gas welding technique (T.I.G.).
Weld Joints:
Supplier shall prepare his own fabrication drawing indicating detailed welding joint
specifications and submit it for purchasers approval prior to start with fabrication.
Welding process:
All welding process should satisfy the minimum requirement of ASME Sec. VIII and all the
welders involved in welding should be qualified as per ASME Sec. IX Boiler and Pressure
Vessel Code.
No mechanical blow shall be applied except as permitted for peening, providing minimum
permissible dimensional changes.
Fillet welds:
In making fillet welds the metal shall be deposited in such a way that adequate penetrations
in to the base metal at the root of the weld is as per code requirement.
Parts to be joined shall be smooth, uniform and free from the loose scales.
Plates that are being welded shall be fitted, aligned and retained in position by suitable
means during the welding operations.
Tacking or other appropriate means may be used to hold the edges to be welded in line.
The edges of butt joints shall be held during welding so that they should not have an offset
of more than 1.5mm for longitudinal as well as circumferential seams. When fillet welds are
used the lapped plates shall fit closely and be kept in contact during welding.
Miscellaneous welding requirements:
The welding process should be such that proper fusion and penetration are obtained and by
which the base of the weld remain free from impurities.
If the welding is stopped for any reason extra care shall be taken in restarting to get the
required penetration and fusion.
When single welded joints are used, particular care shall be in aligning and separating the
components to be joined so that there will be complete penetration and fusion at the bottom
of the joint for its full length.
Repair of weld defects
Visible defects such as cracks, pinholes, incomplete fusion and defects by the hydrostatic
test shall be removed by mechanical means after which the joints shall be re-welded. The
weld metal may be peened when it is deemed necessary or helpful to control distortion, to
release the residual stresses or to improve the quality of welds.
8. Testing :
General:
The manufacturer should have the responsibility of providing to the inspector all specified
information for assuring the quality control of the tank, the detailed examinations, and tests
required that are performed at different stages of fabrication, which are necessary for the
same. The manufacturer of the tank shall arrange for the inspector to have free access to
such places of their works as are concerned with supply of material for the tank, when so
requested. The inspector should also be permitted free access to all parts of manufacturers
shop that concerns the fabrication of tank and to the site of field erected tank during the
period of assembly and testing of tank. The manufacturer shall keep the inspector informed
of progress of the work and shall notify him reasonably in advance when tank will be ready
for any required test or inspection.
Material Used in Fabrication:
All stainless steel materials used for the fabrication of the tanks shall be tested as per
relevant ASTM standards, for conformance to chemical composition, mechanical properties,
metallurgical structure and resistance to sensitization at a laboratory of purchasers choice.
The cost of such testing shall be borne by the fabricator.
The tested and approved materials shall be identified and marked by the purchasers
authorized representative. The markings are to be carried on to the portions cut from the
approved stock of material. Hence, the cutting layout is to be made in the presence of the
purchasers authorized representative.
The plates used for the fabrication shall be examined to ensure that they are free from
laminations and surface cracks.
Before attaching nozzles, manhole frames nozzle reinforcement and other accessories to the
inside or outside of the tank, they shall be examined to make certain that they fit properly to
the tank curvature.
The inspector shall satisfy himself that dimensional requirement have been met. This shall
include making such dimensional measurements, as he consider necessary.
Welding Procedure:
Inspector shall assure himself that the welding procedure employed in fabrication of tank
has been qualified under provision of section IX. The manufacturer shall submit the
evidence to the inspector that the requirements have been met.
Manufacturer shall certify that all welds on the tanks have been done only by welders and
welding operators who have been qualified under the requirements of section IX of ASME
Boiler and Pressure Vessel code.
The manufacturer shall make available to the inspector a certified copy of the qualification
test of each welder / welding operator. The inspector shall have the right at any time to call
for and witness the test for welding procedure and ability of any welder.
Weld Joint Inspection:
All welds, root pass, and final pass will be subjected to D.P. test, for the purpose of detecting
possible weld defects. Article 6 of ASME Section V shall be applied for the detailed
requirements in methods, procedures and qualifications unless specified herewith,
acceptance standard shall apply as specified in Appendix 8 of ASME Section VIII Div-1.
Unacceptable imperfections shall be removed and re-examination made to achieve the
complete removal. Whenever welding is required after defect is removed the area shall be
cleaned and welding performed in accordance with qualified procedure. Completed repairs
shall be re-examined by method originally used for detection.
All butt-welded joints are to be D.P. tested (100%).
Repair of welding shall be performed using qualified procedure and in manner acceptable to
the inspector.
The manufacturer shall certify that personnel performing D.P. have been qualified in
accordance with codes/standards.
Procedure:
Following shall be submitted for approval by purchaser:
Tare in kg.