Inspection of Pressure Vessel Construction based on ASME Sec. VIII

Inspection of Pressure Vessel Construction based on ASME Sec. VIII

The Inspection of Pressure Vessel Construction course based on ASME Section VIII is designed to provide individuals with the knowledge and skills required to inspect pressure vessels during their design, fabrication, and testing stages, ensuring compliance with the ASME Boiler and Pressure Vessel Code. This course is crucial for professionals involved in quality control, inspection, and testing in industries like oil and gas, petrochemicals, and power generation.

Objectives of the Course:

• Understand ASME Section VIII requirements for the design, fabrication, and inspection of pressure vessels.
• Learn inspection techniques for material, welding, non-destructive testing (NDT), and pressure testing.
• Gain knowledge of pressure vessel design principles and how to ensure compliance with codes and standards.
• Develop practical skills for performing inspections, identifying defects, and reviewing documentation.
• Understand roles and responsibilities of inspectors, authorized inspectors (AI), and manufacturers in the pressure vessel construction process.

Key Topics Covered in the Course:

1- Introduction to ASME Section VIII

• Overview of the ASME Boiler and Pressure Vessel Code (BPVC) and its divisions.
  • Division 1: Moderate pressure vessels.
  • Division 2: Higher-pressure vessels.
  • Division 3: Very high-pressure vessels.
• Scope and applicability of ASME Section VIII for different types of pressure vessels.
• Understanding the ASME code stamping system (e.g., U stamp, UM stamp).

2- Pressure Vessel Design and Materials

• Key design considerations according to ASME Section VIII, including wall thickness calculation, material selection, pressure limits, and safety factors.
• Introduction to design formulas and rules for internal and external pressure design.
• Material selection criteria as per ASME Section II (Materials) and their influence on vessel design.
• Material testing requirements and certification (Material Test Reports or MTRs).

3- Fabrication Process of Pressure Vessels

• Key steps in the pressure vessel fabrication process.
  • Cutting, forming, and assembling of pressure vessel parts.
  • Joint design, weld preparation, and fitting.
• Inspection points during the fabrication process, including joint alignment, welding preparation, and cleanliness of surfaces.

4- Welding Inspection Based on ASME Section IX

• Welding processes commonly used in pressure vessel fabrication (SMAW, GTAW, GMAW, etc.).
• Welding Procedure Specification (WPS) requirements and Procedure Qualification Records (PQR) according to ASME Section IX.
• Welder qualification tests and the inspection of welders’ performance.
• Inspection criteria for weld quality, including visual inspection of surface defects, undercutting, and porosity.
• Pre-weld, in-process, and post-weld inspections to ensure compliance with the welding procedure and quality standards.

5- Non-Destructive Testing (NDT) Methods

• Overview of ASME Section V (NDT Methods) and their application in pressure vessel inspection.
• Common NDT techniques used for pressure vessel inspection:
  • Radiographic Testing (RT): Internal weld flaw detection using X-rays or gamma rays.
  • Ultrasonic Testing (UT): Detecting subsurface defects by using high-frequency sound waves.
  • Magnetic Particle Testing (MT): Detecting surface and near-surface discontinuities.
  • Liquid Penetrant Testing (PT): Detecting surface defects using dye penetrants.
  • Visual Testing (VT): Primary inspection method for surface defects, performed before and after welding.
• NDT procedure development and qualification.
• Interpreting NDT results and deciding on the necessary corrective actions.

6- Pressure Testing Requirements

• Types of pressure tests required by ASME Section VIII, including hydrostatic testing and pneumatic testing.
  • Hydrostatic Test: Pressure vessels are filled with water and pressurized to 1.3 times their design pressure.
  • Pneumatic Test: Vessels are tested with air or another gas, often used for special cases where hydrostatic testing isn’t feasible.
• Safety procedures and risks involved during pressure testing.
• Inspection requirements during and after pressure testing (e.g., checking for leaks, deformation, and overall vessel integrity).

7- Post-Weld Heat Treatment (PWHT)

• Conditions under which Post-Weld Heat Treatment (PWHT) is required.
• Importance of PWHT in relieving residual stresses and improving weld properties.
• Monitoring and inspection of PWHT procedures to ensure compliance with the WPS.

8- Dimensional and Tolerance Inspections

• Dimensional checks of pressure vessels to ensure compliance with design specifications.
  • Out-of-roundness and straightness tolerances.
  • Nozzle locations, flange alignments, and other critical dimensions.
• Use of inspection tools such as calipers, micrometers, and gauges.

9- Documentation and Record Review

• Review of key documents such as:
  • Material Test Reports (MTRs).
  • Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR).
  • Welder qualifications and performance records.
  • Non-Destructive Testing (NDT) reports.
  • Pressure test records.
  • Post-Weld Heat Treatment (PWHT) records (if applicable).
  • Inspection checklists and final inspection reports.
• Importance of proper documentation for the certification process.

10 – Marking, Stamping, and Certification

• Requirements for marking and stamping pressure vessels.
• Understanding the ASME Code Stamp system.
• Process for obtaining ASME certification and ensuring compliance with regulatory bodies.

11- Authorized Inspector (AI) Responsibilities

• The role of the Authorized Inspector (AI) in overseeing and verifying all stages of pressure vessel construction.
• AI’s authority to ensure compliance with ASME codes and issue certification upon successful completion of inspections.

Target Audience:

• Inspectors: Aspiring or current pressure vessel inspectors looking to enhance their knowledge of ASME codes.
• Welding Engineers: Professionals involved in welding processes and quality control.
• Quality Control Engineers: Those responsible for ensuring that pressure vessels meet design and code requirements.
• Fabricators: Individuals involved in pressure vessel manufacturing.
• NDT Technicians: Personnel involved in the non-destructive testing of welds and materials.

Certification:

Upon completion of the course, participants typically receive a certification that demonstrates their knowledge and skills in pressure vessel inspection based on ASME Section VIII. This certification is valuable for careers in industries requiring rigorous inspection and quality assurance of pressure vessels.