Bechtel France S.A.S.

Reliance Petroleum Limited

Jamnagar Export Refinery Project

Project Engineering Specification

25194-3PS-GAW-002
(Previously Issued as 22960-3PS-GAW-002)

Inspection of Castings for General Pressure

Service

16/03/06

Issued for Construction

AF

WL

DH

19/01/06

Issued for Design

AF

WL

RL

02/12/05

Issued for Approval

AF

WL

RL

Rev

Date

Revision

By

Chkd

Appr

25194-3PS-GAW-002 Rev 2

Client

Page 1 of 6

Reliance Petroleum Limited

Jamnagar Export Refinery Project

Contents
1. Scope................................................................................................................................................3
2. General..............................................................................................................................................3
3. Casting Inspection Requirements......................................................................................................3
4. Casting Quality Designation.............................................................................................................4
5. Inspection Procedures And Acceptance Standards...........................................................................4
6. Repair Procedures.............................................................................................................................5
7. Hydrostatic Testing...........................................................................................................................6
8. References.........................................................................................................................................6

25194-3PS-GAW-002 Rev 2

Page 2 of 6

Reliance Petroleum Limited

Jamnagar Export Refinery Project

1.

Scope
This Specification covers inspection requirements for castings, suitable for service as pressure
containing parts. For rotating equipment, the inspection requirements are included in the
following specifications:
for API pumps see 25194-3PS-MP-001
for non API pumps see 25194-3PS-MP-002
for Centrifugal/Axial Compressors see 25194-3PS-MP-001
Any relevant Process Licensor requirements are to be in accordance with the relevant Project
Specifications as referenced in the material requisition.

2.

General

2.1.

All castings shall be manufactured in accordance with the requirements given in the Purchase
Order/Contract.

2.2.

Supplier shall demonstrate that he has the experience, quality control and personnel to assure
the production of consistently sound castings.

2.3.

Supplier may submit an alternative inspection programme for review and approval at the bid
stage. The submittal should address all of the issues referred to in this Specification.

3.

Casting Inspection Requirements

A castings quality designation, which indicates inspection requirements are defined as
follows:
a)

Quality A

Visual examination (Clause 5.2) plus magnetic particle examination (Clause 5.3) or dye
penetrant examination (Clause 5.4) of all accessible interior and exterior surfaces, including
machined surfaces, plus radiography of critical areas (Clause 5.5).
b)

Quality B

Visual examination (Clause 5.2) plus magnetic particle examination (Clause 5.3) of all
accessible interior and exterior surfaces including machined surfaces. For non-magnetic
materials, dye penetrant examination methods shall be used (Clause 5.4).
c)

Quality C

Visual examination (Clause 5.2) plus magnetic particle examination (Clause 5.3) of machined
surfaces. For non-magnetic material, dye penetrant examination methods shall be used
(Clause 5.4).

d)

Quality D

25194-3PS-GAW-002 Rev 2

Page 3 of 6

Reliance Petroleum Limited

Jamnagar Export Refinery Project
Visual examination in accordance with Clause 5.2

4.

Casting Quality Designation

The casting quality designation is for each valve or group of valves will be stated in the
purchase order.

5.
5.1.

Inspection Procedures And Acceptance Standards

Surface Preparation
Surfaces of all castings shall be suitably cleaned by chipping or blasting.

5.2.

Visual Examination
All castings shall be visually examined and proven free from sand, scale, cracks,
tears, voids and other harmful effects. Acceptance levels shall be as specified in
MSS-SP-55.

5.3.

Magnetic Particle Examination (MPE)

MPE shall be carried out on ferritic castings in accordance with ASTM E709.
Acceptance Criteria

5.4.

Valves

ASME B16.34, Annex C, Section 2.1

Other
components

ASME VIII 2004, Div.1 Appendix 7,

Section 7.3

Dye Penetrant Examination (DPE)

DPE shall be conducted on non-magnetic castings and where MPE is not
feasible. The testing procedure shall be in accordance with ASTM E165.
Acceptance Criteria

5.5.

Valves

ASME B16.34, Annex D, Section 2.1

Other
components

ASME VIII 2004 , Div.1 Appendix 7,

Section 7.3

Radiographic Examination
Radiographic examination of critical areas only shall be conducted as specified in
the appropriate specification referred to below. Critical areas are defined as an
abrupt change in section, weld ends, at risers, gates or feeders and areas of
highest stress. For valve castings critical areas are as defined Section 8.3 of
ASME B16.34.
Radiographic procedure and acceptance standard shall be as follows:
Procedure

25194-3PS-GAW-002 Rev 2

Page 4 of 6

Reliance Petroleum Limited

Jamnagar Export Refinery Project
Valves
ASME B16.34, Annex B
Other
components

ASME V 2004, Articles 3

Acceptance Level

5.6.

Valves

ASME B16.34, Annex B

Other
components

ASME VIII 2004, Div. 1, Appendix

7, Section 7.3

Ultrasonic Examination
Ultrasonic examination may be carried out by agreement where radiographic
inspection is not feasible
Procedure
ASME VIII, Div. 1, Appendix 7 or ASTM A609
Acceptance Level
ASTM A609
Quality level as follows:

5.7.

Thickness

Acceptance Level

< 50mm

50-100mm

> 100mm

Dimensions
All initial castings and randomly selected castings shall be dimensionally checked
to ensure compliance with the minimum wall thickness specified and the overall
dimensions.

5.8.

Submittal of NDE Procedures

For quality standard A & B, NDT procedures shall be submitted for review.

6.

Repair Procedures

6.1.

The repair of any defect found on castings by plugging, peening, use of plaster or cement
compounds, or impregnation by plastic materials or similar compounds is prohibited. Repairs to the
pressure boundary shall be by welding only.

6.2.

Major repairs are defined as those that require removal of 20% of the casting wall thickness
or 25 mm which ever is less, or those that result in a repair area that exceeds 6,500 mm2. For quality
standard A & B, major weld repair procedures shall be submitted for approval.

25194-3PS-GAW-002 Rev 2

Page 5 of 6

Reliance Petroleum Limited

Jamnagar Export Refinery Project
All repairs by welding shall be made by procedures/welders in accordance with ASTM A488.
The analysis of the deposited weld metal shall conform to the nominal analysis of the parent casting.

6.3.
6.4.

After major weld repairs all castings shall be heat treated or stress relieved as required by the
casting specification, however, the Buyer reserves the right to specify solution heat treatment for
repairs to austenitic stainless steel where considered applicable for process or environmental reasons.

6.5.

All weld repairs shall be re-examined by appropriate methods and as defined in Section 3.0.

7.

Hydrostatic Testing
Unless specified in an individual specification, (for example API) hydrostatic testing
requirements applicable to steel casting shall be in accordance with Paragraph 11 of ASTM
A703.

8.

8.1.

8.2.

References
A 703

General Requirements applicable to steel castings for pressure containing parts.

A 488

Practice for steel castings, welding, qualification of procedures and personnel.

E 165

Liquid penetrant inspection

E 709

Magnetic particle examination

A609

Castings, carbon, low alloy and martensitic stainless steel ultrasonic examination
thereof.

ASME Boiler and Pressure Vessel Code

Section V

Non destructive examination

Section VIII

Pressure Vessels Div. 1

Quality Standard For Steel Castings - Visual Examination

MSS-SP-55

8.3.

ASME B16.34

25194-3PS-GAW-002 Rev 2

Valves - flanged, threaded and welding end

Page 6 of 6