Introduction

Manufacturing

Process of H.E.
Classification of Heat Exchangers
Activities of inspection
Introduction to NDT
Assembly of equipment
Hydro Test
Dispatch

Heat exchanger is a Heat Transfer

device that transfers thermal
energy between two fluids
available at different temperature.
Used in Power Plants,
Petrochemical Plants, Petroleum
Refineries

Heat Exchanger
CHANNEL
OUTLET
NOZZLE
GUIDE RING

HOLDING
STUD FOR
COVER

SHELL

CHANNEL
HEADER

TUBES

TUBESHEET

CHANNEL
THREADS

CHANNEL
INLET
NOZZLE

BAFFLES

Heat Exchanger
OUTER
COMPRESSION
RING

TUBESHEET
PUSHBOLTS
DIAPHRAGM

CHANNEL
GASKET

SPLIT
RING

SPACERS

CHANNEL
BOX

INTERNAL
FLANGE

CHANNEL
COVER

THREADED
LOCK RING

NOZZLE
GLAND

OUTER
PUSHBOLTS /
PUSHRODS

INNER
PUSHBOLTS /
PUSHRODS

INNER
COMPRESSION
RING

INTERNAL
SLEEVE

PARTITION
COVER

GLAND
BOLTS

 Generally

classified in two types:

1) HH type 2) HL type
HH Type: Both shell side & Tube side at high
pressure. Tubesheet designed for differential
pressure.
HL Type: Tubesheets get independently
exposed to full pressure from Shell side or
Tube side. Usually Tube side is high pressure.

HH type

HL type

ACTIVITIES
Inspection
InspectionPlanning
Planning

In-Process
In-Process Inspection
Inspection

Final
Final Inspection
Inspection

OF INSPECTION

1.1.Quality
QualityAssurance
AssurancePlan
Plan
2.2.Inspection
Checklist
Inspection Checklist
3.3.Inspection
InspectionProcedures
Procedures
4.4.Inspection
Formats
Inspection Formats
1.1.Material
MaterialInspection
Inspection
2.2.Visual
Inspection
Visual Inspection
3.3.Dimensional
DimensionalChecks
Checks
4.4.Welding
Inspection
Welding Inspection
5.5.Heat
HeatTreatment
Treatment
6.6.NDT
NDT(RT/UT/PT/MT,
(RT/UT/PT/MT,Hardness,
Hardness,
Ferrite
etc)
Ferrite etc)
1.1.Final
FinalDimensional
DimensionalCheck
Check
2.2.Leak
LeakTest
Test
3.3.Surface
SurfacePreparation
Preparation&&Painting
Painting
3.3.Final
FinalStamping
Stamping
4.4.Documentation
Documentation
5.5.Packing
Packing&&Despatch
DespatchCheck
Check

Inspection Planning
Preparation of :
1. Quality Assurance Plan
2. Inspection Checklist
3. Inspection Procedures
4. Inspection Formats

Quality Assurance Plan

PREPARATION OF QA PLAN
Input
Drawings, Codes
Customers Specification

Comments from :
Welding Engineering
Final Submission to the
Customer for approval.

QA PLAN
CUSTOMER : IOCL - PANIPAT
EQUIPMENT : CCR Platforming Reactor
(Equipment No. 202-R1/R2/R3/R4)
PROJECT NO. 23376
REF. DOCUMENTS : ASME SEC VIII-1 ED. 2001, AD 2001
CUSTOMER SPECIFICATION : 6318-00-RA-LL-6020 Rev B
SR.
NO.
1.0
1.1

INSPECTION ACTIVITY
MATERIALS INSPECTION
MATERIALS AT MILLS:
Plates, Pipes, Forgings,
Fitting, Fasteners, etc.

DESCRIPTION
Chemical analysis
Mechanical
properties (incl. Impact
test, Temper Embrittement test and
Hardness test as appl.)

REFERENCE
DOCUMENT
ASME Sec II A /
Purchase Order
/ Drawing

DOCUMENT NO. : 4P-1314-QCP R0

Page 2 of 4

ACCEPTANCE
STANDARD
ASME Sec II A /
Purchase Order /
Drawing

FORMAT OF
REPORT
Mill Test
Certificate

1.2

MATERIALS AFTER
RECEIPT (for pressure
parts)
Plates, Pipes, Forgings,
Fitting, Fasteners, etc.

&

Identification, correlation & transfer of

markings.

Chemical analysis
Mechanical properties

2.0

INSPECTION OF
FORMED
COMPONENTS

Visual & Dimensional Inspection

3.2

WPQ

ASME Sec II A
Purchase Order /
Drawing /
Mill T.C

ASME Sec II A
Drawing /
Purchase Order

Material
Clearance
Record

Visual & Dimensional inspection

NON-PRESSURE PART

WELDING INSPECTION
WPS AND PQR

---

HT as

1.3

3.0
3.1

---

Inspection by
Manufacturer /
TPI
as
applicable.

Visual & dimensional inspection

Metallograph, Other NDT
applicable
Review of test certificates

INSPECTION
L&T
TPI

QA

QA

QA

QA

QA

ASME Sec II A /
Purchase Order
/ Drawing

ASME Sec II A /
Purchase Order /
Drawing

Drawing

Drawing

Mill Test
Certificate /
Check Test
Report
Insp. Report

Drawing /
ASME Sec VIII-1

ASME Sec VIII-1

HT Chart

QA

Review for conformity of qualification

requirement

ASME Sec IX

ASME Sec IX

WPS / PQR

QA

Review for conformity of qualification

requirement

ASME Sec IX

ASME Sec IX

WPQ

QA

HT Chart review

Inspection Checklist
INSPECTION CHECK LIST :

INPUTS

Lists down stages of Inspection.

Indicates Hold, Witness & Review points.

Welding
& Testing Plan

Indicates Inspection status.

Inspection
INPUTS

Drawings
QA plan

Preparation of
Inspection
Check List
Inspection
Check List

Production

T.P.I.A
Approval

Inspection Procedures
1. NDT Procedures (RT / UT / PT / MT)
2. Hydrotest / Pneumatic test Procedure
3. Helium Leak test Procedure
4. Heat Treatment Procedures
5. Surface Preparation & Painting
6. PMI Procedures

Inspection Formats
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Material Clearance Report (PPS, PCS)

Inspection Checklist
Production Test Coupon Results
PT / MT Reports
Chemical Analysis Requisitions & Report
Ferrite Check
Heat Treatment Charts
Hardness Test Report
Hydrotest Report
Final Dimensional Report
Non-Conformity Report
Marking of Equipment / Name Plate
L&T Certificate of Test & Compliance

Visual Inspection

Visual inspection is commonly defined as the examination

of a material, component, or product for conditions of
nonconformance using light and the eyes, alone or in
conjunction with various aids.
Visual inspection often also involves, shaking, listening,
feeling, and sometimes even smelling the component being
inspected.
Visual inspection consists of at least two major processes.
The first is a search process.
The second is a process of combining relevant knowledge,
sensory input, and pertinent logical processes to provide an
identification that some anomaly or pattern represents a flaw
that poses a risk to the performance of the part.

Visual inspection is commonly employed to support other

NDT methods.
Digital detectors and computer technology have made it
possible to automate some visual inspections. This is
known as machine vision inspection.

Rolling of Shell

Dimensional Inspection
Angle gauge

diameter d2

Offset
check

Rootgap check

Circularity Check with

D/4 template
diameter d1
Ovality Check d2 - d1

Instruments used
Vernier Caliper, Measuring Tape,
Template etc

Dimensional Inspection
Nozzle Projection

Nozzle Elevation
Measuring Tape

Tan line

Elevation
Drg. Dimension
(Projection)

Instruments used
Straight Edge, Measuring Tape

Straight edge

Non-Destructive Test
1. Radiography Examination
2. Ultrasonic Examination
3. Dye-Penetrant Examination
4. Magnetic Particles Examination

Liquid Penetrant Testing

Liquid penetrant inspection is a
method that is used to reveal
surface breaking flaws by bleedout
of a colored or fluorescent dye
from the flaw.

Liquid Penetrant Testing

The technique is based on the ability of a
liquid to be drawn into a "clean" surface
breaking flaw by capillary action.

Penetration

Penetrant
Fluorescent
penetrant on surface
seeps into the crack.

Magnetic Particle Testing

Magnetic Particle Testing

Magnetic particle inspection is a method that can be used
to find surface and near surface flaws in ferromagnetic
materials such as steel and iron.
The technique uses the principle that magnetic lines of force
(flux) will be distorted by the presence of a flaw in a manner
that will reveal it's presence.

IRON POWDER

N
CRACK

Non-conformity
If any deviation, raise NCR

Assembly of Equipment

Made in India by
Larsen & Toubro Limited

WHY HYDROSTATIC TEST

To ensure the integrity of the equipment

To ensure the strength of the weld joints &
material
To ensure the strength of the nozzle flange joints
To relieve the stresses
Ensures safe and reliable performance during
the operational life

Final Documentation
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uality Control

Despatch of Equipment

Made in India by
Larsen & Toubro Limited