This procedure defines the types and extent of inspection and testing to be carried out to verify activities related to holiday detection of applied external coating of pipingFull description
Full description
J UTASAMA AMA SDN. BHD. TUBE TO TUBESHEETJ OINT INT(MO (MOC K-UP K-UP TEST) PROC EDURE &TUBE EXPANSIO XPANSION N PROC EDURE
Doc ument Titl Title e Revision No.
Revision Date Da te
Doc ument ument No. Page Pa ge Number Numbe r
1 OF OF 2
TUBE TO TUBESHEETJ OINT (MOC MOC K-UP K-UP TESTPROC EDU EDURE) 1.0
SCO SCOPE &RESPONSIBILITIES 1.1 1.2 1.3
2.0
This his procedur proce dure e is is ap plied plied for c onduc ting ting Moc k-up tes testt for tube tube to tubes tubesheet heet joint joint.. Produc Produ c tion Depa Dep a rtment is is respons espo nsible ible for p rep a ring the test test sp ec imen imen a nd tes te sting ting equipment. Quality Control Inspector is responsibility to conduct the testing and record all the data.
SPEC IMENT & EQ EQUIPMENT UIPMENT Testblock Test block (simul (simula a ting ting the tubesheet) tub esheet) - thicknes thic kness s of the test test bloc k may be b e les le ss but not no t necessary be more than 50mm. Tubes - materia materia l and dimension dimension are a s to be b e used used in prod prod ucti uc tion. on. Tubes Expander - HB type type Expa nder nde r with with adjus a djustab table le ba ll beari be aring ng c ollar a nd pneumatic pne umatic d rive ive tool. too l. Welding Process oc ess - GTAW process. Mechanical Testing - External External mec mec hanica ha nica l testi testing ng lab orator orato ry.
2.1. 2.2. 2.3. 2.4. 2.5.
3.0
PROC EDURE 3.1
3.1.1
Prep aration ara tion of Te Te st Bloc Bloc k
Test est Block A for for Ma c rosc osc opi op ic Examin Examination ation. 25mm
25mm 25mm a a 25mm
D
A
B
C
Figure 1
a. b. c. d.
Test est block bloc k for Micr Mic rosc osc opi op ic Examin Examinati ation on shall shall be pr p repared ep ared as per pe r Figure gure 1. 1. Tube spa spa c ing a, and weld detail to be used used a re as per pe r ac tual tual joint joint for the the heat exchanger. Tubes materi material, size and thic thic kness ness are as per pe r ac tual tual hea heatt exc exc hange r. Tube length shall b e the thicknes thic kness s of tube p late p lus 25mm 25mm minimum. minimum. Saw cut will be made by mechanical testing laboratory after completion of welding a nd ex e xpa nsion nsion of the test test piece piec e on o n referenc referenc e line line A, A , B, B, C a nd D. Sa Sa w c ut D shall be mad e a t a stop/ start posit position. ion.
J UTASAMA SDN. BHD. Doc ument Title Revision No.
e.
3.1.1
TUBE TO TUBESHEETJOINT(MOCK-UP TEST) PROCEDURE &TUBE EXPANSION PROCEDURE Revision Date
Doc ument No. Page Number
2 OF 2
Eac h weld region on one surfac e of ea ch saw cut shall be carefully prepa red by emerying to a minimum 180's grit emery finish, and then etched in suitable reagent to reveal the weld structure.
Test Block B for Weld Strength Test
Figure 2 a. b. c.
3.2
3.3
3.4 3.5 3.6 3.7
4.0
Test Bloc k for Weld Strength Test shall be prepared as per Figure 2 and their tube to tubesheet joint detail. Tubes material, size and thickness are as per ac tual heat exchanger. Tubes length shall be minimum 200mm. Saw cut will be made by mechanical testing laboratory after completion of welding and expansion on the reference line A and B.
Dimensions listed below shall be rec orded for eac h tube a nd tube holes. a. Tube holes ID b. Tubes ID c. Tubes OD Insert the tubes into tube p late and tack weld on the reverse side of tube plate. J oint configuration shall be a s per actual heat exchang er. Quality Control Inspector to inspect the fit-up of tubes-to-tubesheet to ensure that the joint configurations are correct. Welding to be performed on same proc ess and po sition to be used in production weld. Visual inspection to be c arried out after complete welding. Tubes are then expa nded using tube expender to the required thinning ratio. The Thinning ratio shall be b etween 3% and 6% of the original tube thickness. Tube ID after expa nsion are measured a nd rec orded for calculating the thinning ratio.
EXAMINATION OF TESTPIECE & RECORD 4.1
The completed test piec es shall be examined as follow: a. Visual examination b. Dye Penetrant examination c. Microscopic examination for the test piece A d. Pull Test (Weld Strength Test) for test piece B
4.2 4.3 4.4
The weld shall meet the requirements of ASME Sec tion IX 2015 Ed. The mechanical testing lab oratory shall prepare Microscopic a nd Pull Test Report. J utasama's Quality C ontrol Engineer will prepare WPS, PQR and WQT for the testing.
