METHODOLOGY: PRESSURE VESSEL INSPECTION

Contents
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1. SUMMARY....................................................................................................................................5

2. GENERAL CO-ORDINATION OF THE PARTIES..................................................................................5

2.1 SURVEY.........................................................................................................................................5
2.2 MOBILIZATION................................................................................................................................5
2.2.1 PRE-MOBILIZATION..............................................................................................................................5
2.2.2 MOBILIZATION PLAN............................................................................................................................6
2.3 DESIGN & ENGINEERING WORKS........................................................................................................6
2.4 PROCUREMENT...............................................................................................................................6
2.5 INSPECTION AND EXPEDITING PROCEDURE............................................................................................7
2.6 COST CONTROL...............................................................................................................................8
2.6.1 COST CONTROL PROCEDURE..................................................................................................................8
2.7 PLANNING AND SCHEDULING.............................................................................................................9
2.8 PROGRESS REPORTING.....................................................................................................................9

3. SCOPE OF WORK.........................................................................................................................10

4. PRESSURE VESSEL INSPECTION....................................................................................................10

4.1 INSPECTION CRITERIA.....................................................................................................................10

4.2 PRE-INSPECTION...........................................................................................................................11
4.3 INSPECTION PROCEDURE.................................................................................................................11
4.3.1 EXTERNAL INSPECTION........................................................................................................................12
4.3.2 THICKNESS SURVEY............................................................................................................................14
4.3.3 STRESS ANALYSIS...............................................................................................................................14
4.3.4 INTERNAL INSPECTION........................................................................................................................15
4.3.5 NON-DESTRUCTIVE TESTING................................................................................................................16
4.4 PRESSURE TESTING........................................................................................................................16
4.5 INSPECTION OF SAFETY DEVICES........................................................................................................17
4.6 INSPECTION OF PIPING SYSTEMS.......................................................................................................19
4.6.1 PIPING DEFECTS................................................................................................................................19
4.7 INSPECTION OF PRESSURE GAGES......................................................................................................20

5. PRV MAINTENANCE....................................................................................................................21

5.1 GENERAL HANDLING RULES..............................................................................................................21

5.2 PRESSURE TESTING........................................................................................................................22
5.2.1 TEST FLUID.......................................................................................................................................22
5.2.2 SETUP & APPARATUS.........................................................................................................................22
5.2.3 TEST PRESSURE AND DURATION...........................................................................................................23
5.2.4 ALLOWABLE LEAKAGE RATE.................................................................................................................23
5.2.5 COLD DIFFERENTIAL TEST PRESSURE (CDTP) ADJUSTMENT.......................................................................24
5.2.6 TESTING PROCEDURE.........................................................................................................................24
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5.3 DISASSEMBLY AND MAINTENANCE....................................................................................................26

5.4 CALIBRATION & ADJUSTMENTS:.......................................................................................................28
5.5 RE-ASSEMBLY:..............................................................................................................................30
5.6 ACCEPTANCE CRITERIA..............................................................................................................31

6. PRE-COMMISSIONING, TESTING AND COMMISSIONING.............................................................32

6.1 AS-BUILT AND FINAL DOCUMENTATION.............................................................................................32

6.2 RESPONSIBILITIES OF PARTIES...........................................................................................................33
6.3 QUALITY CONTROL........................................................................................................................33
6.4 HEALTH AND SAFETY......................................................................................................................34
6.5 DEMOBILIZATION PLAN...................................................................................................................35

1. Introduction
Pressure vessels are critical components in industrial processes, designed to hold gases or
liquids at a pressure substantially different from the ambient pressure. Ensuring their safety,
reliability, and compliance with international standards is of utmost importance. Yastronics
Laboratory for Inspection and Calibration has developed this methodology to guide the
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systematic inspection of pressure vessels, aligning with industry standards such as API 510,
ASME Boiler and Pressure Vessel Code (Section VIII), and NACE practices.
This document outlines detailed procedures for conducting pressure vessel inspections,
addressing both internal and external factors that affect their performance and safety. The
methodology aims to identify potential risks, ensure regulatory compliance, and enhance the
operational life of the pressure vessels.

2. Objectives
The objectives of this methodology are as follows:
 Ensure the structural integrity and operational safety of pressure vessels.
 Detect and mitigate potential risks, including corrosion, cracking, and material degradation.
 Facilitate compliance with international codes and regulatory requirements.
 Extend the lifespan of pressure vessels through preventive maintenance and timely
interventions.
 Provide a detailed framework for standardized inspection practices

2.1 Survey
YASTRONICS understand the importance of visiting/conducting a site survey for familiarization
and to get full details of the understanding of sites in relation to the specified scope of work in
the tender document.

2.2 Mobilization
2.2.1 Pre-mobilization
The following shall form the main pre-mobilization activities for Yastronics:
 Acceptance of the Letter of Intent (LOI) from the client.
 Conducting a Kick-off Meeting to align objectives, expectations, and timelines.
 Reviewing and signing the Project Coordination Procedure (PCP), ensuring all parties
agree to operational protocols.
 Performing a Site Handover, confirming readiness for mobilization and project
commencement.
2.2.2 Mobilization Plan
Yastronics will mobilize its team upon the successful completion of pre-mobilization activities.
 The Project Manager will establish a Project Office supported by senior project
personnel handling technical, contractual, and site operational responsibilities.
 Immediate manpower mobilization will be initiated to enable the rapid setup of on-site
facilities, including offices and required utilities.
 The source of workforce will primarily be drawn from available internal resources or
through partnerships with entities such as HEXAGON ENGINEERING LTD (if applicable).

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 Site office locations will be determined in agreement with the client based on
availability, accessibility, and project logistics.

2.3 Design & Engineering Works

Upon contract award, Yastronics will:
1. Conduct a detailed review and update of all existing design/engineering documents.
2. Prepare specifications for long lead items and submit procurement requisitions for
client approval prior to order placement.
3. Ensure confidentiality in the handling of project documentation and enforce this among
all staff members.
4. Collaborate with vendors to review bids, ensuring all technical and contractual
requirements are met before issuing purchase orders.
5. Prepare specifications and procedures for pre-commissioning and commissioning
checks, including integrity testing.
6. Assign a Project Commissioning Engineer to oversee all pre-commissioning and
commissioning activities.

2.4 Procurement
Yastronics' procurement activities will focus on the following:
 Prioritizing the placement of orders for long lead equipment upon client approval.
 Ensuring that all vendors are ISO-certified and meet technical and quality specifications.
 Managing procurement through a dedicated team under the Project Manager, adhering
to the company’s QA Manual.
 Securing test certificates and data books from vendors, which will be audited by the QA
Manager before submission to the client.
 Promoting the use of local suppliers/manufacturers (e.g., in Nigeria or other project-
relevant locations) whenever cost-competitive and technically compliant options are
available.
 Managing transportation, quality checks, and storage for all materials and equipment to
comply with contract specifications.

2.5 Inspection and Expediting Procedure

Inspection Procedures
Yastronics will leverage its extensive inspection experience to ensure all equipment and
materials meet the highest standards:
 Conduct inspections based on detailed client specifications and approved vendor lists.
 Source genuine spare parts/materials and, where applicable, propose alternative
solutions that meet or exceed client requirements.

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 Coordinate inspection activities through trusted partners such as HEXAGON

ENGINEERING LTD, ensuring effective and timely communication with the client.
Expediting Procedure
Expediting activities will focus on:
Materials Expediting:
 Generating inquiries based on specifications and obtaining vendor proposals for client
approval
 Coordinating with clients for importation documentation, Letters of Credit, and local
quotations
 Ensuring timely dispatch and delivery of materials to the site.

Vendor Specialist Services:

 Collaborating with Original Equipment Manufacturers (OEMs) to secure specialist
services.
 Coordinating vendor schedules to align with project timelines.

2.6 Cost Control

Yastronics will develop a cost control system aligned with the client’s requirements to monitor
project expenses effectively.
 Monthly progress reports will include Cost Control Charts/Graphs to evaluate financial
status against work progress.
 A Cost Estimation Engineer will oversee any variation orders, ensuring proper
documentation and approval before execution.
 Variable Work Authorization Forms (VWAFs) will be used to secure client approval for
any additional work not covered under the original contract scope.

2.7 Planning and Scheduling

Yastronics will appoint an experienced Planning Supervisor to oversee project timelines.
 Planning will utilize advanced tools such as Microsoft Project or equivalent software to
prepare execution plans, Critical Path Networks (CPNs), and bar charts.
 Execution plans will be developed and submitted for client approval, ensuring all
activities align with contract specifications.
 Detailed sub-programs will be distributed to supervisors, with regular progress
monitoring and reporting to the Project Manager.

2.8 Progress Reporting

Yastronics recognizes the importance of consistent progress monitoring.
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 Supervisors will track and report progress regularly, highlighting deviations and
proposing corrective actions to maintain project timelines.
 The Critical Path Network and associated bar charts will guide all work schedules,
ensuring alignment with project milestones.
 Progress reports will include metrics on performance, resource utilization, and risk
mitigation measures.

3. Scope of Work

The project scope covers the methods and procedure for pressure vessel inspection, testing
and certification. The main purpose of implementing a pressure vessel inspection program is to
ensure that each pressure vessel is safely operated and maintained. Some of the benefits that
result from regularly scheduled pressure vessel inspections are listed below:

 Improvement of facility, personnel, and public safety

 Prevention of damage to the environment
 Improvement of reliability
 Reduction of operation and maintenance costs
 Minimization of unscheduled outages
 Minimization of liability

This project also includes the maintenance, recalibration and testing of all scheduled pressure
relieve valves and afterwards all tested and OK valves are recertified this summarily entails;

 Disconnection of scheduled valves

 Repairing and overhauling
 Recalibration and testing
 Recertification of tested valves
 Reconnection of certified valves

4. Pressure Vessel Inspection

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4.1 Inspection Criteria

All pressure vessels must be inspected based on the design and construction standards
outlined in the original documentation. The most commonly used standard is the American
Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (Section VIII). The
initial step in any inspection is to verify the code used during the design and fabrication stages
as indicated in the design documentation. This is critical to ensure the vessel complies with its
intended service requirements.

During inspections, the following criteria must be considered:

 Design Code Compliance: Determine whether the vessel was fabricated in accordance
with the applicable code. For vessels not fabricated to a recognized standard, an
evaluation must be conducted to confirm the factor of safety is adequate for continued
operation.
 Service Conditions: Pressure vessels are often designed to operate under specific
conditions, including the type of media contained, operating temperatures, and
pressures. These parameters should guide the inspection process to identify stress
points and risks associated with operational loads.
 Corrosion Allowances: Inspect vessels for material loss due to corrosion, especially in
areas subject to high wear and exposure to aggressive environments.
 Pressure Relief Devices: Confirm that all pressure-relieving devices meet the specified
requirements for the vessel's service conditions.
 Documentation Review: Verify all design calculations, material certifications, and
construction records. These should include joint efficiencies, welding procedures, and
material compatibility assessments.

4.2 Pre-Inspection
Before any physical inspection, a detailed review of the vessel’s operational and maintenance
history must be conducted. This step helps establish a baseline and identify areas of potential
concern. Pre-inspection activities should include the following:
1. Historical Review
 Operating Conditions: Analyze the vessel's typical operating pressures and
temperatures. These parameters provide insights into potential stress areas and
operational challenges.
 Normal Contents: Document the type of media the vessel contains (e.g., gases, liquids,
corrosive chemicals) to assess risks such as material degradation or corrosion.
 Date of Last Inspection: Review the timeline since the last inspection and any previous
findings to identify recurring issues or areas needing close attention.
 ASME Code Compliance: Check for ASME Code symbol stamping or alternative
construction marks to confirm the vessel's adherence to recognized standards.

2. Design and Fabrication Details

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Connections and Joint Efficiencies: Evaluate the type of connections used during

fabrication. This helps determine the proper joint efficiency for stress analysis during
inspections.
 Material and Serial Number Verification: Confirm the materials of construction and
serial number against design and fabrication records to ensure proper traceability.
3. Wall Thickness Surveys
 Inspect previous records of wall thickness measurements, particularly for vessels where
corrosion is a concern. Compare historical data to detect trends or accelerated material
loss.
4. Preparation for Visual Inspection
 Remove Plugs and Covers: Open all inspection ports, plugs, and covers to provide access
to critical areas.
 Cleaning: Ensure the vessel is sufficiently cleaned to allow for an effective visual
inspection of both internal and external surfaces. Cleaning may involve removing
deposits, corrosion products, or insulation covering.
 Lighting and Accessibility: Use adequate lighting and ensure all areas of the vessel are
accessible for inspection, including hard-to-reach regions.

4.3 Inspection Procedure

The type of installation given to pressure vessels should take into consideration the condition
of the vessel and the environment in which it operates. This inspection may be external,
internal, or both and use a variety of non-destructive examination techniques. The inspection
may be performed with the vessel in service or depressurized but should provide the necessary
information that allows an adequate assessment of the pressure vessel.

A thorough inspection of a pressure vessel should include the following items:

I. A thorough external examination of the pressure vessel and associated equipment

including verification of the welded connections to determine the proper joint efficiency
to employ during the stress analysis.

II. An ultrasonic thickness examination of the pressure vessel wall and dished heads and
documentation for permanent record keeping.

III. An internal examination of the pressure vessel, if required. An internal examination may
not be required if the pressure vessel is stamped with the original wall thickness and
the thickness survey shows no loss of material. Pressure vessels in which the original
wall thickness is unknown should have an initial internal examination performed to
determine the baseline condition of the vessel.

IV. Ultrasonic measurement techniques to determine the shell and dished head wall
thicknesses for each pressure vessel. Other types of nondestructive examinations

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should be performed as required for any suspect areas identified during the external or
internal examination.

V. A stress analysis based on actual wall thickness data acquired during the ultrasonic
thickness survey, and the proper joint efficiencies, based on the type of construction
used during fabrication of the pressure vessel. These results should be compared with
the requirements of the applicable code that the pressure vessel was originally
designed to, and these results should ensure that the proper safety factors are being
met.

VI. A thorough inspection of the pressure relief valves and other safety devices to ensure
the vessel is operating within its specified pressure range and is being adequately
protected. Functional testing of the relief valves should be performed by increasing the
operating pressure of the pressure vessel just slightly above the set pressure of the
relief valves to ensure the relief valve will operate as required.

VII. A hydrostatic pressure test to 1.5 times the maximum allowable working pressure
should be performed if any repairs or alterations have been made to the pressure
vessel. Hydrostatic pressure tests may be required by the inspector if there has been
some significant material loss because of corrosion or erosion.

4.3.1 External Inspection

The external inspection provides information regarding the overall condition of the pressure
vessel. The following items should be reviewed:

a) Insulation or other coverings.

If it is found that external coverings such as insulation and corrosion resistant coatings are in
good condition and there is no reason to suspect any unsafe condition behind them, it is not
necessary to remove them for inspection of the vessel. However, it may be advisable to
remove small portions of the coverings to investigate their condition and the condition of the
metal.

b) Evidence of leakage.

Any leakage of gas, vapor, or liquid should be investigated. Leakage coming from behind
insulation coverings, supports, or settings or evidence of past leakage should be thoroughly
investigated by removing any covering necessary until the source is determined.

c) Structural attachments.

The pressure vessel mountings should be checked for adequate allowance for expansion and
contraction. Adequate allowance may be provided by slotted bolt holes or unobstructed saddle

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mountings. Attachments of legs, skirts, or other supports should be examined for distortion or
cracks at welds. Pressure Vessel Mounting Supports

d) Vessel connections.

Manholes, reinforcing plates, nozzles, or other connections should be examined for cracks,
deformations, or other defects. Bolts and nuts should be checked for corrosion or defects.
Weep holes in reinforcing plates should remain open to provide visual evidence of leakage as
well as to prevent pressure buildup between the vessel and the reinforcing plate. Accessible
flange faces should be examined for distortion and to determine the condition of gasket
seating surfaces.

e) Miscellaneous conditions.

The surfaces of the vessel should be checked for erosion. Dents in a vessel are deformations
caused by contact with a blunt object in such a way that the thickness of the metal is not
materially impaired. In some cases, a dent can be repaired by mechanically pushing out the
indentation. If any distortion is suspected or observed, the overall dimensions of the vessel
should be checked to determine the extent and seriousness of the distortion. Cuts or gouges
can cause high stress concentrations and decrease the wall thickness. Depending on the extent
of the defect, it may be necessary to repair the area by welding or patching. Blend grinding
may be a useful method of eliminating some minor types of cuts or gouges.

f) Surface inspection

The surfaces of shells and heads should be examined for possible cracks, blisters, bulges, and
other evidence of deterioration, giving attention to the skirt and to the support attachment and
knuckle regions of the heads.

g) Welded joints.

Welded joints and the adjacent heat affected zones should be examined for cracks or other
defects. Magnetic particle and liquid penetrant examination are a useful means of examining
suspect areas. It is important to determine the weld configuration of the pressure vessel in
order to use the proper joint efficiency when performing stress calculations.

The Boiler and Pressure Vessel Code specifies six types of weld joints.

 Type 1 weld joints are double-welded butt joints. The quality of weld is the same inside
and outside the vessel with double-welded butt joints. Backing strips, if used, are
removed after welding. After the weld is made on one side, the other side of the joint is
cleaned and rewelded. The weld quality is the same on both sides of the joint.

 Type 2 welds are single-welded butt joints with backing strips that remain in place after
welding.
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 Type 3 welds are single-welded butt joints without backing strips.

 Type 4 joints are double full-fillet lap joints.

 Type 5 joints are single full- fillet lap joints with plug welds. Type 6 joints are single full-
fillet lap joints without plug welds. The six weld types are shown in figure 1, with their
typical welding symbols.

For joint efficiencies for welded joints subject to tension, the values depend on the type of
weld and the testing processes. The strongest joints are double-welded butt joints (Type 1).

4.3.2 Thickness Survey

We will carry out the thickness survey using an ultrasonic testing equipment. Thes certificate of
the testing equipment shall be presented to the client. The wall thickness data for each
subsequent inspection should be used for comparisons to determine if any wall thinning may
be taking place and compromising the factor of safety for the pressure vessel.

4.3.3 Stress Analysis

The thickness measurements for the shell and dished heads of the pressure vessels which were
obtained using ultrasonic techniques and the joint efficiencies based on the original fabrication
of the pressure vessel should be used to perform a stress analysis to calculate the factor of
safety. The pressure vessels designed and fabricated according to the ASME Code typically
have safety factors greater than 2.5. Pressure vessels with calculated factors of safety between
2 and 2.5 should be monitored closely, and any necessary repairs should be made to prevent
the factor of safety from becoming lower than 2. It is recommended that any pressure vessel
with a factor of safety lower than 2 be replaced.

4.3.4 Internal Inspection

An internal inspection may be required only if the ultrasonic wall thickness data indicate that
there is some wall thinning occurring or if the pressure vessel does not have a stamp indicating
the original wall thickness of the shell and dished heads. A general visual inspection is the first
step in making an internal inspection. A video borescope may also be used to facilitate the
internal inspection of a pressure vessel. All parts of the vessel should be inspected for
corrosion, erosion, hydrogen blistering, deformation, cracking, and laminations. The following
items should be reviewed

(a) Vessel connections.

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Threaded connections should be inspected to ensure that an adequate number of threads are
engaged. All openings leading to any external fittings or controls should be examined as
thoroughly as possible to ensure they are free from obstructions.

(b) Vessel closures.

Any special closures including those on autoclaves, normally termed quick actuating (quick
opening) closures which are used frequently in the operation of a pressure vessel, should be
checked for adequacy and wear. A check should also be made for cracks at areas of high stress
concentration.

(c) Vessel internals.

Where pressure vessels are equipped with removable internals, these internals need not be
completely removed, provided evidence exists that deterioration in regions rendered
inaccessible by the internals is not occurring to an extent that might constitute a hazard or to
an extent beyond that found in more readily accessible parts of the vessel.

(d) Corrosion.

The type of corrosion (pitted or uniform), its location, and any obvious conditions should be
established. Data collected for vessels in similar service will aid in locating and analyzing
corrosion in the vessel being inspected. The liquid level lines, the bottom, and the shell area
adjacent to and opposite inlet nozzles are often locations of most severe corrosion. Welded
seams and nozzles and areas adjacent to welds are often subjected to accelerated corrosion.

4.3.5 Non-Destructive Testing

Several different methods of nondestructive testing may be used to properly assess the
condition of a pressure vessel. The most important and useful technique is ultrasonic testing to
determine actual wall thickness for the shell and dished heads of the pressure vessels. These
examination techniques should be performed by experienced and qualified individuals. The
type and amount of nondestructive examination should be determined by the inspector.
Generally, some type of surface preparation will be required prior to the use of these
examination methods.

These examination methods include:

 magnetic particle examination,
 liquid penetrant examination,
 ultrasonic examination,
 radiography,
 eddy current examination,

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 visual examination,
 metallographic examination,
 acoustic emission.

4.4 Pressure Testing

The only acceptable medium for pressure testing of Reclamation pressure vessels is hydrostatic
testing of the pressure vessel. It should be noted that any other medium for pressure vessel
pressure tests is prohibited (such as pneumatic testing by using air compressors to build up the
pressure inside a pressure vessel) because this sets up the potential for an explosion. Pressure
testing is not normally part of a periodic pressure vessel inspection. However, a pressure test
may be required when the inspection discloses unusual, hard to evaluate forms of
deterioration that may affect the safety factor of the pressure vessel. A pressure test may also
be necessary after certain repairs and alterations have been made to the pressure vessel. Any
repairs or alterations to a pressure vessel will require recertification or re-stamping of the
pressure vessel. To determine tightness, the test pressure should be no greater than the set
pressure of the pressure relief valve having the lowest setting.

The pressure test should not exceed 1.5 times the maximum allowable working pressure
adjusted for temperature. When the original test pressure includes consideration of corrosion
allowance, the test pressure may be further adjusted based on the remaining corrosion
allowance. During a pressure test, where the test pressure will exceed the set pressure of the
pressure relief device, the device must be prepared as recommended by the valve
manufacturer. The metal temperature during a pressure test should not be less than 60 °F
unless the owner provides information on the toughness characteristics of the vessel material
that indicates the acceptability of a lower test temperature. The metal temperature is not to be
more than 120 °F unless the owner specifies the requirement for a higher test temperature. If
the test is conducted at 1.5 times the maximum allowable working pressure or the owner
specifies a temperature higher than 120 °F, the pressure should be reduced to the maximum
allowable working pressure and the temperature to 120 °F for close examination. A thorough
inspection of the vessel and its associated connections and components should be performed
while under pressure. The test pressure shall be held for a period of 15 minutes. If the pressure
drop exceeds more than 10 percent, leaks should be repaired and the test repeated. If the
pressure drop is less than 10 percent and an inspection does not reveal leaks in the pressurized
parts, it may be assumed that the leaks are through the isolation valves, manholes, and
handholes.

4.5 Inspection of Safety Devices

The most important appurtenances on any pressurized system are the safety devices provided
for over-pressure protection of that system. These are devices such as safety valves, safety
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relief valves, pilot valves, and rupture disks or other non-reclosing devices that are called on to
operate and reduce an over-pressure condition. These devices are not designed or intended to
control the pressure in the system during normal operation. Instead, they are intended to
function when normal operating controls fail or abnormal system conditions are encountered.
A pressure relief valve is required in every compressed air system ahead of the first point that
could conceivably act as an air flow restriction. This includes shutoff valves, check valves, and
even in-line filters because they could clog. A relief valve should also be installed on the
receiver tanks, and there should be no restrictions between the tank and the valve. If there are
no restrictions in the discharge line between the compressor and the receiver tank, the relief
valve mounted on the receiver tank is enough to protect the system. The set pressure of the
relief valve shall be no higher than the maximum allowable working pressure (MAWP) marked
on the pressure retaining item. It should be noted that pressure regulators are not acceptable
for protection against excessive system pressure because they do not vent air. Instead, they
regulate pressure by restricting air flow. Periodic inspection and maintenance of these
important safety devices is critical to ensure their continued functioning and to provide
assurance that they will be available when called on to operate. Inspectors are cautioned that
the operation of these safety devices involves the discharge of high-pressure fluids or gas.
Extreme caution should be used when working around these devices because of hazards to
personnel. Because extremely high noise levels that can damage hearing may be encountered
during testing, suitable hearing protection. The following steps should be performed for each
safety device:

 Compare the nameplate marking or stamping of the device to the stamping on the
pressure retaining item. The set pressure shall be no higher than the maximum
allowable working pressure (MAWP) marked on the pressure retaining item.
 Ensure that the difference between set pressure does not exceed that permitted by the
original code of construction if multiple devices are provided.
 Verify the nameplate capacity and, if possible, compare it to the system capacity
requirements.
 Check identification on seals and ensure they match nameplates or other identification
(repair or reset nameplate) on the valve or device.

following steps should be performed to assist in evaluating the condition of each safety device:

 Check for evidence that the valve or device is leaking or not sealing properly.
 Check that seals are intact and show no evidence of tampering.
 Check that connecting bolting is tight and all bolts intact.
 Examine the valve for deposits or mineral buildup.
 Check for evidence of rust or corrosion.
 Check for damaged or misapplied parts.
 Ensure that visible drain holes are not clogged with debris or deposits.
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The following steps should be performed to assist in evaluating the installation of each safety
device:
 Inspect inlet piping and ensure that it meets the requirements of the original code of
construction. Especially check that the inlet pipe size is not smaller than the device inlet
size.
 Inspect discharge piping and ensure that it meets the original code of construction.
Check that the discharge pipe size is not smaller than the device outlet size.
 Check that the valve drain piping is open.
 Check drainage of discharge piping.
 Check that the discharge piping is not binding on the valve body because binding can
lead to distortion of the valve body and leakage or malfunction.
 Check the adequacy and condition of pipe supports. Discharge piping support should be
independent of the device itself.
 Check for possible hazards to personnel from the valve discharge or discharge pipe.
 Check that there are no intervening valves (such as a block valve) between the pressure
source and the valve inlet or between the valve outlet and the point of discharge. Block
valves may be permitted in some pressure vessel service under certain controlled
conditions when shutting down the vessel to repair a damaged or leaking valve would
be difficult. If block valves are used, their use should be carefully controlled by written
procedures, and the block valves should have provisions to be locked in an open
position when not being used.

4.6 Inspection of Piping Systems

Piping systems are designed for a variety of service conditions. Particular attention should be
given to piping systems that are subject to corrosion, erosion, and fatigue and those that
operate at high temperatures. All pipe material and fittings should be properly rated for the
maximum service conditions to which they are subjected under normal operations. Operating
history should be reviewed to determine if there have been any changes in service conditions
outside the original design. If operating conditions have changed, records should be reviewed
to ensure piping system components are satisfactory. Piping Defects

a. Corrosion
Corrosion occurs in the presence of free oxygen and dissolved salts, such as may be found in
improperly treated boiler feedwater. If corrosion is found in a pressure vessel, the associated
piping systems should be considered suspect. Corrosion can deteriorate large areas of the
metal surfaces or it can be localized in the form of pitting or galvanic corrosion. For the purpose
of estimating the effect of severe corrosion over large areas, the thickness of the remaining
sound metal should be determined by the use of ultrasonic equipment or by drilling. The
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estimated thicknesses of the remaining sound metal will be used to estimate the safe working
pressure.
b. Cracks
Cracks may result from design and operating conditions that cause continual flexing. Flexing
can be caused by thermal or mechanical fluctuations and can lead to metal fatigue. Cracking
under these conditions may be accelerated by corrosion. Cracking may also result from fatigue
at imperfections existing in material at the time of piping system fabrication. Cracks resulting
from fabrication defects will normally occur first in corrosive environments in areas subject to
high stress. Suspect areas should be examined periodically for cracking.

c. Erosion
Erosion may occur as a result of the abrasive action of a liquid or vapor. The presence of solid
particles of matter in suspension, or entrained liquids in vapor are factors in this type of
mechanism. Erosion generally occurs in areas where flow is restricted, or flow direction is
changed. Suspect areas should be examined for evidence of erosion.
d. Leakage
A leak should be thoroughly investigated, and corrective action initiated. A pressure test may
be required to obtain additional information regarding the extent of a defect or detrimental
condition.
e. Improper support.
Visual inspection should include a check for evidence of improper support. The alignment of
connections between anchored equipment should be observed to determine if any change in
position of the equipment resulting from settling or other causes has placed an undue strain on
the piping or its connection. Inadequate support or the lack of provision for expansion may
cause broken attachment welds, cracks, or leakage at fittings. Any signs of leakage should be
investigated to determine the cause and the condition corrected. Missing, damaged, or loose
insulation may be an indication of vibration or pipe movements resulting from improper
support.

4.7 Inspection of Pressure Gages

The pressure indicated by the required gage should be compared with other gages on the same
system. If the pressure gage is not mounted on the vessel itself, it should be installed in such a
manner that it correctly indicates the actual pressure in the vessel. When required, the
accuracy of pressure gauges should be verified by comparing the readings with a standard test
gage or a dead weight tester.

5. PRV Inspection

5.1 General handling rules

Pressure relief valves must be handled carefully and never subjected to sharp impact loads.
They should not be struck, bumped or dropped (as rough handling may alter the pressure
setting, deform valve parts and adversely affect seat tightness and valve performance.
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When it is necessary to use a hoist, the chain or sling should be placed around the valve body
and bonnet in a manner that will ensure that the valve is in a vertical position to facilitate

installation. The valve should never be lifted or handled using the lifting lever. Inlet and outlet
flange cover/protectors should remain in place until the valve is ready to be installed.

It is important to visually inspect the PRV before any work is done to ensure no prior damage
has occurred during operation and handling or while in storage. All protective materials, sealing
plugs and any extraneous material inside the valve body or nozzle must be removed.

PSVs should be mounted vertically in an upright position either directly on a nozzle from the
pressure vessel or on a short connecting fitting that provides direct and unobstructed flow
between the vessel and the valve. Installing a PSV in other than this recommended position
might adversely affect its operation. Where rounded or beveled approaches cannot be
provided ahead of the valve, it is recommended that one size large nozzle or fitting be used. A
valve should never be installed on a fitting having a smaller inside diameter than the inlet
connection of the valve.

Figure 1 A correctly installed PRV (Atmospheric discharge)

5.2 Pressure Testing

After disconnection, the valve will be tested on a test bench before being disassembled, so as
to determine the current set pressure and seat tightness level. This is an important phase of
the maintenance routine and the test results should be recorded for review and determination
of necessary corrective action. The “as found from service” condition of a pressure safety valve
is a very important tool in establishing the proper time intervals between inspections. Also,
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valves which have not been in service for extended periods due to plant shutdown, or long
term storage, or valves which have been repaired or reconditioned, should be tested before
being put into operation.

5.2.1 Test Fluid

Conventionally, the test fluid is air or Nitrogen for valve used for gases and other vapor service.
But water is used for valves used on liquid services. It may be necessary to make a correction
for the adjusted set pressure to compensate for the difference in temperature of the test fluids
(see section on cold differential test pressure).

5.2.2 Setup & Apparatus

In compliance with API 527, the valve shall be mounted vertically on the test stand, and the
test apparatus shall be attached to the valve outlet, as shown in the figure below. All openings
– including but not limited to caps, drain holes, vents, and outlets – shall be closed. Before the
leakage test, the set pressure shall be demonstrated, and all valve body joints and fittings shall
be checked with soup water to ensure all joints are tight.

Figure 2 Test setup and required apparatus

For air test, the leakage shall be measured using a tube with an outside diameter of 5/16 inch
(7.9 mm) and a wall thickness of 0.035 inch (0.89 mm). The tube end shall be cut square and
smooth. The tube opening shall be ½ (12.7mm) below the surface of the water. The tube shall
be perpendicular to the surface of the water. Then for liquid test, the pressure safety valves are
checked for seat tightness by a quantitative seat leakage test. All of the test fluid passing
through the valve from the outlet is collected and measured if it is within acceptable limit.

5.2.3 Test Pressure and Duration

For a valve whose set pressure is greater than 50psi, the leakage rate in bubbles per minute
shall be determined with the test pressure shall be held at 5psi less than the set pressure.
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Before the bubble count, the test pressure shall be applied for at least 1 minute for a valve
whose nominal pipe size is 2 inches or smaller; 2 minutes for a valve whose nominal pipe size is
2 ½, 3, or 4 inches; and 5 minutes for a valve whose nominal pipe size is 6 inches or larger. The
valve shall then be observed for leakage for 1 minute.

5.2.4 Allowable Leakage Rate

For air test, the leakage rate in bubbles per minute for metal-seated valves, shall not exceed
that stipulated in the table below (in compliance with API 527). While for soft-seated valves,
there shall be no leakage for 1 minute (i.e. 0 bubbles per minute). During liquid test for a
metal-seated valve whose inlet has a nominal pipe size of 1 inch or larger, the leakage rate shall
not exceed 10 cubic centimeters per hour per inch of nominal inlet size. For a metal-seated
valve whose inlet has a nominal pipe size of less than 1 inch, the leakage rate shall not exceed
10 cubic centimeters per hour. For soft-seated valves, there shall be no leakage
for 1 minute.

5.2.5 Cold Differential Test Pressure (CDTP) Adjustment

When a pressure relief valve is on a test bench at room temperature and atmospheric
pressure, and is on a system operating at a higher temperature and/or higher back pressure, a
compensating adjustment is necessary. The test pressure required to have the valve open at
the desired set pressure under actual service conditions are know as the cold differential test
pressure.

i. Temperature correction:
A temperature correction factor (or multiplier) is typically required when the
relieving temperature exceeds 250 Fahrenheit’s. The factor compensates for
variations in spring load due to thermal growth in valve components as well as

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changes in the spring material properties. Compensation may also be required for
low temperature service below – 75 Fahrenheit’s. When such temperature
compensation is required, the correction factor should be obtained from the relief
valve manufacturer.
ii. Back Pressure Correction

Conventional relief valves without balancing bellows set with atmospheric pressure at the
outlet and intended for use under elevated constant back pressure conditions shall be adjusted
so that the test pressure is equal to the set pressure minus the expected back pressure.

5.2.6 Testing Procedure

Before commencement of pressure test, verify that the discharge area is safe and adequate,
which includes adequate drainage. Brief all personnel assisting on this procedure to ensure
that they understand their functions and hazards involved.
 Perform visual examination of the valve to detect physical material failures or
anomalies that may make the planned test unsafe; these include anomalies such as:
corrosion, structural integrity, erosion, cracks, bolting integrity, general mechanical
condition etc.
 Install the relief valve on the test stand in like manner as required in the plant for
operation (normally vertically mounted) with the appropriate fittings and apparatus for
measurements.
 Verify accuracy of the test gauge.
 If test medium is water and venting is required, then slowly raise pressure to 85% CDP
value and loosen/retighten the valve connections until the trapped air is vented from
under the valve.
 Raise pressure to the seat leakage test pressure and hold for 3 minutes to ensure stable
conditions.
 If excessive seat leakage does not allow pressure to be maintained at the Seat Leakage
Test Pressure Range in the following step, then reduce pressure to a level that permits
seat leakage testing and record the new test pressure and leakage results.
 Check test equipment for leaks that may affect the accuracy of the test.
 Seat leakage measurement should be in terms of cc/hr when water is the test medium
and bubbles per minute (bpm) using a Snoop solution when the test medium is
air/nitrogen.
 Measure the seat leakage f or 5 minutes and record the “As- Found” seat leakage rate.
 Opening pressure is reached as evidenced by one or more of the following: continuous
unbroken stream of fluid emanating from the valve outlet, flow of 40.0 cc/min, sharp
significant pressure drop, or audible flow noise.
 Observe test pressure gauge and slo wl y rai se pressure until opening pressure is
detected or 125% CDP whichever occurs first.
 When the valve lifts, observe valve f unction (i.e., sticking or erratic operation) and
record any abnormal function.
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 Record set pressure (opening pressure).

 Observe test pressure gauge and slowly de crease pressure until valve re-seats.
 Record the re-seat pressure and lower test pressure to atmospheric.
 Wait at least 5 minutes.
 Repeat the tests until at least two consecutive runs are recorded within the acceptable
range or the need for set-point adjustment is established.
 If the as-found set point is not within the Target Band, then adjust the set point to
within the Target Band, or document the basis for not performing the adjustment.
 If set-point adjustment is required, then obtain access to the set- pressure adjustment
nut (refer to O.E.M Maintenance Manual) and adjust as required to obtain a repeatable
set-pressure within the target set- point, recommended set-point, or acceptable set-
point range.
 Repeat the tests after adjustments have been made.
 Once the correct set point has been achieved, then seal the valve to prevent tamper.

5.3 Disassembly and Maintenance

A. Pressure safety valves shall be disassembled following the manufacturer’s specifications

and guidelines. Parts from each valve shall be duly marked and segregated in boxes, to
prevent mismatch of components during the reassembly stage.

However, the general procedure for relief valves disassembly is as follows:

 Remove the cap and cap gasket. If the valve has a lifting lever device or pilot, then
remove the lifting lever and pilot.
 Remove the nozzle ring set screw and set screw gasket. Record the position of the
nozzle ring with respect to the disc holder by counting the number of notches (or
revolutions) required to raise the ring until it just touches the disc holder. This
information will be needed again when reassembling the valve.
 Loosen the adjusting bolt nut. Before releasing the spring load, make note of the depth
of the adjusting bolt in the bonnet and count the number of turns required to remove
the spring load. This information will help when reassembling the valve to its original
setting.
 Release all the spring load by rotating the adjusting bolt in a counterclockwise direction.
 Remove the bonnet stud nuts.
 Lift the bonnet straight up to clear the spindle and valve spring. Exercise care when
lifting the bonnet as the spring and spindle may fall aside.
 The spring and spring washers can now be lifted off the spindle. The spring and spring
washers are fitted together and must be kept together as a subassembly. Spring
washers are not interchangeable between ends of the spring.

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 Remove the spindle, guide, disc holder and disc insert. For balanced bellows valves,
special care must be taken not to damage the bellows subassembly. If parts are difficult
to remove, due to the presence of corrosive or foreign materials, soaking in a suitable
solvent may be required.
 Remove the spindle from the disc holder.
 Lift the guide off the disc holder.
 Remove the disc insert. Note that, a bolt and jack system may be required to remove
the disc insert from the disc holder due to corrosion.
 Remove the nozzle ring from the nozzle.
 Remove the nozzle from the valve body (if necessary). Unless the valve seat on the
nozzle has been mechanically damaged or shows signs of corrosive attack, it will not be
necessary to remove the nozzle.

B. Cleaning & Damage Analysis: The internal components of the disassembled valves shall
be thoroughly cleaned (with appropriate solvent such as diesel) to expose all anomalies,
after which the valve shall be inspected for damages and root cause failures of integral
components which includes damages such as nicks, gags, dents, wears etc.

All parts shall be checked for wear and corrosion. The valve seats on both the nozzle
and disc insert shall be examined to determine if they have been damaged. If damages
on the seats are not very severe, then the lapping process will be sufficient to correct
the valve and restore it to proper functionality.
In rear cases where the seats are badly damaged, then re-machining of the seats or
outright replacement will be necessary. The valve spring shall be inspected for evidence
of cracking, pitting or deformation. While the bellows shall be thoroughly inspected for
material
weaknesses that may lead to leakage. The bearing surfaces on the guide and disc
holder shall be checked for residual product build up and any evidence of scoring.
C. Lapping Procedure: Usually, lapping the seating surfaces should be enough to restore
the seats to their original condition (if not badly damaged by scale, dents or deep cuts).
Never lap the disc insert against the nozzle. Lap each part separately against a lapping
disc or block of the appropriate grit size and compound.

Extreme care shall be taken throughout to make certain that the seats are kept
perfectly flat, and an oscillating motion maintained also.

If considerable lapping is required, then the lapping process shall start with very coarse
compound and then progressively move down to selection of less coarse compounds such as
the fine and polish grades (with grit sizes ranging from 320 to 900).
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Technical Parameters of lapping:

a. Applied pressure
b. Grain size of abrasive in the lapping paste or compound
c. Concentration of abrasive in the lapping paste.
d. Lapping speed

General Lapping procedure:

 Start by selecting the appropriate grit sizes of the lapping blocks and pastes.
 Coat the lapping plate with a thin layer of lapping paste.
 Follow the appropriate oscillating motion and ensure the seating surfaces are kept flat
all through.
 Apply only light pressure to the workpiece.
 From time to time, change the orientation of the workpiece by 90 degrees (to achieve
even abrasion).
 When removing the workpiece from the lapping plate, be careful to pull it straight up (if
done properly, you should hear a popping sound).
 Use a magnifier and flashlight to inspect if further lapping is needed (with the same grit
size).
 If further lapping is required, you can switch to finer compounds of 500grit or 900grit
and repeat process.

5.4 Calibration & Adjustments:

a) Set Pressure Adjustment:

If the set pressure at which the relief valve actually relieves is different from the
rated set point pressure, then the set point of the valve would have to be re-
adjusted (higher or lower as the case may be) to match the rated set point on the
nameplate.

Before making any adjustments, reduce the pressure under the valve seat to at least
10% below the stamped or rated opening pressure. This will prevent seat damage
due to turning of the disc on the nozzle seat and minimize the chance of an
inadvertent valve opening. A strong (high) ring
position is necessary to obtain a good clean popping action of the valve on air or gas
with the limited volume available on the test bench.

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To adjust the set point of the pressure safety valve, the following general steps shall be
followed:

 Remove the nozzle ring set screw and raise the nozzle ring until it touches the disc
holder, then back it down two (2) notches. Exercise care in counting the number of
notches moved so that the ring can be returned to its proper position following testing.
Moving the notches on the nozzle ring to the left will lower the nozzle ring. Replace the
nozzle ring set screw before each set pressure test. The set screw must engage one of
the ring notches, being careful that it does not bear on the top of a tooth.
 Remove the cap or lifting lever following the instruction for valve disassembly.
 Loosen the adjusting bolt nut and turn the bolt clockwise to increase set pressure or
counterclockwise to reduce set pressure.
 Retighten the adjusting bolt nut following each adjustment.
 Two or three consecutive valve openings at the same pressure are necessary to
accurately verify the opening pressure.
 Once the set pressure has been established, lower the nozzle ring to the installed ring
position and replace the nozzle ring set screw as described above.
 Seal wire the adjusting bolt and adjusting ring set screw with identifying seals.
b) Nozzle Ring Setting:

The nozzle ring adjustment is only done when it is necessary to change the blowdown
or reduce valve simmer.

When required, the following general adjustment procedure shall be followed (in addition to
the valves manufacturer’s specific guidelines):

 Remove the nozzle ring set screw and insert a screw driver to engage the ring notches.
 Turn the ring to the right to raise the ring (thereby increasing blowdown). Turn the ring
to the left to lower the ring (thereby decreasing the blowdown).
 Do not lower the nozzle ring to the point where the valve begins to have excessive
simmer. Raising of the ring will reduce simmer.
 The nozzle ring should not be moved more than two notches before retesting. When
making adjustments, always keep count of the number of notches and the direction in
which the nozzle ring is moved. This will enable returning to the original setting in case
of error.

5.5 Re-assembly:

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All mating parts of the valve shall be made clean and lubricated in readiness for reassembly.
With special attention given to parts such as: the guiding surfaces, bearing surfaces and gasket
surfaces to ensure that they are clean, undamaged and ready for assembly.
The following assembly procedure shall be applied:

 Before installing the nozzle apply lubricant to the flange surf ace in contact with the
valve body and on the body to nozzle threads. Screw the nozzle into the valve body and
tighten with an appropriate wrench.
 Screw the nozzle ring onto the nozzle.
 (For bellows valve): Install the tailpiece gasket. Screw the bellows assembly onto the
disc holder. Tighten with an appropriate wrench.
 Assemble the disc insert and the disc holder, by installing the disc insert retention clip
onto the disc insert, and finally install the disc insert into the disc holder. The disc insert
should snap into place using hand force only.
 Assemble disc holder and guide, by sliding the guide over the disc holder.
 Install the two gaskets, one below and one above the guide.
 While holding the top of the disc holder, install the guide into the valve. Align the hole
of the guide with the body outlet. Once the guide is seated, the disc holder and disc
insert can be lowered onto the nozzle.
 Place the spring and washers onto the spindle and assemble the spindle to the disc
holder with the spindle cutter pins.
 Lower the bonnet over the spindle and spring assembly onto the bonnet studs in the
body. Position the bonnet counter bore on the O.D. of the guide and lower the bonnet
onto the guide.
 Screw the bonnet nuts onto the bonnet studs and tighten down evenly to prevent
unnecessary strains and possible misalignment.
 Screw the adjusting bolt and nut into the top of the bonnet to apply force on the spring.
(The original set pressure can be achieved by screwing the adjusting bolt down to the
predetermined measurement). Move the nozzle ring up to until it touches the disc
holder, then lower it two notches. This is a test stand setting only.
 Place the set screw gasket onto the set screw and screw the set screw into the body
engaging the nozzle ring. The nozzle ring should move back and forth slightly after the
set screw is tightened.
 The valve is now ready for testing.

After assembly and testing, the following measures shall be taken:

 Ensure that the adjusting bolt is locked.

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 Return the nozzle ring to either the original recorded position or to the position
recommended by O.E.M.
 Install the cap or lifting device.
 Seal the cap or lifting lever device and nozzle ring set screw to prevent tampering.

5.6 Acceptance Criteria

i. Valves should exhibit normal relief action during lifting and reset operations. There
should be no signs of valve sticking or erratic operation.
ii. At least two consecutive openings within the set point acceptance criteria are required.
Additional openings at set-pressure are allowed and may be required to demonstrate
satisfactory repeatability.
iii. Valves that comply with their respective acceptance criteria may be returned to service
without any further testing.
iv. Valves that do not comply with their respective acceptance criteria shall be adjusted,
refurbished or replaced, as required, to meet the acceptance criteria.
v. Seat leakage acceptance criteria as shown below and is based on test pressure from
85% to 90% of CDP or 5 psig below CDP for valves with CDP less than 50 psig.
a) Liquid - seat leakage should be less than or equal to 20.0 drops per hour (drops/hr) or
10.0 standard milliliters/cubic centimeters per hour (ml/hr or cc/hr).
b) Air/Gas - seat leakage should be less than or equal to 5.0 standard cubic centimeters
per minute (sccm) or 40.0 bubbles per minute (bpm).
c) Acceptance criteria for soft-seated valves is zero leakage.

6. Pre-Commissioning, Testing, and Commissioning

Following the total completion of works, necessary equipment and sub-system/component
testing shall be carried out in strict adherence to the manufacturer’s specifications and industry
standards. Yastronics Laboratory for Inspection and Calibration will ensure all testing and
commissioning procedures are well-documented and align with project requirements.
Commissioning Procedures
In collaboration with equipment vendors, Yastronics' Engineering Team will prepare
comprehensive commissioning procedures, which will include:
 Personnel organization and qualifications.
 Safety codes of practice and emergency procedures.
 Tests to be performed, checklists, and performance benchmarks.
 Documentation of results for validation and approval.
The following considerations will be instituted during the commissioning activities:

1. Appointment of a Commissioning Engineer:

Yastronics will assign a qualified and experienced commissioning engineer to lead the
commissioning team.

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2. Performance Testing:
Comprehensive performance tests will be carried out to verify that all installations meet
contract specifications and are fit for operation.
3. Special Inspections:
Additional inspections, if specified by the client, will be conducted to address unique
project requirements.
4. Non-Conformance Management:
Any non-conformances identified during commissioning will be immediately relayed to
the Project Manager for corrective action to ensure compliance with project standards.
5. Documentation of Results:
All testing and commissioning operations will be meticulously recorded and
documented following approved procedures. These records will be retained for review,
audit, and project closure purposes.
Submission of Commissioning Procedure
Before initiating the commissioning exercise, Yastronics will submit a detailed commissioning
procedure to the client for review and approval. The commissioning sequence will align with
the activity sequence outlined in the work schedule of the Technical Proposal.

6.1 As-Built and Final Documentation

Yastronics will undertake final surveys and maintain detailed records of completed works. The
deliverables under this phase will include:
 As-Built Drawings: Where applicable, updated drawings reflecting the final project
conditions will be prepared and submitted to the client.
 Material Certificates and Data Books: All material certificates and data books provided
by vendors will be compiled and submitted as part of the final documentation package,
ensuring traceability and compliance with project requirements.

6.2 Responsibilities of Parties

Client Responsibilities
The client will maintain ultimate accountability for the project’s safety, health, and operational
success. Their responsibilities will include:
 Defining project expectations and ensuring alignment with safety and health (S&H)
standards.
 Reviewing and approving contractor competence, resources, and task execution plans.
 Monitoring and auditing the performance of Yastronics against the agreed-upon S&H
plan.
 Ensuring ongoing communication and providing visible leadership throughout the
project lifecycle.

Yastronics Responsibilities

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NPDC/NECONDE WORK METHODOLOGY HEXAGON

Yastronics will assume the following responsibilities during the project:

 Developing and adhering to a robust safety and health (S&H) plan in alignment with
project and regulatory requirements.
 Informing all personnel and subcontractors of the S&H requirements, including site-
specific protocols and procedures.
 Conducting Job Hazard Analyses (JHAs) to identify potential risks and implementing
appropriate mitigation strategies.
 Providing defined safety training, such as First Aid, Permit-to-Work (PTW), and site
inductions, to all team members.
 Coordinating all activities to ensure seamless execution and risk minimization.
 Maintaining proactive communication with the client, identifying risks, and
implementing control measures to ensure operational efficiency and compliance.

5.7 Quality Control

YASTRONICS Board of Directors recognizes the importance of maintaining the corporate quality
objectives, providing services to NPDC with competitive rates, timely completion, safe and
environmentally controlled manner and to specified quality.
YASTRONICS organizational structure allows independent operation of the Quality Assurance
Department, with defined task to identify problems, evaluate these problems, provide and
recommend solutions, and monitor and verify implementation of corrective actions needed.
Quality Assurance is therefore separate function from design and installation operations, thus
ensuring objectivity in interpretation, monitoring and development of quality requirements.
The QA Manager is authorized by YASTRONICS Management to identify problem; initiate
recommend and provide solutions thereto. He is further authorized to prevent further
propagation of non-conforming items or activities until such non-conformance has been
satisfactorily corrected.

5.8 Health and Safety

It is the policy of YASTRONICS Management to ensure that all its operations are conducted in a
manner to avoid injuries or risks to its employees and to other parties affected by the
operations, and also to preserve the Environment.
YASTRONICS is committed to this task and is continually endeavoring to implement and
monitor safety measures set up in YASTRONICS Health, Safety and Environment (HS&E)
Manual, copy of which is enclosed herewith under the title Safety Procedure.
The plan of action in Labor Safety and Medical coverage will be followed. Close link will be
established with the Ministry of Health to ensure up-to-date regulations are being adhered to.
YASTRONICS will appoint qualified personnel to control and attend to this important aspect of
the Project. Adequate medical facilities will be provided at work site.
Both Site Manager and Safety Officer will enforce all HS&E regulations and ensure that these
regulations are adhered to.

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 HEXAGON ENGINEERING LTD
SERVICING FOR SHUTDOWN IN ODIDI AND JONES
CREEK – PRESSURE VESSEL AND PRV CALIBRATION
NPDC/NECONDE WORK METHODOLOGY HEXAGON

A Security Officer will be appointed to take control of security of work sites. The Officer will
keep in direct contact with NPDC Security Office and local security authorities to ensure
protection and deal with incidents as they occur.
Records and reports will be prepared and updated on a monthly basis stating all incidents and
accidents.
YASTRONICS will maintain and check plant and equipment condition for safe use and will
ensure that adequate identification and safety instructions are clearly marked. Visitors are also
given instructions to follow during their presence in work areas and are provided with
protective items as required.
Health and Safety information are displayed on boards and updated information is added as
and when available. The works supervisors are responsible to make sure that this information
is being transmitted to their teams on regular basis. The works supervisors are also responsible
to enforce the HS&E procedures and to inspect their team’s performance in this respect.
YASTRONICS will ensure that smoking; alcohol and drugs are not allowed on sites. Warning
tapes, areas requiring Permit of Work will be performed according to contract conditions.
YASTRONICS will co-ordinate with NPDC Safety personnel on access to work sites and use of
passes. H&S Officer conducts briefing meetings with supervisory and management staff to
ensure their understanding of HS&E requirements for the particular project in hand. Protective
equipment/clothing as specified in YASTRONICS Manual will be secured for this project.

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