Upload
sigit-bintan
View
155
Download
0
Tags:
Embed Size (px)
DESCRIPTION
02 Mechanical
Citation preview
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 1
INDEX
Indicative Inspection & Test Plans
SL. No.
DESCRIPTION
B. MECHANICAL WORKS
I Under Ground Piping
II Above Ground Piping/ Heater Coils
III Storage Tanks
IV Equipment Erection (Static)
V Equipment Erection (Rotary)
VI Crane (EOT/ HOT)
VII Column Internals
HEATER WORKS
I Fired Heaters
II Refractory & Insulation Works Fired Heaters
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 2
HP : HOLD POINT.
A point which requires inspection/verification and acceptance by Owner/ Consultant
before any further processing is permitted. Contractor shall not process the activity
beyond a Hold Point without written approval by Owner/ Consultant.
W : WITNESS POINT.
An activity which requires witnessing by Owner/ Consultant when activity is performed.
Suppose, after proper notification has been provided, the contractor not obliged to
hold further processing, if Owner/ Consultant is not available to witness the activity or
does not provide the comments before the date notified.
Rw : REVIEW of contractors documentation.
S : SURVEILLANCE Inspection by Owner/ Consultant.
Monitoring or making observations to verify whether or not material/ Items or services
conform to specified requirements. Surveillance Activities may include audit,
inspections, witness of testing, review of quality documentation & records, field visit,
personnel qualifications etc.
WC : 100% Examination by CONTRACTOR.
NDT : NON DESTRUCTIVE TESTING.
PWHT : POST WELD HEAT TREATMENT.
NOTE :-
Contractor to submit required formats and job procedures for each activity listed in ITPs and
submit to Owner/ Consultant for approval. Responsibility for execution of the inspection/ testing
is with the contractor. Owner/ Consultant only verify examination or testing done by the
Contractor at important stages. Activities for which ITPs are not given, contractor to develop
and get the same approved by Owner/ Consultant well before start of the work.
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 3
I UNDER GROUND PIPING A PRIOR TO FABRICATION
1 Incoming Material WC W
2 Welding Filler Material Approval/ Qualification. WC HP
3 WPS/ PQR WC HP
4 Welder Performance Qualification. WC HP
5 a NDT Procedure Qualification WC HP
b PWHT Procedures Qualification (if any) WC HP
6 Preparation of Sketches. WC S
7 Joint Numbering. WC S
8 Material traceability & transfer of heat nos. WC S
B FABRICATION (SHOP & FIELD)
1 Material as per piping class (check w.r.t. approved WC S Colour coding procedure).
1 a Fit-up check WC S
b Dimensional check WC S
2 Pre-heat (if any). WC S
3 Check for purity of purging/ shielding gas WC Rw/S
4 Purging (if any) WC S
5 Shielding rate (if any) WC S
6 Basking of Electrodes WC S
SL.
NO. ACTIVITY CONTRACTOR PMC
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 4
7 Interpass cleaning & temperature check WC S
8 Visual check of completed welds WC S
9 Monitoring of PWHT Cycle WC S
10 Hardness Check WC S
11 PT/MT WC S
12 Radiography marking (for Random Radiography) WC W
13 Radiography Interpretation WC HP
14 Check shot for Radiography WC W C PROOF TESTING
1 Procedure WC HP
2 Correctness of Testing arrangements WC S
3 Calibration of Pressure Gauges WC Rw
4 R.F. Pad testing, if any WC W
5 Positive Material Identification as per WC HP Specification after completion.
6 Scrutiny of test packs for Mechanical WC HP & NDT Clearance(As per Annexure A)
7 Air / Water Flushing (preliminary) WC W
8 Pneumatic/ Hydro testing WC P 9 Draining of Water & Air drying WC S D LAYING
1 Trench excavation and levels WC S
2 Cleaning of pipe surface WC S
3 Approval of wrapping/ coating material manufacturers WC HP
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 5
4 Approval of agency for wrapping & coating WC HP
5 Sample test of coating materials in approved laboratory WC Rw
6 Procedure qualification for wrapping & coating WC HP
7 Application of primer WC S
8 Coal tar temperature WC S
9 Coating and wrapping WC S
10 Calibration of Holiday tester WC HP
11 Holiday testing WC HP
12 Thickness of coating WC HP
13 Peel test WC HP
14 Lifting arrangement WC S
15 Lowering (levels & orientation of branches) WC S
16 Checking of wrapping and coating for damages during WC HP lowering, their repair, holiday testing, etc.
17 Back filling WC S
18 Location, Brickwork, Plaster of valve pit WC S
19 Top cover & finish of valve pit WC S E SYSTEM COMPLETION
1 Tie in joins (As per Annexure - B) WC W
2 Scrutiny of test packs for system testing
(As per Annexure - C) WC W
3 System testing WC W
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 6
Inspection & Test Documents
Review Test and Inspection Document HP Rw
Abbreviations:
NDT : Non Destructive Testing
WPS : Welding Procedure Specifications
U/G : Under Ground
PT : Penetrant Testing
MT : Magnetic Particle Testing
PWHT : Post Weld Heat Treatment
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 7
Plant: Report:
Contractor: Area :
Loop No.: Inch Metre
Sketch No.: From: ____________ To : ____________
Sr.No.
Activity Check Clearance by Contractorwith Date & Sign
Clearance by PMC with Date
& Sign
A MECHANICAL COMPLETION RECORD (U/G)
1 Clearance for flushing & testing.
1.a
Mechanical clearance
Conformity with drawing.
1.b
Welding & NDT clearance
Material as per piping class
Fit-up check
Visual check of completed welds
LPI checks
RF pad testing
2 Flushing & Pressure testing
Medium
Test pr. Kg /Sqcm
3
Coating and Wrapping
Surface preparation
Primer application
Coating, wrapping and peel test
Holiday check
4
Laying
Trench leveling
Lowering & checking for damages in wrapping & coating, their repair, holiday
testing, etc.
Backfilling
Remarks:- Test loop sketches duly filled in to be enclosed with this (Jt.No., W.No. X SR. Chart No.
Alongwith XR Films, SR Charts etc.)
Review by Area Co-ordinator
Sign. Date Name Designation
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 8
INSPECTION REPORT FOR TIE IN JOINT
(FOR UNDER GROUND PIPING)
JOINT NO. REPORT NO.
DATE
A TTIME AT THE TIME OF FIT UP
CLEARANCE BY
DATE CONTRACTOR PMC
B FIT UP
C ROOT RUN DP
D FINAL RUN DP
E WELDER NO
F RADIOGRAPHY
G PWHT HARDNESS
H RF PAD TESTING
I CLEANING & PRIMING
J COATING, WRAPPING & PEEL TEST
K HOLIDY CHECKING
L CHECKING FOR ANY DAMAGE IN
WRAPPING & COATING AFTER
LOWERING, THEIR REPAIR, HOLIDAY
TESTING, ETC.
M BACK FILLING
Inspection at above stages has been carried out by concerned and found satisfactory.
Contractor PMC Mechanical PMC Inspection
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 9
Plant: Report:
Contractor: Area:
Loop No.: Inch Meter
Sketch No.: From: ____________ To: ____________
Sr.No.
Activity Check Clearance by Contractorwith Date & Sign
Clearance by PMC with Date
& Sign
A MECHANICAL COMPLETION RECORD (U/G)
1 Clearance for flushing & testing.
1.a
Mechanical clearance
Conformity with drawing.
1.b
Welding & NDT clearance
Material as per piping class
Fit-up check
Visual check of completed welds
LPI checks
RF pad testing
2 Flushing & Pressure testing
Medium
Test pr. Kg /Sqcm
3
Coating and Wrapping
Surface preparation
Primer application
Coating, wrapping and peel test
Holiday check
4
Laying
Trench leveling
Lowering & checking for damages in wrapping & coating, their repair, holiday
testing, etc.
Backfilling
Remarks:- Test loop sketches duly filled in to be enclosed with this (Jt.No., W.No. X SR. Chart No.
Alongwith XR Films, SR Charts etc.)
Review by Area Co-ordinator
Sign. Date Name Designation
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 10
II ABOVE GROUND PIPING
A PRIOR TO FABRICATION
1 Incoming Material WC W
2 Welding Filler Material Approval/ Qualification WC HP
3 WPS/ PQR WC HP
4 Welder Performance Qualification WC HP
5 a NDT Procedure Qualification WC HP b PWHT Procedures Qualification WC HP
6 Joint numbering in Isometries (Big & Small Bore) WC S
7 Preparation of sketches for job in case of off sites WC S A/G piping and Joint Numbering
8 Transfer of Heat Nos. & Traceability WC W
B FABRICATION (SHOP & FIELD)
1 Material as per piping class (check w.r.t. approved WC S Colour coding procedure)
1 a Fit-up check WC S b Dimensional checks WC S
2 Pre-heat (if any) WC S
3 Check for purity of purging/ shielding gas WC Rw/S
4 Purging WC S
5 Shielding rate (if any) WC S
6 Baking of Electrodes WC S
7 Interpass cleaning & Temperature check WC S
8 Visual check of completed welds WC S
9 Monitoring of PWHT Cycle WC S
10 Hardness Check
i) For C.S. Materials WC S ii) For A.S. Materials Piping WC W iii) For A.S. Material Heating Coil WC HP
SL.
NO. ACTIVITY CONTRACTOR PMC
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 11
11 PT/MT WC S 12 Radiography marking (for Random Radiography WC W only)
13 Radiography Interpretation WC HP
i.For Carbon Steel Piping WC HP ii.For Alloy Steel/SS Piping WC HP
14 Spool clearance WC HP
C ERECTION
1 Lifting arrangement WC S 2 Test Certificates for lifting tackles WC Rw
3 Location and orientation of branches WC S
4 Provision of Instrument Tappings WC S
5 Provision of vents and drains WC S
6 Correctness of type of supports, anchors, guides WC S
7 Correctness of gasket/ fasteners WC S
8 Correctness of valves (NRV, Gate, Globe, Control WC S Valves), Steam traps and their direction of flow
9 Provision of cold pull WC HP
D PROOF TESTING (See enclosed checklist in Annexure-A)
1 Procedure WC HP
2 Correctness of testing arrangements WC S
3 All valves to be kept open and chek if testing done WC S against closed valve position
4 Isolation of equipments, control valves, instruments, WC S ellows, before testing. Removal of flappers from
check valves
5 Scrutiny of test packs for Mechanical and NDT WC HP Clearance
6 Positive Material Identification as per specification WC HP after completion of installation
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 12
7 Calibration of pressure gauges WC Rw
8 Preparation of check list WC S
9 Liquidation of check list WC S
10 Air/Water flushing (preliminary) WC W
11 Pneumatic / Hydrotesting (See Annexure - B) WC HP
12 Draining & drying WC S
13 Removal of temporary blinds/ supports WC W
14 Pickling of system, if required WC W
15 Boxing up including reinstallation of flappers WC W of check valves
16 a. Check on fasteners & gaskets and record WC Rw Thereof b. Torque tightening of flange joints WC S
17 System testing WC W
18 Setting of spring supports WC W Inspection & Test Documents
Review Test and Inspection Documents HP Rw
Abbreviations:
NDT : Non Destructive Testing
WPS : Welding Procedure Specifications
A/G : Above Ground
PT : Penetrant Testing
MT : Magnetic Particle Testing
PWHT : Post Weld Heat Treatment
For liquidation of Punch list. See Annexure - C.
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 13
CHECKLIST FOR MECHANICAL CLEARANCE A/G Piping (Sheet 1 of 4)
Project: ___________________
Plant/Unit: ___________________
Contractor: ___________________
Loop No: ___________________
Report No: ___________________
Date : ___________________
Area : ___________________
INCH MTR ___________________
Line No (Isometric No.) Rev. GAD NO. Rev. P&ID No.
Sr. No.
Items to be checked Acceptance by Contractor
Witness by Owner/ PMC as required by
ITP 1 Installation checked as per Isometric w.r.t.
CONFIGURATION : Route, plumb, elevation, clearance
for thermal expansion/ insulation
BRANCH: Location, angle, orientation, type, R.F. pad etc.
STEAM TRAP : Direction
2 Installation checked as per GAD w.r.t. CONFIGURATION : Route clearance for thermal expansion /
insulation
3 Installation checked as per P&ID
4 Isometrics completed for (enclosed) a) Joint numbering (Shop and Field welds)
b) Spool numbering
c) As-built routing and dimensions
Valves (Check Rating, Gaskets, Flow direction, Sheet No.,
Tag No., Spindle direction. CSO, LO/LC, Damage etc.)
Gate valve
Globe valve
Check valve
Control valve Tag Nos.
Safety Valve Tag Nos.
5
Any other valves
FORMAT NO:_______________________________________ (Sheet 2/4)
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 14
CHECKLIST FOR MECHANICAL CLEARANCE A/G Piping (Sheet 2 of 4)
Sr. No.
Items to be checked Acceptance
by Contractor
Witness by Owner/ PMC
as required by ITP
6 Strainers: Check for clearance, flow direction, elements
Flanged joints
Total Nos.
Check for type of flange
Check for Rating
Check for Alignment, (Proper gap and parallelity)
Check for correct studs and nuts dia, length, material, uniform protrusion of
studs, anti seize compound
Check for correct gasket (type, size, spec., thickness, etc.)
7
Torque values used for tightening
8 Seal welding of Screwed connections (If required)
9 Vents/ Drains as per Dwg. And provision of additional high point vents and / or low point drains, if reqd.
10 Reinforcement pads as per piping class
Orifice flanges 11
Check for Tag. No. tapping orientation, tap valve, jack screw, straight run
length of upstream and downstream
12 Local Gauges: Check for accessibility
13 Slope (When applicable)
Supports
a) Guides, Cross Guides, Trunnion etc.
i) Check for correct type, material and dimension
ii) Check welding
iii) Check for vent hole on pads (if applicable)
iv) Check offset for thermal expansion
v) Check clearance of guide
vi) Check U bolt for slide support
b) Spring support
i) Verify tag no. and check details as per data sheet/ spring set
ii) Check for locking arrangement and any damage during transit, etc.
iii) Check for completeness of installation as per drg. Including welding of
mounting cleat/ bracket
iv) Check for locking during installation and pressure test
c) Bracket support and inserts with Anchor fasteners:
i) Check for members dimensions and materiall
ii) Check for welding
iii) Check for bolting
14
iv) Check for appearance damage
Vents/ Drains
As per Drg
Orientation of valve handles
Clearance for hose
15
Requirement of additional vents/ drains (highest/ lowest pt.)
FORMAT NO:_______________________________________ (Sheet 2/4)
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 15
CHECKLIST FOR MECHANICAL CLEARANCE A/G Piping (Sheet 3 of 4)
Sr. No.
Items to be checked
Acceptance by
Contractor
Witness by Owner/ PMC as required by
ITP
16 Earthings:
a) Check for location
b) Check for dimension of lug welding
17 17 Joints History sheets enclosed for
17.1 17.1 Material Traceability as per Procedure No: (refer enclosed suggested format)
17.2 Fit ups checked
17.3 NDT Complete (Radiography, MT, PT)
17.4 Stress Relieving & Hardness Check complete
17.5 Positive Material Identification (PMI)
Checked for Removal Binding off of:
a. Control, Safety and Check valves
b. In-line instruments
c. Rupture discs
d. Equipment nozzles
18
e. Others
19 19 Supports and Weld/Flanged/ Screwed connections free from insulation or other coverage
Checked installation of (Indicate location in Drawings)
a. Temporary Blinds, Spades
b. Temporary Strainers
c. Temporary Dummy-spools
d. Temporary Gaskets
20
e. Others
Expansion Bellows
a) Checks prior to installations
Physical damage
Transit locks are intact
Dimensions as per drgs.
b) Check during installations
Parallelity of mating flanges
Face to face dimensions of mating flanges
Concentricity of mating flanges
No stress on expansion bellows
Record
c) Isolation during pressure tests
Bellow manufacturers recommendations on isolation of
bellow during Pr. Test to be followed
21
If recommended expn, bellow to be dropped during pr. Test
22 Cleanliness internally and externally
23 Rotating equipment final alignment checked with piping
FORMAT NO:______________________________________ (Sheet 3/4)
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 16
CHECKLIST FOR MECHANICAL CLEARANCE A/G Piping (Sheet 4 of 4)
Sr. No. Items to be checked
Acceptance by
Contractor
Witness by
Owner/ PMC
as required by
ITP
24 Removal of unwanted construction supports
25 Instrument tappings provided as per Drawing
26 Physical Walk Through The Line Checked for gross
irregularities including physical damages, unwanted tacks,
arc strikes, spatters and space for thermal expansion
Other
Remarks
Contractor :
Sign. :
Date :
Name : Designation :
PMC
Sign : Review by Area Co-ordinator (PMC)
Date : Sign :
Date : Date :
Name : Designation : Name : Designation :
FORMAT NO:_______________________________________ (Sheet 4/4)
HPCL, Visakh
INDICATIVE INSPECTION & TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 17
DAILY MATERIAL TRACEABILITY REPORT
(FOR ABOVE GROUND PIPING/ HEATER)
Contract No. : _______________________ Report No.: ______________
Contractor : ________________________ Date : ___________________
Verified Remarks Sl.
No.
Line / Heater No. Area
No.
Dia Joint No. Spool
No.
Piping Component Heat / Batch No. Colour Code
Contractor PMC
Contractor PMC
Note : A Sketch of the spool may be enclosed.
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 18
Piping Hydro Test Release / Acceptance Record A/G Piping (Sheet 1 of 2)
Project :
Report No:
Plant / Unit : Date :
Contractor : Area :
Loop No. : REF P & ID No.
INCH MTR
From
______________
To _________________
Line No (s) Isometric No. (s) P & ID No.
Test Medium : Test Duration Design/ Test pressure
Test Pressure Gauge No. Range Calibration
Certificate No. Gauge Calibration Date
Items to check Accept Witness
Contractor PMC
Field installation Checklist prior to Hydrotest
Signed
Punch list prepared Yes/ No
Pre-Hydrotest Punch items cleared
Accessibility to inspection/ witness locations
Capacity of pressurising pump checked
Cordon off area for high pressure testing as
required
Pre-hydrotest flushing carried out
IBR/Others test Witnessing required Yes/ No
System released for Pressure Testing :
Contractor PMC Sign Name Sign Name
Date Date Designation Designation
FORMAT NO:_______________________________________ (Sheet 1/ 2)
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 19
Piping Hydro Test Release / Acceptance Record A/G Piping (Sheet 2 of 2)
Activity
Date Time
Water Filling and Venting started at
Water Filling completed
Vents closed
Isolation of Pressurising pump
Test completed at :
- Water drained
- Air
- Temp Blinds Removed
- Checked for reinstallation of
a. Control & Safety valves
b. On line instruments
c. Rupture disks
d. Deblinding
e. Others
- Cold setting of spring supports carried out
Contractor PMC
Sign Sign
Date Date
Name Designation Name Designation
FORMAT NO:_______________________________________ (Sheet 2 / 2)
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 20
Punchlist
Project:
Report No:
Plant/Unit:
Date :
Contractor:
Area :
Loop No:
REF P&ID No.
Description :
Ref. Document :
Punc h
Item No
Priority
Description of
Punch Items
Location Prepared by
Action by Due Date
Completion Acceptance
Priority: 1 Needed for Pressure test 2. Needed for commissioning 3.Needed for plant acceptance Contractor PMC Sign Sign
Date Date
Name Designation Name Designation
FORMAT NO:_______________________________________
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 21
SL. NO.
ACTIVITY CONTRACTOR PMC
III
STORAGE TANKS
A PRIOR TO FABRICATION
1 Acceptance of the tanks foundation WC W 2 Materials WC W 3 Filler materials tests and approval WC HP 4 WPS/ PQR WC HP 5 Welders performance qualification WC HP 6 Radiography procedure WC HP 7 Joint numbering in drawings WC S 8 Welding equipment and accessories WC S 9 Tools and Tackles WC S 10 Baking ovens
- Portable WC S
- Heavy WC S 11 Jig & Fixtures WC S 12 Suitability of plate bending machine WC S
B FABRICATION/ ERECTION BOTTOM
1 Plate size, marking and cutting WC S 2 Blast cleaning & painting of underneath
bottom plates
WC S
3 Plate layout, overlap and fitup WC S 4 Sequence of welding to follow WC S 5 Size and positioning of backing plate for
annular plates WC S
6 Baking of electrodes/ interpass cleaning WC S 7 Visual check WC S 8 LPI/MPI/ Radiography of annular plate butt
welds and
bottom plate butt welds (if any)
WC HP
9 Vacuum/ MPI/ LPI of shell portion of the bottom plates
WC HP
10 Vacuum box test for the bottom plate welding
WC HP
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 22
SL. NO.
ACTIVITY CONTRACTOR PMC
SHELL 1 Plate size, marking and cutting. WC S 2 Plate bending, curvature check, stacking. WC S 3 Shell course alignments and fitup of vertical
and
circumferential joints.
WC S
4 Shell diameter, circularity, perpendicularity, straightedge before welding.
WC HP
5 Visual and Back chip check WC S 6 Second side visual. WC S 7 Location, size and alignment of nozzles and
other Openings WC
HP
8 R.F.Pads fitup / welding. WC W 9 PWHT of RF pad. Nozzles & manhole, etc.
(As
applicable)
WC HP
10 Radiography marking for Random radiography only
WC W
11 Curbangle and Wind girders fitup / welding WC S 12 MPI/LPI nozzles, wind girders fitup/welding WC W 13 RF Pads air test. WC HP 14 Shell to bottom fit-up WC W 15 Sheel to bottom I/S welding root run visual/
Oil chalk test WC
HP
16 Sheel to bottom O/S welding visual and LPI for toecracks
WC HP
17 Fabrication and erection of stairways WC S 18 Cleates welding for insulation WC S 19a Radiography interpretation. WC HP 19b Extension marking for repair
WC HP
FIXED ROOF
1 Identification of Roof Structure members in AFC drgs
WC Rw
2 Blast cleaning and painting Roof Structure underside of Roof plates
WC S
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 23
SL. NO.
ACTIVITY CONTRACTOR PMC
3 Location and welding of roof supports. WC S 4 Alignment and welding of Roof Structures. WC W
5 Plate layout, overlap and fitup WC S
6 Visual check of roof welds WC W 7 Location, size and alignment of roof man-
holes and vents WC S
8 PWHT (As applicable) WC HP 9 RF pads fit-up & Welding WC W 10 RF pad pneumatic testing WC W 11 PT/MT of Nozzles, vents & other
attachments
WC W
12 Welding of Roof plate with shell / curb angle
WC W
FLOATING ROOF WC 1 Temporary staging spacing and levels WC S 2 Plate size, straightening and cutting WC S 3 Plate layout, overlap and fitup/ welding WC S 4 Buoys fabrications WC S 5 Vacuum testing of roof-plate welds WC HP 6 Location of sleeve supports WC W 7 Pad plate welding with roof and sleeve
support WC W
8 Fixing and welding of Buoys WC S 9 Initial lift WC W 10 Supports fixing through sleeves WC S 11 Seal welding of support sleeves from
beneath after dewatering WC W
12 Air test of Buoys WC HP 13 Pontoon welding WC W 14 Location, fixing and welding of man holes,
drains etc.
WC S
15 Shell to pontoon clearance WC W 16 Seal fixing W W
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 24
SL.
NO. ACTIVITY CONTRACTOR PMC
C TESTING
1 Correctness of testing arrangements especially
size of blind flanges/ vents/ drains/ temporary
piping
WC S
2 Mechanical / Inspection clearances WC HP
3 Earthing of ladder and shell WC W
4 Settlement readings during water filling WC W
5 Hammer test WC HP
6 Air pressure test WC HP
7 Vacuum test WC HP
8 Roof collapsability test in case of floating roof
tanks
WC HP
9 Calibration of tanks in case of floating roof
tanks
WC Rw
D PAINTING AND INSULATION
1 Cleaning WC S
2 Painting WC W
3 Insulation WC W
Inspection & Test Documents
Review Test and Inspection Documents HP Rw
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 25
SL. NO.
ACTIVITY CONTRACTOR PMC
IV
EQUIPMENT ERECTION (STATIC)
1 BEFORE ERECTION A Execution scheme WC Rw B Materials supply WC W C Readiness of erection WC S
I Level of foundation (shims/ packing with marking to be prepared & kept ready)
WC S
II No. & Size of bolts WC S
III Hole dia and no. of hole in base/ structure of equipment and columns
WC S
IV Equipment base with actual foundation WC S V Checking the threads of bolts & nuts WC S VI Chipping & roughening of foundation WC S VII C/L marking on equipment WC S
2 ERECTION SCHEMES FOR CRITICAL EQUIPMENTS
A Approval of Rigging procedure (As per Annexure 1)
WC HP
3
SAFETY TEST
A Load test of cranes, lifting beams, slings and shackles, length and dia. of sling &
condition of wire rope (Broken/ damaged
strands should not be there)
WC W
4
Cross checking if Data-sheet w.r.t.
orientation, base plate Deatails
WC S
5 DURING ERECTION A Orientation to be checked
WC S
B Placement of packing as per marking
WC S
C Outside cleaning, coating/ wrapping, painting for underground equipment
WC W
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 26
SL.
NO. ACTIVITY CONTRACTOR PMC
6 AFTER ERECTION
A Tightening of Bolts and providing washers WC S
B Levelling and alignment of equipments WC HP
C Corresponding requirement elevation and distance
between nozzles in special cases
WC S
D Cleaning of sleeves before grouting WC S
E Grouting WC S
F Final tightening of bolts WC S
G Internals installation after PMI as required
i. Critical equipments WC HP
ii. Other equipments WC W
7 TESTS
As per specification WC W
8 Packing of column (As per Annexure 2) WC W
9 Final Boxing up WC W
Inspection & Test Documents
Review Test and Inspection Documents HP Rw
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 27
SL. NO.
ACTIVITY CONTRACTOR PMC
ERECTION SCHEME FOR CRITICAL EQUIPMENT (Rigging Procedure)
1 BEFORE ERECTION A Checking proper sequence for lifting of the
equipment WC Rw
B To check weight of equipment WC Rw C To check the centre of gravity WC Rw D To check suspension points WC Rw E To check the maximum/ minimum radius at which
the lifting tackle will operate WC Rw
F To check the maximum load to be lifted including wt. Of slings, hook-block, lifting beams and
equipment etc.
WC Rw
G To identify the safe crane with requisite capacity WC Rw
2 DURING ERECTION
A To check counter weight of crane and Boomlength
WC Rw
B To check slew limitations of crane WC Rw C To check ground conditions are adequate for
supporting fully rigged crane and load WC Rw
D To check the crane can be travelled in loaded condition
WC Rw
E To check clearances from overhead electric power cables
WC Rw
F To check maintenance certificates WC Rw G To check whether operators, riggers have received
proper instructions WC Rw
H To verify safe load indicator been supplied to rig the crane
WC Rw
I To check the adequacy of bracing of equipment by guys
WC Rw
J To check the guys, shoring, bracing, interference with other works
WC Rw
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 28
SL.
NO. ACTIVITY CONTRACTOR PMC
PACKING COLUMN
1 BEFORE INSTALLATION
A Identify the material, check thickness,
dimensions, no. and angle of fingers of packing
rings
WC S
2 DURING INSTALLATION
A Degreasing and cleaning of packing material
WC S
B Check packing su
pport plate
WC S
C Check for stacked or dumped packing as per
Specifications
WC S
D Check for nesting WC S
E Check for packings are touching bed limiter
(when issued and top level)
WC S
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 29
SL. NO.
ACTIVITY CONTRACTOR PMC
V
EQUIPMENT ERECTION (ROTARY)
1 BEFORE ERECTION A Execution scheme WC Rw B Foundation check I Level / centreline of foundation WC S II No / Dia / Length of anchor bolts, Depth of
pockets, verticality of pockets WC S
III Chipping, roughing and cleaning of pockets WC W 2 LIFTING TACKLES Crane/beams/ slings/ shackles etc. to be checked for weight of equipments
WC S
3
VISUAL INSPECTION OF EQPTS. TAG/ IDENTIFICATION NO.
A For any damage WC S B Free shaft rotation WC S 4
Drilling and Tapping (if reqd.) hole in the base
plate of eqpt.
a. Size/ Taps WC S DURING ERECTION
A Level/ elevation of base frame WC W B All foundation bolts to be checked WC S C Grouting of base frame / pocket grouting WC W D Orientation of eqpts. WC W E Elevation/ Level of eqpts. WC HP F Shimsize/ material/ thickness WC W G Distance between couplings WC W H No-load run of motors WC W
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 30
SL.
NO. ACTIVITY CONTRACTOR PMC
I Alignment readings WC
- Without piping (Loose bolts) WC HP
- With piping (After tightening the flange bolt) WC HP
J Type of grout and grouting WC S
K All protection and safety guards installation WC S
AFTER ERECTION
A Curing of grout WC S
B Auxiliary connections to be mounted on eqpts.
as per drawing
WC S
C Final tighting of bolts WC S
D Tests as per spec. WC W
E Chemical Cleaning of equipments parts /
connected piping
WC S
F Boxing up of equipment 7 connection piping WC S
G Log book maintenance (For rotating of shaft,
lubrication Oil reservoir full, all plugs in
positions)
WC S
H No load run of Motor WC W
I Recoupling of motor & reconfirmation of
alighnment
WC W
INSPECTION & TEST DOCUMENTS
Review test and Inspection documents HP Rw
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 31
SL. NO.
ACTIVITY CONTRACTOR PMC
VI CRANE (EOT/ HOT) 1 BEFORE ERECTION A Execution scheme WC Rw B Materials supply (contractor) WC W C Readiness for erection I Structural steel girder span centre to centre and
elevation Difference WC S
II Check centre to centre distance of rails, gaps, elevations, crab wheels distances
WC S
III Check buffer stops WC S 2 A Erection and assembly of components like LT,
Crane Girders, Crab, Platforms, etc. WC S
B Review of hoist ropes and assembly of hook blocks
WC S
3 A Electrical installation, testing and no load test of motor
WC S
B Coupling of motors to drives WC S
4 NO LOAD TEST A. Winding & unwinding test WC W B. Traversing test WC W C. Travelling test WC W
5 LOAD TEST A. Winding & unwinding test WC W B. Traversing test WC W C. Travelling test WC W D. Load & Over load testing WC W E. Deflection of girder WC W
INSPECTION & TEST DOCUMENTS Review test and Inspection Documents HP Rw
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 32
SL.
NO. ACTIVITY CONTRACTOR PMC
VII INSTALLATION OF COLOUMS INTERNALS
A Before Installation
1 Avalable of Venders representatives at site WC HP
2 Material Inspection
a) Manufactures Test Certificate WC Rw
b) Testing, If any WC S*
c) Positive Material Identification WC* Rw
3 Fabricated materials receipt WC Rw
4 Level check on TSRs WC S
5 Check for down corner clearance and Tray
clearance
WC S
6 Distance between TSRs WC S
B After Installation
Check for
1 Exit weir height WC S
2 UDFC WC S
3 Tightness of bolts WC S
4 Orientation and tightness of clamps WC S
5 Provision of lock nuts / seal pates WC S
6 Correctness of installation of shimming / bolting
for top down corner
WC S
7 Correctness of gasketing (if any) WC S
8 Tray to tray distance and level of tray WC S
9 Leak testing of seal pans as applicable WC HP
10 Damaged, missing valves and valve movement
for valve trays
WC S
11
Fitting of proper valve combination
WC
S
12 Damage to deck components WC S
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 33
13 Level and alignment of inlet weir and exit weir WC S
14 Check for slots on tray components to be fully
covered
WC S
15 Gaps at down corner ends WC S
16 Removal of temporary plugs after testing WC S
17 Cleaning of all trays & inside of equipment WC S
18 Certification of installation by Vendors
representative and operation groups of PMC /
Owner
WC HP
19 Final boxing up and intertisation, if any WC Rw
INSPECTION & TEST DOCUMENTS
Review test and Inspection documents HP Rw
NOTE:- All activities pertaining to material receipt, identification. Pre installation checks
checks and installation to be carried out in the presence of Vendors
representative and duly certified and documented for submission as final
document.
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 34
SL.
NO. ACTIVITY CONTRACTOR PMC
I FIRED HEATERS (FABRICATION & ERECTION
A PRIOR TO FABRICATION
1 Material Inspection
a) Manufacturing Test Certificate WC Rw
b) Testing, if any WC S
c) Positive Material Identification for Alloy
Steel & Stainless Steel material by alloy
analyzer
WC S*/RW
2 WPS / PQR WC HP
3 Welders Performance WC HP
4 Welding Consumable WC HP
5 a) NDT Procedure Qualification WC HP
b) PWHT Procedure Qualification WC HP
6 Availability of AFC drawing (Reviewed by
PMC) WC S
7 Joint Numbering for coils / pressure parts WC S/Rw
8 Structural members identification WC S/Rw
9 Layout Checking WC S/Rw
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 35
SL.
NO. ACTIVITY CONTRACTOR PMC
B FABRICATION
STEEL WORKS
1 Materials as per AFC drawing WC S
2 Dimensional check WC S
3 Fit-up check WC S
4 Weld Visual Inspection WC S
5 Radiography as Applicable
a) RT Marking (for random radiography only) WC HP
b) RT Interpretation WC HP
6 Completion of structures as per AFC
drawings WC HP
7 Surface cleaning for primer painting WC S
8 Primer Coating as applicable
COIL WORK
1 Edge Preparation WC S
2 Fit-up of joints WC S
3 Weld Visual Inspection WC S
4 PT/MT Check as required WC S/Rw
5 PWHT & Hardness check as applicable WC S/Rw
6 a) RT Marking (for random radiography only) WC HP
b) RT Inspection WC HP
7 Check Short for Radiography WC HP
8 Clearance for Hydro testing WC HP
9 Hydro testing
WC HP
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 36
SL.
NO. ACTIVITY CONTRACTOR PMC
C ERECTION
1 Foundation check as per AFC drawing WC Rw
2 Lifting arrangements WC Rw
3 Test certificates for lifting tools and tackles WC Rw
4 Lifting of radiant section columns WC S
5 Bottom plate fit-up & welding WC S
6 Radiant shell course fit-up and welding WC S
7 Weld visual inspection WC S
8 Radiography as required WC HP
9 Cutout for burners in bottom / shell plate
a) Marking WC HP
b) Cutting WC S
10 Coil erection in Radiant section WC S
11 Erection of convection box & APH with all
sheet work & tube Supports
a) Erection Procedure WC HP
b) Erection WC S
12 Check Shot for radiography for coil field joints WC W
13 Clearance for Hydro test WC HP
14 Hydro test field joints WC HP
15 Erection fit-up & welding of stack
a) Erection Procedure WC HP
b) Erection WC S
16 Erection fit-up & Welding of ducts WC S
17 Radiography as required
a) RT Marking WC HP
b) RT Interpretation WC HP
18
FD & ID
19 Installation of soot blowers
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 37
a) Marking WC HP
b) Erection WC S
20 Erection of all Platforms, ladders, Hand rails &
miscellaneous structures WC S
21 Final Painting
INSPECTION & TEST DOCUMENTS
Review Test And Inspection Document WC Rw
Abbreviations:
NDT : Non Destructive Testing
WPS : Welding Procedure Specifications
RT : Radiography Testing
PT : Penetrant Testing
MT : Magnetic Particle Testing
PWHT : Post Weld Heat Treatment
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 38
SL.
NO. ACTIVITY CONTRACTOR PMC
II REFRACTORY & INSULATION WORKS (HEATERS)
A RADIANT SECTION
1 Radiant shell
Fixing of Ceramic fiber blanket /
I. Material Inspection
Manufacturing Test Certificate WC Rw
Testing, if any WC S
II. Clearance for hot work WC* HP
III. Marking of studs WC S
IV. Welding of studs with approved PS&PQR WC S
V. Surface Cleaning WC S
VI. Check for individual layers of ceramic fiber
blankets and SS foils WC W
VII. Check for overlap of ceramic blanket WC S
VIII. Fixing of speed fix washer and cup lock WC S
IX. Cleaning and final inspection WC HP
2 Arch Plate
I. Material Inspection
Manufacturing Test Certificate WC Rw
Testing, if any WC S
II. Clearance for hot work WC* HP
III. Marking of studs / anchors WC S
IV. Welding of studs / anchors with approved
PS&PQR WC S
V. Surface Cleaning WC S
VI. Check for individual layers of ceramic fiber
Blankets (CFB) modules and SS foils
WC
S
VII. Check for overlap of CFB and modules WC S
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 39
VIII. Cleaning and final inspection WC HP
3 Floor Plate
Laying of castable / fire bricks
I. Material Inspection
Manufacturing Test Certificate WC Rw
Testing, if any WC S
II. Clearance for hot work WC HP
III. Surface Cleaning WC S
IV. Check Shelf life prior to application WC HP
V. Check for undulations on floor WC S
VI. Check for castable mix WC W
VII. Check for proper compaction WC S
VIII. Check for thickness of castable WC S
IX. Curing WC S
X. Cleaning after laying of castable WC S
XI. Check for cracks and repair WC W
XII. Fixing of tar paper, If applicable WC S
XIII. Cleaning and final inspection WC HP
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 40
SL.
NO. ACTIVITY CONTRACTOR PMC
II REFRACTORY & INSULATION WORKS
(HEATERS)
B CONECTION SECTION
1 Convection Walls
Laying of castable
I. Material Inspection
Manufacturing Test Certificate WC Rw
Testing, if any WC S
II. Clearance for hot work WC* HP
III. Marking of studs / anchors WC S
IV. Welding of studs / anchors with approved
PS&PQR WC S
V. Surface Cleaning WC W
VI. Check for undulations on wall WC S
VII. Check for castable mixing WC W
VIII. Check for proper compaction WC S
IX. Check for thickness of castable WC S
X. curing WC S
XI. Cleaning after laying of castable WC S
XII. Check for cracks and repair WC W
XIII. Cleaning and final inspection WC HP
2 End tubesheets
Laying of Castable
i. Material Inspection
Manufacturing Test Certificate WC Rw
Testing, if any WC S
ii. Clearance for hot work WC HP
iii. Marking of studs / anchors WC S
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 41
iv. Welding of studs / anchors with approved
PS&PQR WC S
v. Surface Cleaning WC S
vi. Check for castable mixing WC W
vii. Check for proper compaction WC S
viii. Check for thickness of castable WC S
ix. curing WC S
x. Cleaning after laying of castable WC S
xi. Check for cracks and repair WC W
xii. Cleaning and final inspection WC HP
3 Breeching Plate
Laying of castable
I. Material Inspection
Manufacturing Test Certificate WC Rw
Testing, if any WC S
II. Clearance for hot work WC* HP
III. Marking of studs / anchors WC S
IV. Welding of studs / anchors with approved
PS&PQR WC S
V. Surface Cleaning WC S
VI. Check for undulations on plate WC S
VII. Check for castable mixing WC W
VIII. Check for proper compaction WC S
IX. Check for thickness of castable WC S
X. curing WC S
XI. Cleaning after laying of castable
WC
S XII. Check for cracks and repair WC W
XIII. Cleaning and final inspection WC HP
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 42
4 Header box
Laying of castable
i. Material Inspection
Manufacturing Test Certificate WC Rw
Testing, if any WC S
ii. Clearance for hot work WC* HP
iii. Marking of studs / anchors WC S
iv. Welding of studs / anchors with approved
PS&PQR WC S
v. Surface Cleaning WC S
vi. Check for undulations on box WC S
vii. Check for castable mixing WC W
viii. Check for proper compaction WC S
ix. Check for thickness of castable WC S
x. curing WC S
xi. Cleaning after laying of castable WC S
xii. Check for cracks and repair WC W
xiii. Cleaning and final inspection WC HP
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 43
SL.
NO. ACTIVITY CONTRACTOR PMC
II
REFRACTORY & INSULATION WORKS (HEATERS)
C STACK
Laying of castable
I. Material Inspection
Manufacturing Test Certificate WC Rw
Testing, if any WC S
II. Clearance for hot work WC* HP
III. Marking of studs / anchors WC S
IV. Welding of studs / anchors with approved
PS&PQR WC S
V. Surface Cleaning WC S
VI. Check for undulations on stack shell WC S
VII. Check for castable mixing WC W
VIII. Check for proper compaction WC S
IX. Check for thickness of castable WC S
X. curing WC S
XI. Cleaning after laying of castable WC S
XII. Check for cracks and repair WC W
XIII. Cleaning and final inspection WC HP
HPCL, Visakh
INDICATIVE INSPECTION &
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261 TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 44
SL.
NO. ACTIVITY CONTRACTOR PMC
II
REFRACTORY & INSULATION WORKS (HEATERS)
D HOT AIR DUCT
I. Material Inspection
Manufacturing Test Certificate WC Rw
Testing, if any WC S
II. Clearance for insulation WC HP
III. External Surface cleaning WC S
IV. Provide spacer ring / anchors WC S
V. Check for thickness of the mineral wool
insulation WC S
VI. Check for staggering of joints in insulation WC S
VII. Check for providing expansion joints WC W
VIII. Overlapping of metal sheet as per
specification WC S
IX. Overlap on joints for aluminium sheets
as per specifications WC S
X. Sealing alluminium sheets WC S
E Final Inspection & Acceptance WC HP
INSPECTION & TEST DOCUMENTS
Review Test and Inspection Documents WC Rw