02 Mechanical
Short Description
02 Mechanical...
Description
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
INDEX Indicative Inspection & Test Plans SL. No. B.
DESCRIPTION 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
Sheet 1
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
HP
:
Sheet 2
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 contractor’s 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 ITP’s 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 ITP’s are not given, contractor to develop and get the same approved by Owner/ Consultant well before start of the work.
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL.
ACTIVITY
NO.
Sheet 3
CONTRACTOR
PMC
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 Colour coding procedure).
WC
S
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
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
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 Specification after completion.
WC
HP
6
Scrutiny of test packs for Mechanical & NDT Clearance(As per Annexure A)
WC
HP
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
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
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 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
System testing
WC
W
3
HP
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
Sheet 6
Inspection & Test Documents Review Test and Inspection Document
HP
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
Rw
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
Sheet 7
Plant:
Report: Area :
Contractor: Loop No.: Sketch No.:
Sr.No.
Inch Metre From: ____________ To : ____________
Activity
1.b
2
3 4
Clearance by PMC with Date & Sign
MECHANICAL COMPLETION RECORD (U/G)
A
1 1.a
Check
Clearance by Contractorwith Date & Sign
Clearance for flushing & testing. Mechanical clearance Conformity with drawing. Welding & NDT clearance Material as per piping class Fit-up check Visual check of completed welds LPI checks RF pad testing Flushing & Pressure testing Medium Test pr………. Kg /Sqcm Coating and Wrapping Surface preparation Primer application Coating, wrapping and peel test Holiday check 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
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
Sheet 8
INSPECTION REPORT FOR TIE IN JOINT (FOR UNDER GROUND PIPING) JOINT NO. A
REPORT NO. DATE
TTIME AT THE TIME OF FIT UP CLEARANCE BY DATE
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
CONTRACTOR
PMC
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
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
Sheet 9
Plant:
Report: Area:
Contractor: Loop No.: Sketch No.:
Sr.No.
Inch Meter From: ____________ To: ____________
Activity
1.b
2
3 4
Clearance by PMC with Date & Sign
MECHANICAL COMPLETION RECORD (U/G)
A
1 1.a
Check
Clearance by Contractorwith Date & Sign
Clearance for flushing & testing. Mechanical clearance Conformity with drawing. Welding & NDT clearance Material as per piping class Fit-up check Visual check of completed welds LPI checks RF pad testing Flushing & Pressure testing Medium Test pr………. Kg /Sqcm Coating and Wrapping Surface preparation Primer application Coating, wrapping and peel test Holiday check 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
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL.
ACTIVITY
NO.
Sheet 10
CONTRACTOR
PMC
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
5a b
NDT Procedure Qualification PWHT Procedures Qualification
WC WC
HP HP
6
Joint numbering in Isometries (Big & Small Bore) WC
S
7
Preparation of sketches for job in case of off sites A/G piping and Joint Numbering
WC
S
8
Transfer of Heat Nos. & Traceability
WC
W
B
FABRICATION (SHOP & FIELD)
1
Material as per piping class (check w.r.t. approved WC Colour coding procedure)
S
WC WC
S S S
1a b
Fit-up check Dimensional checks
2
Pre-heat (if any)
WC
3
Check for purity of purging/ shielding gas
WC
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 WC WC WC
S W HP
i) For C.S. Materials ii) For A.S. Materials Piping iii) For A.S. Material Heating Coil
Rw/S
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
Sheet 11
11
PT/MT
WC
S
12
Radiography marking (for Random Radiography only)
WC
W
13
Radiography Interpretation
WC
HP
i.For Carbon Steel Piping ii.For Alloy Steel/SS Piping
WC WC
HP HP
14
Spool clearance
WC
HP
C
ERECTION
1 2
Lifting arrangement Test Certificates for lifting tackles
WC WC
S 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 Valves), Steam traps and their direction of flow
S
9
Provision of cold pull
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 against closed valve position
S
4
Isolation of equipments, control valves, instruments, WC ellows, before testing. Removal of flappers from check valves
S
5
Scrutiny of test packs for Mechanical and NDT Clearance
WC
HP
6
Positive Material Identification as per specification WC after completion of installation
HP
WC
HP
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
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 of check valves
WC
W
16
a.
Check on fasteners & gaskets and record Thereof
WC
Rw
b.
Torque tightening of flange joints
WC
S
17
System testing
WC
W
18
Setting of spring supports
WC
W
HP
Rw
Inspection & Test Documents Review Test and Inspection Documents
Abbreviations: NDT
: Non Destructive Testing
WPS
: Welding Procedure Specifications
A/G
: Above Ground
PT
:
MT
: Magnetic Particle Testing
PWHT
:
Penetrant Testing
Post Weld Heat Treatment
For liquidation of Punch list. See Annexure - C.
INDICATIVE INSPECTION & HPCL, Visakh
TEST PLAN TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
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:
___________________
Line No (Isometric No.)
Sr. No. 1
2
3 4
5
Rev.
Report No:
___________________
Date :
___________________
Area :
___________________
INCH MTR
___________________
GAD NO.
Items to be checked 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 Installation checked as per GAD w.r.t. CONFIGURATION : Route clearance for thermal expansion / insulation Installation checked as per P&ID 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. Any other valves
FORMAT NO:_______________________________________ (Sheet 2/4)
Rev.
Acceptance by Contractor
P&ID No.
Witness by Owner/ PMC as required by ITP
INDICATIVE INSPECTION & HPCL, Visakh
TEST PLAN TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
Sheet 14
CHECKLIST FOR MECHANICAL CLEARANCE – A/G Piping (Sheet 2 of 4) Sr. No. 6 7
8 9 10 11
12 13 14
Items to be checked 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.) Torque values used for tightening Seal welding of Screwed connections (If required) Vents/ Drains as per Dwg. And provision of additional high point vents and / or low point drains, if reqd. Reinforcement pads as per piping class Orifice flanges Check for Tag. No. tapping orientation, tap valve, jack screw, straight run length of upstream and downstream Local Gauges: Check for accessibility 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:
15
i) Check for members dimensions and materiall ii) Check for welding iii) Check for bolting iv) Check for appearance damage Vents/ Drains As per Drg Orientation of valve handles Clearance for hose Requirement of additional vents/ drains (highest/ lowest pt.)
FORMAT NO:_______________________________________ (Sheet 2/4)
Acceptance by Contractor
Witness by Owner/ PMC as required by ITP
INDICATIVE INSPECTION & HPCL, Visakh
TEST PLAN TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
Sheet 15
CHECKLIST FOR MECHANICAL CLEARANCE – A/G Piping (Sheet 3 of 4) Sr. No. 16
17 17.1 17.2 17.3 17.4 17.5 18
19 20
21
22
Items to be checked
Earthings: a) Check for location b) Check for dimension of lug welding 17 Joints History sheets enclosed for 17.1 Material Traceability as per Procedure No: (refer enclosed suggested format) Fit ups checked NDT Complete (Radiography, MT, PT) Stress Relieving & Hardness Check complete 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 e. Others 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 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 manufacturer’s recommendations on isolation of bellow during Pr. Test to be followed If recommended expn, bellow to be dropped during pr. Test Cleanliness internally and externally 23 Rotating equipment final alignment checked with piping
FORMAT NO:______________________________________ (Sheet 3/4)
Acceptan ce by Contracto r
Witness by Owner/ PMC as required by ITP
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
Sheet 16
CHECKLIST FOR MECHANICAL CLEARANCE – A/G Piping (Sheet 4 of 4)
Acceptance by Sr. No.
Contractor
Items to be checked
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 :
FORMAT NO:_______________________________________ (Sheet 4/4)
Designation :
INDICATIVE INSPECTION & TEST PLAN HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
Sheet 17
DAILY MATERIAL TRACEABILITY REPORT
(FOR ABOVE GROUND PIPING/ HEATER) Report No.: ______________ Date : ___________________
Contract No. : _______________________ Contractor : ________________________ Sl. No.
Line / Heater No.
Area
Dia
Joint No.
No.
Spool
Piping Component
No.
Contractor Note : A Sketch of the spool may be enclosed.
Heat / Batch No.
Colour Code
Verified Contractor
PMC
Remarks PMC
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
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 : Contractor : Loop No. :
Date : Area : REF P & ID No. INCH MTR
Line No (s)
Test Medium : Test Pressure Gauge No.
Range
Items to check
From ______________ Isometric No. (s)
To _________________
Test Duration Calibration Certificate No.
Design/ Test pressure
Accept Contractor
P & ID No.
Gauge Calibration Date
Witness 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 Sign
PMC Name
Date Designation
FORMAT NO:_______________________________________ (Sheet 1/ 2)
Sign Date Designation
Name
INDICATIVE INSPECTION & HPCL, Visakh
TEST PLAN TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
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 Name
Designation
Date Name
FORMAT NO:_______________________________________ (Sheet 2 / 2)
Designation
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
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
FORMAT NO:_______________________________________
Designation
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO.
ACTIVITY
III
STORAGE TANKS
A 1 2 3 4 5 6 7 8 9 10
PRIOR TO FABRICATION Acceptance of the tanks foundation Materials Filler materials tests and approval WPS/ PQR Welders performance qualification Radiography procedure Joint numbering in drawings Welding equipment and accessories Tools and Tackles Baking ovens - Portable - Heavy Jig & Fixtures Suitability of plate bending machine
11 12 B 1 2 3 4 5 6 7 8
9 10
FABRICATION/ ERECTION BOTTOM Plate size, marking and cutting Blast cleaning & painting of underneath bottom plates Plate layout, overlap and fitup Sequence of welding to follow Size and positioning of backing plate for annular plates Baking of electrodes/ interpass cleaning Visual check LPI/MPI/ Radiography of annular plate butt welds and bottom plate butt welds (if any) Vacuum/ MPI/ LPI of shell portion of the bottom plates Vacuum box test for the bottom plate welding
Sheet 21
CONTRACTOR
PMC
WC WC WC WC WC WC WC WC WC
W W HP HP HP HP S S S S
WC WC WC WC
S S S
WC WC
S S
WC WC WC
S S S
WC WC WC
S S HP
WC
HP
WC
HP
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO. 1 2 3
4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19a 19b
ACTIVITY SHELL Plate size, marking and cutting. Plate bending, curvature check, stacking. Shell course alignments and fitup of vertical and circumferential joints. Shell diameter, circularity, perpendicularity, straightedge before welding. Visual and Back chip check Second side visual. Location, size and alignment of nozzles and other Openings R.F.Pads fitup / welding. PWHT of RF pad. Nozzles & manhole, etc. (As applicable) Radiography marking for Random radiography only Curbangle and Wind girders fitup / welding MPI/LPI nozzles, wind girders fitup/welding RF Pads air test. Shell to bottom fit-up Sheel to bottom I/S welding root run visual/ Oil chalk test Sheel to bottom O/S welding visual and LPI for toecracks Fabrication and erection of stairways Cleates welding for insulation Radiography interpretation. Extension marking for repair
Sheet 22
CONTRACTOR
PMC
WC WC
S S S
WC WC WC WC WC WC
HP S S HP W HP
WC WC WC WC WC WC WC WC WC WC WC WC
W S W HP W HP HP S S HP HP
FIXED ROOF 1 2
Identification of Roof Structure members in AFC drgs Blast cleaning and painting Roof Structure underside of Roof plates
WC WC
Rw S
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO. 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Sheet 23
ACTIVITY
CONTRACTOR
PMC
Location and welding of roof supports. Alignment and welding of Roof Structures. Plate layout, overlap and fitup Visual check of roof welds Location, size and alignment of roof manholes and vents PWHT (As applicable) RF pads fit-up & Welding RF pad pneumatic testing PT/MT of Nozzles, vents & other attachments Welding of Roof plate with shell / curb angle FLOATING ROOF Temporary staging spacing and levels Plate size, straightening and cutting Plate layout, overlap and fitup/ welding Buoys fabrications Vacuum testing of roof-plate welds Location of sleeve supports Pad plate welding with roof and sleeve support Fixing and welding of Buoys Initial – lift Supports fixing through sleeves Seal welding of support sleeves from beneath after dewatering Air test of Buoys Pontoon welding Location, fixing and welding of man holes, drains etc. Shell to pontoon clearance Seal fixing
WC WC WC WC WC
S W S W S
WC WC WC WC
HP W W W
WC
W
WC WC WC WC WC WC WC WC
S S S S HP W W
WC WC WC WC
S W S W
WC WC WC
HP W S
WC W
W W
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO. C
Sheet 24
ACTIVITY
CONTRACTOR
Correctness of testing arrangements especially size of blind flanges/ vents/ drains/ temporary piping
WC
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
HP
Rw
1
PMC
TESTING S
Inspection & Test Documents Review Test and Inspection Documents
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO. IV 1
ACTIVITY
Sheet 25
CONTRACTOR
IV V VI VII
EQUIPMENT ERECTION (STATIC) BEFORE ERECTION Execution scheme Materials supply Readiness of erection Level of foundation (shims/ packing with marking to be prepared & kept ready) No. & Size of bolts Hole dia and no. of hole in base/ structure of equipment and columns Equipment base with actual foundation Checking the threads of bolts & nuts Chipping & roughening of foundation C/L marking on equipment
2
ERECTION SCHEMES FOR CRITICAL EQUIPMENTS
A B C I II III
PMC
WC WC WC WC
Rw W S S
WC WC
S S
WC WC WC WC
S S S S
WC
HP
WC
W
WC
S
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
A Approval of Rigging procedure (As per Annexure – 1) 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) Cross checking if Data-sheet w.r.t. 4 orientation, base plate Deatails 5
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO. 6
ACTIVITY
Sheet 26
CONTRACTOR
PMC
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
As per specification
WC
W
8
Packing of column (As per Annexure – 2)
WC
W
9
Final Boxing up
WC
W
HP
Rw
7
TESTS
Inspection & Test Documents Review Test and Inspection Documents
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO.
ACTIVITY
Sheet 27
CONTRACTOR
PMC
ERECTION SCHEME FOR CRITICAL EQUIPMENT (Rigging Procedure)
1
BEFORE ERECTION A Checking proper sequence for lifting of the equipment B To check weight of equipment C To check the centre of gravity D To check suspension points E To check the maximum/ minimum radius at which the lifting tackle will operate F To check the maximum load to be lifted including wt. Of slings, hook-block, lifting beams and equipment etc. G To identify the safe crane with requisite capacity
2 A B C D E F G H I J
DURING ERECTION To check counter weight of crane and Boomlength To check slew limitations of crane To check ground conditions are adequate for supporting fully rigged crane and load To check the crane can be travelled in loaded condition To check clearances from overhead electric power cables To check maintenance certificates To check whether operators, riggers have received proper instructions To verify safe load indicator been supplied to rig the crane To check the adequacy of bracing of equipment by guys To check the guys, shoring, bracing, interference with other works
WC
Rw
WC WC WC WC
Rw Rw Rw Rw
WC
Rw
WC
Rw
WC
Rw
WC WC
Rw Rw
WC
Rw
WC
Rw
WC WC
Rw Rw
WC
Rw
WC
Rw
WC
Rw
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO.
ACTIVITY
Sheet 28
CONTRACTOR
PMC
WC
S
A Degreasing and cleaning of packing material
WC
S
B Check packing su pport plate C Check for stacked or dumped packing as per
WC
S
WC
S
WC
S
WC
S
PACKING COLUMN 1
BEFORE INSTALLATION A Identify the material, check thickness, dimensions, no. and angle of fingers of packing rings
2
DURING INSTALLATION
Specifications D Check for nesting E Check for packings are touching bed limiter (when issued and top level)
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO.
ACTIVITY
V 1 A B I II
EQUIPMENT ERECTION (ROTARY) BEFORE ERECTION Execution scheme Foundation check Level / centreline of foundation No / Dia / Length of anchor bolts, Depth of pockets, verticality of pockets III Chipping, roughing and cleaning of pockets
2
3
LIFTING TACKLES Crane/beams/ slings/ shackles etc. to be checked for weight of equipments
Sheet 29
CONTRACTOR
PMC
WC
Rw
WC WC
S S
WC
W
WC
S
VISUAL INSPECTION OF EQPTS. TAG/ IDENTIFICATION NO. WC A For any damage Free shaft rotation B WC
4
A B C D E F G H
S S
Drilling and Tapping (if reqd.) hole in the base plate of eqpt. a. Size/ Taps
WC
S
DURING ERECTION Level/ elevation of base frame All foundation bolts to be checked Grouting of base frame / pocket grouting Orientation of eqpts. Elevation/ Level of eqpts. Shimsize/ material/ thickness Distance between couplings No-load run of motors
WC WC WC WC WC WC WC WC
W S W W HP W W W
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO.
ACTIVITY I Alignment readings
Sheet 30
CONTRACTOR
PMC
WC
- Without piping (Loose bolts)
WC
HP
- With piping (After tightening the flange bolt)
WC
HP
WC
S
WC
S
WC
S
WC
S
WC
S
D Tests as per spec. E Chemical Cleaning of equipments parts / connected piping F Boxing up of equipment 7 connection piping
WC
W
WC
S
WC
S
G Log book maintenance (For rotating of shaft, lubrication Oil reservoir full, all plugs in
WC
S
WC
W
WC
W
HP
Rw
J Type of grout and grouting K All protection and safety guards installation
AFTER ERECTION A Curing of grout B Auxiliary connections to be mounted on eqpts. as per drawing C Final tighting of bolts
positions) H No load run of Motor I Recoupling of motor & reconfirmation of alighnment INSPECTION & TEST DOCUMENTS Review test and Inspection documents
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO. VI 1 A B C I II III 2 A B 3 A B 4
5
ACTIVITY
Sheet 31
CONTRACTOR
PMC
WC WC
Rw W
WC
S
WC
S
WC WC
S S
WC
S
WC
S
WC
S
WC WC WC
W W W
LOAD TEST A. Winding & unwinding test B. Traversing test C. Travelling test D. Load & Over load testing E. Deflection of girder
WC WC WC WC WC
W W W W W
INSPECTION & TEST DOCUMENTS Review test and Inspection Documents
HP
Rw
CRANE (EOT/ HOT) BEFORE ERECTION Execution scheme Materials supply (contractor) Readiness for erection Structural steel girder span centre to centre and elevation Difference Check centre to centre distance of rails, gaps, elevations, crab wheels distances Check buffer stops Erection and assembly of components like LT, Crane Girders, Crab, Platforms, etc. Review of hoist ropes and assembly of hook blocks Electrical installation, testing and no load test of motor Coupling of motors to drives NO LOAD TEST A. Winding & unwinding test B. Traversing test C. Travelling test
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO. VII
ACTIVITY
Sheet 32
CONTRACTOR
PMC
WC
HP
a) Manufacture’s 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
WC
S
6
clearance Distance between TSRs
WC
S
B
After Installation
INSTALLATION OF COLOUMS INTERNALS
A
Before Installation
1
Avalable of Venders representatives at site
2
Material Inspection
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
WC
S
for valve trays 11
Fitting of proper valve combination
WC
S
12
Damage to deck components
WC
S
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
Sheet 33
13
Level and alignment of inlet weir and exit weir
WC
S
14
WC
S
15
Check for slots on tray components to be fully covered 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
Certification
Vendor’s
WC
HP
representative and operation groups of PMC / Owner Final boxing up and intertisation, if any
WC
Rw
HP
Rw
18 19
of
installation
by
INSPECTION & TEST DOCUMENTS Review test and Inspection documents
NOTE:-
All activities pertaining to material receipt, identification. Pre installation checks checks and installation to be carried out in the presence of Vendor’s representative and duly certified and documented for submission as final document.
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO. I
ACTIVITY
Sheet 34
CONTRACTOR
PMC
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
WC
S*/RW
analyzer 2
WPS / PQR
WC
HP
3
Welder’s 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 member’s identification
WC
S/Rw
9
Layout Checking
WC
S/Rw
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO. B
ACTIVITY
Sheet 35
CONTRACTOR
PMC
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
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO. C
ACTIVITY
Sheet 36
CONTRACTOR
PMC
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
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
20
a) Marking
WC
HP
b) Erection
WC
S
WC
S
WC
Rw
Erection of all Platforms, ladders, Hand rails & miscellaneous structures
21
Sheet 37
Final Painting
INSPECTION & TEST DOCUMENTS Review Test And Inspection Document
Abbreviations: NDT
: Non Destructive Testing
WPS
: Welding Procedure Specifications
RT
: Radiography Testing
PT
:
MT
: Magnetic Particle Testing
PWHT
:
Penetrant Testing
Post Weld Heat Treatment
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO. II
ACTIVITY
Sheet 38
CONTRACTOR
PMC
REFRACTORY & INSULATION WORKS (HEATERS)
A
RADIANT SECTION
1
Radiant shell Fixing of Ceramic fiber blanket / I.
Manufacturing Test Certificate
WC
Rw
Testing, if any
WC
S
Clearance for hot work
WC*
HP
III.
Marking of studs
WC
S
IV.
Welding of studs with approved PS&PQR
WC
S
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
Cleaning and final inspection
WC
HP
II.
V.
IX. 2
Material Inspection
Arch Plate I.
Material Inspection
Manufacturing Test Certificate
WC
Rw
Testing, if any
WC
S
Clearance for hot work
WC*
HP
III.
Marking of studs / anchors
WC
S
IV.
Welding of studs / anchors with approved PS&PQR
WC
S
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
II.
V.
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
VIII. 3
Cleaning and final inspection
Sheet 39
WC
HP
Floor Plate Laying of castable / fire bricks I.
Material Inspection
Manufacturing Test Certificate
WC
Rw
Testing, if any
WC
S
Clearance for hot work
WC
HP
III.
Surface Cleaning
WC
S
IV.
Check Shelf life prior to application
WC
HP
Check for undulations on floor
WC
S
Check for castable mix
WC
W
Check for proper compaction
WC
S
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
II.
V. VI. VII. VIII.
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO. II
ACTIVITY
Sheet 40
CONTRACTOR
PMC
REFRACTORY & INSULATION WORKS (HEATERS)
B
CONECTION SECTION
1
Convection Walls Laying of castable I.
Manufacturing Test Certificate
WC
Rw
Testing, if any
WC
S
Clearance for hot work
WC*
HP
III.
Marking of studs / anchors
WC
S
IV.
Welding of studs / anchors with approved PS&PQR
WC
S
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
II.
V.
2
Material Inspection
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
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
3
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
Breeching Plate Laying of castable I.
Material Inspection
Manufacturing Test Certificate
WC
Rw
Testing, if any
WC
S
Clearance for hot work
WC*
HP
III.
Marking of studs / anchors
WC
S
IV.
Welding of studs / anchors with approved PS&PQR
WC
S
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
II.
V.
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
4
Sheet 42
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
WC
S
PS&PQR 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
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO.
ACTIVITY
II C
Sheet 43
CONTRACTOR
PMC
REFRACTORY & INSULATION WORKS (HEATERS) STACK Laying of castable I.
Material Inspection
Manufacturing Test Certificate
WC
Rw
Testing, if any
WC
S
Clearance for hot work
WC*
HP
III.
Marking of studs / anchors
WC
S
IV.
Welding of studs / anchors with approved
WC
S
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
II.
PS&PQR V.
INDICATIVE INSPECTION & TEST PLAN
HPCL, Visakh
TOYO ENGINEERING INDIA LTD.
ISSUED :01.06.2009
JOB NO. : 6261
DOC.No. 6261-CD-303
DHT PROJECT
SL. NO.
ACTIVITY
II D
CONTRACTOR
PMC
REFRACTORY & INSULATION WORKS (HEATERS) HOT AIR DUCT I.
Material Inspection
Manufacturing Test Certificate
WC
Rw
Testing, if any
WC
S
Clearance for insulation
WC
HP
III.
External Surface cleaning
WC
S
IV.
Provide spacer ring / anchors
WC
S
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 Overlap on joints for aluminium sheets as per specifications
WC
S
WC
S
WC
S
WC
HP
WC
Rw
II.
V.
IX. X. E
Sheet 44
Sealing alluminium sheets
Final Inspection & Acceptance
INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents
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