Inspection and Test Plans ITPs

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INSPECTION & TESTPLANS MECHANICAL 1IYORKS

STANDARDSPECF|eAnONNo-

6€2-1100RevI p a o "*

lol

^

5d

INSP CTION & TEST PLANS (ITPs) R MECIIANICAL WORI$ TEM RATE CONTRACTS)

REVISED& UPDATEO

^+,.4-

ISSUEO ASSTANDARD SPECTFICATION Connltt€o convenor

Bu.eau Chalman

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(x)

|NSPECT|ON & TESTiLANS MECHANTCALWOBKS

STANDARDSPECIFICATION Nd

6-82-t'100 RevI ^ Paqera!! a 6f

Abbreviations: AFC A,/G AS CFB

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ApprovedForConstruction AboveGround Alloy St€eli.e.Cr-MosteelslikeA33 Gr PIl, P5,P9,P22,etc, CerarnicFibreBlankets CarbonSteel Cat S€alOpen FreeDraught CeneralAnargementDrawings HydrogenInducei Cracking IndianBoiler R€gulations hduoedDraught InnerSide lnck Oper/Lock Close LongitudinalTraverse Low Temperature CaxbonSteel MagneticParticleTesting NationalAssociationof Conosion Non D€sftuctiveTesting Non ReturnValve OverDimension Consignment OuterSide PositiveMaterialIdentification ProcedueQualificationRecord PenetrantTesting PostWeld HeatTreafircnt Reinforcement Radiographic Testing Stainless SteellikeA3l2 T? 304,316 321,304L,316L,316Mo, e&. SulphideStressConosionCaacking Tray SupportRing UndorDox,nFIowClearance WeldingProcadure Specification

Construction

Committee

cs cso FD GAD HIC IBR ID

vs

.

M

LOl LC LT LTCS T NACE NDT NRV

oDc

o/s

PMI PQR PT PWIIT RF RT

ss sscc

TSR UDFC

Convenor:

V.N. Prasad,GM (Conskuction)

Members :

A.K. Mittal, DCM (Projects) . M.P. JaiD,AGM (Conskuction) , R. Kannan,AGM (Conshuction) RakeshNanda, Sr, Manager(Piping)

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INSPECTION & TESTPLANS MECHANICALWORKS

STANDARDSPECIFICAIION No.

6+2-'1100 Rov I Paqe FE

,

I dn_

5O

GENERAL NOTE Tfte enclose.l Droebiolsitt 'Charge may givei, contiactor Conlractor lo an.l sah lt to

EIUOwner, C'

s thall be followed for the works to be pedomed bv the confiactot The lfor stagewiseinspeciion by Ell)Owner areihd mlnimuit and the Enpi eer-|hI to increase Hold Points/ lyitness Poinls, Ac.livities for tehich ITPIS ue nol daelop and gd the sameapprovedb! BIAO net reel[before stafl ofthe work required repo inp fotmats ond iob prccedurcs-of for e.tch activitv listed in ITp's wnerlor qpprcval;iell belorc cbmiuncement the actfity. Il the cohfiactor ,he giren ITP lor a t)alid rcason, he shal ob,sin pior ';t ilen aDDrcwl of 'or ro carry out 1000,4examinalion of oll activilies.

LEGEND

m i,rhichrequireswitnessing/inspe.tion/verificadon andacceptarc€ by Ov,ner/EIL anyfurtherprocessing is permitted. Contraclorshallnot processthe activity/itembeyonda Hold Pointwilhoutwdtten by Owner/EILexceptwhereprior writtenperrnission for firrtherprocessing is

activity which requir€switnessing/inspection/verification by Orvner.iEllwhenthe is performed. propq notificationhasbe€nprovided(notificationmodalitie,s andperiodshallbe before hand), the Contractor is not obliged to hold ftrther processingif js nol availableto wihessthe aclirity or doesnol providecommenrs before datenotified. Basisofacceptanceshallbc asper relevant@hnical specification.

Rw

of Contractor'sdocumentation.

s

Inspection by Owner/EIL. or makingobservations to veri& whetheror not materiavitems or services to specifiedrequiremenls. Surveillance activitiesmayincludeaudit,inspections, essof testing re ew of quality documerfation& recods, pelsonllel qualifications,

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Examinationby Contractor.

Responsibility exccution of th€ inspection/testingis with ihc Contractor; OrYner/EILonly v€rifi* eaami

or testiDg dotre by the Contractor at important stages.

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INSPECTION & TESTPLANS MECHANICALWORKS

ITP NO.

STANDARDSPECTFICATION No.

6-82-l'100Rev1 t.t " 56 Pas.A (Steetr of 12.)

1110REV1

4BOVD GROUNDPIPING

sl.

Acfivif

No PRIOR

lwc HP

FormatM2 FormatM2

WC*

Rw*

Yes

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W W

FormatM3, M4 FormatM3, M4

wc

HP

FormatM5

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HP HP HP

FormatM6 FormatM6 FormatM5, M6

wc

W

FormatM7

WC

HP

FormatM8

ure Qualification a) Revier^. proposed procedure b)w of ProposedPros€dureT€sting c) ofQualified Proc€dure

WC WC

HP HP

wc

t{P

Revi€w of oint rumbering in Isom€txics(Big &

WC

HP

WC WC

Rw HP

Yes

S W HP

FormatM9 Fornat M9 FormatM9

ii)Alloy WPS/?QR a) Review ProPosed procedure b) Testing D Car Steel ii) AIloy

c)A 4.

Steel

offinal WPS/PQR

W€lder

QualificationTest

5,

& approvalofwelders

6.

Recordsto be Submitted Form{t No.

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supplyincludingohecktesting

WeldingF MaterialApproval/Qualifi cation a) Test Certifi cate,/Documents b) Testin& f aoy Steel ,

3.

EIL

FABRICATION

hcoming a) Owner's b)

l.

Contractor

NDT

7.

Smallbore) 8.

Lines

9.

4

Isometri€snot available of sketches

b) Joint

beringin sketches

Matedal

- c.s.

ilitt & Transferof HeatNos,

- C.S.pi

< 60t)#nting 600#ratiogandabove

- A.S.P

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S.SPiping,NACE piping,H,

WC

ary othert€sts/documentation requi

of fillerm€tals:

i)

For Alloy

& Stainless St€€l welding filler netals, chemical analysis to be caried out for v€ry

ii)

For LTCS

filler metals,Impacttestto be carriedout for ev€rybatch metals,conosiontesrslike HlC, SSCC,etc.to be caniedout for everybatch.

iii) ForNACE

Pl. refer page 5 of 07 for definitionof WC, Rw,HP,W, S andSection-B(page43 of 107)for fomats FomatNo.8-00-000

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IMSPECTION & TESTPLANS MECHANIGALWOBKS

STANDARD SPECIFICATIONNo.

6-82-1100Rev1 . Paa.* 5 + 56 (Sheet2 of 12)

l 0REVI ABOVEGROUI{DPIPINC

ITP NO.

EIL

Activity

Recods to be Submitted FontratNo.

TION (SHOP& FIELN) Material p€rpipingclass(checkw.r.t. approved codingprccedure)

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Dimens

checks

s

Fit-up

for buttjoints and socketjoints

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s

wc

Rw

wc wc wc

S

for branchjoints

Fit-up

Pre-heat(i any) of purity ofpurging/shi€ldingGas(if

FormatMl0

FormatMl0 Fomat Ml0

Yes

any.) ?urging

(if a[y) and arrangement

(if any)

Shielding Bakingof Int€r-pass

& Temperature check.

Visual

of oompletedwelds having

- Random - t00%

9.

ofPWHTCycle

t0.

graph Review Time - Temperature

n.

HardIr€ss a) For C . Materials b) For A

Materials Piping

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S

wc

S

wc

HP

Y€s

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S

Fonat M12

Format Ml I

marking(for Random Radiography

13.

wc

FormatMl I

FormatMl2

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12. PTA4T

Pl. rcf€r page 5

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s s s

FormatMl3, Ml4

HP

FormatMl5

107 for definition of WC, Rw, HP, W, S and Section-B (page 43 of l0?) for formats

Formst No.8{0-0001

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STANDARD SPECIFICATIONNO.

6{2.1100Rev1 r' 6t o.^6fl

a

(Sheet3 of 12)

ITP NO.

sl.

Activity

No.

t4.

1110REV1 ABOI'E GROUNDPIPING

Radio

R€cordsto be Submitte FormatNo.

CJntractor

Inte$retation/ R€view

a) For

SteelPiping

b) For

Piping SteeVSS

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Check

for Radiography

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andprimerapplication

16.

Surfacecl

1.

Lifting

2.

Test

3.

Location

4.

Provision Inst. Tappings

5.

Provision

(for critical pipingonly) for lifting tackles orientationof Branchconnections

6.

oft'?e of supports,Anchors,Guides

7.

of gaskets/fasteners

HP

M16 Format

HP

FornatM 16 FormatMl6

wc

S

FormatMl?

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Rw

Yes

Rw

Y€s

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Rw HP

Annex-l

Rw HP

Annex-1

S.SPipin&NACEpipins (N'RV, toapsand

9.

6lobe, controlValvesetc), steam ir directionofflow

- C.S.pip

np

- A.S.Pi ng,S.SPiping,NACEpiping

HP

Provision coldpull,ifany.

HP

PL ref€rpage5

Fomet No.8{6000

Annex-l

107 for definition of WC, Rw, HP, W, S and Section-B (page 43 of 107) for formats

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& TESTPLANS INSPECTION MECHANICALWO

STANDARD SPECIFICAIION No.

6{2-1100 ReY'l , P.oe Ls

+ d+

(She€t4 ol12)

1110RXV1 ABOI.EGROI'NDPIPINC

ITP NO.

sl,

Activity

No.

D

PROOF

l.

Proc€dure

Recods to be Submitted/ Formsl No.

Contractor

TING

2,

ofT€shngarrangements

HP

Annex-2

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Annex-2 Annex-2

lveskeptopenandconfirmthat doneagainstclosedvalv€seat

3.

Checkall testingis

4.

controlvalves, Isolation equipments, bellows. Removalofflappersfrom

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Annox-2

HP

Annex-I, Format M21

HP

FormatMl8

HP

FormatMl

if any

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8.

ofchecklist (Punchlist)

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HP

AImex-3

9.

ofchecklist

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HP

Annex-3

chgck

Scrutiny testpacksfor M€chanical& NDT Cleamnce

ial Identification asper

Positive

6.

after corilpletion of installation,

7.

Calibration certificatesof pressure

a) Review Gauges

b) Field

ing(preliminary)

10, .

Visuali

ofall weldjoints for leak

HP

Hydrotesting

dudng

12. Draining Water& Air Drying 1 3 . Removal temporary blinds/supports.

Pl. refer page 5

Yes

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Annex-2 Annex-2

107 for definition ofWC; Rw, IIP, W, S and Section-B (page 43 of 10?) for formats

FomalNo.S{0{001

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& TESTPLANS TNSPECTION MECHANICALWORKS

No, STANDARD SPEcIFIoATION

B{2-1t00 Revt P"o" Eg

r

t or

(Sheet 5 of 12)

I1? NO.

1110RXV 1 ABOVE GROI]ND PIPING

st.

Activity

No,

11.

EIL

Boxing inoluding reinstallation of flappcrs of

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Review Recordsoffasteners& gaskets

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HP

WC

s

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HP

FormatM20

WC

HP

Annex-2

wc

Rw

Yes

Picklirg system,if required

t5.

Contracto]

Recordsto be Submitted/ Format No.

Torqueti

g/ tensioningof flangejoints,

FormatMl9 Annex-2

ioable

18.

System

19.

Settingo INSP

supports & TESTDOCI'MENTS ss of Insp€ction and Test Records

** Refer at siteNo. 5-

for Identification and Boxing up of flangejoints not subject€dto hydrostatictest 120. enclosedels€wherein the contmct.

NOTES: i)

For

ii)

Fori

Pl. refer page 5

works.referITP for PaintinsworksNo. 6-82-I 50I worksNo. 6-82-1505 works,ref€rITPfor lnsulation

107for definitionof vC, Rw,H?, W, S andSection-B(page43 of 107)for formats Copyrighi ErL- All ghtsEserued

,€ffi@

& TESTPLANS INSPECTION MECHANICALWORKS

No. STANDARDSPECIFICATION

Rev1 / ,^ 6-82-1100 'q P.de lt=i,

61-

(Sheet6 of 12) ITP NO.

1110REV 1 ABOVE GROUND PIPING

ANNEX_1 Checklist for Mechanical Clearance- A-lG Piping

Plant/Unit : Contractor :

Witnessby OwD€r/PMC

It€ms to be Itrstallation

BRANCH

as per Isometric w,r.t TION i Route,plumb,elevation, Clearancefor thermal expansior/insulation : Location,angle,orientation, type, RF pad,etc.

STEAM ked as per GAD w.r.t

forthermal TION : Route,clearance leted for ( enclos€d ):

& Fieldwelds

Rating, Gaskets, Flow Direction, ag No., Spindle direction, CSO

FORiv|A-

( sht 1/4)

Job No. --

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& TESTPLANS INSPECTION MECHANICALWORKS

No, SPECIFICATION STANDARD

6.82-1100Rev1 Pde *,

r 5o

ta ar

(Sheet7 of 12)

ITP NO.

1110 RrV r ABOVE GROUNDPIPING ANNEX_1 - A/C Pi Checklist for Mechaoical Clearance

Studs& nuts- dia.,length,Mat€rial,uniform

per Drg and Provision of additional high point

No.. lapping orienhtion. tap valve.jack screw.

of uostream& downstr€am

material& dimension

andcheckderailsas Derdata sh arrangementand any damageduring of installation as per drg.

ine cleay'bracket rt & Insertswith Anchor Fasteners: dimensions andmaterials

( sht 2i4 )

Job No. --CopyrighlEIL- All dghtseseNed

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& TESTPLANS INSPEGTION

No. STANDARDSPECIFICATION

MECHANICALWORKS

6-82.1100Rev '1

".""ry

r, "l

(Sheet8 of 12)

1110Rf,V I

ITP NO.

ABOI'E GROUND PIPING

ANNEX_1 Cheoklist for Mechanical Cleaance - A/G Piping

sheetsenclosedfor : as per SpecificationNoi

and CheckValves

freefrom weld./Flanced/Scrcwed connections

mfs, rccommendations onisolation of expn.bellowto bedropped during

( shr 3/4)

FornatNo.8-00-0001

Job No, -

56

,.ffffiH@

& TESTPLANS INSPECTION MECHANICALWORKS

STANDARosPEctFlCATloNNo.

6-82.t100 Rev'l Padet-e3

tt

dT

(She€l9 of 12) 1110R.EV1 ABO\'E GROIIND PIPING

ITP NO.

ANNf,X_ 1 - A/G Piping Cheoklistfor MechanicalQlearance

-Thmugh - Th€ - Line, checkedfor goss

unwantedtacks, including physicaldamages, and sDacefor tlemal

FORMAT

Foinat N6.840-0001

( sht 4/4)

Job No. -.

CopydghlEIL- All dghlsreserved

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& TESTPLANS INSPECTION MECHANICALWORKS

No. STANDARDSPECIFICATION

Rev1 6-82-'l'100 ProelE€

|

13 o{

4o

(Sheet10ol 12) ITP NO.

1110REV 1 ABOVE GROIJND PIPING

ANNEX-2

Record- A/G Piping Piping Hydro Test Release/Acceptance

Conhactor:

REFP&IDNo.:

LoopNo:

INCH MTR : From

To

LineNo,(s

ChecklistPriorto Hvdrotest

IBR/OtheN

for PressureTestins:

TNO:

( sht 1,2)

Copyright EIL- AllrightsrcseNed

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NEERS \ UMTTD

& TESTPLANS INSPECTION WORKS MECHANICAL

No. STANDARDSPECIFICAT|ON

6-92.1t00Rev1 Paqe€

t4 dt 56

(Sheet 11of12) ITP NO.

1110REV 1 ABOVE GROUNDPIPING

ANNEX_ 2

Record* A/C Piping PipingHydro T€stRelease/Acceptance

Waterlilling andV

Checkedfor rci a. Control& b. Online c. Rupture d. Deblinding e. Others

FORMAT NO;

Format No.8{0-000

( Shr2/2 )

CopyightEl! -All righhFserved

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& TESTPLANS INSPECTION MECHANICALWORKS

No, SPECIFICAnON STANDARD

6€2-t100 Revt tt 6t 50 Panetu (Sheet12of 12)

ITP NO.

1110RXV 1 ABOVE GROUNDPIPING ANNEX - 3 Punchlist

sh. 1/1

FonralNo,840.0001

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& TESTPLANS INSPECTION MECHANICALWORKS

NO. SPECIFICATION STANDARD

6.82-tt00 Rev1 e^ ae

ta d 56

(Sheet1of4)

1150Rf,V 1 f, QUIPMENTERECTION(STATIC) Contractor

EIL

R€cordsto be Submitt€d/ Formrt No.

of equipmentfoundation

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Rw

FormatM27

Rw

FormatM2

supply,includingchecktesting,if

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HP

FormatM2

sl.

Activity

No 1.

BEFORE

a.

Execution

b.

Materials

ly

. Owner's

ly

any Readiness erection Centre irc markingon equipm€ntand

i)

i;) Level

iiD iv) Hole equlp Matcl actual

foundation (shims/ packing with to b€ prepared& kept rcady)

bolts ofno. & sizeofFoundation andno. ofholes in base/structureof columns equipmentbasebolt hol€swith

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FornatM27

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FormatM27

FormatM27

FormatM27

w

FormatM27

Rw

FormatM27

s

FormatM2?

S

FormatM27

wc

HP

Annexwe-1

cranes,Iifting beams,slings and and dia.of sling& conditionof

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W,A.W

Yes

Placement of Main & tailing cran€ as per

WC

Rw

o vi)

vii)

ation bolt layout orientation

thetfueadsofbolts& nuts & rougheningof fourdation

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SCMMES FOR CRITICAI EQPTS Approval Riggingprocedure SAFETY Load rest shackles, wire rope b.

Pl. ref€rpage5

107for defioitionof WC,Rw, IIP, W, S andSection-B(page43 of 107)for fornats

CopyrlghtEIL- AI nghbreseffed

I.IMITD

& TESTPLANS INSPECTION MECHANICALWORKS

No. SPECIFICATION STANDARD

6-82-1100Revt pane.F'' l+ b+ 5o (Sheet2 of4)

1150REV1 EQIIIPMENT EBJCTION (STATIC)

ITP NO,

SL

Activity

No

R€cordsto be Subnitted/ FormatNo.

Contractor

DURING of competentRiggingcr€w

a. b.

Orientation be checked Placement

d.

packingasperAIC drg.

coating/wmpping painting Outside (for equipmentonly) Orientation €quipmentasperAFC drg. AT'TER

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R$,

s Yes Rw

ON washers ofBoltsandProviding

Fomat M28,M29

WC

b. Leveli andAlignmentof equipments.

i) Cri

ODCS €quipments/

ii)

& elevation rcquirement nozzlesin specialcases. distance d. Cleari of Sleevesbefore grouting

i)A ii)

iiD f. Final

Pl. referpage5

of Specifiei groutingmaterials

of grouting of grout. g ofbolts

wc wc wc wc

HP

FormatM2E,M29

w

FormatM28,M29

s

FormatM28,M29

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Rw

FormatM28,M29

w

Fomat M28,M29

s

FormatM28,M29

S

FormatM28,M29

FormatM28,M29

10?for definitionof WC,Rw, HP,W, S andSection-B(page43 of 10?)for formats

copydghtEIL- All rlght!reserued

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INSPECTION & TEST PLANS MECHANICAL WORKS

6-82-1100RevI P^6a*

sl,

Activity

No

,

lg 44' 5O

{Sheet3 of4)

1150REV1 EQUIPMENTERECTION(STATIC)

ITP NO.

6.

STANDARD SPECIFICATION No.

EIL

Recordsto be Submitted/ FormatNo.

wc wc wc wc wc

S

Yes

WC

Rw

Contractor

PACKED 1. Before

stallation

a.tdentit,

material,checkthickness, no. andangleoffingersofpacking

wc

flngs

2. Duri

lnstallNtion

g andcleaningofpacking material ing supportplate

b. Chesk c. Check

stack€dor dumpedpacking as p€r

spe€l d. Check

nestrng packingsar€touchingbedlimiter

e. Check

S S

Yes

S

s

& Tf,ST DOCIMENTS of Inspection and Test Recods

Pl. referpage5

Yes

107for definitionof WC,Rw, HP,W, S andSection-B(page43 of 107)for formats

Fomal No.&00-0001

Coptrighl EIL- Allrights re€orved

dffFffi q*,ffik

INSPECTION & TEST PLANS MECHANICALWORKS

STANoARD SPECiFICATIONNo.

6-82-tt00 Rev1 Paoeffi

-

lq 61 6a

(Sheet 4 of 4)

ITP NO.

1150REV1 EQUIPMENTERJCTION(STATIC) ANI{EXURE.I

sl, No

Activity

Contractor

EIL

SCIAME FOR CRITICAL (RiggingProcedure) l.

Before

n

b. To

weightof€quipment

o. To

tb€centreof gavity

WC

Rw

d. To

suspension points

WC

Rw

€. To maximum/minimum radiusat which thelifti tacklewill operate f. To the max.Loadto be lifted includins wt. of sl hook-block, lifting be3msand

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Rw

g. Toi

WC

Rw

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Rw

the crane can be haveled in loaded

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Rw

e. To

cleannces from overheadelectric

Rw

f. To

maintenance ce(if icates

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s

propersequence for lifting ofthe

eq

2,

Yes

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a. ch

Recordsto be Sut mitt€d/ trormatNo.

the safecranewith requisite

Rw Rw

Rw

DuringE a. To

counterweight of omneand Boom

Iengt]t b. To

slew limitations of crane

c. To

supp d. To

g, To is i, To Requi

j. ro ch

Pl. referpage5

groundconditionsareadequate for irlly riggedcraneandload

whetheropemtols,riggershave proper instructions that safe load indicator on the cmne inE condition

theprovisions of bracing of asp€rEngg/Manufacturefs Approv€d drgs. the guys, shoring, bmcing, with other works

Rw Rw

Rw Rw

Rw

107for definitionof WC,Rw, HP,W, S ard Section-B(pag€43 of 107)for formats

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