Descon PROJECT :

PROJECT :

DOCUMENT TITLE : INSPECTION AND TEST PLAN

ORIGINATOR:

Descon Engineering FZE

3/10/2012 DATE

0 REV.NO.

Issued for Client Review / Comments DESCRIPTION

RM

SK

SK APPROVED BY

PREPARED CHECKED BY BY

DOCUMENT NUMBER :

Des-XXXX-QA&QC-01

SHT.

OF

REV.

INSPECTION AND TEST PLAN (ITP)

PROJECT COMPANY MANUFACTURER CLIENT ITEM TAG COMPANY DOC No: LEGEND: H - HOLD, W - WITNESS, SW - SPOT WITNESS, R - REVIEW OF RECORD, RW-RANDOM WITNESS, A - APPROVAL , M - MONITORING DESCON ENGINEERING FZE PREPARED BY REVIEWED BY APPROVED BY RASHID MAHMOOD SAKET KUMAR SAKET KUMAR

Doc. No. : DES-QA&QC/FRM-05A Rev.: 01 Date: April 22, 2010

SIGNATURE

PO No.: DESCON PROJECT No.: DESCON DOC No.:

INSPECTION BY

DES-PROP-QA&QC-01

ITEM

QC ACTIVITY

PRIME RESPONSIBILTY

REFERENCE DOCUMENTS / ACCEPTANCE CRITERIA

VERIFYING DOCUMENT

DESCON QA/QC

ASME Authorized Inspector

NOBO (CE Marking)

JZ

End User

STATUS

SIGN

STATUS

SIGN

STATUS

SIGN

STATUS

SIGN

STATUS

SIGN

1
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10

DOCUMENTATION
Pre- Inspection Meeting Inspection and Test Plan Drawings and Design Calculations Welding Book Welders Qualification Record NDE Procedures Weld Repair Prcoedure Hydrostatic and Pneumatic test procedure Surface Preparation & Painting Procedure NDE Operator Qualification I/C QA&QC QC Engineer PIM Agenda ITP & Applicable Code Minutes of meeting DES-PROP-QA&QC-01 Approved drawings Welding Book DES-QA&QC/FRM-40 RT,MT,UT DPT Procedures Weld Repair Proceudre Hydro static and Pneumatic test procedure S.P & Painting Procedure Qualification Certificates H H H H H H H H H H

I/C Product Engineering ASME Sec.1 Welding Engineer Welding Engineer QC Engineer QC Engineer QC Engineer Coating Inspector NDE Engineer ASME IX, B31.1 , ASME IX ASME Sec.V ASME Sec.VIII Div.1 & Sec.I ASME Sec.VIII Div.1 & Sec.I ASTM / SSPC / Swedish Certificates / SNT-TC-1A

2
2.1

MATERIAL CONTROL
Material Inspection / Verification / Certificate review QC Material Inspector Drawings/ P.O/ ASME Sec.II Part A Material inspection report / MTC'S H

2.2

Controlling of Heat Number and stamp transfer for pressure parts and those which are directly weld with pressure parts / Traceability check

QC Material Inspector

Drawings/ P.O/ ASME Sec.II Part A

Material traceability report / MTC'S

3
3.1

DISH END FORMING

Inspection of Dish End QC Material Inspector ASME Sec.VIII Div.1+ DWG Inspection Report H

Do not duplicate. controlled copy if stamped in red. Descon Engineering FZE 2 of 6

INSPECTION BY

ITEM

QC ACTIVITY

PRIME RESPONSIBILTY

REFERENCE DOCUMENTS / ACCEPTANCE CRITERIA

VERIFYING DOCUMENT

DESCON QA/QC

ASME Authorized Inspector

NOBO (CE Marking)

JZ

End User

STATUS 3.2 MT on Knuckle radius QC Material Inspector ASME Sec.VIII Div.1 + DWG MT Report H

SIGN

STATUS

SIGN

STATUS

SIGN

STATUS

SIGN

STATUS

SIGN

3.3

Thickness Check of Head

QC Material Inspector

ASME Sec.VIII Div.1 + DWG

Thickness Report

FABRICATION STEAM DRUM

4.1

Rolling Inspection ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications Physical verification / Signed ITP for record

4.2

Rolling / Re Rolling of Shell Course

QC Inspector

4.3

Fit up Inspection ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications Physical verification / Signed ITP for record Physical verification / Signed ITP for record Physical verification / Signed ITP for record Physical verification / Signed ITP for record Physical verification / Signed ITP for record Physical verification / Signed ITP for record Physical verification / Signed ITP for record

4.4

LS and CS Fit-up of shell course.

QC Inspector

4.5

Nozzles and Stubs Fit-up

QC Inspector

4.6

Marking of tube holes on the shell of Steam Drum

QC Inspector

4.7

Marking of tube holes on the shell of Mud Drum

QC Inspector

4.8

Holes drilling in Steam Drum and Mud Drum

QC Inspector

4.9

Insertion of Tubes in Tube Holes in the Shell of Steam Drum and Mud Drum

QC Inspector

4.10

Fit up of Tubes with Steam Drum Shell

QC Inspector

4.11

Fit up of Tubes with Mud Drum Shell

QC Inspector

ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications

Physical verification / Signed ITP for record

4.12

Expansion of tubes

QC Inspector

ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications

Tubes Expansion report

4.13

Fit up of Saddles

QC Inspector

ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications

Physical verification / Signed ITP for record

4.14

MUD DRUM
Rolling Inspection

4.15

4.16

Rolling / Re Rolling of Shell Course

QC Inspector

ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications

Physical verification / Signed ITP for record

4.17

Fit up Inspection Do not duplicate. controlled copy if stamped in red. Descon Engineering FZE 3 of 6

INSPECTION BY

ITEM

QC ACTIVITY

PRIME RESPONSIBILTY

REFERENCE DOCUMENTS / ACCEPTANCE CRITERIA

VERIFYING DOCUMENT

DESCON QA/QC

ASME Authorized Inspector

NOBO (CE Marking)

JZ

End User

STATUS ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications Physical verification / Signed ITP for record Physical verification / Signed ITP for record Physical verification / Signed ITP for record

SIGN

STATUS

SIGN

STATUS

SIGN

STATUS

SIGN

STATUS

SIGN

4.18

LS and CS Fit-up of shell course.

QC Inspector

4.19

Nozzles and Stubs Fit-up

QC Inspector

4.20

Marking of Tube holes on the shell of Steam Drum

QC Inspector

4.21

FLASH VESSEL
Rolling Inspection

4.22

4.23

Rolling / Re Rolling of Shell Course

QC Inspector

ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications

Physical verification / Signed ITP for record

4.24

Fit up Inspection ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications Physical verification / Signed ITP for record Physical verification / Signed ITP for record Physical verification / Signed ITP for record

4.25

LS and CS Fit-up of shell course.

QC Inspector

4.26

Nozzles and Stubs Fit-up

QC Inspector

4.27

Marking of Tube holes on the shell of Steam Drum

QC Inspector

4.28

SUPER HEATER HEADER

ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications Physical verification / Signed ITP for record Physical verification / Signed ITP for record Physical verification / Signed ITP for record Physical verification / Signed ITP for record

4.29

Final Visual and Dimensional inspection of Header

QC Inspector

4.30

Final Visual and Dimensional inspection of Coil

QC Inspector

4.31

NDE as per apporved drawing

QC Inspector

4.32

Hydrostatic test of Header as per approved drawing

QC Inspector

4.33

PIPING SPOOLS
Fit Up Inspection of Piping Spools QC Inspector ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V Physical verification / Signed ITP for record Physical verification / Signed ITP for record H

4.34

4.35

NDE as per approved Drawings

QC Inspector

4.36

LADDERS AND PLATFORMS

Final visual and dimensional Inspection of Ladders and Platforms Trial Assembly of Ladders and Platforms Do not duplicate. controlled copy if stamped in red. Descon Engineering FZE 4 of 6 QC Inspector ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications Physical verification / Signed ITP for record H

4.37

4.38

INSPECTION BY

ITEM

QC ACTIVITY

PRIME RESPONSIBILTY

REFERENCE DOCUMENTS / ACCEPTANCE CRITERIA

VERIFYING DOCUMENT

DESCON QA/QC

ASME Authorized Inspector

NOBO (CE Marking)

JZ

End User

STATUS

SIGN

STATUS

SIGN

STATUS

SIGN

STATUS

SIGN

STATUS

SIGN

4.39

NDE as per approved Drawings

QC Inspector

ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications

Physical verification / Signed ITP for record

5
6.4

WELDING INSPECTION
Welders Qualification Welding Inspector ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications Physical verification / Signed ITP for record H

6.6

Final weld visual Inspection

Welding Inspector

Weld visual Inspection report

6.7

Complete compliance of approved WPS

Welding Inspector

Physical verification / Signed ITP for record

PWHT
ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications

6.1

PWHT Specification

Welding Engineer

DES-QA&QC/FRM-56

6.2

PWHT Report and Graph (Chart)

Welding Engineer

DES-QA&QC/FRM-74

6.3

Hardness test of welds after PWHT

Welding Engineer

Hardness test report

7
7.1

NDE
BEFORE PWHT
RT as per approved Drawings NDE Inspector ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications , ASME Sec.V ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V DES-QA&QC/FRM-60 + 62 H

7.2

7.3

MPT / DPT after grinding smooth temporary welds 100 % MT on Lifting Lugs 100% UT on Lifting Lugs (Full Penetration Joints) 10 % MT of LS & CS weld joints

NDE Inspector

DES-QA&QC/FRM-63 + 62

7.4

NDE Inspector

DES-QA&QC/FRM-62

7.5

NDE Inspector

DES-QA&QC/FRM- 62

7.6

10 % MT on Fillet Welds UT of Nozzle to Shell welds

NDE Inspector

DES-QA&QC/FRM-63 + 62

7.7

NDE Inspector

DES-QA&QC/FRM-61 + 62

7.8

AFTER PWHT
RT as per approved Drawings NDE Inspector ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V DES-QA&QC/FRM-60 H

7.9

7.10

UT of Nozzle to Shell welds 10 % MT or PT on all nozzle welds and welded accessories 10 % MT of LS & CS weld joints

NDE Inspector

DES-QA&QC/FRM-61 + 62

7.11

NDE Inspector

DES-QA&QC/FRM-63 + 62

7.12

NDE Inspector

DES-QA&QC/FRM- 62

7.13

10 % MT on Fillet Welds

NDE Inspector

ASME Sec.VIII Div.1+Sec.I + DWG + DES-QA&QC/FRM-63 + 62 Project Specifications, ASME Sec.V Do not duplicate. controlled copy if stamped in red. Descon Engineering FZE

5 of 6

INSPECTION BY

ITEM

QC ACTIVITY

PRIME RESPONSIBILTY

REFERENCE DOCUMENTS / ACCEPTANCE CRITERIA

VERIFYING DOCUMENT

DESCON QA/QC

ASME Authorized Inspector

NOBO (CE Marking)

JZ

End User

STATUS 7.14 100 % MT on Lifting Lugs 100% UT on Lifting Lugs (Full Penetration Joints) NDE Inspector ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V DES-QA&QC/FRM-62 H

SIGN

STATUS

SIGN

STATUS

SIGN

STATUS

SIGN

STATUS

SIGN

8
8.1

FINAL INSPECTION
Final visual and dimensional Inspection QC Inspector ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications ASME Sec.VIII Div.1 / Sec.I Dimensional inspection report Physical verification / Signed ITP for record Dimensional inspection report H

8.2

Internal Inspection before Hydrostatic test

QC Inspector

8.3

Visual Inspection after PWHT

QC Inspector

8.4

NDT Verifications

QC Inspector QC Inspector / QA Engineer QC Inspector

NDE Summary sheet

8.5

Verification of Close out of NCR's (if any) Leak test on RF Pads

NDE Summary sheet

8.6

DES-QA&QC/FRM-52

8.7

Hydrostatic testing

QC Inspector

ASME Sec.VIII Div.1 / Sec.I ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications

DES-QA&QC/FRM-52 Physical verification / Signed ITP for record

8.8

Draining & Drying after Hydrostatic test

QC Inspector

9
9.1

NAME PLATE
Stamping & Attachment of name plate QC Inspector ASME Sec.VIII Div.1 / Sec.I Name plate copy H

9.2

Signing of Manufacturer Data Report

QC Inspector

ASME Sec.VIII Div.1 / Sec.I

MDR

10
10.1

SURFACE PREPARATION AND PAINTING

Final Coat DFT and Final Colour Check Coating Inspector SSPC / Swedish Painting inspection report H

11
11.1

PRE-SHIPMENT INSPECTION AND DOCUMENTATION

Inspection of packing of shipment QC Inspector Packing and Shipping Instructions Packing List Physical verification / Signed ITP for record IRC H

11.2

Flange Protection inspection

QC Inspector

Packing and Shipping Instructions

11.3

Issuance of inspection release note

QC Inspector

Release Note

11.4

Manufacturer data record book

QC Inspector

Final Data Book

Final Data Book

Do not duplicate. controlled copy if stamped in red. Descon Engineering FZE 6 of 6