Code

Inspection & Test Plan

( ITP )
Package Boiler
TON 183B001

I.E.M.S.A

UAN (for QMHA)

Page

11-3090

1 of 5

Inspection & Test Plan (ITP)

Package Boiler
TON 183B001
Owner
: ENPC
Main contractor : Uhde
Project name
: AMMONIA UREA ENPC PROJECT
Legend:
H: Hold point
R: Report review
W: Witness
S: Spot check
A : Approval

DWG

00
Rev

Status

CC Category Code:
1 = for approval
2 = for review
3 = for information
4 = for internal use
AC Acceptance Code:
1 = approved / reviewed
2 = approved / reviewed as
noted
3 = not accepted
4 = received

Check DWG ,Approval last

DWG

First Issue

18-7-2010

Emad Omar

18-7-2010

Hassan Basha

Description

Date

Prepared

Date

Checked

Status Code:
A = Issued for Design
D = Issued for Inquiry
E = Issued for Order
F = Issued for Prefabrication
G = Issued for Construction /
Fabrication
H = Issue for Work
Preparation
I = As- built

Approved DWG with last

Date

Approved

Acc.

Space for Bar Code label

M = General Issue

Copyright 2010 Uhde GmbH

Doc. ID-Code
PT-BM-183-DC-00001

Category

Code
EAgrium

Title
/var/www/apps/conversion/tmp/scratch_2/305957768.docx

(Logo Subcontractor/Vendor)

2
3
4

revision.
Visual inspection for external IEMSA visual procedure PTdamage for all parts.
BM-183-DC-00005
Marking & traceability.
IMESA material traceability
procedure PT-BM-183-DC00010
WPS & PQR
The WPS and WPAR have to
be in place of work prior
welding (Approved).

UAN (for QMHA)

Page

11-3090

2 of 5

revision.
Visual report.

Drawing IEMSA
procedure

Traceability report.

TRD AD 2000
welding procedure
qualification EN ISO
15614-1
EN 287-1

Approved WPS & PQR

Welder's certificates.

IEMSA quality
procedure for control
of measuring
inspection and test
equipment PT-BM183-DC-0011
Approved WPS &
PQR.

Calibration certificates.

WPS

EN 5817-B

Welders qualifications

General equipment steel

structure, plate work.

Welding M/C calibration

control.

Calibration record for M/C.

Welding performance
(Preheating, interpass
temperature,........)

Check as per Approved WPS

Fit up checking

Check fit up as per drawing

and WPS.

Drawing and WPS

Fit-up report

Testing and certificating of

pressure parts.

-Welding map
drawing and data
sheet.
-Hitachi erection
manual 5.5.
- Hitachi erection
manual 5.5.
- Hitachi erection
manual 5.5.
*Acceptance DIN EN
1435 & ADHP 5/3

Data sheet record

RT report
RT report
NDT report

10

NDT %

11

Hardness test

Welding map has to be

issued +welding
summary.
Mirror welds 100% RT in
principles
All welds which are not
accessible or difficult to
reach needs 100% RT.
Defects have the
consequence of
progressively increase to
100%.
In general NDT apply after
PWHT and visual test based
on material and working
pressure.
After PWHT ,visual and
hardness preparation .

12

Check of foundation

13

Shim plates for the boiler

saddle placed

14

Boiler support and fixing

point.

Copyright 2007 Uhde GmbH

Hitachi erection
NDT report
manual & attachment
No. 3,DIN EN 6507-1

Hitachi erection
manual attachment
no. 3 part 2

Hardness report

Evenness, distance of anchor

bolts in both direction
evaluation of foundation
existing of reference points.
Clean and solid.
Thickest plate as possible

Civil acceptance
criteria ,certificate.

Civil acceptance report

According general
measurements

Visual report

Check the left and right ball

bearing locations and
levelling.

UD- ACI-183-DZ00001-190 drawing.

Fit up report (visual).

Doc. ID-Code

Rev.

00

15

Assembly real wall on the

ground.

Visual inspection

Drawing ,Hitachi
erection manual

Visual report

16

Welding of real wall

Check, welding equipment

,approved WPS

WPS approved

Visual report

17

Lifting real wall with

temporary support beam

Right location and orientation

Drawing UD-ACI183-DZ-00001-105

Fit up report

18

Placing left side wall 2nd

pass at boiler support with
temporary support

Right location and orientation

Fit up report

19

Site welds

Welding preparation
Visual inspection

Drawing UD-ACI183-DZ-00001-96
Drawing UD-ACI183-DZ-00001-97
Drawing and WPS

Visual report

20

NDT %

RT,UT,MT,PT or HT applying
after PWHT

IEMSA procedures
PT-BM-183-DC00002,3,4,5,6
Hitachi erection and
attached see 9,10

NDT report

21

PWHT

Suitable heat treatment

equipment and procedure

IEMSA PWHT
procedure PT-BM183-DC-00007

PWHT report, equipment

calibration certificate.

22

Placing right side wall 2nd

pass at boiler support with
temporary support

Visual inspection for correct

orientation

Fit up report

23

Erection economizer

Welding preparation
Visual inspection

Drawing UD-ACI183-DZ-00001-94
Drawing UD-ACI183-DZ-00001-95
Drawing, welding
map ,as per
approved WPS

Fit up report

24

Lifting super heater I,II,III

Welding preparation
Visual inspection

Drawing, welding
map ,as per
approved WPS

Fit up report

25

Dividing wall assembly on

the ground

Fit up Welding preparation

Drawing UD-ACI183-DZ-00001101,102
WPS
Hitachi erection
manual

Fit up report

26

Assembly the left side wall

1st pass on the ground and
placing

Fit up Welding preparation

Drawing UD-ACI183-DZ-00001-86,87
WPS
Hitachi erection
manual

Fit up report

27

Assembly the right side wall

1st pass on the ground and
placing

Fit up Welding preparation

Drawing UD-ACI183-DZ-00001-88,89
WPS
Hitachi erection
manual

Fit up report

28

Furnace

Place the boiler feet to the

furnace onto steel structure
align and fasten temporarily
Completely tack weld the
walls ,welding for flue gastightness of the walls

The boiler feet have

to be placed onto the
right multi ball
bearings.

Fit up record
Visual control record

29

Buck stays

Completion of welds for

membrane walls

Drawing, HITACHI
Erection Manual

Welding map
NDE report

30

Precise alignment

Before placing the drum, all

boiler feet have to be
loosened and the boiler
precisely aligned using
hydraulic presses.
The fixed point is completely
welded and the multi
bearings have to be fixed into
right position.

Drawing, HITACHI
Erection Manual

Measurement record

31

Steam drum

Inspection required
prior pressure testing

NDE-reports
Visual inspection reports

32

Internal piping including

valves

Welding preparation
Steam drum is placed onto
boiler rear wall in sling until
root and filler welding have
been executed and 2
overflow tubes have been tack
welded
Upper and lower connected d
pipes have to be adjusted and
welded.
All immersion sleeves have to
be welded,
Initial shut off devices have
to be welded to the pressure
branches.

Drawing, HITACHI
Erection Manual

33

Spray attemperator

Consider flow direction

34

External piping including

All weld s have to fitted stress
valves, control valves ,safety less. Supports need control
valve and silencer
Hangers need control.
Check the routing under
consideration of insulation
thickness.

Drawing, HITACHI
Erection Manual
Drawing, HITACHI
Erection Manual

35

Burner 1 to 4

Hoisting after installation and

fixing

36

Erection of the firing system

37

Gas measuring/regulation
skid
Burner skid

Install the stations, erect

burners and laying on the
connecting pipe work.
The station is assembled on
the skid
The 4 burner skid are
completely pre-mounted
Adjustment of duct to boiler
end to the stack.

38
39

Flue gas duct from boiler

end to stack

40

Combustion air fan

41

Air ducts with suction

silencer

42

Cooling air fan

Install, align, and fasten the

forced draught fan with
suction silencer and venture
suction tube.
Pr-erect the air ducts and lift
into position. A
Assembly of silencer as per
instruction.
Mounting performed and
checked

Measurement record

Drawing, HITACHI
Erection Manual
attached No. 5
Drawing, HITACHI
Erection Manual

Measurement record

Measurement record

Drawing, HITACHI
Erection Manual
Drawing, HITACHI
Erection Manual
Drawing, HITACHI
Erection Manual

Measurement record

Measurement record

Measurement record

Drawing, HITACHI
Erection Manual

Measurement record

Drawing, HITACHI
Erection Manual

Measurement record

Drawing

Measurement record

43

Flash tank

44

cleanliness of pressure parts Perform final inspection

Visual control
Test package with P&ID
Test package preparation

HITACHI
Erection Manual
Test pack and D&ID

46

Testing of equipment
Pressure test

46.1

Water quality and quantity

Filling of the boiler for

pressure test-.
Safety valves are to be
locked and shut off valves of
the pressure extraction lines
are to be closed.
All vents must be opened
during filling,
Overfill drum and super
heater,
Adjust test pressure
Preservation has to be applied
immediately after testing.
Full dematerialized pressure
water.
Max Temperature not higher
than 40C.
Pressure boiler at 40C of
testing water

46.2

Check of leakage

Visual inspection inside and

outside only after the pressure
has dropped to 80 bar.

46.3

Certification of pressure
testing
Pressure testing of gas
pipes

Issue Acceptance certificate

48

49

45

47

It has to be fixed on the

ground according
measurement.

Drawing

Measurement record

H
Punch list certificate

HITACHI erection
Manual attachment 6
Test pressure at
highest point 150
bar(g).
Pressure increase: to
135 bar 5bar/min
To 180 bar-2bar/min
Holding time at least
30 min.
No reducing of
pressure is allowed
during this time.
PH of water 10.0 to
10.5
Follow manufactures
instruction for
chemical contains.

Pressure testing
certificate
Calibration certificate for
manometer.

Water analyse record

certificate

Visual checks .No

leakage is allowed.
In case of leakage
depends of location
,type and damage it
can be repaired and
100% radiographic.
Metrication Manual

Leakage test record

Pressure test record

Soap agent is to be used

Pressure :1.1 x
working pressure.

Flue gas tightness test

Penetration test on site welds

as far as both sides
accessibly. In other case
surface crack test required.

HITACHI erection
Manual

Acceptance Certificate
with dates: testing
procedure, medium, test
pressure and result.
Acceptance Certificate
NDT records.

Boiler preservation between

hydrostatic test and start up.

Close all covers, hatches and

locks after hydro testing.
Fill boiler including super
heater with feed water as per
manufactures instructions.

HITACHI erection
Manual

Final Acceptance
Certificate.
Water analysis certificate

Repeat steps 19,20 and 21 after every erection stage that contains on site welding joints.