Zealcon Engineering (Pvt.) Ltd.

Inspection Test Plan for Fabrication Of

Steel Structure And Steel Equipment

Zealcon-DGK-9000 TPD-MS-004

Issue # 001

Issue Date

Page 1 of 5

16-06-2016

Inspection Test Plan

For
Fabrication Of Steel Structure And Steel Equipment

00

28 July,2016

Client:

DG Khan Cement

Contractor:

Zealcon Engineering (Pvt.) Ltd

Issued for Approval

SDH

Initial
Rev

Date

Signature

Initial

Signature

Initial

Signature

Initial

Signature

Description
Prepared By

Checked By

Verified By

Client Approval / FL
Smidth

Zealcon Engeering(Pvt.) Ltd.

Doc. No.

QA&QC/FRM-21

Inspection Test Plan

Rev.:

00

FABRICATION OF STEEL STRUCTURE AND STEEL EQUIPMENT

Date:

August 13, 2003

DG Cement

Page No:

2 of 4

INSPECTION PARTIES INVOLVED

ITP No : Zealcon-ITP-SS-001

CYCLONE, DUCTING, CHUTE AND SILO

INSPECTION CODE
W = Witness Point
H = Hold Point

S = Surveillance Inspection

1 - Contractor:

Zealcon

R= Record Review

2 - Client :

D G CEMENT

Sr.

Description of

No.

Inspections & Tests

Inspections*

Frequency
(If applicable)

Acceptance Criteria

Verifying
Documents

Zealcon

Each

General Workshop instruction

520530-8.0

Document Transmittal

1.0

Drawings

1.1

Check Approved Drawings for Latest Revision

2.0

CONTROL OF INSPECTION, MEASURING

AND TEST EQUIPMENT

2.1

Torque Wrench.

As per calibration
standard

Manufacturer specification

Calibration Certificate

2.2

Theodolite

As per calibration
standard

Manufacturer specification

Calibration Certificate

3.0

FOUNDATIONS ACCEPTANCE

3.1

Foundations Survey

As per Approved drawings

QA&QC-FRM-166,44

3.2

Leveling Plates Installed

As per Approved drawings

QA&QC-FRM94/166,44

3.3

Surface Preparation for grouting

As per drawings

QA&QC-FRM-186

4.0

QUALITATIVE ACCEPTANCE OF
FABRICATED ITEMS

4.1

Material identification/Verification/ Control of

Heat Number

General Workshop Verification of stamps on material

instruction 520530-8.0 as per Mill Test Certificates

Zealcon-ST-SOP-001F009

4.2

Procured steel material inspection criteria

General Workshop
Check the plate surface should not Zealcon-ST-SOP-001instruction 520530-8.0
rusted and pitted
F009

4.3

Consumable material Storage and handling

General Workshop
instruction 520530-8.0

Verification on packing in
accordance with MTC (If
Applicable)

Each Section

Each Section

General Workshop instruction

520530-8.0

Zealcon-ST-SOP-001F009

FL Smidth

COMPANY

Remarks

Zealcon Engeering(Pvt.) Ltd.

Doc. No.

QA&QC/FRM-21

Inspection Test Plan

Rev.:

00

FABRICATION OF STEEL STRUCTURE AND STEEL EQUIPMENT

Date:

August 13, 2003

DG Cement

Page No:

2 of 4

INSPECTION PARTIES INVOLVED

ITP No : Zealcon-ITP-SS-001

CYCLONE, DUCTING, CHUTE AND SILO

INSPECTION CODE
W = Witness Point
H = Hold Point

S = Surveillance Inspection

1 - Contractor:

Zealcon

R= Record Review

2 - Client :

D G CEMENT

Sr.

Description of

No.

Inspections & Tests

5.0

Marking & Cutting and Fabrication

5.1

Marking, Stamp transferring

(Applicable for Pressure part)

5.2

Cutting of parts

5.3

Grinding / beveling of parts

5.4

Rolling of Shell Plates

5.6

Fit up of joints

6.0

Welding

6.1

WPS/PQR Approval

6.2

NDE

7.0

ERECTION CHECKING

7.1
7.2

Frequency
(If applicable)

Inspections*

Verifying
Documents

Zealcon

QA&QC-FRM-110

QA&QC-FRM-110

QA&QC-FRM-110

Check rolling of shell plates is

accordance to the required radius.

QA&QC-FRM-110

General Workshop
Check Fit up of joint is accordance
instruction 520530-8.0
to the drawing

QA&QC-FRM-110

Acceptance Criteria

General Workshop
instructions
Verification of stamps transferring
520530- 8.0 , Sec 1.2
on parts in accordance with
material
As
per
Drawings
General Workshop
instructions
Check before & after cutting
plates dimensions are as per
520530- 8.0 , para
3.1, 3.2,
drawings or in tolerance given in
attached tolerance sheets
As per Drawings
Check beveling is in accordance
General Workshop
General Workshop instruction
instruction 520530-8.0
520530-8.0
According to drawing

Before starting welding

ASME Section IX

Approved WPS/PQR
QA&QC/FRM-66 &
QA&QC/FRM-67

If applicable

Project Specification

NDT Reports

Weld quality (visual Inspection )

Each Section

AWS D 1.1 Welding Code

QA&QC/FRM-44

Dimensional checks

Each Section

As per drawings

QA&QC/FRM-99,44

FL Smidth

COMPANY

Remarks

Zealcon Engeering(Pvt.) Ltd.

Doc. No.

QA&QC/FRM-21

Inspection Test Plan

Rev.:

00

FABRICATION OF STEEL STRUCTURE AND STEEL EQUIPMENT

Date:

August 13, 2003

DG Cement

Page No:

2 of 4

INSPECTION PARTIES INVOLVED

ITP No : Zealcon-ITP-SS-001

CYCLONE, DUCTING, CHUTE AND SILO

INSPECTION CODE
W = Witness Point
H = Hold Point

S = Surveillance Inspection

1 - Contractor:

Zealcon

R= Record Review

2 - Client :

D G CEMENT

Sr.

Description of

No.

Inspections & Tests

Inspections*

Frequency
(If applicable)

Acceptance Criteria

Verifying
Documents

Zealcon

7.3

Plumbness

Each Section

As per drawings

QA&QC/FRM-99,44

7.4

Alignment

Each Section

As per drawings

QA&QC/FRM-99,44

7.5

Horizontally, level of beams/Elevation

Each Section

As per drawings

QA&QC/FRM-99,44

7.6

Tightness of high strength bolt

Each Section

As per drawings

QA&QC/FRM-99,44

7.7

Anchor bolts tightening

Each Section

As per specification

QA&QC/FRM-99,44

7.8

Release for Grouting / Placement

As per drawings

QA&QC/FRM-186,44

7.9

Bolts, sleeves, washers, nuts as per

specifications and drawings

As per specification

Visual

7.10

Stairs,Ladders,Safety Cages, Safety bars

As per drawings

QA&QC/FRM-99,44

7.11

Final visual check

Each Section

As per drawings

QA&QC/FRM-100,44

If any Non-conformance observed at any

stage CAR (Corrective Action Report) will be
raised

If applicable

Construction Drawings / Project

Specification

QA&QC/FRM-08

8
NOTE:
1)
2)
3)
4)
5)

Inspection codes will be finailized on agreement at site between all parties involved.
Extent of testing and examination shall be as per project specification.
H-Hold Point, W-Witness Notification necessory but presence not mandatory,
MAR- Material Approval Request
MTC- Mill Test Certificates

R-Review of documents.

FL Smidth

COMPANY

Remarks