Beruflich Dokumente
Kultur Dokumente
PIPEWORK
INSPECTION & TEST PROCEDURE
A) INTRODUCTION
The following procedure is intended to ensure that the quality of procured product and its associated
activities are completed by competent persons and:
1. Comply with current and applicable specified requirements (including Corporation specifications /
contract terms and conditions, national / international standards, manufacturer’s
recommendations and industry best practices.
2. Are conducted in a safe and professional manner.
3. Provide an audit trail for verification of Quality Assurance and Quality Control compliance.
This procedure is for all PIPEWORK of various materials of construction inclusive of fittings and gaskets.
This may include carbon steel, mild steel cement lined (MSCL), ductile (DICL) and cast iron cement lined
(CML), galvanised steel, stainless steel (SS) , copper, cast and ductile iron (DI), polymer based
(ABS/PE/HDPE/PVC-U/PVC-M) and fibreglass (GRP).
Competent personnel shall complete all inspection / construction activities and record all activities on
Water Corporation Document (ITP-SV-M- PIPEWORK) for each asset inspected. Note a welding and
corrosion /coating inspector maybe required particularly for prefabricated welded pipe specials/spools.
NOTE:
Please ensure that all ITP documents are completed by a competent person and that all Water
Corporation SAFETY and operational requirements are to be complied with at all times in
relation with Water Corporation and Australian Standards where applicable.
B) COMPLETED DOCUMENTS
Completed documents are to be scanned and saved as a .pdf file in the relevant AQUA folder utilising
the following naming convention:
LOCATION - DISCIPLINE - ASSET – ASSET TYPE – VENDOR NAME – DOCUMENT TYPE – P&ID
TAG – REVISION NUMBER
E.g. RavenswoodPS_M_Valve_Butterfly_Tyco_SV_1000BV3422_1
The commissioning manager shall coordinate incorporation of completed ITPs in conjunction with the
CAMEL.
Feedback on improvements to ITPs should be directed to MESB Mechanical for incorporation into future
versions.
PIPEWORK
INSPECTION & TEST PROCEDURE
* All Supply Verification documents shall contain the following sections (1 – 2) which capture generic asset
information
1. REFERENCE INFORMATION
INSPECTION DATA ASSET DATA
PROJECT NAME: MANUFACTURER:
ATTENDEES:
2. INSPECTION PREPARATION
OSH compliance requirements.
Obtain QA / QC documentation (review outstanding items).
Relevant Water Corporation standards.
Relevant Australian Standards.
Supporting contract documentation / approved drawings.
Provision of required test equipment.
Provision of required test reports and certificates; i.e. hydrostatic test, material certificates, etc.
*Contents of Section 3 (Inspection) and Section 4 (Test) are Asset Specific and shall reflect relevant SPS /
Australian Standard(s) where practicable. Entries shall also be worded to reflect the procedures involved in
a step-by-step manner; i.e. “Conduct visual inspection and ensure pre-start photographs are taken”,
“Extract bearing housing covers to expose bearings and full shaft length”.
GENERAL
Check:
Locate and verify that pipework label details
1 match specification and contract Design Standard/Nominal Bore
Diameter/Design Pressure/Type of Fluid/Max
requirements Surge Pressure
PIPEWORK
INSPECTION & TEST PROCEDURE
Pipes
PIPEWORK
INSPECTION & TEST PROCEDURE
valve opening/closing
Ensure where ABS joins to PVC piping that
21 the solvent cement is compatible to both
materials
Confirm PVC-U is not being used on
22
compressed air lines
For copper pipe check for signs of work
23
hardening, kinks and zinfication
For copper confirm the pipe is designed to
24 accommodate capilliary or compression cone
fittings
For galvanise steel confirm pipe has been
25
hot dipped galvanised
For GRP piping confirm the nominal stiffness
26
(SN) is 5000 or greater
For buried ductile iron (DI) pipe confirm
internals are CML and external is cold
27
applied bituminous paint (short term) and
external polyethylene sleeve (long term)
For polyethylene pipe (PE) ensure it is either
Note the colour and striping of the pipe for
28 medium or high density with a PN12.5 or identification
greater rating
For stainless steel pipe (SS) confirm the
29 schedule is 10S or greater and low grade
carbon content when welding is required
For spiral welded (SS) pipe confirm this has
30 been TIG welded and used only upto 75mm
pipe
Confirm stainless steel pipework has been
31
pickled and passivated
Threaded/Flanged/Victaulic/Welded/
/Compression/Camlock/Bevelled/Elastomeric
Confirm end connections are correct to suit
32 Seal Joint/Solvent Cement Welding/ Rubber
fittings Ring joints
Flanges
33 Design Standard: AS……../EN…….….
Confirm flange standard correct
34 Weldneck/Plate/Slip-
Check flange type is correct On/Threaded/Loose/Socket Weld/Blind
35 Raised/Flat
Ensure flange facing and finish is correct
36 Check flange thickness is correct Thickness: ……..mm
37 Confirm outside diameter is correct Class:
38 Confirm pitch circle diameter is correct PCD: _____________ mm
39 Ensure number and diameter of drilled bolt No.:______ Dia.:________ mm
holes are correct
40 Check number and diameter of threaded bolt No.:______ Dia.:________ mm
holes are correct
41 Check threads on holes are free of defects Use GO/NO-GO gauge if applicable
42 Confirm spot facing on bolt head landings
Elbows/Bends/Tees/Reducers/Strainers
43 Confirm end connection correct ? Threaded/Flanged/Victaulic
/Compression/Camlock
PIPEWORK
INSPECTION & TEST PROCEDURE
PIPEWORK
INSPECTION & TEST PROCEDURE
Gasketing
67 Confirm compressed fibre gasket are utlised
in-lieu of o-rings and reinforced fabric
gaskets
68 For compressed fibre gaskets confirm Thickness normally 1.5mm to 3mm
thickness is as specified
69 Where natural rubber or EPDM is being used
confirm hydrocarbons are not present in the Use NBR in high hydrocarbon applications
gas or liquid
70 Confirm for gaseous chlorine and chlorine
solution lines that gaskets are made of FPM
(Viton)
71 Confirm the gasket is correctly full or narrow
faced to suit pressure rating and pipework
size
*Contents of Section 5 to be retained where applicable; i.e. if coatings inspection is required. Sections 6-9
to be retained in all ITPs.
1
Refer to AS/NZS 1627 series for Metal Finishing – Preparation and Pretreatment of Surfaces
2
Refer to AS/NZS 3894.7 for practical procedure for Determination of Surface Temperature of metal surfaced (pre-coating)
Warning: Document Uncontrolled When Printed Page 6 of 10
AQUADoc No: 6259963 Document Custodian: Team Leader – Mechanical
Version Date: 30/12/2015 Next Review Date: 30/12/2017
SUPPLY VERIFICATION ITP-SV-M- PIPEWORK
PIPEWORK
INSPECTION & TEST PROCEDURE
testing
Fully cured coating system should be adherent while
6 Failure force (if known):
in their service condition (Method AS/NZS 3894.9)
Assess degree of cure and hardness of coating is
acceptable (method AS 3894.4). Allow sufficient
7 drying and curing of the coating prior conducting Method used:
testing. The length of time shall be obtained from
the coating manufacture.
Checked that flange faces are clean and are free
8 from any defects resulting from corrosion or any
other cause
Visually inspect surfaces and ensure is adequately
9 Method/chemicals used:
clean and dry prior to testing
Check internal coating type and verify in accordance
with relevant specification (circle PH: Epoxy Coating
10 PA / PH / OTHER _____________
on Steel/Cast Iron or state, PA: Protective Coating
on Steel/Cast Iron or state Other)
Visually inspect condition of internal coating
appearance including uniformity, colour and free
11
from any defect that could impair performance
and/or appearance of coating.
Check external coating type and verify in accordance
with relevant specification (circle PH: Epoxy Coating
PA / PH / PS/ OTHER
12 on Steel/Cast Iron or state, PA: Protective Coating
_____________
on Steel/Cast Iron or state, PS: Inorganic zinc
silicate primed two pack acrylic coating or Other )
Visually inspect condition of external coating
appearance including uniformity, colour and free
13
from any defect that could impair performance
and/or appearance of coating.
Calibrate thickness tester to standard of uniform and Method/instrument used3:
14 calibrated thickness, covering appropriate range of
film thicknesses to be measured
Visually inspect and measure4 dry film thickness (DFT) in at least 10 locations on coated surfaces. Record
15 values, ensure compliance with spec and record in table below (note that Flange Thickness is not considered
acceptable if not within minimum – maximum range)
Ensure coating fully cured prior continuity testing by
Temp/time:
16 checking datasheet for required time to full cure or
Test method:
other appropriate test method
Calibrate holiday detector (spark tester) electrode
with appropriate volt meter which has been
17 laboratory calibrated within the last 2 years to Brand/model used:
proposed voltage. Record brand and model of spark
tester to be used.
18 Carry out spark test on internal coating in Test Voltage: V
accordance to AS/NZS 3894.1 Continuity testing of
3
Refer to AS/NZS 3894.3 methods for Determination of Dry Film Thickness
4
Method AS 3894.3 refers Determination of Dry Film Thickness
Warning: Document Uncontrolled When Printed Page 7 of 10
AQUADoc No: 6259963 Document Custodian: Team Leader – Mechanical
Version Date: 30/12/2015 Next Review Date: 30/12/2017
SUPPLY VERIFICATION ITP-SV-M- PIPEWORK
PIPEWORK
INSPECTION & TEST PROCEDURE
Coating Complies
Internal (micrometers): External (micrometers): Flange (micrometers ):
Thickness: with Spec?
Specified min N/A
Specified max N/A
Measured 1
Measured 2
Measured 3
Measured 4
Measured 5
Measured 6
Measured 7
Measured 8
Measured 9
Measured 10
Average
Note any comment or variation to test procedure that will assist in interpretation of results:
Refer to AS/NZS 1627 series for Metal Finishing – Preparation and Pretreatment of Surfaces
2
Refer to AS/NZS 3894.7 for practical procedure for Determination of Surface Temperature of metal surfaced (pre-coating)
3
Refer to AS/NZS 3894.3 methods for Determination of Dry Film Thickness
4
Method AS 3894.3 refers Determination of Dry Film Thickness
TARGET
6. REMARKS / REMEDIAL / FOLLOW UP ACTIONS ACTION BY STATUS
DATE
PIPEWORK
INSPECTION & TEST PROCEDURE
7. SIGNOFFS
NAME (PRINT) COMPANY / ROLE SIGNATURE DATE
PIPEWORK
INSPECTION & TEST PROCEDURE
9. SIGNOFFS
NAME (PRINT) COMPANY / ROLE SIGNATURE DATE