SULZER LTHE EIL

Project: CDU/VDU, VRMP- HPCL, EIL Ref Spec No :6-14-0016 REV 4 & 6-14-0015 REV 3,
Package Title :CDUVDU Doc No: LTHE/HPCL/CDU-VDU/ITP/M/013
VISAKAPATTANAM 6-14-0003-Rev.05

INSPECTION TEST PLAN FOR INTERNAL INSTALLATION OF COLUMNS

Agency

SL No. Activity /Nature of Check / Test SULZER LTHE EIL REMARK / FORM OF RECORD

1 GENERAL REQURIMENTS

a Availability of latest Copy of approved Drawing with concern Engineer Rw Rw - Drg Register

b Check & Ensure the correctness of the welding consumables Received for the job. WC S Rw IMIR, TC

c Approval of WPS/PQR WC Rw Rw Approvaed WPS

Welder Qualification Test
d & Certification WC HP W Welder certificate / Welder ID card
2 INCOMING MATERIAL INSPECTION
Packing List, Drawings &BOM, MIN / TC
a Visual Inspection of Trays/ Packings/ feed, distributer pipes/ attachments WC W W

b Mockup assembly WC W Rw FO-SQA-5.117

3 IN PROCESS INSPECTION

a Initial Inspection before installation WC W W FO-SQA-5.011/ 3-0542-4001-Rev1

b TSR level checking WC W Rw FO-SQA-5. 054.G1/G2 /3-0542-4001-Rev1

c Fit-up And Welding of tower attachmets As Per Drg WC W Rw FO-SQA-5.011/ 3-0542-4001-Rev1

d NDT of welded joints as per scope WC WC Rw FO-SQA-5.011/ Client Formats

e Modification of drawings, scope, procedure as per site condition WC HP HP FO-SQA-5.029/ Client Formats

f Installation of valve trays WC W S FO-SQA-5.45.E1/E2/A1/A2 / 3-0542-4001-Rev1

g Installation of Chimney Trays WC W S FO-SQA-5. 046.G/ 3-0542-4001-Rev1

h Installation of seal pan WC W S FO-SQA-5.011/ 3-0542-4001-Rev1

FO-SQA-5. 046.D/ Client Formats
i Leak test of seal pan/chimney tray WC W W
FO-SQA-5. 046.F/
j Installation of feed pipe/ distributor pipe WC Rw S
FO-SQA-5.011/ 3-0542-4001-Rev1
k Installation of Mist Eliminator/ demister pad WC Rw S FO-SQA-5. 046.B/ 3-0542-4001-Rev1
FO-SQA-5. 046.C/
l Installation of Structured packing/ random packing WC W S
FO-SQA-5.011/ 3-0542-4001-Rev1
4 COMPLETION REQUIREMENTS
Final Inspection - Check all activities completed in conformance with contract requirement. No
a WC WC WC FO-SQA -5.011/ 3-0542-4001-Rev1
loose item / Debris / Thickness Survey
b Tray manway box up WC HP HP FO-SQA-5. 045 B/ Client Formats

c Equipment box up - Check completion of all activities as per G.A drawing WC HP HP FO-SQA-5.45. B/ 3-0542-4002-Rev1

d Mechanical Completion - Check completion of all activities as per Drg WC HP Rw FO-SQA-5.054/ Client Formats

e Review of all documents w.r.t above ITP WC Rw Rw ITP/ Client Formats

HP- Hold Point, W- Witness, S- Surveillance, Rw- Review, WC - 100% examination by SULZER
NOTES
FO-SQA -5.011 - General inspection format
Approved By EIL
Description Date Rev Prepared By SULZER Checked By L&T

INSPECTION TEST PLAN FOR INTERNAL

INSTALLATION OF COLUMNS 23/07/2019 0
Doc No: LTHE/HPCL/CDU-VDU/ITP/M/013
 SULZER LTHE EIL
Client HPCL PMC ENGINEERS INDIA LIMITED

Contractor L&T Hydrocarbon Engineering Limited Inspection Report No.

Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM Date:
Vendor Sulzer FO-SQA-5.011 Page :

Equipment Tag:
Description

Drawing No:

Items:      

Item Initial Item Initial Item Initial

Material
      Dimensional Survey       Hardness Survey      
Traceability

Identification
      Heat Treatment       Pressure Testing      
Mark

Fit-up
      Welding       Coatings      
Inspection

Visual
      NDT Testing       Certification Records      
Inspection

Remarks:

SULZER LTHE EIL

Signature : Signature : Signature :

Name : Name : Name :

Designation : Designation : Designation :

Date : Date : Date :

 SULZER LTHE EI

Client HPCL PMC

Contractor L&T Hydrocarbon Engineering Limited

Inspection Report No.

Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM Date:

Vendor Sulzer FO-SQA-5.117

Equipment
Tag:

MOCK UP ASSEMBLY REPORT

DESCRIPTION/TRAY NO DRAWING NO. TYPE OF TRAY

REMARKS:-
REMARKS:-

SULZER LTHE
Signature : Signature :

Name : Name :

Designation : Designation :

Date : Date :
 EIL

ENGINEERS INDIA LIMITED

Inspection Report No.

Date:

FO-SQA-5.117 Page :

OCK UP ASSEMBLY REPORT

NO OF PASSES
 EIL
Signature :

Name :

Designation :

Date :
 SULZER LTHE

Client HPCL

Contractor L&T Hydrocarbon Engineering Limited

Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM

Vendor Sulzer

Equipment Tag:

1. DISTANCE BETWEEN TRAY SUPPORT RING ( BETWEEN CONSECUTIVE TRAYS )

Tray No.

Drg. Dimension

C
As Built Dimesion at
Point D

Dimesion to be taken from top to top of TSR with points marked on the same orientation for all trays minimum at four p
points above 2000Ø
2. LOCATION OF BOLTING BAR
Tray No.

Drg. Dimension
G1
Actual

Drg. Dimension
G2
Actual

Drg. Dimension
G3
Actual

Drg. Dimension
G4
Actual

Drg. Dimension
G5
Actual
 Drg. Dimension
G6
Actual

Drg. Dimension
G7
Actual

Drg. Dimension
G8
Actual
REMARK;-

SULZER LTHE
Signature : Signature :

Name : Name :

Designation : Designation :

Date : Date :
 EIL

PMC ENGINEERS INDIA LIMITED

Inspection Report No.

Date:

FO-SQA-5.45.G1 Page :

CONSECUTIVE TRAYS )

on the same orientation for all trays minimum at four points upto 2000Ø & minimum six
 EIL
Signature :

Name :

Designation :

Date :
 SULZER LTHE EIL
Client HPCL PMC ENGINEERS INDIA LIMITED

Contractor L&T Hydrocarbon Engineering Limited Inspection Report No.

Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM Date:

Vendor Sulzer FO-SQA-5.45.G2 Page :

Equipment Tag:
3. LEVEL READING
TSR Ref
Level at
(Tray / Internal )
Ref. Point
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q

Level at A, B, C, D, ….. Taken with water tube with ''A'' as references point minimum at four points upto 2000Ø & maximum six points above
2000Ø . Minimum 3 points per TSR segments shall be selected.

REMARKS;-

SULZER LTHE EIL

Signature : Signature : Signature :

Name : Name : Name :

Designation : Designation : Designation :

Date : Date : Date :

 SULZER LTHE EIL

Client HPCL PMC

Contractor L&T Hydrocarbon Engineering Limited Inspection Report No.
Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM Date:

Vendor Sulzer FO-SQA-5.29

hgggggggggggg
Equipment Tag:
gggggggggggggggg
gggggggggggggggg
gggggggggggggggg
gggggggggggggggg
gggggggggggggggg
Query:
gggggggggggggggg
gggggggggggggggg
gggggggggggggggg
gggggggggggggggg
gggggggggggggggg
gggggggggggggggg
gggggggggggggggg
gggggggggggggggg
ggggggggggg

For information /
action
*(Delete as
Reply Required by:
required)

Response:
Response by: Date:
 EIL

ENGINEERS INDIA LIMITED

tion Report No.

Page :
 SULZER LTHE EIL
HPCL ENGINEERS INDIA LIMITED
Client PMC
Contractor L&T Hydrocarbon Engineering Limited Inspection Report No.
Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM Date:
Vendor Sulzer FO-SQA-5.45.E1 Page no

Equipment Tag:
COLUMN INTERNAL AFTER INSTALLATION
Tray No.
Drg. Dimension
A1, A3, A4, A5, A7, A8,
A
A2, A6

A1

A2

A3

Height of exit weir in mm. (From top of A4

tray deck to top of weir)
A5

A6

A7

A8
Drg. Dimension
B1, B3, B4, B5, B7, B8
B
B2, B6

B1

B2

B3
Under downflow clearance in mm. (distance B4
between downcomer bottom & tray deck / recessed
seal pan plate) B5

B6

B7

B8
Drg. Dimension
C1, C3, C4, C5, C7, C8
C
C2, C6

C1

C2

C3

Horizontal distance between downcomer plate & C4

recessed seal pan (mm)
C5

C6

C7

C8
REMARKS:-
REMARKS:-

SULZER LTHE EIL

Signature : Signature : Signature :

Name : Name : Name :

Designation : Designation : Designation :

Date : Date : Date :

 EIL
ENGINEERS INDIA LIMITED

Inspection Report No.

Date:

RNAL AFTER INSTALLATION

EIL
 SULZER LTHE EIL
Client HPCL PMC ENGINEERS INDIA LIMITED

Contractor L&T Hydrocarbon Engineering Limited Inspection Report No.

Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM Date:
Vendor Sulzer FO-SQA-5.45.E2
Equipment Tag:
COLUMN INTERNAL AFTER INSTALLATION
Tray No.
Drg. Dimension D1, D3, D4, D5, D7, D8
D
D2, D6
D1
D2
D3
Under downflow clearance in mm. D4
(distance between downcomer plate & seal
pan D5
D6
D7
D8
Drg. Dimension
E1, E3, E4, E5, E7, E8
E
E2, E6
E1
E2
E3
Clear distance between downcomer plate & E4
seal pan (mm)
E5
E6
E7
E8
Remarks :-

SULZER LTHE EIL

Signature : Signature : Signature :

Name : Name : Name :

Designation : Designation : Designation :
Date : Date : Date :
 EIL
GINEERS INDIA LIMITED

Report No.

Page : of

TION

EIL
signation :
 SULZER LTHE
Client HPCL
Contractor L&T Hydrocarbon Engineering Limited
Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM
Vendor Sulzer
Equipment Tag:

CHECKLIST FOR COLUMNS AFTER INTERNAL INSTALLATION

Tray No.
Check the following

Check each bolt for tightness

Check orientation, proper mark (type) and tightness of each

clamp

Check provision of lock Nuts and Seal Plates wherever

specified

Check each top downcomer piece for correct installation of

shimming including tack Welding / Bolting

Check seal welding / Gasketing wherever applicable

Check leak testing of seal pans, recessed seal pan, chimney

trays, distributor, drawoff boxes etc. as per drawing

Check overlapping of decks

Check for damaged missing valves and valve movement for all
valves for vale trays

Check for fitting of proper valve combination (MR2, MR6

etc. )

Check for noticeable damage to deck components

Check levelness and alignment of internal weir and exit weir

and adjust if necessary

Check beam & clips are properly fitted

Check that Tray manway can be opened from top as well as
from bottom

Check that all slots on Tray components are fully covered

Check that gaps at downcomer ends and other places are

within specified limits

Check orientation in case of ripple trays

For lattice girders, check the levelness of primary members

and completeness of welding of all the bracings and
secondery members

Check temporary plugs wherever provided for testing have

been removed

Check that trays have been cleared of all foreign materials

REMARKS:-

(1) This format shall be filled for all Trays by Installation Contractor and counter checked by Engineer in Charge

(2) Tolerance on various drawing dimensions shall be as per applicable drawing / standard

(3) Ref standard 7 - 14 - 0202 for abbreviations & typical detail of trays

SULZER LTHE
Signature : Signature :

Name : Name :

Designation : Designation :

Date : Date :
 EIL
PMC ENGINEERS INDIA LIMITED

Inspection Report No.

Date:
FO-SQA-5.45A1 Page : of

STALLATION

Tray No.
ge

EIL
Signature :

Name :

Designation :

Date :
 SULZER LTHE
Client HPCL
Contractor L&T Hydrocarbon Engineering Limited
Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM
Vendor Sulzer
Equipment Tag:

CHECKLIST FOR COLUMNS AFTER INTERNAL INSTALLATION

Tray No.
Check the following

Check the multibeam support plate sits properly on the TSR with
no undesired gaps. All spacings and gaps are evenly distributed
across the level diameter

Check for proper levelling of top of bed and gap between top of
bed and bed limiter (No gaps preferred; maximum gap at few
locations not to exceed one packing size)

Check that bed limiter is properly bolted and the gap on the
periphery is uniform and not more than that specified in the
drawing. Also check that packing is not free to come out from
any opening. Also check that bed limiter mesh is intact

Check levelness for distributor/ redistributors/ flash gallaries/

spary header. Same to be within tolerance specified in the
Drawings/ Standards and to be recorded in Sht. 1

Check that the distributors/ redistributorire/ flash gallaries/ spray

headers are properly clamped/ bolted

Check that the distributors/ redistributors/ flash gallaries (if

required) are properly gasketted as specified in the drawing

Check leak tightness of the distributor/ redistributor/ flash gallary

(if required), to be ensured by filling water and checking leakages
from gasketted joints

For chimney / collector tray, draw off boxes, wherever applicable,

check completeness of seal welding, gasketting, proper fitment of
vapour riser covers and review record for leak testing
For spray nozzle distributor, check for
i) Hydrtest for spray header
ii) Clogging of spray nozzles, by running pump, if feasible iii)
Check tip distance from top of the bed (to be within 25mm)
iv) check
gasket at flange joint, thread sealant at threaded joints
v) Any
obstruction in the uniform spray pattern

Review of proper orientation of various tower internals like bed

limiter wrt distributor/ redistributors, as per detail shown in
respective drawings

Check temporary plugs wherever provided have been removed

after testing

REMARKS:-

SULZER LTHE
Signature : Signature :

Name : Name :
Designation : Designation :
Date : Date :
 EIL
PMC ENGINEERS INDIA LIMITED

Inspection Report No.

Date:
FO-SQA-5.45A2 Page : of

LLATION
y No.
 EIL
Signature :

Name :
Designation :
Date :
 SULZER LTHE EIL
Client HPCL PMC ENGINEERS INDIA LIM
Contractor L&T Hydrocarbon Engineering Limited Inspection Report No.
Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM Date:
Vendor Sulzer FO-SQA-5.46.G
Equipment Tag:
CHIMNEY TRAY INSTALLATION REPORT
DESCRIPTION YES NO N/A

Are the Risers installed to the correct height?

Are the Chimney hats installed correctly?

Is the required Gasketing in place?

Are the correct size bolts installed and secure?

Has the seal welding been completed?

Is the Chimney tray level?

Are all the drain holes clear?

Are the support beams fastened correctly?

Are the support beams level?

Is the Chimney tray orientation correct?

Has the completed tray been cleaned prior box up?

Are the leak test results Acceptable?

REMARKS:-

SULZER LTHE EIL

Signature : Signature : Signature :
Name : Name : Name :
Designation : Designation : Designation :
Date : Date : Date :
 EIL
ENGINEERS INDIA LIMITED

Inspection Report No.

Date:
Page : of

AY INSTALLATION REPORT
REMARKS

EIL
 SULZER LTHE EIL
Client HPCL PMC ENGINEERS INDIA LIMITED
Contractor L&T Hydrocarbon Engineering Limited Inspection Report No.
Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM Date:
Vendor Sulzer FO-SQA-5.46C Page : of

Equipment Tag:

PACKED BED INSPECTION REPORT

DESCRIPTION YES NO N/A

Is the support grid secure properly?

Is the support grid in correct orientation?

Is the correct type of Pall Ring installed?

Has the bed height been achieved?

Is the hold hown device secured properly?

Is the hold down device oriented correctly?

Are the structured layers oriented correctly?

Are the wall wipers installed correctly?

Is the bed limiter installed properly as per drawing?

REMARKS:-

SULZER LTHE EIL

Signature : Signature : Signature :
Name : Name : Name :
Designation : Designation : Designation :
Date : Date : Date :
 SULZER LTHE
Client HPCL PMC

Contractor L&T Hydrocarbon Engineering Limited

Inspection R

Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM Date:

Vendor Sulzer FO-SQA-5.046B

Equipment Tag:

Demister Inspection Checklist

N/A Yes No

1 Is the Demister seated correctly?

2 Are all the Demister Tie Wires in place?

3 Are the correct size bolts installed and secure?

4 Has the Retaining Ring been secured?

5 Are there any gaps between Demister Sections?

6 Are the “J” Bolts secured correctly?

7 Are the Support Bars level?

8 Is the Demister orientation correct?

9 Has the Demister been cleaned prior to “Box Up”?

10 Is the Demister the correct size?

 SULZER LTHE
Signature : Signature : Signature :

Name : Name : Name :

Designation : Designation : Designation :

Date : Date : Date :

 EIL
ENGINEERS INDIA LIMITED

Inspection Report No.

Date:

FO-SQA-5.046B Page : of

spection Checklist

REMARKS
 EIL

Designation :
 SULZER LTHE EIL
Client HPCL PMC
Contractor L&T Hydrocarbon Engineering Limited Inspection Report No.

Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM

Date:
Vendor Sulzer
Page : of
Equipment Tag: FO-SQA-5.46.E
DISTRIBUTOR INSTALLATION REPORT
DESCRIPTION YES NO

All Distributor Parts are fitted correctly as per Drg.?

Is Hard ware correct to Drg?

All Orientations and measurements are correct as per Drg?

Distributor troughs installed and leveled to specification?

Bolting is tight & fastened as required in Drg?

Main Channels installed correctly?

Distributor drip holes free from debris?

Distributor Filter installed correctly?

Feed pipes installed correctly as per Drg?

Is the Center Parting Box level/Pipe level?

REMARS:-

SULZER LTHE EIL

Signature : Signature : Signature :

Name : Name : Name :

Designation : Designation : Designation :
Date : Date : Date :
 EIL
ENGINEERS INDIA LIMITED

tion Report No.

of

A-5.46.E

N/A REMARKS

EIL
 SULZER LTHE
Client HPCL PMC
Contractor L&T Hydrocarbon Engineering Limited
Inspection Rep
Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM
Date:
Vendor Sulzer Page : of
Equipment Tag: FO-SQA-5.46D

LEAK TEST REPORT

DESCRIPTION
TEST NO.1 TEST NO.2(IF APPLICABLE)

DATE OF TEST

START TIME & HIEGHT OF LIQUID

FINAL TIME & HEIGHT OF LIQUID

ACCEPTABLE(YES/NO)

CHECK FOR TSR CLAMP ORIENTATION OF SEAL PAN

CHECK FOR GASKET ON TSR OF SEAL PAN PANEL & RECTANGULAR

WASHER ON SEAL PAN TRAY PANEL.
REMARKS:-

SULZER LTHE EIL

Signature : Signature : Signature :

Name : Name : Name :

Designation : Designation : Designation :

Date : Date : Date :
 EIL
ENGINEERS INDIA LIMITED

ection Report No.

e: of

QA-5.46D

REMARKS

EIL
 SULZER LTHE
Client HPCL PMC
Contractor L&T Hydrocarbon Engineering Limited
Inspection R
Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM
Date:
Vendor Sulzer Page : of
Equipment Tag: FO-SQA-5.45
TRAY MANWAY CLOSURE CHECKLIST

TRAY MANWAY NO :

DESCRIPTION
YES NO

Check– Is hardware and gasket correct to drawing

Check- Bolting is tight & fastened as required

Check -No loose hardware is left inside

Check - Column is clean & free from Debris

REMARKS:-

SULZER LTHE
Signature : Signature : Signature :

Name : Name : Name :

Designation : Designation : Designation :

Date : Date : Date :

 EIL
ENGINEERS INDIA LIMITED

Inspection Report No.

Date:

Page : of

FO-SQA-5.45B1
NWAY CLOSURE CHECKLIST

NOT APPLICABLE

EIL
Signature :

Designation :
 SULZER LTHE EIL
Client HPCL PMC ENGINEERS INDIA LIMIT
Contractor L&T Hydrocarbon Engineering Limited Inspection Report No.
Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM Date:
Vendor Sulzer Page : of
Equipment Tag: FO-SQA-5.45.B2

EQUIPMENT BOX UP REPORT

MANHOLE NO
DESCRIPTION YES NO NOT APPLICABLE

Check– Is hardware and gasket correct to drawing

Check- – Platform Area is clean and free from debris

Check -No loose hardware is left inside

Check - Column is clean & free from Debris

Column handed over to Client for regular operation

Permission for Manhole box up granted

REMARKS:-

SULZER LTHE EIL

Signature : Signature : Signature :
Name : Name : Name :
Designation : Designation : Designation :
Date : Date : Date :
 EIL
ENGINEERS INDIA LIMITED

Inspection Report No.

Date:

Page : of
FO-SQA-5.45.B2

UIPMENT BOX UP REPORT

NOT APPLICABLE

EIL
 SULZER LTHE EIL
ENGINEERS INDIA
Client HPCL PMC
Contractor L&T Hydrocarbon Engineering Limited Inspection Report No.
Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM Date:

Vendor Sulzer
Page : of
Equipment Tag: FO-SQA-5.54

MECHANICAL COMPLETION REPORT

DESCRIPTION

APPLICABLE DRAWING NO'S

C
O
M
M
E
N
T
S

SULZER LTHE EIL

Signature : Signature : Signature :
Name : Name : Name :
Designation : Designation : Designation :
Date : Date : Date :
 EIL
ENGINEERS INDIA LIMITED

Inspection Report No.

Date:

Page : of

FO-SQA-5.54

AL COMPLETION REPORT

DESCRIPTION

ABLE DRAWING NO'S

Client HPCL PMC ENGINEERS INDIA L
Contractor L&T Hydrocarbon Engineering Limited Inspection Report No.
Project CDU/VDU, VRMP- HPCL, VISAKAPATTANAM Date:
Vendor Sulzer Page : of
Equipment Tag:

punch point number Referance document number Status of punch poi

REMARKS

SULZER EIL
Name : Name:
SIGN : SIGN :
Date : Date:
DESIGNATION : DESIGNATION :
EIL-COMMISSINING HPCL
Name : Name:
SIGN : SIGN :
Date : Date:
DESIGNATION : DESIGNATION :
NGINEERS INDIA LIMITED
n Report No.

atus of punch point