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INDICATIVE INSPECTION &

TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

INDEX
Indicative Inspection & Test Plans
SL.
No.
B.

DESCRIPTION
MECHANICAL WORKS

Under Ground Piping

II

Above Ground Piping/ Heater Coils

III

Storage Tanks

IV

Equipment Erection (Static)

Equipment Erection (Rotary)

VI

Crane (EOT/ HOT)

VII

Column Internals
HEATER WORKS

Fired Heaters

II

Refractory & Insulation Works


Fired Heaters

Sheet 1

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

HP

Sheet 2

HOLD POINT.
A point which requires inspection/verification and acceptance by Owner/ Consultant
before any further processing is permitted. Contractor shall not process the activity
beyond a Hold Point without written approval by Owner/ Consultant.

WITNESS POINT.
An activity which requires witnessing by Owner/ Consultant when activity is performed.
Suppose, after proper notification has been

provided, the contractor not obliged to

hold further processing, if Owner/ Consultant is not available to witness the activity or
does not provide the comments before the date notified.
Rw

REVIEW of contractors documentation.

SURVEILLANCE Inspection by Owner/ Consultant.


Monitoring or making observations to verify whether or not material/ Items or services
conform to specified requirements. Surveillance Activities may include audit,
inspections, witness of testing, review of quality documentation & records, field visit,
personnel qualifications etc.

WC

100% Examination by CONTRACTOR.

NDT

NON DESTRUCTIVE TESTING.

PWHT

POST WELD HEAT TREATMENT.

NOTE

:Contractor to submit required formats and job procedures for each activity listed in ITPs and
submit to Owner/ Consultant for approval. Responsibility for execution of the inspection/ testing
is with the contractor. Owner/ Consultant only verify examination or testing done by the
Contractor at important stages. Activities for which ITPs are not given, contractor to develop
and get the same approved by Owner/ Consultant well before start of the work.

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.

ACTIVITY

NO.

Sheet 3

CONTRACTOR

PMC

UNDER GROUND PIPING

PRIOR TO FABRICATION

Incoming Material

WC

Welding Filler Material Approval/ Qualification.

WC

HP

WPS/ PQR

WC

HP

Welder Performance Qualification.

WC

HP

NDT Procedure Qualification

WC

HP

PWHT Procedures Qualification (if any)

WC

HP

Preparation of Sketches.

WC

Joint Numbering.

WC

Material traceability & transfer of heat nos.

WC

FABRICATION (SHOP & FIELD)

Material as per piping class (check w.r.t. approved


Colour coding procedure).

WC

Fit-up check

WC

Dimensional check

WC

Pre-heat (if any).

WC

Check for purity of purging/ shielding gas

WC

Rw/S

Purging (if any)

WC

Shielding rate (if any)

WC

Basking of Electrodes

WC

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 4

Interpass cleaning & temperature check

WC

Visual check of completed welds

WC

Monitoring of PWHT Cycle

WC

10

Hardness Check

WC

11

PT/MT

WC

12

Radiography marking (for Random Radiography)

WC

13

Radiography Interpretation

WC

HP

14

Check shot for Radiography

WC

PROOF TESTING

Procedure

WC

HP

Correctness of Testing arrangements

WC

Calibration of Pressure Gauges

WC

Rw

R.F. Pad testing, if any

WC

Positive Material Identification as per


Specification after completion.

WC

HP

Scrutiny of test packs for Mechanical


& NDT Clearance(As per Annexure A)

WC

HP

Air / Water Flushing (preliminary)

WC

Pneumatic/ Hydro testing

WC

Draining of Water & Air drying

WC

LAYING

Trench excavation and levels

WC

Cleaning of pipe surface

WC

Approval of wrapping/ coating material manufacturers WC

HP

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 5

Approval of agency for wrapping & coating

WC

HP

Sample test of coating materials in approved laboratory WC

Rw

Procedure qualification for wrapping & coating

WC

HP

Application of primer

WC

Coal tar temperature

WC

Coating and wrapping

WC

10

Calibration of Holiday tester

WC

HP

11

Holiday testing

WC

HP

12

Thickness of coating

WC

HP

13

Peel test

WC

HP

14

Lifting arrangement

WC

15

Lowering (levels & orientation of branches)

WC

16

Checking of wrapping and coating for damages during WC


lowering, their repair, holiday testing, etc.

17

Back filling

WC

18

Location, Brickwork, Plaster of valve pit

WC

19

Top cover & finish of valve pit

WC

SYSTEM COMPLETION

Tie in joins (As per Annexure - B)

WC

Scrutiny of test packs for system testing


(As per Annexure - C)

WC

System testing

WC

HP

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 6

Inspection & Test Documents


Review Test and Inspection Document

HP

Abbreviations:
NDT

Non Destructive Testing

WPS

Welding Procedure Specifications

U/G

Under Ground

PT

Penetrant Testing

MT

Magnetic Particle Testing

PWHT

Post Weld Heat Treatment

Rw

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 7

Plant:

Report:
Area :

Contractor:
Loop No.:
Sketch No.:

Sr.No.

Inch Metre
From: ____________ To : ____________

Activity

1.b

3
4

Clearance by
PMC with Date
& Sign

MECHANICAL COMPLETION RECORD (U/G)

1
1.a

Check

Clearance by
Contractorwith
Date & Sign

Clearance for flushing & testing.


Mechanical clearance
Conformity with drawing.
Welding & NDT clearance
Material as per piping class
Fit-up check
Visual check of completed welds
LPI checks
RF pad testing
Flushing & Pressure testing
Medium
Test pr. Kg /Sqcm
Coating and Wrapping
Surface preparation
Primer application
Coating, wrapping and peel test
Holiday check
Laying
Trench leveling
Lowering & checking for damages in
wrapping & coating, their repair, holiday
testing, etc.
Backfilling

Remarks:-

Test loop sketches duly filled in to be enclosed with this (Jt.No., W.No. X SR. Chart No.
Alongwith XR Films, SR Charts etc.)

Review by Area Co-ordinator

Sign.

Date

Name

Designation

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 8

INSPECTION REPORT FOR TIE IN JOINT


(FOR UNDER GROUND PIPING)
JOINT NO.
A

REPORT NO.
DATE

TTIME AT THE TIME OF FIT UP


CLEARANCE BY
DATE

FIT UP

ROOT RUN DP

FINAL RUN DP

WELDER NO

RADIOGRAPHY

PWHT HARDNESS

RF PAD TESTING

CLEANING & PRIMING

COATING, WRAPPING & PEEL TEST

HOLIDY CHECKING

CHECKING FOR ANY DAMAGE IN

CONTRACTOR

PMC

WRAPPING & COATING AFTER


LOWERING, THEIR REPAIR, HOLIDAY
TESTING, ETC.
M

BACK FILLING

Inspection at above stages has been carried out by concerned and found satisfactory.

Contractor

PMC Mechanical

PMC Inspection

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 9

Plant:

Report:
Area:

Contractor:
Loop No.:
Sketch No.:

Sr.No.

Inch Meter
From: ____________ To: ____________

Activity

1.b

3
4

Clearance by
PMC with Date
& Sign

MECHANICAL COMPLETION RECORD (U/G)

1
1.a

Check

Clearance by
Contractorwith
Date & Sign

Clearance for flushing & testing.


Mechanical clearance
Conformity with drawing.
Welding & NDT clearance
Material as per piping class
Fit-up check
Visual check of completed welds
LPI checks
RF pad testing
Flushing & Pressure testing
Medium
Test pr. Kg /Sqcm
Coating and Wrapping
Surface preparation
Primer application
Coating, wrapping and peel test
Holiday check
Laying
Trench leveling
Lowering & checking for damages in
wrapping & coating, their repair, holiday
testing, etc.
Backfilling

Remarks:-

Test loop sketches duly filled in to be enclosed with this (Jt.No., W.No. X SR. Chart No.
Alongwith XR Films, SR Charts etc.)

Review by Area Co-ordinator

Sign.

Date

Name

Designation

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.

ACTIVITY

NO.

Sheet 10

CONTRACTOR

PMC

II

ABOVE GROUND PIPING

PRIOR TO FABRICATION

Incoming Material

WC

Welding Filler Material Approval/ Qualification

WC

HP

WPS/ PQR

WC

HP

Welder Performance Qualification

WC

HP

5a
b

NDT Procedure Qualification


PWHT Procedures Qualification

WC
WC

HP
HP

Joint numbering in Isometries (Big & Small Bore) WC

Preparation of sketches for job in case of off sites


A/G piping and Joint Numbering

WC

Transfer of Heat Nos. & Traceability

WC

FABRICATION (SHOP & FIELD)

Material as per piping class (check w.r.t. approved WC


Colour coding procedure)

WC
WC

S
S
S

1a
b

Fit-up check
Dimensional checks

Pre-heat (if any)

WC

Check for purity of purging/ shielding gas

WC

Purging

WC

Shielding rate (if any)

WC

Baking of Electrodes

WC

Interpass cleaning & Temperature check

WC

Visual check of completed welds

WC

Monitoring of PWHT Cycle

WC

10

Hardness Check
WC
WC
WC

S
W
HP

i) For C.S. Materials


ii) For A.S. Materials Piping
iii) For A.S. Material Heating Coil

Rw/S

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 11

11

PT/MT

WC

12

Radiography marking (for Random Radiography


only)

WC

13

Radiography Interpretation

WC

HP

i.For Carbon Steel Piping


ii.For Alloy Steel/SS Piping

WC
WC

HP
HP

14

Spool clearance

WC

HP

ERECTION

1
2

Lifting arrangement
Test Certificates for lifting tackles

WC
WC

S
Rw

Location and orientation of branches

WC

Provision of Instrument Tappings

WC

Provision of vents and drains

WC

Correctness of type of supports, anchors, guides

WC

Correctness of gasket/ fasteners

WC

Correctness of valves (NRV, Gate, Globe, Control WC


Valves), Steam traps and their direction of flow

Provision of cold pull

PROOF TESTING (See enclosed checklist in Annexure-A)

Procedure

WC

HP

Correctness of testing arrangements

WC

All valves to be kept open and chek if testing done WC


against closed valve position

Isolation of equipments, control valves, instruments, WC


ellows, before testing. Removal of flappers from
check valves

Scrutiny of test packs for Mechanical and NDT


Clearance

WC

HP

Positive Material Identification as per specification WC


after completion of installation

HP

WC

HP

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 12

Calibration of pressure gauges

WC

Rw

Preparation of check list

WC

Liquidation of check list

WC

10

Air/Water flushing (preliminary)

WC

11

Pneumatic / Hydrotesting (See Annexure - B)

WC

HP

12

Draining & drying

WC

13

Removal of temporary blinds/ supports

WC

14

Pickling of system, if required

WC

15

Boxing up including reinstallation of flappers


of check valves

WC

16

a.

Check on fasteners & gaskets and record


Thereof

WC

Rw

b.

Torque tightening of flange joints

WC

17

System testing

WC

18

Setting of spring supports

WC

HP

Rw

Inspection & Test Documents


Review Test and Inspection Documents

Abbreviations:
NDT

: Non Destructive Testing

WPS

: Welding Procedure Specifications

A/G

: Above Ground

PT

MT

: Magnetic Particle Testing

PWHT

Penetrant Testing

Post Weld Heat Treatment

For liquidation of Punch list. See Annexure - C.

INDICATIVE INSPECTION &


HPCL, Visakh

TEST PLAN
TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 13

CHECKLIST FOR MECHANICAL CLEARANCE A/G Piping (Sheet 1 of 4)

Project:

___________________

Plant/Unit:

___________________

Contractor:

___________________

Loop No:

___________________

Line No (Isometric No.)

Sr.
No.
1

3
4

Rev.

Report No:

___________________

Date :

___________________

Area :

___________________

INCH MTR

___________________

GAD NO.

Items to be checked
Installation checked as per Isometric w.r.t.
CONFIGURATION : Route, plumb, elevation, clearance
for thermal expansion/ insulation
BRANCH: Location, angle, orientation, type, R.F. pad etc.
STEAM TRAP : Direction
Installation checked as per GAD w.r.t.
CONFIGURATION : Route clearance for thermal expansion /
insulation
Installation checked as per P&ID
Isometrics completed for (enclosed)
a) Joint numbering (Shop and Field welds)
b) Spool numbering
c) As-built routing and dimensions
Valves (Check Rating, Gaskets, Flow direction, Sheet No.,
Tag No., Spindle direction. CSO, LO/LC, Damage etc.)
Gate valve
Globe valve
Check valve
Control valve Tag Nos.
Safety Valve Tag Nos.
Any other valves

FORMAT NO:_______________________________________ (Sheet 2/4)

Rev.

Acceptance by
Contractor

P&ID No.

Witness by
Owner/ PMC
as required by
ITP

INDICATIVE INSPECTION &


HPCL, Visakh

TEST PLAN
TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 14

CHECKLIST FOR MECHANICAL CLEARANCE A/G Piping (Sheet 2 of 4)


Sr.
No.
6
7

8
9
10
11

12
13
14

Items to be checked
Strainers: Check for clearance, flow direction, elements
Flanged joints
Total Nos.
Check for type of flange
Check for Rating
Check for Alignment, (Proper gap and parallelity)
Check for correct studs and nuts dia, length, material, uniform protrusion of
studs, anti seize compound
Check for correct gasket (type, size, spec., thickness, etc.)
Torque values used for tightening
Seal welding of Screwed connections (If required)
Vents/ Drains as per Dwg. And provision of additional high point vents and /
or low point drains, if reqd.
Reinforcement pads as per piping class
Orifice flanges
Check for Tag. No. tapping orientation, tap valve, jack screw, straight run
length of upstream and downstream
Local Gauges: Check for accessibility
Slope (When applicable)
Supports
a) Guides, Cross Guides, Trunnion etc.
i) Check for correct type, material and dimension
ii) Check welding
iii) Check for vent hole on pads (if applicable)
iv) Check offset for thermal expansion
v) Check clearance of guide
vi) Check U bolt for slide support
b) Spring support
i) Verify tag no. and check details as per data sheet/ spring set
ii) Check for locking arrangement and any damage during transit, etc.
iii) Check for completeness of installation as per drg. Including welding of
mounting cleat/ bracket
iv) Check for locking during installation and pressure test
c) Bracket support and inserts with Anchor fasteners:

15

i) Check for members dimensions and materiall


ii) Check for welding
iii) Check for bolting
iv) Check for appearance damage
Vents/ Drains
As per Drg
Orientation of valve handles
Clearance for hose
Requirement of additional vents/ drains (highest/ lowest pt.)

FORMAT NO:_______________________________________ (Sheet 2/4)

Acceptance
by
Contractor

Witness by
Owner/ PMC
as required by ITP

INDICATIVE INSPECTION &


HPCL, Visakh

TEST PLAN
TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 15

CHECKLIST FOR MECHANICAL CLEARANCE A/G Piping (Sheet 3 of 4)


Sr.
No.
16

17
17.1
17.2
17.3
17.4
17.5
18

19
20

21

22

Items to be checked

Earthings:
a) Check for location
b) Check for dimension of lug welding
17 Joints History sheets enclosed for
17.1 Material Traceability as per Procedure No:
(refer enclosed suggested format)
Fit ups checked
NDT Complete (Radiography, MT, PT)
Stress Relieving & Hardness Check complete
Positive Material Identification (PMI)
Checked for Removal Binding off of:
a. Control, Safety and Check valves
b. In-line instruments
c. Rupture discs
d. Equipment nozzles
e. Others
19 Supports and Weld/Flanged/ Screwed connections free from insulation or other
coverage
Checked installation of (Indicate location in Drawings)
a. Temporary Blinds, Spades
b. Temporary Strainers
c. Temporary Dummy-spools
d. Temporary Gaskets
e. Others
Expansion Bellows
a) Checks prior to installations
Physical damage
Transit locks are intact
Dimensions as per drgs.
b) Check during installations
Parallelity of mating flanges
Face to face dimensions of mating flanges
Concentricity of mating flanges
No stress on expansion bellows
Record
c) Isolation during pressure tests
Bellow manufacturers recommendations on isolation of
bellow during Pr. Test to be followed
If recommended expn, bellow to be dropped during pr. Test
Cleanliness internally and externally
23
Rotating equipment final alignment
checked with piping

FORMAT NO:______________________________________ (Sheet 3/4)

Acceptan
ce by
Contracto
r

Witness by
Owner/ PMC
as required by
ITP

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 16

CHECKLIST FOR MECHANICAL CLEARANCE A/G Piping (Sheet 4 of 4)

Acceptance by
Sr. No.

Contractor

Items to be checked

Witness by
Owner/ PMC
as required by
ITP

24

Removal of unwanted construction supports

25

Instrument tappings provided as per Drawing

26

Physical Walk Through The Line Checked for gross


irregularities including physical damages, unwanted tacks,
arc strikes, spatters and space for thermal expansion
Other

Remarks

Contractor :
Sign. :
Date :
Name :

Designation :

PMC
Sign :

Review by Area Co-ordinator (PMC)

Date :

Sign :

Date :

Date :

Name :

Designation :

Name :

FORMAT NO:_______________________________________ (Sheet 4/4)

Designation :

INDICATIVE INSPECTION & TEST PLAN


HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 17

DAILY MATERIAL TRACEABILITY REPORT

(FOR ABOVE GROUND PIPING/ HEATER)


Report No.: ______________
Date : ___________________

Contract No. : _______________________


Contractor : ________________________
Sl.
No.

Line / Heater No.

Area

Dia

Joint No.

No.

Spool

Piping Component

No.

Contractor
Note : A Sketch of the spool may be enclosed.

Heat / Batch No.

Colour Code

Verified
Contractor

PMC

Remarks
PMC

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 18

Piping Hydro Test Release / Acceptance Record A/G Piping (Sheet 1 of 2)


Project :

Report No:

Plant / Unit :
Contractor :
Loop No. :

Date :
Area :
REF P & ID No.
INCH MTR

Line No (s)

Test Medium :
Test Pressure Gauge No.

Range

Items to check

From
______________
Isometric No. (s)

To _________________

Test Duration
Calibration
Certificate No.

Design/ Test pressure

Accept
Contractor

P & ID No.

Gauge Calibration Date

Witness
PMC

Field installation Checklist prior to Hydrotest


Signed
Punch list prepared Yes/ No
Pre-Hydrotest Punch items cleared
Accessibility to inspection/ witness locations
Capacity of pressurising pump checked
Cordon off area for high pressure testing as
required
Pre-hydrotest flushing carried out
IBR/Others test Witnessing required Yes/ No
System released for Pressure Testing :
Contractor
Sign

PMC
Name

Date
Designation

FORMAT NO:_______________________________________ (Sheet 1/ 2)

Sign
Date
Designation

Name

INDICATIVE INSPECTION &


HPCL, Visakh

TEST PLAN
TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 19

Piping Hydro Test Release / Acceptance Record A/G Piping (Sheet 2 of 2)


Activity

Date

Time

Water Filling and Venting started at


Water Filling completed
Vents closed
Isolation of Pressurising pump
Test completed at :
- Water drained
- Air
- Temp Blinds Removed
- Checked for reinstallation of
a. Control & Safety valves
b. On line instruments
c. Rupture disks
d. Deblinding
e. Others
- Cold setting of spring supports carried out

Contractor

PMC

Sign

Sign

Date
Name

Designation

Date
Name

FORMAT NO:_______________________________________ (Sheet 2 / 2)

Designation

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 20

Punchlist
Project:

Report No:

Plant/Unit:

Date :

Contractor:

Area :

Loop No:

REF P&ID No.

Description :
Ref. Document :
Punc
h
Item
No

Priority

Description of
Punch
Items

Location

Prepared
by

Action by

Due Date

Completion
Acceptance

Priority: 1 Needed for Pressure test 2. Needed for commissioning 3.Needed for plant
acceptance
Contractor

PMC

Sign

Sign

Date

Date

Name

Designation

Name

FORMAT NO:_______________________________________

Designation

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.

ACTIVITY

III

STORAGE TANKS

A
1
2
3
4
5
6
7
8
9
10

PRIOR TO FABRICATION
Acceptance of the tanks foundation
Materials
Filler materials tests and approval
WPS/ PQR
Welders performance qualification
Radiography procedure
Joint numbering in drawings
Welding equipment and accessories
Tools and Tackles
Baking ovens
- Portable
- Heavy
Jig & Fixtures
Suitability of plate bending machine

11
12
B
1
2
3
4
5
6
7
8

9
10

FABRICATION/ ERECTION BOTTOM


Plate size, marking and cutting
Blast cleaning & painting of underneath
bottom plates
Plate layout, overlap and fitup
Sequence of welding to follow
Size and positioning of backing plate for
annular plates
Baking of electrodes/ interpass cleaning
Visual check
LPI/MPI/ Radiography of annular plate butt
welds and
bottom plate butt welds (if any)
Vacuum/ MPI/ LPI of shell portion of the
bottom plates
Vacuum box test for the bottom plate
welding

Sheet 21

CONTRACTOR

PMC

WC
WC
WC
WC
WC
WC
WC
WC
WC

W
W
HP
HP
HP
HP
S
S
S
S

WC
WC
WC
WC

S
S
S

WC
WC

S
S

WC
WC
WC

S
S
S

WC
WC
WC

S
S
HP

WC

HP

WC

HP

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.
1
2
3

4
5
6
7
8
9

10
11
12
13
14
15
16
17
18
19a
19b

ACTIVITY
SHELL
Plate size, marking and cutting.
Plate bending, curvature check, stacking.
Shell course alignments and fitup of vertical
and
circumferential joints.
Shell diameter, circularity, perpendicularity,
straightedge before welding.
Visual and Back chip check
Second side visual.
Location, size and alignment of nozzles and
other Openings
R.F.Pads fitup / welding.
PWHT of RF pad. Nozzles & manhole, etc.
(As
applicable)
Radiography
marking
for
Random
radiography only
Curbangle and Wind girders fitup / welding
MPI/LPI nozzles, wind girders fitup/welding
RF Pads air test.
Shell to bottom fit-up
Sheel to bottom I/S welding root run visual/
Oil chalk test
Sheel to bottom O/S welding visual and LPI
for toecracks
Fabrication and erection of stairways
Cleates welding for insulation
Radiography interpretation.
Extension marking for repair

Sheet 22

CONTRACTOR

PMC

WC
WC

S
S
S

WC
WC
WC
WC
WC
WC

HP
S
S
HP
W
HP

WC
WC
WC
WC
WC
WC
WC
WC
WC
WC
WC
WC

W
S
W
HP
W
HP
HP
S
S
HP
HP

FIXED ROOF
1
2

Identification of Roof Structure members in


AFC drgs
Blast cleaning and painting Roof Structure
underside of Roof plates

WC
WC

Rw
S

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.
3
4
5
6
7
8
9
10
11
12

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Sheet 23

ACTIVITY

CONTRACTOR

PMC

Location and welding of roof supports.


Alignment and welding of Roof Structures.
Plate layout, overlap and fitup
Visual check of roof welds
Location, size and alignment of roof manholes and vents
PWHT (As applicable)
RF pads fit-up & Welding
RF pad pneumatic testing
PT/MT of Nozzles, vents & other
attachments
Welding of Roof plate with shell / curb
angle
FLOATING ROOF
Temporary staging spacing and levels
Plate size, straightening and cutting
Plate layout, overlap and fitup/ welding
Buoys fabrications
Vacuum testing of roof-plate welds
Location of sleeve supports
Pad plate welding with roof and sleeve
support
Fixing and welding of Buoys
Initial lift
Supports fixing through sleeves
Seal welding of support sleeves from
beneath after dewatering
Air test of Buoys
Pontoon welding
Location, fixing and welding of man holes,
drains etc.
Shell to pontoon clearance
Seal fixing

WC
WC
WC
WC
WC

S
W
S
W
S

WC
WC
WC
WC

HP
W
W
W

WC

WC
WC
WC
WC
WC
WC
WC
WC

S
S
S
S
HP
W
W

WC
WC
WC
WC

S
W
S
W

WC
WC
WC

HP
W
S

WC
W

W
W

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.
C

Sheet 24

ACTIVITY

CONTRACTOR

Correctness of testing arrangements especially


size of blind flanges/ vents/ drains/ temporary
piping

WC

Mechanical / Inspection clearances

WC

HP

Earthing of ladder and shell

WC

Settlement readings during water filling

WC

Hammer test

WC

HP

Air pressure test

WC

HP

Vacuum test

WC

HP

Roof collapsability test in case of floating roof


tanks

WC

HP

Calibration of tanks in case of floating roof


tanks

WC

Rw

PAINTING AND INSULATION

Cleaning

WC

Painting

WC

Insulation

WC

HP

Rw

PMC

TESTING
S

Inspection & Test Documents


Review Test and Inspection Documents

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.
IV
1

ACTIVITY

Sheet 25

CONTRACTOR

IV
V
VI
VII

EQUIPMENT ERECTION (STATIC)


BEFORE ERECTION
Execution scheme
Materials supply
Readiness of erection
Level of foundation (shims/ packing with
marking to be prepared & kept ready)
No. & Size of bolts
Hole dia and no. of hole in base/ structure of
equipment and columns
Equipment base with actual foundation
Checking the threads of bolts & nuts
Chipping & roughening of foundation
C/L marking on equipment

ERECTION SCHEMES FOR CRITICAL EQUIPMENTS

A
B
C
I
II
III

PMC

WC
WC
WC
WC

Rw
W
S
S

WC
WC

S
S

WC
WC
WC
WC

S
S
S
S

WC

HP

WC

WC

DURING ERECTION
A Orientation to be checked

WC

B Placement of packing as per marking

WC

C Outside cleaning, coating/ wrapping,


painting for underground equipment

WC

A Approval of Rigging procedure


(As per Annexure 1)
3

SAFETY TEST
A Load test of cranes, lifting beams, slings and
shackles, length and dia. of sling &
condition of wire rope (Broken/ damaged
strands should not be there)
Cross checking if Data-sheet w.r.t.
4
orientation, base plate Deatails
5

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.
6

ACTIVITY

Sheet 26

CONTRACTOR

PMC

AFTER ERECTION

Tightening of Bolts and providing washers

WC

Levelling and alignment of equipments

WC

HP

Corresponding requirement elevation and distance


between nozzles in special cases

WC

Cleaning of sleeves before grouting

WC

Grouting

WC

Final tightening of bolts

WC

Internals installation after PMI as required


i. Critical equipments

WC

HP

ii. Other equipments

WC

As per specification

WC

Packing of column (As per Annexure 2)

WC

Final Boxing up

WC

HP

Rw

TESTS

Inspection & Test Documents


Review Test and Inspection Documents

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.

ACTIVITY

Sheet 27

CONTRACTOR

PMC

ERECTION SCHEME FOR CRITICAL EQUIPMENT (Rigging Procedure)

BEFORE ERECTION
A Checking proper sequence for lifting of the
equipment
B To check weight of equipment
C To check the centre of gravity
D To check suspension points
E To check the maximum/ minimum radius at which
the lifting tackle will operate
F To check the maximum load to be lifted including
wt. Of slings, hook-block, lifting beams and
equipment etc.
G To identify the safe crane with requisite capacity

2
A
B
C
D
E
F
G
H
I
J

DURING ERECTION
To check counter weight of crane and
Boomlength
To check slew limitations of crane
To check ground conditions are adequate for
supporting fully rigged crane and load
To check the crane can be travelled in loaded
condition
To check clearances from overhead electric power
cables
To check maintenance certificates
To check whether operators, riggers have received
proper instructions
To verify safe load indicator been supplied to rig
the crane
To check the adequacy of bracing of equipment
by guys
To check the guys, shoring, bracing, interference
with other works

WC

Rw

WC
WC
WC
WC

Rw
Rw
Rw
Rw

WC

Rw

WC

Rw

WC

Rw

WC
WC

Rw
Rw

WC

Rw

WC

Rw

WC
WC

Rw
Rw

WC

Rw

WC

Rw

WC

Rw

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.

ACTIVITY

Sheet 28

CONTRACTOR

PMC

WC

A Degreasing and cleaning of packing material

WC

B Check packing su
pport plate
C Check for stacked or dumped packing as per

WC

WC

WC

WC

PACKING COLUMN
1

BEFORE INSTALLATION
A Identify the material, check thickness,
dimensions, no. and angle of fingers of packing
rings

DURING INSTALLATION

Specifications
D Check for nesting
E Check for packings are touching bed limiter
(when issued and top level)

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.

ACTIVITY

V
1
A
B
I
II

EQUIPMENT ERECTION (ROTARY)


BEFORE ERECTION
Execution scheme
Foundation check
Level / centreline of foundation
No / Dia / Length of anchor bolts, Depth of
pockets, verticality of pockets
III Chipping, roughing and cleaning of pockets

LIFTING TACKLES
Crane/beams/ slings/ shackles etc. to be
checked for weight of equipments

Sheet 29

CONTRACTOR

PMC

WC

Rw

WC
WC

S
S

WC

WC

VISUAL INSPECTION OF EQPTS. TAG/ IDENTIFICATION NO.


WC
A For any damage
Free
shaft
rotation
B
WC

A
B
C
D
E
F
G
H

S
S

Drilling and Tapping (if reqd.) hole in the base


plate of eqpt.
a. Size/ Taps

WC

DURING ERECTION
Level/ elevation of base frame
All foundation bolts to be checked
Grouting of base frame / pocket grouting
Orientation of eqpts.
Elevation/ Level of eqpts.
Shimsize/ material/ thickness
Distance between couplings
No-load run of motors

WC
WC
WC
WC
WC
WC
WC
WC

W
S
W
W
HP
W
W
W

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.

ACTIVITY
I Alignment readings

Sheet 30

CONTRACTOR

PMC

WC

- Without piping (Loose bolts)

WC

HP

- With piping (After tightening the flange bolt)

WC

HP

WC

WC

WC

WC

WC

D Tests as per spec.


E Chemical Cleaning of equipments parts /
connected piping
F Boxing up of equipment 7 connection piping

WC

WC

WC

G Log book maintenance (For rotating of shaft,


lubrication Oil reservoir full, all plugs in

WC

WC

WC

HP

Rw

J Type of grout and grouting


K All protection and safety guards installation

AFTER ERECTION
A Curing of grout
B Auxiliary connections to be mounted on eqpts.
as per drawing
C Final tighting of bolts

positions)
H No load run of Motor
I Recoupling of motor & reconfirmation of
alighnment
INSPECTION & TEST DOCUMENTS
Review test and Inspection documents

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.
VI
1
A
B
C
I
II
III
2 A
B
3 A
B
4

ACTIVITY

Sheet 31

CONTRACTOR

PMC

WC
WC

Rw
W

WC

WC

WC
WC

S
S

WC

WC

WC

WC
WC
WC

W
W
W

LOAD TEST
A. Winding & unwinding test
B. Traversing test
C. Travelling test
D. Load & Over load testing
E. Deflection of girder

WC
WC
WC
WC
WC

W
W
W
W
W

INSPECTION & TEST DOCUMENTS


Review test and Inspection Documents

HP

Rw

CRANE (EOT/ HOT)


BEFORE ERECTION
Execution scheme
Materials supply (contractor)
Readiness for erection
Structural steel girder span centre to centre and
elevation Difference
Check centre to centre distance of rails, gaps,
elevations, crab wheels distances
Check buffer stops
Erection and assembly of components like LT,
Crane Girders, Crab, Platforms, etc.
Review of hoist ropes and assembly of hook
blocks
Electrical installation, testing and no load test of
motor
Coupling of motors to drives
NO LOAD TEST
A. Winding & unwinding test
B. Traversing test
C. Travelling test

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.
VII

ACTIVITY

Sheet 32

CONTRACTOR

PMC

WC

HP

a) Manufactures Test Certificate

WC

Rw

b) Testing, If any

WC

S*

c) Positive Material Identification

WC*

Rw

Fabricated materials receipt

WC

Rw

Level check on TSRs

WC

Check for down corner clearance and Tray

WC

clearance
Distance between TSRs

WC

After Installation

INSTALLATION OF COLOUMS INTERNALS

Before Installation

Avalable of Venders representatives at site

Material Inspection

Check for
1

Exit weir height

WC

UDFC

WC

Tightness of bolts

WC

Orientation and tightness of clamps

WC

Provision of lock nuts / seal pates

WC

Correctness of installation of shimming / bolting


for top down corner

WC

Correctness of gasketing (if any)

WC

Tray to tray distance and level of tray

WC

Leak testing of seal pans as applicable

WC

HP

10

Damaged, missing valves and valve movement

WC

for valve trays


11

Fitting of proper valve combination

WC

12

Damage to deck components

WC

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 33

13

Level and alignment of inlet weir and exit weir

WC

14

WC

15

Check for slots on tray components to be fully


covered
Gaps at down corner ends

WC

16

Removal of temporary plugs after testing

WC

17

Cleaning of all trays & inside of equipment

WC

Certification

Vendors

WC

HP

representative and operation groups of PMC /


Owner
Final boxing up and intertisation, if any

WC

Rw

HP

Rw

18
19

of

installation

by

INSPECTION & TEST DOCUMENTS


Review test and Inspection documents

NOTE:-

All activities pertaining to material receipt, identification. Pre installation checks


checks and installation to be carried out in the presence of Vendors
representative and duly certified and documented for submission as final
document.

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.
I

ACTIVITY

Sheet 34

CONTRACTOR

PMC

FIRED HEATERS (FABRICATION & ERECTION

PRIOR TO FABRICATION

Material Inspection
a) Manufacturing Test Certificate

WC

Rw

b) Testing, if any

WC

c) Positive Material Identification for Alloy


Steel & Stainless Steel material by alloy

WC

S*/RW

analyzer
2

WPS / PQR

WC

HP

Welders Performance

WC

HP

Welding Consumable

WC

HP

a) NDT Procedure Qualification

WC

HP

b) PWHT Procedure Qualification

WC

HP

Availability of AFC drawing (Reviewed by


PMC)

WC

Joint Numbering for coils / pressure parts

WC

S/Rw

Structural members identification

WC

S/Rw

Layout Checking

WC

S/Rw

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.
B

ACTIVITY

Sheet 35

CONTRACTOR

PMC

FABRICATION
STEEL WORKS

Materials as per AFC drawing

WC

Dimensional check

WC

Fit-up check

WC

Weld Visual Inspection

WC

Radiography as Applicable
a) RT Marking (for random radiography only)

WC

HP

b) RT Interpretation

WC

HP

Completion of structures as per AFC


drawings

WC

HP

Surface cleaning for primer painting

WC

Primer Coating as applicable

COIL WORK
1

Edge Preparation

WC

Fit-up of joints

WC

Weld Visual Inspection

WC

PT/MT Check as required

WC

S/Rw

PWHT & Hardness check as applicable

WC

S/Rw

a) RT Marking (for random radiography only)

WC

HP

b) RT Inspection

WC

HP

Check Short for Radiography

WC

HP

Clearance for Hydro testing

WC

HP

Hydro testing

WC

HP

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.
C

ACTIVITY

Sheet 36

CONTRACTOR

PMC

ERECTION

Foundation check as per AFC drawing

WC

Rw

Lifting arrangements

WC

Rw

Test certificates for lifting tools and tackles

WC

Rw

Lifting of radiant section columns

WC

Bottom plate fit-up & welding

WC

Radiant shell course fit-up and welding

WC

Weld visual inspection

WC

Radiography as required

WC

HP

Cutout for burners in bottom / shell plate


a) Marking

WC

HP

b) Cutting

WC

10

Coil erection in Radiant section

WC

11

Erection of convection box & APH with all


sheet work & tube Supports
a) Erection Procedure

WC

HP

b) Erection

WC

12

Check Shot for radiography for coil field joints

WC

13

Clearance for Hydro test

WC

HP

14

Hydro test field joints

WC

HP

15

Erection fit-up & welding of stack


a) Erection Procedure

WC

HP

b) Erection

WC

16

Erection fit-up & Welding of ducts

WC

17

Radiography as required
a) RT Marking

WC

HP

b) RT Interpretation

WC

HP

18

FD & ID

19

Installation of soot blowers

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

20

a) Marking

WC

HP

b) Erection

WC

WC

WC

Rw

Erection of all Platforms, ladders, Hand rails &


miscellaneous structures

21

Sheet 37

Final Painting

INSPECTION & TEST DOCUMENTS


Review Test And Inspection Document

Abbreviations:
NDT

: Non Destructive Testing

WPS

: Welding Procedure Specifications

RT

: Radiography Testing

PT

MT

: Magnetic Particle Testing

PWHT

Penetrant Testing

Post Weld Heat Treatment

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.
II

ACTIVITY

Sheet 38

CONTRACTOR

PMC

REFRACTORY & INSULATION WORKS (HEATERS)

RADIANT SECTION

Radiant shell
Fixing of Ceramic fiber blanket /
I.

Manufacturing Test Certificate

WC

Rw

Testing, if any

WC

Clearance for hot work

WC*

HP

III.

Marking of studs

WC

IV.

Welding of studs with approved PS&PQR

WC

Surface Cleaning

WC

VI.

Check for individual layers of ceramic fiber


blankets and SS foils

WC

VII.

Check for overlap of ceramic blanket

WC

VIII.

Fixing of speed fix washer and cup lock

WC

Cleaning and final inspection

WC

HP

II.

V.

IX.
2

Material Inspection

Arch Plate
I.

Material Inspection


Manufacturing Test Certificate

WC

Rw

Testing, if any

WC

Clearance for hot work

WC*

HP

III.

Marking of studs / anchors

WC

IV.

Welding of studs / anchors with approved


PS&PQR

WC

Surface Cleaning

WC

VI.

Check for individual layers of ceramic fiber


Blankets (CFB) modules and SS foils

WC

VII.

Check for overlap of CFB and modules

WC

II.

V.

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

VIII.
3

Cleaning and final inspection

Sheet 39

WC

HP

Floor Plate
Laying of castable / fire bricks
I.

Material Inspection


Manufacturing Test Certificate

WC

Rw

Testing, if any

WC

Clearance for hot work

WC

HP

III.

Surface Cleaning

WC

IV.

Check Shelf life prior to application

WC

HP

Check for undulations on floor

WC

Check for castable mix

WC

Check for proper compaction

WC

Check for thickness of castable

WC

IX.

Curing

WC

X.

Cleaning after laying of castable

WC

XI.

Check for cracks and repair

WC

XII.

Fixing of tar paper, If applicable

WC

XIII.

Cleaning and final inspection

WC

HP

II.

V.
VI.
VII.
VIII.

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.
II

ACTIVITY

Sheet 40

CONTRACTOR

PMC

REFRACTORY & INSULATION WORKS


(HEATERS)

CONECTION SECTION

Convection Walls
Laying of castable
I.

Manufacturing Test Certificate

WC

Rw

Testing, if any

WC

Clearance for hot work

WC*

HP

III.

Marking of studs / anchors

WC

IV.

Welding of studs / anchors with approved


PS&PQR

WC

Surface Cleaning

WC

VI.

Check for undulations on wall

WC

VII.

Check for castable mixing

WC

VIII.

Check for proper compaction

WC

IX.

Check for thickness of castable

WC

X.

curing

WC

XI.

Cleaning after laying of castable

WC

XII.

Check for cracks and repair

WC

XIII.

Cleaning and final inspection

WC

HP

II.

V.

Material Inspection

End tubesheets
Laying of Castable
i.

Material Inspection


Manufacturing Test Certificate

WC

Rw

Testing, if any

WC

ii.

Clearance for hot work

WC

HP

iii.

Marking of studs / anchors

WC

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 41

iv.

Welding of studs / anchors with approved


PS&PQR

WC

v.

Surface Cleaning

WC

vi.

Check for castable mixing

WC

vii.

Check for proper compaction

WC

viii.

Check for thickness of castable

WC

ix.

curing

WC

x.

Cleaning after laying of castable

WC

xi.

Check for cracks and repair

WC

xii.

Cleaning and final inspection

WC

HP

Breeching Plate
Laying of castable
I.

Material Inspection


Manufacturing Test Certificate

WC

Rw

Testing, if any

WC

Clearance for hot work

WC*

HP

III.

Marking of studs / anchors

WC

IV.

Welding of studs / anchors with approved


PS&PQR

WC

Surface Cleaning

WC

VI.

Check for undulations on plate

WC

VII.

Check for castable mixing

WC

VIII.

Check for proper compaction

WC

IX.

Check for thickness of castable

WC

X.

curing

WC

XI.

Cleaning after laying of castable

WC

XII.

Check for cracks and repair

WC

XIII.

Cleaning and final inspection

WC

HP

II.

V.

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

Sheet 42

Header box
Laying of castable
i.

Material Inspection


Manufacturing Test Certificate

WC

Rw

Testing, if any

WC

ii.

Clearance for hot work

WC*

HP

iii.

Marking of studs / anchors

WC

iv.

Welding of studs / anchors with approved

WC

PS&PQR
v.

Surface Cleaning

WC

vi.

Check for undulations on box

WC

vii.

Check for castable mixing

WC

viii.

Check for proper compaction

WC

ix.

Check for thickness of castable

WC

x.

curing

WC

xi.

Cleaning after laying of castable

WC

xii.

Check for cracks and repair

WC

xiii.

Cleaning and final inspection

WC

HP

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.

ACTIVITY

II
C

Sheet 43

CONTRACTOR

PMC

REFRACTORY & INSULATION WORKS (HEATERS)


STACK
Laying of castable
I.

Material Inspection


Manufacturing Test Certificate

WC

Rw

Testing, if any

WC

Clearance for hot work

WC*

HP

III.

Marking of studs / anchors

WC

IV.

Welding of studs / anchors with approved

WC

Surface Cleaning

WC

VI.

Check for undulations on stack shell

WC

VII.

Check for castable mixing

WC

VIII.

Check for proper compaction

WC

IX.

Check for thickness of castable

WC

X.

curing

WC

XI.

Cleaning after laying of castable

WC

XII.

Check for cracks and repair

WC

XIII.

Cleaning and final inspection

WC

HP

II.

PS&PQR
V.

INDICATIVE INSPECTION &


TEST PLAN

HPCL, Visakh

TOYO ENGINEERING INDIA LTD.

ISSUED :01.06.2009

JOB NO. : 6261

DOC.No. 6261-CD-303

DHT PROJECT

SL.
NO.

ACTIVITY

II
D

CONTRACTOR

PMC

REFRACTORY & INSULATION WORKS (HEATERS)


HOT AIR DUCT
I.

Material Inspection


Manufacturing Test Certificate

WC

Rw

Testing, if any

WC

Clearance for insulation

WC

HP

III.

External Surface cleaning

WC

IV.

Provide spacer ring / anchors

WC

Check for thickness of the mineral wool


insulation

WC

VI.

Check for staggering of joints in insulation

WC

VII.

Check for providing expansion joints

WC

VIII.

Overlapping of metal sheet as per


specification
Overlap on joints for aluminium sheets
as per specifications

WC

WC

WC

WC

HP

WC

Rw

II.

V.

IX.
X.
E

Sheet 44

Sealing alluminium sheets

Final Inspection & Acceptance

INSPECTION & TEST DOCUMENTS


Review Test and Inspection Documents