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INSPECTION AND TEST PLAN FOR HEAT EXCHANGERS QAP. No. : HDO/QAP/8164-75 REV.01 DTD. 12.10.2010 HDO Ref No. : BYC 210968 P.O.NO. : 00774 91 PO 0610 02 10588 R0 DT.05/05/2010
CLIENT : TECHNIP KT INDIA LTD.(NOIDA) PROJECT : HGU FOR DHT PROJECT INSPECTION BY : M/S. TECHNIP/TPIA INSPECTION CATEGORY - A
GENERAL APPLECABLE SPECIFICATION : 00774-91-SP-0610-02, E-102, D-123, O-301-A, D-102 SR.NO ITEM NO EQUIPMENT NAME 91-E-26 PROCESS BFW PREHEATER I 1 91-E-27 CLEAN BFW PREHEATER I 2 91-E-28 DEMIN W ATER PREHEATER 3 91-E-21 NAPHTHA VAPOURIZER 4 91-E-01A/B SOUR NAPHTHA PREHEATER- I 5 91-E-05A/B/C FEED PRODUCT EXCHANGERS 6 91-E-06 STRIPPER REBOILER 7 91-E-08 SOUR NAPHTHA PREHEATER II 8 91-E-31A/B FUEL NAPHTHA VAPOURIZER 9 10 91-E-32 FUEL NAPHTHA SUPERHEATER 91-E-33 N2 HEATER 11
HDO JOB NO 8164 8165 8166 8167 8168A/B 8169A/B/C 8170 8171 8172/73 8174 8175
SPECIFIC APPLICABLE SPECIFICATION (Refer Note-1) (Refer Note-1) (Refer Note-1) (Refer Note-1) 00774-91-SP-0800-001,003 & 004 (Refer Note-1) 00774-91-SP-0800-001,003 & 004 (Refer Note-1) 00774-91-SP-0800-001 00774-91-SP-0800-001 & 004 00774-91-SP-0800-001 & 004 (Refer Note-1) ----------(Refer Note-1) SCOPE OF INSPECTION
S.R. NO. 1.0
INSPECTION ACTIVITY & COMPONENT MATERIALS INSPECTION
CHARACTERISTICS
QUANTUM OF CHECK
Visual & Dimensional
1.1
1.2
1.3
1.4 2 2.1
Pressure parts (Plates, Pipes) (To be procured from Approved Vendor list attached with MR) Inspection At HDO's works
Bought out items (forgings, Tubes Fittings,) inspection at Vendor's W orks (To be procured from Approved Vendor ) Fasteners and Gaskets Inspection at HDO's Works (To be procured from reputed Mfgrs) Non Pressure Parts (including internals, supports, baffles, sliding plate etc.) Inspection At HDO's works WELDING BOOK Weld Map
- Co-relation of markings with test certificates. - Chemical and Physical properties. - T ra ra ns ns fe fe r o f i de den titi fifi ca ca titi on on marks, wherever required. Chemical & Physical properities Review of test certificates / Chemical & Physical properities Review of test certificates /
100%
100%
100%
Chemical & Physical properities Review of test certificates / Check test report.
100%
REFERENCE DOCUMENT
ACCEPTANCE STD.
FORMAT OF REPORT
PR/A PR/ASM SME E SEC. SEC.II IIA, A, PR/A PR/ASM SME E SEC. SEC.II IIA, A, IIB/ IIB/SE SEC. C.VI VIII II DI DIV. V.1/ 1/ II IIB/ B/SE SEC. C.VI VIII II DI DIV. V.1/ 1/ TEMA-R/APPD DRGS/ TEMA-R/APPD DRGS/ MANUF MANUFACT ACTURE URER'S R'S MANUF MANUFACT ACTURE URER'S R'S Inspn. Report TEST CERTIFIC CERTIFICATES ATES TEST CERTIFI CERTIFICATES CATES EN 10204 EN 10204 T YP YP E 3 .2 .2 /3 /3 .1 .1 T YP YP E 3. 2/ 2/ 3. 3. 1 Approved TPS Approved TPS ASME Sec IIA / ASME Sec IIA / VIII Div.I / TEMA-R / VIII Div.I / TEMA-R / Insp. Report PR/S PR/Spe pec/ c/Dr Draw awin ings gs PR/S PR/Spe pec/ c/Dr Draw awin ings gs ASME Sec IIA / ASME Sec IIA / VIII Div.I / TEMA-R / VIII Div.I / TEMA-R / Insp. Report PR/Spec/Drawings PR/Spec/Drawings ASME Sec IIA / IIB / ASME Sec IIA / IIB / VIII Div.I / TEMA-R / VIII Div.I / TEMA-R / Insp. Report PR/Spec/Drawings PR/Spec/Drawings
HDO
TPI
W
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R
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R New-W Old-R
W elding procedures
100%
ASME Sec IX /Spec.
ASME Sec IX /Spec.
W PS
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2.2
W PS/PQR/W PQ
W elding parameters
100%
ASME Sec IX /Spec.
ASME Sec IX /Spec.
WPS/PQR
W
2.3
Mock up Procedure for tube-to-tubesheet joint (Note-2)
Qualification Requirement
100%
A SM SME Se Sec IIX X / Sp Spec ..// Drawings
AS ME ME S ec ec IX IX / Sp Spec ..// Drawings
W PQ PQ
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INSPECTION AND TEST PLAN FOR HEAT EXCHANGERS Page 2 of 3 SCOPE OF INSPECTION
S.R. NO. 3
3.1
3.2
INSPECTION ACTIVITY & COMPONENT INSPECTION DURING FABRICATION W eld Edge preparation & set up of Major pressure parts like L/S, C/S (PTC to be provided if applicable as per CL. No. IN 42.0 of AXENS Spec. )
Assembly of Nozzles Inspection of Completed welds
3.3
3.4 3.5 3.6
RADIOGRAPHY EXAMINATION OF WELDS (As per Approved Drgs.) Visual and Dimensional Insp.shell/ch.shell Assl.(Internals & externals) positive Material Identification (Applicable for SS Materials) Ferrite check of SS welds
CHARACTERISTICS
Visual & Dimensional inspection,Marking, WEP, Offset, Ovality,etc Sound metal after backchipping WEP, Dimensions, completeness of assembly Visual inspection for reinforcement, Undercuts, Weld bead, surface defects etc. Soundness of Full Weld
Dimensions, completeness of assembly Alloying Element check in Parent metal & weld
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE STD.
FORMAT OF REPORT
HDO
TPI
100%
Spec./Drawings ASME SEC VIII Div.1 Spec./Drawings Sec V/ VIII-1 Spec./Drawings Sec V/ VIII-1 Drawings/ Spec / ASME Sec VIII-1
Spec./Drawings ASME SEC VIII Div.1 ASME Sec V / Sec VIII-1 Spec./Drawings Sec V / Sec VIII-1 Drawings/ Spec / ASME Sec VIII-1
Insp. Report
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W-FOR FIRST L SEAM or C-SEAM
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Drawings/ Spec / ASME Sec VIII-1/ V
Drawings/ Spec / ASME Sec VIII-1 / V
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FILM REVIEW
Drawings/ Spec / ASME Sec VIII-1/ V Spec./Drawings Sec.II part 2a & Part C Approved Procedure
Drawings/ Spec / ASME Sec VIII-1/ V Spec./Drawings Sec.II part 2a & Part C Approved Procedure
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100% 100% 100% As per Drg.
100% As per TOYO spec. & Appd.Proc.
Insp. Report Insp. Report Insp. Report
NDT Report Reviewe of RT films Insp. Report Insp. Report
3.7
PWHT OF SHELL/CH. SHELL (As per approved drawings)
Heating Time Cooling Time Soaking Time & Temp.
100%
ASME SEC VIII Div.1 Drawing/Spec
Drawing/ ASME SEC-VIII-1
Insp.Report/ PWHT CHART
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3.8
NDE After PWHT (If Applicable) Note-5
Soundness of welds
As per Drg./ NDE MAP
Drawing/Spec
Drawing/ ASME SEC-VIII-1
Insp.Report
W
W(10%)
Visual & Dimensional
100%
Insp. Report
W
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FILM REVIEW
W
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4
INSPECTION OF FORMED COMPONENT
inspection, Thickness & Profile check. RT of weld seam (If applicable) 4.1
Dished ends/ formed components
PT Examination
100% 100%
On Inside & Out side KR,SF & EDGE H T c har t r ev iew
5
5.1 5.2 5.3 5.4
Drawings/Spec.
Drawings/Spec.
ASME SEC.VII Div.1
ASME Sec.VIII-1
ASME Sec.VIII Div.1/
ASME Sec.V/
SEC.V/Spec.
Spec.
RT Report
ASME Sec.V
ASME VIII Div.I
Spec./Drawings
& Sec.V. Spec./DRG
Insp. Report H T C har t
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Insp. Report
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Insp.Report
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Insp.Report
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RW
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A SME S ec .V III -1
A SME S ec .VII I- 1
If applicable
100%
/Spec./DRG/Appd.Drg.
/Spec./DRG
Test Coupon (If applicable)
100%
Spec./Drawings.
ASME Sec.VIII Div.1
100%
Inspection of Tube To Tube Sheet joint Welding/expansion
Hole Dia/PPCD/Ligament/Layout OTL/Steps/OD/Thk./Grooving/Hole Finish % of expansion 100% PT for Root, First & Final layer
Ins pect ion of Tube Bundl e bef or e Instertion into the shell Main shell inside surface inspection bef or e t ube Bundl e ins ter ti on in t o s hell
vi sual & D imens ional i ns pec ti on As per Approved DRG. Insde flush of nozzle conn & c leani nes s of s hel l
100%
Drawings/ Spec / TEMA Drawings/ Spec / ASME Sec VIII-1 TEMA D rawings / S pec / TEMA Drawings/ Spec /
Drawings/ Spec / TEMA Drawings/ Spec / ASME Sec VIII-1 TEMA D rawi ngs/ S pec / TEMA Drawings/ Spec /
INSPECTION OF TUBE BUNDLE
Tube sheet Maching/ Drilling
This document is electronically generated, Signature is not required.
100%
100%
Insp.Report insp. Report
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TO YO
INSPECTION AND TEST PLAN FOR HEAT EXCHANGERS PAGE 3 OF 3 S.R. NO. 6
6.1 6.2
6.3 `7.0 `8.0 `9.0
INSPECTION ACTIVITY & COMPONENT
`12.0 `13.0
QUANTUM OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE STD.
FORMAT OF REPORT
HDO
TPI
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TO YO
TESTINGS
Soap Suds test of RF PADS at Test Pressure as per Appd.Drg. Leak test of Tube To Tube sheet joint weld/Expansion Hydrostatic test as per Appd Drg. Shell Side Tube Side Drying of equipment Pickling & Passivation of SS parts Surface preparation/cleaning Painting
`10.0 `11.0
CHARACTERISTICS
Spare Item Varification Spares shall include in IRN Final Stamping of equipment and marking etc. Nitrogen Filling ( If required as per Drg.) DOCUMENTATION
`14.0
Leak checking Leak checking from TTS joint
Drawings/Spec. ASME SEC VII Div.1 Drawings/Spec. ASME SEC VIII Div.1 Appd.Procedure Drawings/Spec./ ASME Sec.VIII-1 Appd.Procedure Drawings / Spec.
100% 100%
leak Check
100%
Cleanliness of Shell Side/Tube Side Visual inspection afer Pickling & Passivation Visual insp for workmanship Visual insp & DFT Measurement
Shell side Tube side 100%
100% 100%
Drawings / Spec. Appd.Procedure Drawings./Spec. Appd.Procedure Drawings./Spec.
Mandatory spare varifed as per DRG. Verifying stamping details
100%
Drawings./Spec.
N2 pressure & non return valve. Verification & Compilation of inspection & test records and other documents with Index
Drawings/Spec. ASME SEC VII Div.1 Insp. Report Drawings/Spec. ASME SEC VII Div.1 Insp. Report Appd.Procedure Drawings/Spec./ Insp. ASME Sec.VIII-1 Report Appd.Procedure Drawings / Spec. Insp. Report Drawings / Spec. Insp. Appd.Procedure Report Drawings./Spec. Appd.Procedure Insp. Report Drawings./Spec. Insp. Report Drawings./Spec.
Insp. Report
Name plate & Rub off Full exchenger
Drawings / Spec. Drawings/Spec.
Drawings / Spec. Drawings/Spec.
Name Plate/ Rub-Off Insp. Report
100%
Spec. (VDR)
Spec.
Q.C. Dossier
NOTES : 1 ) For Above Mentioned items Hydrogen service is required. All requirement as per Clause no.3.8.10 of D-102 shall be followed. 2) In absence of old mock up procedure New mock up procedure shall be carried out under TPIA. 3) Where AXENS Spec. IN-042.0 Applicable and PW HT required in the job, Simulation Tensile shall be carried out after Actual PWHT cycle plus one additional cycle & Simulation Impact shall be carried out after Actual PWHT cycle For major Bought out items such as plates,Pipes,Forgings, Tube sheet, Girth flanges and Fittings only as per Clause No.5.0(Inspection and Testing) of 00774 -91-SP-0610-02 Rev.0 4) Inspection of major bought out items like Plates, Tube sheet, Girth flanges and Fittings shall be c arried out at sub vendor's work under TPIA 5) UT after PWHT required where thickness of butt weld is 50 mm (for CS) and 38mm (for SS). er , a r n es s o a se m e a , w e m e a s a e c ec e a x. e xc ep e xc a ng er u n e r s er v c es o r s er v c e, a r n es s s a e a x. 7) For Tag NO. E-01A/B. E-05A/B/C, E-06 & E-08, The Tests specimen, subjected to anticipated heat treatment cycle, are taken through the thickness and the said reduction shall not be less than35% of the initial cross section as pe ASTM A770 8) NDE Shall be performed as per Approved NDE MAP. 9) All areas where temporary attachment was welded and removed s hall be examined by MT or PT. 10) Chloride content of water used for Hydro test s hall have <100ppm for CS/LAS material and <30 ppm for austenitic stainless material. 11) Inspection Requirements of Appendix-B of E-102 shall be followed as applicable. Main dimensions of HE shall be checked after PWHT 12) welding surface shall be inspected by PT after hydrostatic test for all SS HE's and CS HE's ( base metal thk>38 mm or 100% RT is specified) HOLD -H : MANDATORY INSPECTION POINT WORK SHALL NOT PROCEED FURTHER WITHOUT THE PRESENCE OF THE REPRESENTATIVE OF THE TPI. WITNESS-W :I NSPECTION POINT OF THE HDO-QC IN CASE THE REPRESENTATIVE OF THE TPI DOES NOT ATTEND WITHIN AGREED PERIOD. REVIEW-R : THE ENTAILS REVIEW OF APPROPRIATE DOCUMENTATION. LEGENDS :
H - HOLD W - WITNESS
H.T. - HEAT TREATMENT R.T. - RADIOGRAPHIC TEST
R - REVIEW A - APPROVAL
U.T. - ULTRASONIC TEST T.C. - TEST CERTIFICATES
R/W - REVIEW OR WITNESS RW - RANDOM WITNESS TPIA - THIRD PARTY INSPECTION AGENCY
PREPARED BY
REVIEWED BY
APPROVED BY
P.V.CHAUDHARI SR. ENGINEER (HDO, A'BAD)
R.R.SHARMA SR. MANAGER (Q.C.) HDO, A'BAD
TECHNIP
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