08. Sample ITP Boiler

DOCUMENT TITLE :

3/10/2012 0

DOCUMENT NUMBER : SHT. 1 OF 6 REV.

ORIGINATOR:

Descon PROJECT :

Descon Engineering FZE

DATE REV.NO. DESCRIPTION

PROJECT :

INSPECTION AND TEST PLAN

RM

Des-XXXX-QA&QC-01

Issued for Client Review / Comments

0

SK SK

PREPARED BY CHECKED BY APPROVED BY

PO No.:

1

1.1 PIM Agenda H

1.2 ITP & Applicable Code H

1.3 ASME Sec.1 H

1.4 ASME IX, B31.1 , H

1.5 ASME IX H

1.6 ASME Sec.V H

1.7 ASME Sec.VIII Div.1 & Sec.I H

1.8 ASME Sec.VIII Div.1 & Sec.I H

1.9 ASTM / SSPC / Swedish H

1.10 Certificates / SNT-TC-1A H

2

2.1 Drawings/ P.O/ ASME Sec.II Part A H

2.2 Drawings/ P.O/ ASME Sec.II Part A H

3

3.1 ASME Sec.VIII Div.1+ DWG H

Material Inspection / Verification / Certificate review QC Material Inspector

Inspection of Dish End QC Material Inspector

Material inspection report / MTC'S

Controlling of Heat Number and stamp transfer for pressure parts and those which are directly weld with pressure parts / Traceability check

QC Material Inspector Material traceability report / MTC'S

End User

DESCON DOC No.:

Coating Inspector

DOCUMENTATION

INSPECTION BY

DES-PROP-QA&QC-01

DES-QA&QC/FRM-40

QC Engineer

QC Engineer

Welding Engineer

MATERIAL CONTROL

STATUS SIGN SIGN

QC ACTIVITY

STATUS

JZNOBO (CE Marking)

STATUS

Weld Repair Proceudre

SIGNATURE

DESCON PROJECT No.:

SIGN

Hydrostatic and Pneumatic test procedure

PROJECT

COMPANY DOC No:

ASME Authorized Inspector

COMPANY

DES-PROP-QA&QC-01

ITEM TAG

REFERENCE DOCUMENTS / ACCEPTANCE CRITERIA

PREPARED BY

SAKET KUMAR

VERIFYING DOCUMENT

STATUSSIGNSTATUS SIGN

Welding Book

DESCON ENGINEERING FZE

CLIENT

MANUFACTURER

INSPECTION AND TEST PLAN (ITP)

RASHID MAHMOOD

DESCON QA/QC

REVIEWED BY

I/C Product Engineering

PRIME RESPONSIBILTY

-

APPROVED BY

LEGEND: H - HOLD, W - WITNESS, SW - SPOT WITNESS, R - REVIEW OF RECORD, RW-RANDOM WITNESS, A - APPROVAL , M - MONITORING

I/C QA&QC Minutes of meeting

Qualification Certificates

DISH END FORMING

NDE Operator Qualification

Surface Preparation & Painting Procedure

ITEM

SAKET KUMAR

Inspection and Test Plan

Welding Book Welding Engineer

S.P & Painting Procedure

Weld Repair Prcoedure

Pre- Inspection Meeting

Drawings and Design Calculations

Welders Qualification Record

NDE Procedures

Approved drawings

QC Engineer

Hydro static and Pneumatic test procedure

RT,MT,UT DPT Procedures

NDE Engineer

QC Engineer

Inspection Report

Doc. No. : DES-QA&QC/FRM-05ARev.: 01Date: April 22, 2010

Do not duplicate. controlled copy if stamped in red.Descon Engineering FZE

2 of 6

End User

INSPECTION BY

STATUS SIGN SIGN

QC ACTIVITY

STATUS

JZNOBO (CE Marking)

STATUS SIGN


REFERENCE DOCUMENTS / ACCEPTANCE CRITERIA VERIFYING DOCUMENT


DESCON QA/QCPRIME RESPONSIBILTYITEM

3.2 ASME Sec.VIII Div.1 + DWG H

3.3 ASME Sec.VIII Div.1 + DWG H

4

4.1

4.2 ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications H

4.3











4.14

4.15


4.17

MUD DRUM

Rolling Inspection

Rolling / Re Rolling of Shell Course

QC Inspector

Marking of tube holes on the shell of Mud Drum

Marking of tube holes on the shell of Steam Drum QC Inspector

Physical verification / Signed ITP for recordQC Inspector

QC Inspector Physical verification / Signed ITP for record

Physical verification / Signed ITP for record

QC Inspector


Fit up of Tubes with Steam Drum Shell

Fit up Inspection


Nozzles and Stubs Fit-up


Tubes Expansion report

LS and CS Fit-up of shell course. QC Inspector



QC Inspector

Rolling Inspection

FABRICATION

Thickness Check of Head QC Material Inspector Thickness Report

QC Material Inspector MT ReportMT on Knuckle radius

Holes drilling in Steam Drum and Mud Drum

Insertion of Tubes in Tube Holes in the Shell of Steam Drum and Mud Drum


QC Inspector

STEAM DRUM


Fit up of Tubes with Mud Drum Shell QC Inspector Physical verification / Signed ITP for record

Expansion of tubes


Fit up Inspection

Fit up of Saddles


3 of 6

End User

INSPECTION BY

STATUS SIGN SIGN

QC ACTIVITY

STATUS

JZNOBO (CE Marking)

STATUS SIGN








4.21

4.22


4.24




4.28



4.31 ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V H


4.33



4.36


4.38

SUPER HEATER HEADER

Hydrostatic test of Header as per approved drawing QC Inspector Physical verification / Signed ITP for record

Final Visual and Dimensional inspection of Coil QC Inspector Physical verification / Signed ITP for record

NDE as per apporved drawing QC Inspector Physical verification / Signed ITP for record

Final Visual and Dimensional inspection of Header QC Inspector Physical verification / Signed ITP for record

PIPING SPOOLS

Fit Up Inspection of Piping Spools QC Inspector Physical verification / Signed ITP for record

NDE as per approved Drawings QC Inspector Physical verification / Signed ITP for record


QC Inspector

Final visual and dimensional Inspection of Ladders and Platforms QC Inspector


Nozzles and Stubs Fit-up

FLASH VESSEL

Rolling Inspection


Fit up Inspection

Nozzles and Stubs Fit-up QC Inspector Physical verification / Signed ITP for record



LS and CS Fit-up of shell course.


QC Inspector

Marking of Tube holes on the shell of Steam Drum

QC Inspector

Marking of Tube holes on the shell of Steam Drum QC Inspector Physical verification / Signed ITP for record


LADDERS AND PLATFORMS

LS and CS Fit-up of shell course.

Trial Assembly of Ladders and Platforms


4 of 6

End User

INSPECTION BY

STATUS SIGN SIGN

QC ACTIVITY

STATUS

JZNOBO (CE Marking)

STATUS SIGN






5


6.6 ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications W

6.7 ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications W

6

6.1 PWHT Specification ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications H

6.2 PWHT Report and Graph (Chart) ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications H


7

7.1



7.4 ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications , ASME Sec.V H

7.5 10 % MT of LS & CS weld joints ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V H

7.6 10 % MT on Fillet Welds ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V H


7.8




7.12 10 % MT of LS & CS weld joints ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V H

7.13 10 % MT on Fillet Welds ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications, ASME Sec.V H

WELDING INSPECTION

DES-QA&QC/FRM- 62

NDE Inspector DES-QA&QC/FRM-63 + 62

Complete compliance of approved WPS

PWHT

DES-QA&QC/FRM-74

DES-QA&QC/FRM-56

BEFORE PWHT

DES-QA&QC/FRM-63 + 62


Final weld visual Inspection

Welding Inspector

UT of Nozzle to Shell welds NDE Inspector

RT as per approved Drawings

NDE Inspector DES-QA&QC/FRM- 62

NDE Inspector


AFTER PWHT

10 % MT or PT on all nozzle welds and welded accessories NDE Inspector

NDE Inspector


DES-QA&QC/FRM-62

RT as per approved Drawings NDE Inspector DES-QA&QC/FRM-60

100 % MT on Lifting Lugs100% UT on Lifting Lugs (Full Penetration Joints) NDE Inspector

NDE Inspector

UT of Nozzle to Shell welds


Welding Engineer

Hardness test of welds after PWHT

Welders Qualification Welding Inspector

NDE Inspector DES-QA&QC/FRM-61 + 62

Welding Inspector


Weld visual Inspection report


NDE

MPT / DPT after grinding smooth temporary welds

Welding Engineer

Welding Engineer

Hardness test report

NDE Inspector

NDE as per approved Drawings QC Inspector Physical verification / Signed ITP for record


5 of 6

End User

INSPECTION BY

STATUS SIGN SIGN

QC ACTIVITY

STATUS

JZNOBO (CE Marking)

STATUS SIGN






8





8.5 Verification of Close out of NCR's (if any) ASME Sec.VIII Div.1+Sec.I + DWG + Project Specifications H

8.6 ASME Sec.VIII Div.1 / Sec.I H



9



10

10.1 SSPC / Swedish H

11

11.1 Packing and Shipping Instructions H

11.2 Packing and Shipping Instructions H

11.3 Release Note H

11.4 Final Data Book H

QC Inspector / QA Engineer NDE Summary sheet

DES-QA&QC/FRM-62

Visual Inspection after PWHT QC Inspector Dimensional inspection report

Dimensional inspection reportQC Inspector


100 % MT on Lifting Lugs100% UT on Lifting Lugs (Full Penetration Joints) NDE Inspector

Draining & Drying after Hydrostatic test

NDT Verifications

FINAL INSPECTION

NDE Summary sheet

SURFACE PREPARATION AND PAINTING

Flange Protection inspection Physical verification / Signed ITP for record

MDR


PRE-SHIPMENT INSPECTION AND DOCUMENTATION

Final Coat DFT and Final Colour Check

QC Inspector

Manufacturer data record book

QC Inspector

QC Inspector

Inspection of packing of shipment QC Inspector

Final Data Book

Stamping & Attachment of name plate QC Inspector Name plate copy

Signing of Manufacturer Data Report

IRCIssuance of inspection release note QC Inspector

Packing List

Coating Inspector

Leak test on RF Pads QC Inspector

Final visual and dimensional Inspection

DES-QA&QC/FRM-52Hydrostatic testing QC Inspector

NAME PLATE

QC Inspector

Internal Inspection before Hydrostatic test

Painting inspection report

DES-QA&QC/FRM-52

QC Inspector


6 of 6

Documents

08. Sample ITP Boiler