EPCC05_6-3_Constn_QA-QC Rev 0

EPCC-05 : Rehabilitation and Adaptation Process Plants, Utilities, Offsites and Pipelines

Section: VI – 3 Construction 6648-00-19-43-0002 Rev 0

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EPCC05_VI.3_Constn._QA/QC_Rev.0 Copyrights EIL – All rights reserved

N A F T E C . S P A

Project: REHABILITATION AND ADAPTATION PROJECT,

SKIKDA REFINERY, ALGERIA Owner: NAFTEC Spa PMC: Engineers India Limited

Package No.: EPCC-05 Package Title: Rehabilitation and Adaptation Process Plants,

Utilities, Offsites and Pipelines Section: Requirements for quality assurance and

quality control during construction Discipline: Construction

0 30.10.2007 ISSUED FOR FEED

Constn Proj.Rev. No Date Purpose Prepared

by Checked

by Approved by



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INDEX

____________________________________________________________________________ Clause Title Sheet No. N0. ____________________________________________________________________________ 1.0 SCOPE 4 2.0 RESPONSIBILITY 4 3.0 METHODOLOGY 3.1 PROCUREMENT OF MATERIALS REQUIRED 4 FOR THE CONSTRUCTION WORKS 3.2 EXECUTION OF WORKS 4 3.3 QA/ QC AUDITS 7 4.0 DOCUMENTATION AND RECORDS 7

DOCUMENT NO.

INDICATIVE INSPECTION & TEST PLANS 6648-00-19-43-2000 FOR CONSTRUCTION WORKS (pl. refer index on page

2 of 3 for document no. of disciplinewise ITPs)

INDICATIVE FORMATS FOR REPORTING 6648-00-19-43-5000 INSPECTION & TEST RESULTS (pl. refer index on page

2 of 2 for document no. of disciplinewise Formats)

REQUIREMENTS FOR POSITIVE MATERIAL 6648-00-19-43-9001 IDENTIFICATION (PMI) AT CONSTRUCTION SITES



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Abbreviations: ITP : Inspection & Test Plan PMC : Project Management Consultant QA/QC : Quality Assurance/ Quality Control



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1.0 SCOPE

This document shall be applicable to all construction works to be executed by EPCC CONTRACTORs.

2.0 RESPONSIBILITY

It is EPCC CONTRACTOR's prime responsibility to arrange/produce the product conforming to contract specifications and inspect all equipment, materials and works at various stages of execution as per the approved QA Plans. In addition, they have to coordinate all efforts in this regard directly with the OWNER/ PMC and other involved agencies to give adequate confidence that the activities are performed as per agreed ITPs and necessary documentation is available. Verification by Owner/PMC or his representative at any stage shall not relieve EPCC CONTRACTOR of his responsibility towards quality of the product. The EPCC CONTRACTOR shall comply with all statutory rules & regulations in force during execution of work and interface with such authorities as required (refer Section-XVIII for details).

3.0 METHODOLOGY

The management of construction quality control is divided into the following categories:- (1) Procurement of materials required for the construction work. (2) Execution of work (3) QA/QC Audits 3.1 Procurement of Materials Required for the Construction Work

The EPCC CONTRACTOR shall develop list(s) defining the items to be procured along with proposed Vendors for approval of the Owner/PMC. The list shall comprise of all items except vessels, equipments, pumps, electrical/ instrumentation panels etc. which may be available directly ready for installation or requiring small fabrication as per requirement. The vendor list shall be in line with the contract document. In case, no vendor list exists in the contract for a particular item, the EPCC CONTRACTOR shall propose a list of Vendors to Owner/PMC. EPCC CONTRACTOR has to satisfy himself with the capability of the vendor to deliver the product in time with quality before proposing him as a prospective vendor. EPCC CONTRACTOR shall submit the QA/QC plans for all major items and carry out their procurement in line with the approved plans. The EPCC CONTRACTOR can either provide his own adequate qualified staff for inspection or employ a separate third-party inspection agency with prior approval to carry out these functions. Involvement of OWNER/ PMC in the quality control plan, if required, shall be defined during approval of the same.

3.2 Execution of Work

(i) The QA plans for execution shall be developed by the EPCC CONTRACTOR. OWNER/ PMC’s approval for the same shall be taken well before start of the work. The final Inspection & Test Plans (ITPs) and formats, based on the indicative ITPs and Formats enclosed in document Nos. 6648-00-19-43-2000 and 6648- 00- 19- 43- 5000 respectively, shall be developed by the EPCC



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CONTRACTOR as per contract specifications for approval by OWNER/ PMC.

For the activities which are identified as Witness or Hold Point, specific inspection call shall be raised by the EPCC CONTRACTOR with OWNER/ PMC in the requisite format well in advance. The indicative ITPs and Formats enclosed in the feed package are for guidance to the EPCC CONTRACTOR and may not cover some of the activities to be performed during execution of works under the scope of this contract. The EPCC CONTRACTOR shall develop Inspection & Test Plans and Formats for all such activities also and submit the same to OWNER/ PMC for approval, before actually undertaking such activities.

EPCC CONTRACTOR shall be completely responsible for management of

approved quality plans and OWNER/PMC involvement will be only of Surveillance in nature to randomly check the works at selective/critical junctures. Their role shall be to monitor that the EPCC CONTRACTOR is executing the quality plans as per the approved drawings, employing adequately qualified staff and other resources for various items of works. Any deviation to the specifications shall be brought to the notice of OWNER/ PMC in prescribed formats by EPCC CONTRACTOR for approval.

(ii) It is likely that the EPCC CONTRACTOR may engage sub-contractor(s)/vendors

for performance of the work. EPCC CONTRACTOR shall be responsible for ensuring the implementation of approved QA plan, contract specifications and contract conditions through their sub-contractor’s to achieve the quality during all stages of construction. It shall be the responsibility of the EPCC CONTRACTOR to ensure proper coordination between his sub- contractor(s) and other agencies working at site.

The sub-contractor(s)/vendors selection shall be done after evaluation by the

EPCC CONTRACTOR inline with contract requirements and shall be got approved by Owner/PMC before engaging them for the works.

(iv) Storage All the materials procured shall be stored/stacked as per the standard norms and

as recommended in various clauses of relevant codes and contract document. The storage of material shall be such as to avoid damage to life/properties (physical and chemical) of the materials. The storage shall not cause deterioration, rusting, mix-up etc. and hamper the other related works in any way. EPCC CONTRACTOR shall submit his detailed warehouse plan for OWNER/ PMC approval to manage the above in open/covered areas.

The materials susceptible to fire shall be kept away in a separate protected

place. In general, the materials shall be kept systematically in order of their class, batch

number and identification number, so that they are accessible for the inspection by OWNER/ PMC whenever required and to avoid the mix up in those materials.



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(v) Use The materials shall be stacked in such a way that the lot, which is procured first,

will be consumed first. For materials which are having specific expiry date/ shelf life shall not be used beyond that date and shall be removed from site. Wherever there is any doubt about the change in properties of the materials, such materials shall be sent to reputed approved laboratory for testing and acceptance.

(vi) Inspection The EPCC CONTRACTOR shall be responsible for carrying out inspection of the

materials brought at site and conducting tests/ checks (at site or in approved laboratories) at predefined frequencies as per contract. It is the responsibility of the EPCC CONTRACTOR to ensure that the materials used at site shall conform to relevant codes/ standards and Manufacturer Test Certificates are available for correlation as and when required. The EPCC CONTRACTOR shall maintain the records of all materials brought at site and tests conducted on them.

(vii) In process and final Inspection EPCC CONTRACTOR shall be responsible to arrange verification of products

during in- process and final inspection. Relevant checks and tests shall be arranged for the works performed and records maintained. Tolerances achieved with respect to contract specification and execution drawings for various activities/processes shall be ascertained and submitted to OWNER/ PMC for approval. Efforts shall be made to keep checks and controls in such a way that a non-conforming product is avoided. However, if in an isolated case, the tolerances are beyond the acceptable values given in the contract/execution drawings/codes, non-conformance resolution/Deviation permit need to be raised by the EPCC CONTRACTOR and got approved/resolved from OWNER/ PMC.

The EPCC CONTRACTOR shall arrange verification of ingredients used and

validation of the software used at the batching plant(s). OWNER/ PMC reserve the right to inspect the working of batching plant including validation of the software used and calibration of measuring & monitoring devices any time. The EPCC CONTRACTOR shall ensure the quality of the concrete delivered by the transit mixers, as applicable and maintain verifiable records.

EPCC CONTRACTOR shall mobilize Portable Alloy Analyser(s) with printout

facility and carry out 'Positive Material Identification (PMI)' of materials and welds after erection/installation but prior to hydro-testing (refer document No.6648-00-19-43-9001). Any non-conformance detected shall be removed and replaced prior to final hydro testing.

The EPCC CONTRACTOR shall develop colour coding scheme of piping materials to avoid mixing up of material at different stages of construction and submit it to OWNER/PMC for approval.



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3.3 QA/QC Audits

During the execution of the works, EPCC CONTRACTOR shall carry out periodical Quality Audits at least quarterly in all areas of work. These audits will be conducted by a team of specialists in the respective areas. The auditors shall not be directly involved in the jobs being audited. The EPCC CONTRACTOR shall prepare an Audit Plan and Procedure and submit the same to OWNER/ PMC for approval. A copy of the Audit Report containing the findings of the Audit team will be submitted to OWNER/ PMC. After completion of rectification/modifications/corrective actions on the issues indicated in Audit Report, Compliance Report shall be submitted by the EPCC CONTRACTOR to OWNER/ PMC for review. Over and above the EPCC Contractor’s Internal QA/QC Audits outlined above, OWNER/ PMC shall also reserve the right to conduct QA/QC audits at the frequency decided by them.. EPCC CONTRACTOR shall participate and provide full support to the Audit Team and furnish all documents/reports/records as desired by the Audit Team. The EPCC CONTRACTOR shall take all actions required to comply with the findings of the Audit Report and issue regular Compliance Reports for the same to OWNER/ PMC till all the findings of the Audit Report are fully complied. In case major Non conformities are observed during execution of the works OWNER/ PMC reserve the right to appoint an independent person/Third Party Agency to conduct QA/QC Systems Audit for full/part of the facilities being executed by the EPCC CONTRACTOR. This audit will be in addition to the audits described above and may be carried out intermittently/continuously for all or part of the facilities being executed by the EPCC CONTRACTOR. EPCC CONTRACTOR shall bear the total cost of such audits and shall participate & provide full support to the Audit Team and ensure compliance of the audit observations.

4.0 DOCUMENTATION AND RECORDS

All the necessary documentation & records shall be maintained by EPCC CONTRACTOR till completion of project and handed over to OWNER/ PMC in requisite copies as a part of completion documents. Wherever OWNER/ PMC personnel were directly involved particularly in witness and hold point, the copies of the records shall also be provided to personnel on completing inspection of those activities. The documentation & records shall include the following as a minimum but not limited to:

i) Approved Quality Assurance Plan ii) Approved Inspection and Test Plans iii) Inspection and test documents covering

a) Manufacturer Test Certificate b) Material Receipt Report including Inspection Release Note, if applicable

and Site Inspection and acceptance Report on quality and quantity of material



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c) Site test/laboratory test Report reviewed by EPCC CONTRACTOR for

acceptance vis-à-vis to contract/code requirements for materials/including PMI report at warehouse

d) In process Verification reports of EPCC CONTRACTOR representative

and OWNER/ PMC as applicable e) Final verification report including any test checks done for compliance f) As-built vis-à-vis to contract/drawings including tolerances g) As-built for erection h) Non conformance resolution raised by EPCC CONTRACTOR/OWNER/

PMC i) Concession/Deviation approval by OWNER/ PMC j) Change order approval by OWNER/ PMC incase there is variation from

contract k) QA/QC Audit Reports and compliance Reports thereof l) Mechanical Completion formats



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N A F T E C . S P A

INDICATIVE

INSPECTION & TEST PLAN (ITP)

FOR

CONSTRUCTION WORKS



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N A F T E C . S P A

INDEX

S.NO

DESCRIPTION DOCUMENT NO. REV.

1. Indicative Inspection & Test Plans for Mechanical works 6648-00-19-43-2100 0

2 Indicative Inspection & Test Plans for General works 6648-00-19-43-2500 0

3 Indicative Inspection & Test Plans for Instrumentation works 6648-00-19-43-2600 0

4. Indicative Inspection & Test Plans for Civil works 6648-00-19-43-2700 0

5. Indicative Inspection & Test Plans for Electrical works 6648-00-19-43-2800 0

6. Indicative Inspection & Test Plans for Pipeline works 6648-00-19-43-2900 0



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GENERAL NOTE The enclosed indicative ITPs shall be used as a basis for developing ITPs for specific jobs/ activities to be executed by the EPCC CONTRACTOR. EPCC CONTRACTOR shall obtain OWNER/PMC’s approval on all such finalized ITPs. The provisions indicated for stagewise inspection by OWNER/ PMC are the minimum and the OWNER/ PMC may decide to increase Hold Points/ Witness Points. Activities for which ITP's are not given, EPCC CONTRACTOR to develop and get the same approved by OWNER/ PMC well before start of the work. EPCC CONTRACTOR to submit required reporting formats and job procedures for each activity listed in ITP's and submit to OWNER/ PMC for approval, well before commencement of the activity. If the EPCC CONTRACTOR has to deviate from the given ITP for a valid reason, he shall obtain prior written approval of OWNER/ PMC. EPCC CONTRACTOR to carry out 100% examination of all activities.

LEGEND HP : Hold Point ;

A point which requires inspection/verification and acceptance by OWNER/ PMC before any further processing is permitted. The EPCC CONTRACTOR shall not process the activity/item beyond a Hold Point without written approval by OWNER/ PMC except where prior written permission for further processing is available.

W : Witness Point ; An activity which requires witnessing by OWNER/ PMC when the activity is performed. After proper notification has been provided (notification modalities and period shall be finalized before hand), the EPCC CONTRACTOR is not obliged to hold further processing if OWNER/ PMC is not available to witness the activity or does not provide comments before the date notified. Basis of acceptance shall be as per relevant technical specification.

Rw : Review of EPCC CONTRACTOR’s documentation.

S : Surveillance Inspection by OWNER/ PMC.

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, personnel qualifications, etc.

WC : 100% Examination by EPCC CONTRACTOR.

Responsibility for execution of the inspection/testing is with the EPCC CONTRACTOR; OWNER/ PMC only verifies examination or testing done by the EPCC CONTRACTOR at important stages


Section: VI – 3 Construction 6648-00-19-43-2100 Rev. 0

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N A F T E C . S P A

INDICATIVE INSPECTION & TEST PLAN (ITP)

MECHANICAL WORKS



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INDEX

S.NO

DESCRIPTION

DOCUMENT NO.

REV.

MECHANICAL WORKS

1. Above Ground Piping 6648-00-19-43-2110 0

2. Tie-In 6648-00-19-43-2111 0

3. Column Internals 6648-00-19-43-2120 0

4. Fired Heaters 6648-00-19-43-2130 0

5. Refractory & Insulation Works- Fired Heaters 6648-00-19-43-2140 0

6. Equipment Erection (Static) 6648-00-19-43-2150 0

7. Equipment Erection (Rotary) 6648-00-19-43-2160 0

8. Storage Tanks 6648-00-19-43-2180 0



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INDICATIVE ITP FOR ABOVE GROUND PIPING

SL. NO

ACTIVITY EPCC CONTRACTOR

OWNER/ PMC

A.

PRIOR TO FABRICATION

1.

Incoming Material

a) Documents (MRIR etc.): Review & acceptance

WC

HP

b) Physical verification

WC

W

2.

Welding Filler Material Approval/Qualification a) Review of Manufacturer’s Test Certificates/Documents & Sampling b) Laboratory Testing, if any i) Carbon Steel ii) All other materials

WC*

WC WC

HP*

Rw W

3.

WPS/PQR a) Review of proposed procedure b) Welding of Test Coupens and subsequent testing i) Carbon Steel, Stainless Steel (type 304) ii) All other materials c) Approval of final WPS/PQR.

WC

WC WC WC

HP

Rw W

HP

4. 4a.

Welder performance Qualification Certification & approval of welders.

WC

WC

S

HP 5.

NDT Procedure Qualification i) Review of proposed procedure ii) Witnessing of Proposed Procedure Testing iii) Approval of Qualified Procedure

WC WC WC

HP W HP

6.

Review of Joint numbering Procedure numbering in Isometrics (Big & Small bore)/Sketches

WC

HP

7 . Material traceability & Transfer of Heat Nos. (material traceability not mandatory for utility piping)

WC

S

* Notwithstanding any other tests/documentation required for qualification/approval of filler metals : i) For Alloy Steel & Stainless Steel welding filler metals, chemical analysis to be carried out for every

batch. For NACE filler metals, corrosion tests like HIC, SSCC, etc. to be carried out for every batch. However, HIC/SSCC tests done earlier & duly witnessed by a reputed third party, will be acceptable.

Pl. refer document No. 6648-00-19-43-2000 for definition of WC, Rw, HP, W and S



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SL. NO.


OWNER/ PMC

B. 1. 2. 3. 4. 5. 6. 7. 8. 9. 9a. 10. 11. 12. 13.

FABRICATION (SHOP & FIELD) Material as per piping class (check w.r.t. approved colour coding procedure), Fit-up check and Traceability check Pre-heat (if any) Certificate of purity of purging/shielding Gas (if any) Purging rate (if any) and arrangement Shielding rate (if any) Baking of Electrodes Inter-pass cleaning & Temperature check. Visual Examination of completed welds Monitoring of PWHT Cycle Review of Time – Temperature graph i) CS ii) AS Hardness Check PT/MT Identification of Joints for Radiography (for Random Radiography only) Review of Radiographs interpreted by the EPCC Contractor i) For Carbon Steel Piping, SS Piping(type 304) ii) All other materials

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC WC

WC

WC

WC

WC WC

S

S

S

Rw

S

S

S

S

S

S W

S

S

S

S W




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N A F T E C . S P A

SL. NO.


OWNER/ PMC

C 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

PROOF TESTING (See enclosed checklist in Annex-1) Procedure Review Preparation of Punch list (Ref. Annex-3) Review of Punch List Liquidation of check list, if applicable Correctness of Testing arrangements Scrutiny of test packs for Mechanical & NDT Clearance Positive Material Identification as per specification after completion of installation. a) Review of Calibration certificates of pressure Gaugesb) Field Calibration, if any Air/Water Flushing (preliminary) Visual inspection of all weld joints for leak during Pneumatic/ Hydrotesting (See Annex-2)

a) Category 'D' services b) All other services

Draining of Water & Air Drying Removal of temporary blinds/supports.

WC

WC

WC

WC

WC

WC

WC

WC WC

WC

WC WC

WC

WC

HP

S

HP

HP

S

HP

S

HP S

S

S W

S

S




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SL. NO.


OWNER/ PMC

13. 14. 15.

Boxing up including reinstallation of flappers of check valves Review of Records of fasteners & gaskets Torque tightening/ tensioning of flange joints, wherever applicable INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

WC

WC

WC

WC

S

S

S

Rw

For liquidation of Punch list, see Annex - 3 Note : Pre-commissioning activities such as chemical cleaning, card board blasting, system testing

are not covered by these ITP's. The EPCC Contractor shall develop ITP's for such activities and obtain Owner/ PMC/ Licensor's approval.

A/G Above Ground NDT Non Destructive Testing AS Alloy Steel i.e. Cr-Mo steels like A335

Gr P11, P5, P9,P22,etc NRV Non Return Valve

CS Carbon Steel PMI Positive Material Identification CSO Car Seal Open PQR Procedure Qualification Record GAD General Arrangement Drawings PT Penetrant Testing HIC Hydrogen Induced Cracking PWHT Post Weld Heat Treatment LO/ LC Lock Open/ Lock Close RF Reinforcement MT Magnetic Particle Testing SS Stainless Steel like A312 TP 304, 316,

321, 304L, 316L, 316Mo, etc. SSCC Sulphide Stress Corrosion Cracking NACE National Association of Corrosion

Engineers WPS Welding Procedure Specification




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ANNEX – 1 Checklist for Mechanical Clearance - A/G Piping

Project : ___________________________ Plant/Unit : _________________________ EPCC Contractor : _________________ Loop No : _________________________

Report No : ____________________________ Date : ________________________________ Area : ________________________________ INCH MTR : __________________________

Line No (Isometric No.) Rev. GAD No. Rev. P&ID No. Rev. Items to be checked Accept Remarks EPCC

Contractor

1. Installation checked as per Isometric w.r.t. CONFIGURATION : Route, plumb, elevation, Clearance for thermal expansion/ insulation BRANCH : Location, angle, orientation, type, RF pad, etc. STEAM TRAP : Direction

2. Installation checked as per GAD w.r.t. CONFIGURATION : Route, clearance for thermal expansion/insulation

3. Installation checked as per P&ID 4. Isometrics completed for ( enclosed ): a. Joint Numbering (Shop & Field Welds) b. Spool Numbering c. As-built routing & dimensions 5. Valves(Check Rating, Gaskets, Flow

Direction, Sheet No., Tag No., Spindle direction, CSO LO/LC, Damage, etc)

Nos

Gate Valves Globe Valves Check Valves Control Valves Tag Nos.: Safety Valves Tag Nos.: Any other valves : 6. Strainers : Check for clearance, flow

direction, elements

FORMAT NO: ____________________ ( Sht 1/4 )



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Checklist for Mechanical Clearance - A/G Piping

Item to check Accept Remarks EPCC

Contractor

7. Flanged Joints Total Nos. Check for type of flange Check for Rating Check for Alignment, (proper gap & parallelity Check for Correct Studs & 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 8. Seal Welding of Screwed Connections (if Required) 9. Vents/Drains as per Dwg and Provision of additional high

point Vents and/or low point Drains, if reqd.

10. Reinforcement pads as per piping class 11. Orifice Flanges : Check for Tag No., tapping orientation, tap valve, jack

screw, straight run length of upstream & downstream

12. Local Gauges : Check for accessibility 13. Slope (When Applicable) 14. Supports a) Guides, Cross Guides, Trunnion, etc. i) Check for correct type, material & 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 & Inserts with Anchor Fasteners : i) Check for members dimensions and materials ii) Check for welding iii) Check for bolting iv) Check for appearance/ damage

FORMAT NO: ____________________ ( Sht 2/4 )



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Contractor

15. Vents/ Drains : - As per drg. - Orientation of valve handles - Clearance for hose - Requirement of additional vents/ drains (highest/lowest pt.) 16. Earthings : a) Check for location b) Check for dimension of lug welding 17. Joists History sheets enclosed for : 17.1 Material Traceability as per Procedure No:__________

(refer enclosed suggested Format)

17.2 Fit ups checked 17.3 NDT Complete (Radiography, MT, PT) 17.4 Stress Relieving & Hardness check complete 17.5 Positive Material Identification (PMI) 18. Checked for Removal/Blinding-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` 20. Checked Installation of (Indicate Location in Drawings) a. Temporary Blinds/Spades b. Temporary Strainers c. Temporary Dummy-Spools d. Temporary Gaskets e. Others 21. Expansion Bellows - a) Checks prior to installations - Physical damages - Transit locks are intact - Dimensions as per drgs. b) Check during installation - Parallelity of mating flanges - Face to face dimension of mating flanges - Concentricity of mating flanges - No stress on expansion bellows - Record

FORMAT NO: ____________________ ( Sht 3/4 )



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Contractor

c) Isolation during pressure tests - Bellow mfg. recommendations on isolation of

bellow during pr. Test to be followed

- If recommended expn. bellow to be dropped during pr. test.

22. Cleanliness Internally and Externally 23. Rotating Equipment Final Alignment Checked with

piping

24. Removal of unwanted construction supports 25. Instrument tapings 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 Reviewed by EPCC Contractor (one level higher than the checker) Name : Designation : Date :

OWNER/ PMC Sign : Date : Name : Designation :

FORMAT NO: ____________________ ( Sht 4/4 )



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ANNEX – 2

Piping Hydro Test Release Record – A/G Piping

Project : ______________________________ Plan : ________________________________ EPCC Contractor : ___________________ Loop No : ____________________________

Report No : __________________________ Date : _______________________________ Area : _______________________________ REF P & ID No. : _____________________ INCH MTR : _________________________ From ________________ To _____________

Line No. (s) Isometric No. (s) P&ID No. (s) Test Medium : Test Duration : Design/Test Pressure :

Test Pressure Gauge No.

Range Calibration Certificate No.: Gauge Calibration Date:

Items to check Accept Witness EPCC

Contractor OWNER

/ PMC

Field Installation Checklist Prior to Hydro-test Signed Punch list Prepared Yes No Pre – Hydrotest Punch items Cleared Accessibility to Inspection/Witness Locations Capacity of pressurizing 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 : EPCC Contractor :

OWNER/ PMC:

Sign : Name : Sign : Name : Date : Date : Designation : Designation:

FORMAT NO: ____________________ ( Sht 1/2 )



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N A F T E C . S P A

Piping Hydro Test Record – A/G Piping

ACTIVITY Date Time Water Filling and Venting started at Water Filling Completed Vents Closed Isolation of Pressurizing pump Test completed at : - Water drained - Air - Temp Blinds Removed - Checked for reinstallation of

a. Control & Safety vales b. On line Instruments c. Rupture disks d. Deblinding e. Others

- Cold setting of spring supports carried out - Test Result Acceptable Not Acceptable EPCC Contractor :

OWNER/ PMC :

Sign :

Sign:

Date : Date: Name : Designation Name: Designation:

FORMAT NO: ____________________ ( Sht 2/2 )



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N A F T E C . S P A

ANNEX - 3

Punchlist

Project : _____________________________ Plan : _______________________________ EPCC Contractor : ___________________ Loop No : ___________________________

Report No : ___________________________ Date : ________________________________ Area : ________________________________ REF P & ID No. : _______________________

Description : _________________________________________________________________ Ref Document : _______________________________________________________________ ____________________________________________________________________________ Punch Item No.

Pri-ority

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 start up 4. Needed for plant acceptance EPCC Contractor : OWNER/ PMC : Sign : Sign : Date : Date : Name : Designation : Name : Designation :

FORMAT NO: ____________________ Sh. 1/1



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N A F T E C . S P A

INDICATIVE ITP FOR TIE-IN

Sl. No. Activity EPCC

Contractor Owner/

PMC

1 Bevel/Thickness WC HP

2. Fit up WC HP

3 Root run welding WC HP

4 DP check of root run WC HP

5. Final Welding WC HP

6. PWHT (if applicable) WC HP

7. DP check of final welding WC HP

8 Radiography check WC HP

9. Hydrostatic test (if applicable) WC HP

INSPECTION & TEST DOCUMENTS

Review Test and Inspection Documents

WC

Rw




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N A F T E C . S P A

INDICATIVE ITP FOR COLUMN INTERNALS

SL. NO. ACTIVITY EPCC

CONTRACTOR OWNER/

PMC INSTALLATION OF COLUMN INTERNALS A. 1. 2. 3. 4. 5. B. 1. 2. 3. 4.

Before Installation Internal Installation Procedure including identification of confined space hazards & mitigation thereof Material inspection a) Review of Manufacturer’s Test Certificates/ TPI Inspection Release Note b) Positive Material Identification, if required in Field Level check on TSRs Check for downcomer clearance and Tray clearance Distance between TSRs After Installation Check for Exit weir height UDFC Tightness of bolts Orientation and tightness of clamps

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

Rw

HP

HP

S

S

S

S

S

S

S




Page 2 of 2


N A F T E C . S P A

SL. NO ACTIVITY EPCC

CONTRACTOR OWNER/

PMC 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Provision of lock nuts/seal plates Correctness of installation of shimming/bolting for top downcomer Correctness of gasketing (if any) Tray to tray distance and level of trays Leak testing of seal pans as applicable Damaged, missing valves and valve movements for valve trays Fitting of proper valve combination Damage to deck components Level and alignment of inlet weir and exit weir Check for slots on tray components to be fully covered Gaps at downcomer ends Removal of temporary plugs after testing Cleaning of all trays & inside of equipment Certification of installation by Vendor’s representative Final boxing up, if any INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC*

WC*

WC

S

S

S

S

S

S

S

S

S

S

S

S

S

HP

HP**

Rw

* Vendor Representative to Check 100% ** By Owner/ Process Licensor




Page 1 of 4


N A F T E C . S P A

INDICATIVE ITP FOR

FIRED HEATERS


CONTRACTOR OWNER/

PMC A. 1. 2. 3. 4. 5. 6. 7. B. 1. 2. 3.

PRIOR TO FABRICATION Incoming Material: a) Documents: Review & acceptance b) Physical verification Welding Filler Material Approval/Qualification a) Review of Manufacturer's Test Certificate/Documents b) Laboratory testing, if any i) Carbon Steel ii) Alloy Steel/Stainless Steel WPS/PQR a) Review of proposed Procedure b) Welding of Test Coupens and subsequent testing c) Approval of final WPS/PQR Welder performance Qualification Test Certification & Approval of welders before deployment on job NDT Procedure Qualification i) Review of proposed Procedure ii) Witnessing of Proposed Procedure Testing iii) Approval of Qualified Procedure Joint Numbering for coils/ pressure parts FABRICATION STEEL WORK Materials as per AFC drawing Dimensional check Fit-up check

WC WC

WC

WC WC

WC

WC

WC

WC

WC

WC WC WC

WC

WC

WC

WC

HP W

HP*

Rw W

HP

W

HP

S

HP

HP W HP

S

S

S

S




Page 2 of 4


N A F T E C . S P A


CONTRACTOR OWNER/

PMC 4. 5. 1. 1a. 1b. 1c. 2. 3. 4. 5. 6. 7. 8. 9. 9a. 10. 11. 12.

Radiography, as applicable a) RT Marking (for random/spot radiography only) b) RT Interpretation Completion of structures as per AFC drawings COIL WORK Material as per specification (check w.r.t. approved colour coding procedure) and traceability Dimensional checks Fit-up check for butt joints and socket joints Fit-up checks for branch joints Pre-heat (if any) Certificate of purity of purging/shielding Gas (if any) Purging rate (if any) and arrangement Shielding rate (if any) Baking of Electrodes Inter-pass cleaning & Temperature check.

Visual check of completed welds having

- Random Radiography - 100% Radiography

Monitoring of PWHT Cycle Review of Time – Temperature graph Hardness Check (i) For C.S. Coils (ii) For A.S. Coils (iii) For Heater coils of A.S. material PT/MT Radiography marking (for Random Radiography only)

WC WC

WC

WC

WC WC WC

WC

WC

WC

WC

WC

WC

WC WC

WC

WC

WC WC WC

WC

WC

S S

W

W

S S S

S

S

S

S

S

S

S S

S

W

S S W

W

S




Page 3 of 4


N A F T E C . S P A


CONTRACTOR OWNER/

PMC 13. 14. 15. 16. 17. C. 1. 2. 3. 4. 5. 6. 7. 8. 9.

Radiography Interpretation/ Review i) For Carbon Steel and SS304 coils ii) For Alloy Steel and other SS Check Shot for Radiography Clearance for Hydrostatic testing Positive Material Identification, as applicable Hydrostatic testing ERECTION Review of foundation check as per AFC drawing Lifting of radiant section columns and their alignment Bottom plate fit-up & welding Radiant shell courses fit-up and welding Weld visual inspection Review of radiographs interpreted by the EPCC Contractors Cutout a) Marking for burners, sight doors, soot blowers b) Marking for balance cut outs c) Cutting

Coil erection in Radiant section a) Fixing of coil support castings b) Clearance for erection of coil c) Alignment of completed coil work

Assembly and erection of convection box a) Erection Procedure review b) Structural including plate work c) End tube sheets and intermediate tube sheets with support brackets d) Clearance of coil erection e) Erection of box (if applicable)

WC WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC WC WC

WC WC WC

WC WC WC

WC WC

S W

W

HP

W

HP

W

S

S

S

S

W

S S S

S W W

S S S

W W




Page 4 of 4


N A F T E C . S P A


CONTRACTOR OWNER/

PMC 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Check Shot for radiography for coil field joints Clearance for Hydrostatic testing Hydrostatic Testing Erection, fit-up & welding of stack i) Erection procedure ii) Erection iii) Alignment Erection Fit-up, welding of ducts and its support structural Radiography, as required on steel work i) RT Marking ii) RT Interpretation FD & ID Fan Installation of auxiliary equipment a) Burner alongwith ignition system and transformer b) Soot blower alongwith sequential control panel and electrical wirings c) Damper with control panel and winch d) Air pre-heater (cast, glass, plate) and steam air heater e) Skin thermocouples Erection of all Platforms, ladders, Hand rails & miscellaneous structures Insulation/ refractory lining Final Painting Liquidation of checklist

Final inspection and acceptance INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

WC

WC

WC

WC WC WC

WC

WC WC

**

WC WC

WC WC WC

WC

WC

#

WC

WC

WC

W

HP

HP

W S W

S

S W

**

W W

W W W

S

S

#

HP

HP

Rw

# as per painting ITP ** as per separate ITP for FD & ID fan




Page 1 of 5


N A F T E C . S P A

INDICATIVE ITP FOR REFRACTORY & INSULATION WORKS-FIRED HEATERS


CONTRACTOR OWNER/

PMC A. 1. 2. 3.

RADIANT SECTION Radiant shell Fixing of Ceramic fibre blanket i) Material inspection - Manufacturing test certificates - Testing, if any ii) Clearance for hot work iii) Marking of studs iv) Welding of studs with approved WPS&PQR v) Surface cleaning vi) Check for individual layers of ceramic fibre blankets and SS foils vii) Check for overlap of ceramic blanket viii) Fixing of speed fix washer and cup lock ix) Cleaning and final inspection Arch Plate i) Material inspection - Manufacturing test certificates - Testing, if any ii) Clearance for hot work iii) Marking of studs/anchors iv) Welding of studs/anchors with approved WPS & PQR v) Surface cleaning vi) Check for individual layers of Ceramic Fibre Blankets (CFB) modules and SS foils vii) Check for overlap of CFB and modules viii) Cleaning and final inspection Floor Plate Laying of castable/fire bricks i) Material inspection - Manufacturing test certificates - Testing, if any

WC WC WC WC WC WC WC

WC WC WC


WC WC

WC WC

Rw W W S S S W

S S

HP

Rw W W S S S S

S HP

Rw W




Page 2 of 5


N A F T E C . S P A


CONTRACTOR OWNER/

PMC B.

ii) Clearance for hot work iii) Surface cleaning iv) Check Shelf life prior to application v) Check for undulations on floor vi) Check for castable mix vii) Check for proper compaction viii) Check for thickness of castable ix) Curing x) Cleaning after laying of castable xi) Check for cracks and repair xii) Fixing of tar paper, if applicable xiii) Cleaning and final inspection CONVECTION SECTION 1) Convection walls Laying of castable i) Material inspection - Manufacturing test certificates - Testing, if any ii) Clearance for hot work iii) Marking of studs/anchors iv) Welding of studs/anchors with approved WPS & PQR v) Surface cleaning vi) Check for undulations on wall vii) Check for castable mixing viii) Check for proper compaction ix) Check for thickness of castable x) Curing xi) Cleaning after laying of castable xii) Check for cracks and repair xiii) Cleaning and final inspection 2) End tubesheets Laying of castable i) Material inspection - Manufacturing test certificates - Testing, if any ii) Clearance for hot work

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

WC WC WC WC WC

WC WC WC WC WC WC WC WC WC

WC WC WC

W S W S W S S S S W S

HP

Rw W W S S

W S W S S S S W HP

Rw W W




Page 3 of 5


N A F T E C . S P A


CONTRACTOR OWNER/

PMC

iii) Marking of studs/anchors iv) Welding of studs/anchors with approved WPR & PQR v) Surface cleaning vi) Check for castable mixing vii) Check for proper compaction viii) Check for thickness of castable ix) Curing x) Cleaning after laying of castable xi) Check for cracks and repair xii) Cleaning and final inspection 3) Breeching Plate Laying of castable i) Material inspection - Manufacturing test certificates - Testing, if any ii) Clearance for hot work iii) Marking of studs/anchors iv) Welding of studs/anchors with approved WPR & PQR v) Surface cleaning vi) Check for undulations on plate vii) Check for castable mixing viii) Check for proper compaction ix) Check for thickness of castable x) Curing xi) Cleaning after laying of castable xii) Check for cracks and repair xiii) Cleaning and final inspection 4) Header box Laying of castable i) Material inspection - Manufacturing test certificates - Testing, if any ii) Clearance for hot work iii) Marking of studs/anchors iv) Welding of studs/anchors with approved WPR & PQR v) Surface cleaning vi) Check for undulations on box

WC WC

WC WC WC WC WC WC WC WC

WC WC WC WC WC


WC WC WC WC WC

WC WC

S S

S W S S S S W HP

Rw W W S S

S S W S S S S W HP

Rw W W S S

S S




Page 4 of 5


N A F T E C . S P A


CONTRACTOR OWNER/

PMC C D

vii) Check for castable mixing viii) Check for proper compaction ix) Check for thickness of castable x) Curing xi) Cleaning after laying of castable xii) Check for cracks and repair xiii) Cleaning and final inspection STACK Laying of castable i) Material inspection - Manufacturing test certificates - Testing, if any ii) Clearance for hot work iii) Marking of studs/anchors iv) Welding of studs/anchors with approved WPR & PQR v) Surface cleaning vi) Check for undulations on stack shell vii) Check for castable mixing viii) Check for proper compaction ix) Check for thickness of castable x) Curing xi) Cleaning after laying of castable xii) Check for cracks and repair xii) Cleaning and final inspection HOT AIR DUCT i) Material inspection - Manufacturing test certificates - Testing, if any ii) Clearance for insulation iii) External Surface cleaning iv) Provide spacer rings/anchors v) Check for thickness of the mineral wool insulation


WC WC WC WC WC


WC WC WC WC WC WC

W S S S S W HP

Rw W W S S

S S W S S S S W HP

Rw W W S S S




Page 5 of 5


N A F T E C . S P A


CONTRACTOR OWNER/

PMC

vi) Check for staggering of joints in insulation vii) Check for providing expansion joints viii) Overlapping of metal sheet as per specification ix) Overlap on joints for aluminium sheeting as per specifications x) Sealing aluminium sheeting Final inspection & acceptance INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

WC WC WC WC

WC

WC

WC

S W S W

S

HP

Rw




Page 1 of 3


N A F T E C . S P A

INDICATIVE ITP FOR

EQUIPMENT ERECTION (STATIC)


CONTRACTOR OWNER/

PMC 1. a. b. c. d. 2. a. 3. a.

BEFORE ERECTION Review of foundation acceptance report Incoming material i) Documents : Review & Acceptance ii) Physical verification, if required Readiness for erection i) Centre line marking on equipment and foundation ii) Level of foundation (shims/ packing with marking

to be prepared & kept ready) iii) Correctness of no. & size of Foundation bolts iv) Hole dia and no. of holes in base/ structure of

equipment columns v) Matching equipment base bolt holes with actual foundation bolt layout vi) Marking orientation vii) Checking the threads of bolts & nuts viii) Chipping & roughening of foundation Outside cleaning, coating/wrapping, painting (for underground equipment only)

ERECTION SCHEMES FOR CRITICAL EQPTS Review of rigging procedure SAFETY TEST Load test of cranes, lifting beams, slings and shackles, length and dia. of sling & condition of wire rope by competent authority

WC

WC WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

Rw

Rw W

S

S

S

S

S

S

S

S

W

HP

Rw




Page 2 of 3


N A F T E C . S P A


CONTRACTOR OWNER/

PMC 4. a. b. c. d. 5.

DURING ERECTION Orientation to be checked Placement of packing as per AFC drg. Placement of Main & trailing crane as per approved rigging procedure Orientation of equipment as per AFC drg. AFTER ERECTION a. Tightening of Bolts and Providing washers b. Leveling and Alignment of equipments. i) Critical equipments/ ODCs ii) Others c. Corresponding requirement elevation & distance between nozzles in special cases. d. Cleaning of Sleeves before grouting e. Grouting i) Acceptance of Specified grouting materials ii) Placement of grouting iii) Curing of grout. f. Final tightening of bolts

WC

WC

WC

WC

WC

WC WC

WC

WC

WC WC WC

WC

S

S

S

S

S

HP W

S

S

HP S S

S




Page 3 of 3


N A F T E C . S P A


Contractor OWNER/

PMC 6.

PACKED EQUIPMENTS 1. Before Installation a. Identify the material, check thickness, dimensions,

no. and angle of fingers of packing rings 2. During Installation a. Degreasing and cleaning of packing material b. Check packing support plate c. Check for stacked or dumped packing as per specifications d. Check for nesting e. Check that packings are touching bed limiter INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

WC

WC

WC

WC

WC

WC

WC

S

S

S

S

S

S

Rw




Page 1 of 3


N A F T E C . S P A

INDICATIVE ITP FOR

EQUIPMENT ERECTION (ROTARY)


CONTRACTOR* OWNER/

PMC 1. 2. 3. 4. 5.

PRE – ERECTION ACTIVITIES a. Review of foundation acceptance report b. Material Supply

- Owner's supply including templates, if any - EPCC Contractor's supply & check testing, if any -

c. Readiness for erection i. Level of foundation (shims/packing with markings to be prepared & kept ready) ii. Marking/Centre line of foundation & equipment iii. No./dia./length of anchor bolts, depth of pockets, verticality of pockets iv. Chipping, roughing & cleaning of pockets/top of

foundation A. Normal equipments B. Critical equipments v. Acceptance of grouting materials as per

specifications/ Manufacturer’s recommendations LIFTING TACKLES a. Certificate from competent authority b. Load test of Cranes/Lifting beams/slings/ shackles/

Wire ropes, etc. for weight of equipments to be handled VISUAL INSPECTION OF EQPT. TAG/IDENTIFICATION NO. a. For any damage b. Free shaft rotation Drilling & Tapping, holes in the base plate of eqpt. (if reqd.) Submission of Rigging procedure (for critical equipments only)

WC

WC WC

WC

WC WC

WC WC WC

WC WC

WC WC

WC

WC

HP

Rw HP

S

S S

S HP HP

Rw Rw

S S

S

HP

* Inspection by Vendor/Manufacturer for all critical equipments




Page 2 of 3


N A F T E C . S P A


CONTRACTOR* OWNER/

PMC 6.

DURING ERECTION a. Level/elevation of base frame b. Checking of foundation bolts (for location, threading, greasing, etc.) c. Checking orientation of equipment d. Placement of Crane(s), if applicable e. Elevation/level of equipment and placement of

shims/packings as per AFC drawings f. Distance between couplings g. Rough alignment of equipment h. Availability of Vendor’s engineer at site (For critical equipments) i. Cleaning of pockets/ grouting of foundation bolts’

pockets/base frame j. Erection of auxiliary equipment/ Accessories k. Final alignment of equipment - Without piping - With piping (After tightening the flange bolts) l. All protection & safety guards installation

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC WC

WC

S

S

S

S

S

S

S

HP

S

S

W W

S





Page 3 of 3


N A F T E C . S P A


CONTRACTOR* OWNER/

PMC 7.

POST ERECTION ACTIVITIES a. Curing of grout b. Auxiliary connections to be mounted on eqpts as per

drawing. c. Final tightening of bolts d. Chemical cleaning of equipment parts/ connected piping e. Boxing up of equipment & connected piping f. Log book maintenance (For rotating of shaft and any

other activity to be performed as per vendor’s recommendations) g. No load run of motors h. Re-coupling of motor & reconfirmation of alignment. INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

WC

WC

WC

WC

WC

WC

WC

WC

WC

S

S

S

S

S

S

W

W

Rw




Section: VI – 3 Construction 6648-00-19-43-2180 Rev.0

Page 1 of 5

EPCC05_VI.3_Constn._QA/QC_Rev.0

N A F T E C . S P A

Copyright EIL – All rights reserved

INDICATIVE ITP FOR STORAGE TANKS


CONTRACTOR OWNER/

PMC

A. 1. 2. 3. 4. 5. 6. 7. 8. B. 1.

PRIOR TO FABRICATION Review Acceptance Report of the tanks foundation Incoming Material

- Documents Review - Physical verification

Welding Filler Material Approval/Qualification a) Review of Manufacturer’s Test Certificate/ Documents b) Laboratory testing, if any i) Carbon Steel ii) Alloy Steel/Stainless Steel iii) Low Temperature Services WPS/PQR a) Review of proposed procedure b) Testing i) Carbon Steel ii) Alloy Steel/Stainless Steel c) Approval of Final WPS/PQR a) Welder performance Qualification Test b) Certification & approval of welders NDT Procedure Qualification i) Review of Proposed Procedure ii) Witnessing of the proposed procedure testing iii) Approval of Qualified Procedure Review of Joint numbering in drawings Review fabrication, erection, testing procedures for job FABRICATION/ERECTION BOTTOM Blast cleaning & painting of underside of bottom plates

WC

WC WC

WC*

WC WC WC

WC

WC WC WC

WC WC

WC WC WC

WC

WC

WC

HP

HP W

HP

Rw Rw HP

HP

Rw HP HP

S

HP

HP HP HP

HP

HP

W

* Notwithstanding any other tests/documentation required for qualification/approval of filler metals : i) For Alloy Steel & Stainless Steel welding filler metals, chemical analysis to be carried out for every batch. ii) For Low Temperature application, Impact testing to be carried out for every batch of the filler metal, to be

witnessed by PMC/Owner. iii) For NACE filler metals, corrosion tests like HIC, SSCC, etc. to be carried out for every batch. However,

HIC/SSCC tests done earlier & duly witnessed by a reputed third party, will be acceptable.

(Pl. refer document No. 6648-00-19-43-2000 for definition of WC, Rw, HP, W and S)



Page 2 of 5


N A F T E C . S P A


CONTRACTOR OWNER/

PMC 2. 3. 4. 5. 6. 7. 8. 9. 1. 2. 3. 4. 5. 6. 7. 8. 9.

Plate lay out, overlap and fit up Sequence of welding Size and positioning of backing plate for annular plates Baking of electrodes Inter-pass cleaning Visual check of welding PT/MT/NDT of annular plate butt welds and bottom plate butt welds (As applicable) Vacuum box test for bottom plate welding SHELL Shell course alignments and fit-up of vertical and circumferential joints before welding a) Check Shell diameter, circularity, perpendicularity, straight edge before welding. b) Check Shell diameter, circularity, perpendicularity, straight edge after welding. Visual check of welding and Back chipping Inner side welding visual check Location, size, alignment and fit-up of nozzles & other openings R.F. Pads fit-up/welding PWHT of shell, RF pads, Nozzles, manholes, etc. (As applicable) Radiography marking (for Random radiography only) Curb angle and Wind girders fit-up/welding

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

S

S

S

S

S

S

W

S

W

S

W

S

S

W

S

HP

HP

S




Page 3 of 5


N A F T E C . S P A


CONTRACTOR OWNER/

PMC 10. 11. 12. 13. 14. 15. 16. 17.

1.

2.

3.

4.

5.

6.

PT/MT of nozzles, wind girders and other attachments (as applicable) RF pads pneumatic test Shell to bottom fit up Shell to bottom I/S welding root run visual/Oil chalk test Shell to bottom O/S welding visual and PT Fabrication and erection of stair ways Cleats welding for insulation Review of radiographs interpreted by the contractors FIXED ROOF Blast cleaning and painting Roof Structure, underside of Roof plates Location and Welding of Roof supports Alignment and welding of Roof structures Plate layout, overlap and fit-up Visual check of roof welds Location, size and alignment of roof nozzles, man-holes vents, etc.

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

W

HP

W

W

W

S

S

W

W

S

S

S

S

W




Page 4 of 5


N A F T E C . S P A


CONTRACTOR OWNER/

PMC 7. 8. 9. 10. 11. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

PWHT (as applicable) i) Procedure review ii) PWHT cycle monitoring iii) Time-Temp Chart Review 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 layout, overlap, fit-up/welding Availability of approved calculations for design of buoys 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

WC WC WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

HP W HP

S

W

W

S

S

S

HP

S

W

S

S

S

S

S

S

W

S




Page 5 of 5


N A F T E C . S P A


CONTRACTOR OWNER/

PMC 14. 15. 16. 17. C. 1. 2. 3. 4. 5. 6. 7. 8. 9.

Location, fixing and welding of man holes, drains etc Shell to pontoon clearance Seal fixing Floating Roof Testing, as required e.g. flooding etc. TESTING Correctness of testing arrangements especially size of blind flanges/vents/drains/ temporary piping. Mechanical / Inspection clearances Earthing of ladder & shell Settlement readings during water filling Hammer test Air pressure test Vacuum test Roof collapsibility test in case of floating roof tanks Calibration of tanks from Statutory authorities

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

W

W

W

W

S

HP

HP

HP

HP

HP

HP

HP

Rw



WC Rw

NOTE : 1) For cleaning & painting, please refer ITP No. 6648-00-19-43-2501 2) For Insulation, please refer ITP No. 6648-00-19-43-2505




Page 1 of 2


N A F T E C . S P A

INDICATIVE


FOR

GENERAL WORKS



Page 2 of 2


N A F T E C . S P A

INDEX

S.NO

DESCRIPTION

DOCUMENT NO.

REV.

GENERAL WORKS

1. Painting

6648-00-19-43-2501 0

2.

Insulation

6648-00-19-43-2505 0

3.

Refractory Lining

6648-00-19-43-2510 0

4.

Ceramic Fibre Lining

6648-00-19-43-2515 0



Page 1 of 2


N A F T E C . S P A

INDICATIVE ITP FOR

PAINTING


CONTRACTOR OWNER/

PMC A. 1. 2. 3. 4. 5. 6. 7.

BEFORE FABRICATION a) Approved supplier, product and supplier's materials test

certificate b) Check manufacturing date, expiry period and shelf life a) Physical condition of materials; original manufacturers packing/ containers b) Confirm identification/ Transfer of identification of

materials before painting a) Adequacy of blasting machine capacity for blast cleaning b) Type and quality of abrasive being used for blast cleaningc)Adequacy of Airless spray equipment, air spray equipment and paint brushes Performance test of paint applicator and blast cleaning operator Check quality of dry air for blast cleaning and spray application Inspection of blast cleaning operation - Inspect for surface cleanliness by visual stds. of

ISO 8501/SSPC - Measurement of surface profile by

Micrometer/Elkometer/Stylus instrument Wet film thickness and over coating interval for each coat of paint during application

WC

WC

WC

WC

WC WC WC

WC

WC

WC

WC

WC

HP

HP

HP

Rw

Rw Rw Rw

W

S

S

S

S

8. Dry film thickness after final coat WC S

9. Inspection of final curing/ drying, adhesion, hardness, surface finish, sagging, hiding and pinhole detection

WC W

10. Painting identification band/ code, etc. WC S

11. Acceptance prior to shifting to fabrication shop, if applicable WC S




Page 2 of 2


N A F T E C . S P A


CONTRACTOR OWNER/

PMC B. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

AFTER INSTALLATION a) Approved supplier product : Suppliers materials test certificate b) Manufacturing date, expiry period and shelf life Physical condition of materials; original manufacturers packing/ containers Confirm completion of a) Hydro testing of piping b) Mechanical clearance of structure & equipments a) Adequacy of surface preparation tools and tackles b) Check the quality of surface preparation a) Performance test for paint applicator for spray application b) Adequacy of airless spray equipment and air spray equipment and paint brushes and quality of dry air for paint application Wet film thickness and over coating interval for each coat of application Dry film thickness after final coat Inspection of final curing/ drying, adhesion, hardness, surface finish, sagging, hiding and pinhole detection Identification of colour bands, direction marking Final Acceptance

WC

WC

WC

WC WC

WC WC

WC

WC

WC

WC

WC

WC

WC

HP

HP

HP

S Rw

Rw S

W

Rw

S

S

S

S

HP



WC Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

INSULATION


CONTRACTOR OWNER/

PMC 1. 2. 3.

PRIOR TO APPLICATION OF INSULATION a. Material Test certificates from supplier of insulation material and acceptance thereof b. Check testing, if required DURING APPLICATION OF INSULATION a. Surface preparation b. Fixing of spacer rings and checking their spacing c. Fixing of support rings and checking their spacing in case of vertical piping

d. Fixing of insulation lugs and angle rings in case of vessels, tanks, etc. e. Thickness of insulation f. Aluminium foil for S.S. Piping/Vessels g. Overlap of cladding at vertical and horizontal joints h. Expansion joints, if any i. Inspection windows j. S.S. foil for S.S. piping k. Final finish ADDITIONAL CHECKS FOR COLD INSULATION a. Wooden supports b. Vapour barrier c. Vapour sealant d. Insul coat

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

Rw

Rw*

S

S

S

S

S

S

S

S

S

S

W

S

S

S

S


Review Test and Inspection Documents WC Rw




Page 1 of 2


N A F T E C . S P A

INDICATIVE ITP FOR

REFRACTORY LINING SL. NO. ACTIVITY EPCC

CONTRACTOR OWNER/

PMC

PRIOR TO START OF LINING a. Material Test certificates from suppliers b. Field tests and tests from approved laboratories c. Availability of Refractory specialist at site (Contactor’s/ Vendor’s) DURING LINING a. INSULATING FIRE BRICKS i. Clearance for completion of structural works

including cleats/ lugs/ anchors/ hooks, etc. ii. Cleanliness of the surfaces to be lined iii. Insulating layer application, wherever applicable iv. Metal foil application, wherever applicable v. Checking of bricks for their soundness (squareness, cracks and for any other damages) vi. Mix proportion vii. Laying of bricks as per specifications viii. Line and verticality ix. Identifying location of expansion joints x. Filling expansion joints, wherever applicable xi. Finishing works

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N A F T E C . S P A


CONTRACTOR OWNER/

PMC

b. INSULATING CASTABLE CONCRETE i. Clearance for completion of structural steel work

including cleats/ support lugs/ anchors/hooks, etc. ii. Cleanliness of the surface to be lined iii. Insulating layer application, wherever applicable iv. Metal foil application, wherever applicable v. Fixing of wire mesh vi. Fixing of shuttering/ scaffolding and providing

pockets for pouring mortar vii. Mix proportion viii. Identifying location of expansion joints ix. Ramming of mortar for achieving uniform density x. Filling expansion joints, wherever applicable xi. Wetting of previous layer prior to casting the

Construction joints xii. Pointing xiii. Curing

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NOTE : Surveillance/witness may be increased in case of boilers, heaters, etc. as per specific requirements given in the specifications.




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

CERAMIC FIBRE LINING SL. NO ACTIVITY EPCC

CONTRACTOR OWNER/

PMC

PRIOR TO START OF LINING i. Material Test certificates from suppliers ii. Field tests and tests from approved laboratories, if

applicable iii. Availability of Refractory specialist at site (EPCC Contactor’s/ Vendor’s/PMCs) DURING LINING i. Clearance for completion of structural works

including welding of cleats/ lugs/ anchors/hooks, etc. ii. Cleanliness of surfaces to be lined iii. Laying of Ceramic fibre blanket layer wise (As per AFC drawings) iv. Provision of cups locks/ arrangement for CF lining

holding v. Identifying location of expansion joints vi. Filling expansion joints as per specifications/ AFC

drawings vii. Finishing works INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

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Page 1 of 2

EPCC05_VI.3_Constn._QA/QC_Rev.0 Copyright EIL – All rights reserved

N A F T E C . S P A

INDICATIVE


INSTRUMENTATION WORKS



Page 2 of 2


N A F T E C . S P A

INDEX

S.NO

DESCRIPTION

DOCUMENT NO.

Rev.


FIELD INSTRUMENTATION WORKS

1. Incoming Material Check 6648-00-19-43 - 2601 0 2. Shop Fabrication 6648-00-19-43 - 2602 0 3. Calibration of Instruments 6648-00-19-43 – 2603 0 4. Fabrication, Erection of Cable Duct 6648-00-19-43 – 2604 0 5. Fabrication, Erection of Cable Tray, Angle Tray for Cable

Laying & Tube Laying 6648-00-19-43 – 2605 0

6. Fabrication, Installation of Instrument Support/ Stanchions, Panel Supports, Canopies, JB Supports

6648-00-19-43 – 2606 0

7. Installation of Field Instruments 6648-00-19-43 – 2607 0 8. Installation of Impulse Lines 6648-00-19-43 – 2608 0 9. Cable Laying, Glanding and Termination 6648-00-19-43 – 2609 0 10. Installation of Junction Boxes, Local Control Panel 6648-00-19-43 – 2610 0 11. Fabrication & Erection of Air Lines and Tubing of

Pneumatic Lines 6648-00-19-43 – 2611 0

12. Installation of Level Switches, Level Gauges and Float Type Level Instruments

6648-00-19-43 – 2612 0

13. Installation of Test Thermowells, Temperature Gauges and Temperature Elements

6648-00-19-43 – 2613 0

14. Loop Checking 6648-00-19-43 – 2614 0 15. Impulse Piping 6648-00-19-43 – 2615 0

CONTROL ROOM INSTRUMENTATION WORKS

16. Incoming Material Inspection and Panel Erection 6648-00-19-43 – 2631 0 17. Fabrication & Erection of Cable Trays 6648-00-19-43 – 2632 0 18. Laying, Glanding & Termination of Interconnection Cables,

Prefabricated Cables, System Cables, Power Cables and Field Cables

6648-00-19-43 – 2633 0

19. Power ‘ON’ of Panels and Pre-commissioning of the System

6648-00-19-43 – 2634 0

20. Field Loop Checking and ‘System Acceptance Test’ 6648-00-19-43 - 2635 0

Pl. refer document No.6648-00-19-43-2111 for Tie-In.



Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR INCOMING MATERIAL CHECK

(FIELD INSTRUMENTATION WORKS)


CONTRACTOR OWNER/

PMC 1. 2.

Material receipt as per material specifications / standards Proper storage of owner supplied items & EPCC contractor supplied items INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR SHOP FABRICATION



CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6. 7. 8.

Material receipt as per purchase specification Qualification of WPS /Welders Usage of approved consumables Following proper job procedure NDT PWHT & Hardness test Shop testing Painting and Storage INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR CALIBRATION OF INSTRUMENTS



CONTRACTOR OWNER/

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

Availability of approved standard calibrated test equipments Validity of calibration equipments Air conditioning, dust free environment Availability of approved data sheets, calibration procedures, standards, vendor’s manuals Usage of appropriate tools and tackles Usage of qualified /trained personnel Mounting of instruments, instrument tag & model during calibration Checking of Instrument ranges, supply & output for proper connections Calibration of local gauges Calibration of electronic instruments/control valves Calibration of safety valves, shutdown valves and trip switches Calibration of special instruments /float type instruments Ensuring procedure and record Plugging of free entries Stamping of calibration date on instruments INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR FABRICATION, ERECTION OF CABLE DUCT(GI)



CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Availability of correct material Usage of proper tools and tackles Use of approved consumables Correctness of dimensions of duct Welding as per Standards / specifications Installation & alignment of support as per structural drg. & Documents Painting of support Grinding of sharp edges before erection Alignment of cable duct Covering of duct after completion of cable laying / dressing Usage of proper clamp & fasteners Installation of guide supports INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR FABRICATION, ERECTION OF CABLE TRY, ANGLE TRAY FOR CABLE LAYING AND TUBE LAYING



CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6.

Correct size & routing of tray/angle Supporting as per standards / specifications Removal of sharp edges and sharp bends Fastening / welding of trays / angles Check for fouling with piping / structures Check for any obstruction / space for maintenance INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR FABRICATION, INSTALLATION OF INSTRUMENT

SUPPORT/STANCHIONS, PANEL SUPPORTS, CANOPIES, JB SUPPORT



CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Availability of correct material Usage of proper tools and tackles Availability of approved Junction Box layout and instrument location plan Correctness of dimensions, height etc. Approved welder, consumables, standards Check for installation, hole to hole dimension & alignment / fit up Check for no sharp edges Painting Ensure physical walk through the line Maintenance space Providing of vent holes on stanchion Sealing of vent holes INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR INSTALLATION OF FIELD INSTRUMENTS



CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6. 7.

Availability of approved location plans, piping GADs, P&ID, vendor’s manual etc. Installation of proper support / instrument stanchion, canopy Instrument tag as per P &ID, model & make as per instruments data sheet Physical walk through the line Alignment of the instruments Mounting of accessories as per instrument data sheet Visibility & maintenance clearance INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR INSTALLATION OF IMPULSE LINES



CONTRACTOR OWNER/

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

Direction of flow, tapping orientation, standard, piping material Upstream & downstream straight runs Usage of appropriate tools & tackles Usage of approved welder, consumables & procedures No burrs & sharp edges on tube bends Correctness & hardness of tubes and fittings Smooth bends/ free draining Ferrule punching Supporting as per standards/ specifications Direction of valves / valve manifolds NDT, PWHT, DT Radiography Usage of approved sealant etc. Testing Material Traceability PMI (before Leak Test) INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR CABLE LAYING, GLANDING & TERMINATION



CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Correctness of cable type as per cable schedule Measurement & routing Check cable for continuity, insulation resistance, megger values Identification tags/ tag plates & proper dressing & clamping Separation of signal / thermocouple and power cables Cable glands as per area classification, size of cable, JB entry etc. Identification / ferrule and dressing inside junction boxes and instrument Crimpable type lugs and proper crimping Telephone wire connection inside JB Shield wire dressing / sleeving and termination Insulation of shield wire on instrument end INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR INSTALLATION OF JUNCTION BOXES (JB),

LOCAL CONTROL PANEL (LCP)



CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Correct tag, type, location, size of junction box / LCP Correct cable entries Alignment & fasteners Tightening of fasteners Tightening & numbering of terminal blocks Availability of telephone sockets (for JBs) & earthing point Earthing of JB / LCP Plugging of free entries with correct plugs Wiring of various hardwares in LCP s per approved wiring drawings Protection of JB and LCP INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR FABRICATION & ERECTION OF AIR LINES AND

TUBING OF PNEUMATIC LINES



CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Availability of AFC air distribution drawings Usage of correct size, thread etc. Jigs/ die sets for threading of pipes Packing material / sealant used at thread joints Providing of three piece union at each loop for easy maintenance Drain & vent assemblies Tightening at joints Supporting and clamping Test air lines as per standards / specifications and record Check for inlet, outlet, signal, test and drain connection on the instrument Check for correct supply as per data sheets Flush lines before connection Ensure punching of ferrules Tagging at both ends of tubes INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR INSTALLATION OF LEVEL SWITCHES, LEVEL GAUGES AND FLOAT TYPE LEVEL



CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Usage of correct flanges and piping materials Deployment of approved welding man power, usage of approved consumables & procedures Alignment of flanges, visibility of gauges and orientation of instrument Verticality of the instrument Installation of float, displacer, instrument accessories as per data sheet / vendor’s instruction manuals QA/QC clearances for welding & testing Tightness of guide wires Usage of correct size, rating & type of gasket and stud/nuts as per PMS Required tightness of the stud/nuts Testing as per standards and specifications INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR INSTALLATION OF TEST THERMOWELLS, TEMPERATURE GAUGES AND TEMPERATURE ELEMENTS



CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6.

Correctness of range, rating, immersion length (U length) as per P &ID / Instrument data sheets Check for tapping size, orientation, location as per P&ID Usage of correct size, rating & type of gasket and stud/nuts as per PMS Required tightness of stud/nuts Visibility & orientation of gauges Plugging of free entries with correct size plugs INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR LOOP CHECKING



CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6. 7. 8. 9.

Completeness of installation as per standards & specifications Liquidation of punch point list as per ITP Availability of standard calibration equipment Coordination with DCS vendor Simulation of instruments as per specifications Re calibrate / fine tune instruments for accurate response Check for interlocks and response of final control element Ensure proper response and record Loop acceptance INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

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N A F T E C . S P A

INDICATIVE ITP FOR IMPULSE PIPING


SL. NO

ACTIVITY

EPCC

CONTRACTOR

OWNER/

PMC A.

PRIOR TO FABRICATION

1.

Incoming Material

a) Documents (MRIR etc.): Review & acceptance

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b) Physical verification

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2.

Welding Filler Material Approval/Qualification a) Review of Manufacturer’s Test Certificates/Documents & Sampling b) Laboratory Testing, if any i) Carbon Steel ii) Alloy Steel/Stainless Steel

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3.

iii) All other Materials including NACE CS and CS for H2Service

WPS/PQR a) Review of proposed procedure b) Welding of Test Coupens and subsequent testing i) Carbon Steel, Stainless Steel ii) Alloy Steel iii) All other Materials including NACE CS and CS for H2

Service c) Approval of final WPS/PQR.

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4. 4a.

Welder performance Qualification Certification & approval of welders.

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NDT Procedure Qualification i) Review of proposed procedure ii) Witnessing of Proposed Procedure Testing iii) Approval of Qualified Procedure

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6.

Review of Joint numbering Procedure, numbering in Isometrics (Big & Small bore)/Sketches

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7 . Material traceability & Transfer of Heat Nos. (Material Traceability not required for utility services)

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* Notwithstanding any other tests/documentation required for qualification/approval of filler metals : i) For Alloy Steel & Stainless Steel welding filler metals, chemical analysis to be carried out for every batch. ii) For low temp. services piping, Impact testing to be carried out for every batch of the filler metal, to be

witnessed by Owner/ PMC. For NACE filler metals, corrosion tests like HIC, SSCC, etc. to be carried out for every batch. However, HIC/SSCC tests done earlier & duly witnessed by a reputed third party, will be acceptable.




Page 2 of 11


N A F T E C . S P A


CONTRACTOR OWNER/

PMC B. 1. 2. 3. 4. 5. 6. 7. 8. 9. 9a. 10. 11. 12. 13.

FABRICATION (SHOP & FIELD) Material as per piping class (check w.r.t. approved colour coding procedure), Fit-up check and Traceability check Pre-heat (if any) Certificate of purity of purging/shielding Gas (if any) Purging rate (if any) and arrangement Shielding rate (if any) Baking of Electrodes Inter-pass cleaning & Temperature check. Visual Examination of completed welds Monitoring of PWHT Cycle Review of Time – Temperature graph i) CS ii) AS Hardness Check PT/MT Identification of Joints for Radiography (for Random Radiography only) Review of Radiographs interpreted by the EPCC Contractor i) For Carbon Steel Piping, SS Piping(type 304) ii) For Alloy Steel Piping and other SS piping iii) For H2, NACE piping, other exotic material

piping

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N A F T E C . S P A

SL. NO.

ACTIVITY

EPCC

CONTRACTOR

OWNER/

PMC C 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

PROOF TESTING (See enclosed checklist in Annex-1) Procedure Review Preparation of Punch list (Ref. Annex-3) Review of Punch List Liquidation of check list, if applicable Correctness of Testing arrangements Scrutiny of test packs for Mechanical & NDT Clearance Positive Material Identification as per specification after completion of installation. a) Review of Calibration certificates of pressure Gaugesb) Field Calibration, if any Air/Water Flushing (preliminary) Visual inspection of all weld joints for leak during Pneumatic/ Hydrotesting (See Annex-2)

a) Category ‘D’ services b) All other services

Draining of Water & Air Drying Removal of temporary blinds/supports.

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N A F T E C . S P A

SL. NO.

ACTIVITY

EPCC

CONTRACTOR

OWNER/

PMC 13. 14. 15.

Boxing up including reinstallation of flappers of check valves Review of Records of fasteners & gaskets Torque tightening/ tensioning of flange joints, wherever applicable INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

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For liquidation of Punch list, see Annex - 3 Note : Pre-commissioning activities such as chemical cleaning, card board blasting, system testing

are not covered by these ITP's. The EPCC Contractor shall develop ITP's for such activities and obtain Owner/ PMC/ Licensor's approval.

A/G Above Ground NDT Non Destructive Testing AS Alloy Steel i.e. Cr-Mo steels like A335

Gr P11, P5, P9,P22,etc NRV Non Return Valve

CS Carbon Steel PMI Positive Material Identification CSO Car Seal Open PQR Procedure Qualification Record GAD General Arrangement Drawings PT Penetrant Testing HIC Hydrogen Induced Cracking PWHT Post Weld Heat Treatment LO/ LC Lock Open/ Lock Close RF Reinforcement MT Magnetic Particle Testing SS Stainless Steel like A312 TP 304, 316,

321, 304L, 316L, 316Mo, etc. NACE National Association of Corrosion

Engineers SSCC Sulphide Stress Corrosion Cracking

WPS Welding Procedure Specification




Page 5 of 11


N A F T E C . S P A

ANNEX – 1 Checklist for Mechanical Clearance - IMPULSE Piping

Project : ___________________________ Plant/Unit : _________________________ EPCC Contractor : _________________ Loop No : _________________________

Report No : ____________________________ Date : ________________________________ Area : ________________________________ INCH MTR : __________________________

Line No (Isometric No.) Rev. GAD No. Rev. P&ID No. Rev. Items to be checked Accept Remarks EPCC

Contractor

1. Installation checked as per Isometric w.r.t. CONFIGURATION : Route, plumb, elevation, Clearance for thermal expansion/ insulation BRANCH : Location, angle, orientation, type, RF pad, etc. STEAM TRAP : Direction

2. Installation checked as per P&ID

3. Isometrics completed for ( enclosed ): a. Joint Numbering (Shop & Field Welds) b. Spool Numbering c. As-built routing & dimensions

4. Valves(Check Rating, Gaskets, Flow Direction, Sheet No., Tag No., Spindle direction, CSO LO/LC, Damage, etc)

Nos

Gate Valves Globe Valves Check Valves Control Valves Tag Nos.: Safety Valves Tag Nos.: Any other valves : 5. Strainers : Check for clearance, flow

direction, elements

FORMAT NO: ____________________ ( Sht 1/4 )



Page 6 of 11


N A F T E C . S P A

Checklist for Mechanical Clearance - IMPULSE Piping


Contractor

6. Flanged Joints Total Nos. Check for type of flange Check for Rating Check for Alignment, (proper gap & parallelity Check for Correct Studs & 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

7. Seal Welding of Screwed Connections (if Required)

8. Vents/Drains as per Dwg and Provision of additional high point Vents and/or low point Drains, if reqd.

9. Orifice Flanges : Check for Tag No., tapping orientation, tap valve, jack

screw, straight run length of upstream & downstream

10. Local Gauges : Check for accessibility

11. Supports as per drg. and specifications

FORMAT NO: ____________________ ( Sht 2/4 )



Page 7 of 11


N A F T E C . S P A



Contractor

12. Vents/ Drains : - As per drg. - Orientation of valve handles - Clearance for hose - Requirement of additional vents/ drains (highest/lowest pt.)

13. Earthings : a) Check for location b) Check for dimension of lug welding

14. Joists History sheets enclosed for : 14.1 Material Traceability as per Procedure No:__________

(refer enclosed suggested Format)

14.2 Fit ups checked

14.3 NDT Complete (Radiography, MT, PT)

14.4 Stress Relieving & Hardness check complete

14.5 Positive Material Identification (PMI) Checked for Removal/Blinding-off of: a. Control, Safety and Check Valves b. In-Line Instruments c. Rupture Discs d. Equipment Nozzles e. Others

15. Supports and Weld/Flanged/Screwed connections free from insulation or other coverage`

16. Checked Installation of (Indicate Location in Drawings) a. Temporary Blinds/Spades b. Temporary Strainers c. Temporary Dummy-Spools d. Temporary Gaskets e. Others

FORMAT NO: ____________________ ( Sht 3/4 )



Page 8 of 11


N A F T E C . S P A



Contractor

17. Cleanliness Internally and Externally

18. Removal of unwanted construction supports

19. Instrument tapings provided as per Drawing

20. Physical-Walk-Through – The – Line, checked for gross irregularities including physical damages, unwanted tacks, arc strikes, spatters and space for thermal expansion.

Other : Remarks Reviewed by EPCC Contractor (one level higher than checker) Name : Designation : Date :

OWNER/ PMC Sign : Date : Name : Designation :

FORMAT NO: ____________________ ( Sht 4/4 )



Page 9 of 11


N A F T E C . S P A

ANNEX – 2

Piping Hydro Test Release Record – IMPULSE Piping

Project : ______________________________ Plan : ________________________________ EPCC Contractor : ___________________ Loop No : ____________________________

Report No : __________________________ Date : _______________________________ Area : _______________________________ REF P & ID No. : _____________________ INCH MTR : _________________________ From ________________ To _____________

Line No. (s) Isometric No. (s) P&ID No. (s) Test Medium : Test Duration : Design/Test Pressure :

Test Pressure Gauge No.

Range Calibration Certificate No.: Gauge Calibration Date:

Items to check Accept Witness EPCC

Contractor OWNER

/ 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 pressurizing pump checked Cordon off area for high pressure testing, as required Pre-hydrotest flushing carried out Statutory Authorities/Others test Witnessing Required Yes No

System Released for Pressure Testing : EPCC Contractor :

OWNER/ PMC:

Sign : Name : Sign : Name : Date : Date : Designation : Designation:

FORMAT NO: ____________________ ( Sht 1/2 )



Page 10 of 11


N A F T E C . S P A

Piping Hydro Test Record – IMPULSE Piping

ACTIVITY Date Time Water Filling and Venting started at Water Filling Completed Vents Closed Isolation of Pressurizing pump Test completed at : - Water drained - Air - Temp Blinds Removed - Checked for reinstallation of

f. Control & Safety vales g. On line Instruments h. Rupture disks i. Deblinding j. Others

- Cold setting of spring supports carried out - Test Result Acceptable Not Acceptable EPCC Contractor :

OWNER/ PMC :

Sign :

Sign:

Date : Date: Name : Designation Name: Designation:

FORMAT NO: ____________________ ( Sht 2/2 )



Page 11 of 11


N A F T E C . S P A

ANNEX - 3

Punchlist

Project : _____________________________ Plan : _______________________________ EPCC Contractor : ___________________ Loop No : ___________________________

Report No : ___________________________ Date : ________________________________ Area : ________________________________ REF P & ID No. : _______________________

Description : _________________________________________________________________ Ref Document : _______________________________________________________________ ____________________________________________________________________________ Punch Item No.

Prio-rity

Description of Punch Items

Location PreparedBy

Action By

Due date

Completion Acceptance

Priority: 1. Needed for pressure test 2. Needed for commissioning 3. Needed for start up 4. Needed for plant acceptance EPCC Contractor : OWNER/ PMC : Sign : Sign : Date : Date : Name : Designation : Name : Designation :

FORMAT NO: ____________________ Sh. 1/1



Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR INCOMING MATERIAL INSPECTION & PANEL ERECTION

(CONTROL ROOM INSTRUMENTATION WORKS)


CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6. 7.

Check for receipt of materials/ panels as per purchase requisition, inspection release note, bill of materials, etc. Ensure proper storage of materials at site Ensure shifting of panels into the control room without damage Check for hole to hole dimensions of the base frames with the as built drawings of the panels Check alignment, fastening, welding & painting of the base frame. Ensure erection of panels as per approved layout drawing, after completion of all welding works Check for tagging/identification of all panels INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

WC

WC

WC

WC

WC

WC

WC

WC

W

S

S

S

S

S

S

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR FABRICATION & ERECTION OF CABLE TRAYS



CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6.

Ensure availability of latest revision of approved tray layout drawings. Ensure welding & painting of supports before erection of panels. Check for fastening and joining of cable trays. Ensure no sharp edges. Ensure covering of cable trays for unarmoured and system cable trays Erect separate cable trays for power and signal cables. Check for separation distance between the power & signal cable INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

WC

WC

WC

WC

WC

WC

WC

Rw

S

S

S

W

S

Rw




Page 1 of 1


N A F T E C . S P A

LAYING, GLANDING & TERMN OF INTERCON. CABLES, PREFAB CABLES, SYSTEM CABLES, POWER CABLES & FIELD CABLES

(CONTROL ROOM INSTRUMENTATION WORKS


CONTRACTOR OWNER/

PMC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Check for receipt of correct size & type of cables as per cable schedule Testing of cable before laying as per specification (continuity, megger, etc.) Ensure exact distance and cut cables accordingly Tag of cables as per specification Confirm availability of proper cable gland size, type of specified thread Tightening of check nut (after termination) Cable continuity & insulation resistance Dressing of cables inside PVC Duct and covering of PVC Duct after complete cabling. Ferruling of cables Ensure usage of sleeved crimp able type lugs Crimping of lugs Correct tightness of cables in the terminal block Correct numbering of terminal blocks Continuity of fuses in terminal blocks INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

Rw

Rw

Rw

S

Rw

S

S

S

S

S

S

S

S

S

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR POWER ‘ON’ OF PANELS AND PRE-

COMMISSIONING OF THE SYSTEM




CONTRACTOR OWNER/

PMC

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

Check earth pit resistance Check earth connection to system earth, panel earth etc. Ensure interconnectivity of panel earth bus Check incoming power supply and termination of the power cables Power ‘ON’ the system and observe system booting and self diagnostic check. Reload the softwares, if necessary Check for alarms by switching ‘ON’/‘OFF’ the sub systems Start simulation of individual loops from respective ‘Field Terminal Blocks’ (FTBs) Observe the response and tune the controllers Check the interlocks as per P&ID Record the input & outputs Check for proper, trend reports, logging reports/shift reports & alarm, sequence and functioning of all peripheral units. Check for back-up operation of PLC cards, system memory & power supply switch over Check for lighting and ventilation fan operation Check functioning of complex loop INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

HP

HP

W

W

W

S

S

S

S

W

Rw

Rw

W

S

W

Rw



Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR FIELD LOOP CHECKING AND ‘SYSTEM

ACCEPTANCE TEST’

(CONTROL ROOM INSTRUMENTATION WORKS SL. NO. ACTIVITY EPCC

CONTRACTOR OWNER/

PMC

1. 2. 3. 4. 5. 6.

Ensure record as per loop checking sheet duly signed Check for system booting, bus-degradation, scan time, loop error, etc. Check for operation of sub systems and peripheral systems Check for ‘Back-up’ system operations Ensure feedback/commands from/to electrical system System acceptance INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

WC

WC

WC

WC

WC

WC

WC

Rw/HP

W

W

W

W

HP

Rw




Page 1 of 2


N A F T E C . S P A

INDICATIVE INSPECTION & TEST PLAN (ITP)

CIVIL, STRUCTURAL AND ARCHITECTURAL WORKS



Page 2 of 2


N A F T E C . S P A

INDEX

S.NO DESCRIPTION DOCUMENT NO. REV.

GENERAL CIVIL WORKS

1. Preliminary Civil works 6648-00-19-43-2701 0 2. Site Grading 6648-00-19-43-2703 0 3. Excavation 6648-00-19-43-2704 0 4. Back Filling 6648-00-19-43-2705 0 5. Underground Piping Works (RCC/CI) 6648-00-19-43-2706 0 6. WBM Roads 6648-00-19-43-2707 0 7. Black Topping (Premix Carpeting) 6648-00-19-43-2708 0 8. Tanks Pads 6648-00-19-43-2709 0 9. Micro Grading 6648-00-19-43-2710 0 10. Underground Piping (Carbon Steel) 6648-00-19-43-2740 0

STRUCTURAL WORKS

1. Plain Cement Concrete 6648-00-19-43-2741 0 2. RCC (Sub-Structure) 6648-00-19-43-2742 0 3. RCC (Super Structure) 6648-00-19-43-2743 0 4. Flooring/ Pavement 6648-00-19-43-2745 0 5. Brick Work 6648-00-19-43-2746 0 6. Structural Works 6648-00-19-43-2747 0

ARCHITECTURAL WORKS

1. Plastering 6648-00-19-43-2772 0 2. Roofing Accessories 6648-00-19-43-2779 0



Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

PRELIMINARY CIVIL WORKS


Contractor Owner/

PMC

1 Boundary markings and submission of drgs./sketches WC S

2 a) Review of calibration certificates of instruments/ testing equipments

WC HP

b) Field calibration, if any

WC W

3 Block levels, contour plans, establishing permanent bench marks with ref. to Standard B.Ms. by check levels and submission of relevant drgs. & records

WC S

4 Protection of control points, permanent bench marks and regular rechecking

WC S

5 Submission of Master plan showing monuments, structures exposed rocks, weirs, water works, ponds, underground services if crossing that area, etc.

WC S






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

SITE GRADING


Contractor Owner/

PMC

1. Clearing and stripping of soil including disposal of unsuitable material

WC S

2 a) Review of calibration certificates of instruments/ testing equipments

WC HP


WC W

3. Taking and plotting of initial joint levels at specified intervals for cutting as well as filling areas

WC W

4. Classification (Levels of strata) and testing of filling soil for suitability including preparation of Lead Charts to filling/disposal areas.

WC S

5. Proper warning of explosions, misfires and storage of explosive materials (As applicable).

WC S

6. Breaking up of clods, lumps, etc. at the time of filling and compaction.

WC S

7. Identification and suitability of borrow areas for filling soil/murrum including verification of payments for royalty, etc.

WC S

8. Compaction test for earth filling in specified layers including finished areas.

WC W/Rw

9. Verification of final finished grade levels. WC S

10. Computation of Earth works. WC Rw

11. Record of tree cuttings, stacking of blasted rocks and other quarry materials including handing over to Owner

WC S

12. Preparation of “As built drawings” indicating culverts, other open drainage facilities etc.

WC Rw

13. Removal of Surplus earth/excavated material and leveling in disposal areas.

WC S

14. Resolution of obstacles/hindrances WC S






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

EXCAVATION


Contractor Owner/

PMC

1. a) Review of calibration certificates of instruments/ testing equipments

WC HP


WC W

2. Layout checking WC S

3. Taking initial levels WC S

4. Slopes of excavation, benching, overburden, shoring & strutting (in case of deep excavation)

WC S

5. Check for sub-soil water, dewatering requirements as per specifications.

WC S

6. Bottom level of excavation and compaction WC S

7. Stacking of different type of soils separately WC S

8. List of obstacles encountered (cables, pipes, conduits, etc) WC S

9. Barricading of excavated pits for safety & protection from rain

WC S

FOR HARD ROCK

1 Obtaining license from Statutory authorities for undertaking blasting operations

WC Rw

2 Storing of explosive materials as per explosive rules WC S

3 Prominent display of red flags around the area to be blasted WC S

4 Check the dimensions of bore holes WC S

5 Stacking of hard rock for useable/non useable including handing over to owner

WC S






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

BACKFILLING


Contractor Owner/

PMC

1. Selection of materials/selected earth

WC W

2. Check for treatment of soil, if any

WC S

3. a) Calibration certificates of instruments/ testing equipments

WC Rw


WC W

4. Filling in specified layers, consolidating, watering.

WC S

5. Compaction tests for layers

WC W/Rw

6. Filling to required levels WC S






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

UNDERGROUND PIPING (RCC/CI)


Contractor Owner/

PMC

1. Checking of material WC W

2. Adequate slope, benching in excavation for safety purposes (if required)

WC S


WC Rw


WC W

4. Layout, line & level WC S

5. Laying & jointing, grouting at manholes/chambers WC S

6. Check for supports/ firm bed/ sub soil water level WC S

7. Testing for leakages by blocking pipe ends WC S

8. Hydro-testing and other tests, Removal of blockages, Cleaning & flushing of system

WC S

9. Backfilling in layers WC S

10. Check for MS rungs in proper position, inlet/outlet pipe levels in manholes

WC S

11. Preparation of “As-built drawings” WC Rw






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

WBM ROADS


Contractor Owner/

PMC


WC HP


WC W

2. Layout checking including Road crossings and taking initial levels

WC S

3. Approval of source & checking/testing of materials (wherever required)

WC HP

4. Filling (if any), compaction, providing cambers in sub-base including levels

WC S

5. Spreading metal to required thickness, line & levels, dry rolling including spreading of screening material

WC S

6. Check for camber and levels over metalling

WC S

7. Spreading murrum/ sand, watering and rolling

WC S

8. Checking thickness after each layer and rectification thereof (if any)

WC W

9. Checking quantity of aggregate by excavation of trial pits

WC W






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

BLACK TOPPING (PREMIX CARPETING)


Contractor Owner/

PMC

1. Approval of source of materials WC Rw


WC HP


WC W

3. Surface preparation & check for camber/level

WC S

4. Checking/ testing of material wherever required

WC W

5. Tack coat application

WC S

6. Premix carpeting (including thickness of carpeting) and rolling

WC S

7. Seal coat (including thickness of seal coat)

WC S

8. Check for camber and levels

WC S

9. Check for bitumen temperature and consumption

WC S

10. Premix sample check test (As applicable)

WC W

11. Removal of surplus earth

WC S

12. Berm preparation

WC S

13. Final Inspection

WC HP






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

TANK PADS


Contractor Owner/

PMC


2. Stripping the area WC S


WC HP


WC W

4. Layout and marking of ground level WC S

5. Excavation to required level, compaction of sub-base WC W

6. Checking/ testing of materials WC W

7. Filling selected materials in specified layers, rolling, watering

WC S

8. Compaction tests WC W/Rw

9. Gravel filling under annular ring with compaction and adding graded filler material (As applicable)

WC W

10. Anti-corrosive layer, consolidation WC S

11. Premix carpeting on side slopes WC S

12. Preparation of “As-built drawing” for erection WC Rw

13. Check for settlement of pads during hydrostatic testing of tanks

WC W






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

MICRO GRADING


Contractor Owner/

PMC


WC HP


WC W

2. Taking initial levels

WC S

3. Clearing/ Removal of extra soil, debris, etc. from site by transportation

WC S

4. Taking final levels

WC S

5. Verification of gradient of ground

WC S

6. Finishing of ground surface by hand compactor/ Roller (As applicable)

WC S

7. Final inspection

WC HP






Page 1 of 5


N A F T E C . S P A

INDICATIVE ITP FOR

UNDERGROUND PIPING (CARBON STEEL)


Contractor Owner/

PMC A. 1. 2. 3. 4. 4a. 5. 6. 7. 8 9. B. 1.

PRIOR TO FABRICATION Checking/ testing of incoming materials Welding Filler Material Approval/Qualification i) Review of Manufacturer's Test Certificates/ other

documents ii) Testing, if any WPS/PQR i) Review of proposed Procedure ii) Testing iii) Approval of Final WPS Welder Performance Qualification Test Certification & approval of welders NDT Procedure Qualification i) Review of proposed Procedure ii) Testing iii) Approval of Qualified procedure Preparation of sketches from General Arrangement drawings Joint numbering Approval of colour coding scheme

Monitoring of colour coding on pipes & fittings FABRICATION (SHOP & FIELD) Material as per piping class (check w.r.t. approved colour coding procedure) i) Fit-up check ii) Dimensional check

WC

WC

WC

WC WC WC

WC WC

WC WC WC

WC

WC

WC

WC

WC

WC WC

S

Rw

Rw

HP W/Rw

HP

W HP

HP HP HP

Rw

Rw

HP

S

W

S S




Page 2 of 5


N A F T E C . S P A


Contractor Owner/

PMC 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. C. 1. 2. 3. 4. 5. 6. 6a.

Pre-heat (if any) Check for purity of purging/shielding Gas (if any) Purging (if any) Shielding rate (if any) Baking of Electrodes Inter-pass cleaning & Temperature check. Visual check of completed welds PT/MT Radiography marking (for Random Radiography) Radiography Interpretation HYDROSTATIC/ PNEUMATIC TESTING Procedure Review Correctness of Testing arrangements Calibration of Pressure Gauges R.F. Pad testing, if any Scrutiny of test packs for Mechanical & NDT Clearance (Refer Annexure-1) Air/Water Flushing (preliminary) Addition of corrosion inhibitors, if required – Approval of make & quality

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC WC

S

S

S

S

S

S

S

S

W

W

HP

S

W

HP

HP

S HP




Page 3 of 5


N A F T E C . S P A


Contractor Owner/

PMC 7. 8. D. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Pneumatic/ Hydrostatic testing Draining of water & Air drying LAYING Trench excavation and levels Cleaning of pipe surface Approval of wrapping/coating material manufacturers Approval of agency for wrapping & coating Sample test of coating materials in approved laboratory Procedure qualification for wrapping & coating Application of primer Coal tar temperature Coating & wrapping Check Thickness of coating (if applicable) Review Calibration Certificate of Holiday tester Holiday testing Peel test

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

WC

W

W

S

S

HP

HP

Rw

HP

S

S

S

W

HP

W

HP




Page 4 of 5


N A F T E C . S P A


Contractor Owner/

PMC 14. 15. 16. 17. 18. 19. E. 1. 2. 3.

Lifting arrangement Lowering (levels & orientation of branches) Checking of wrapping & coating for damages during lowering, their repair, Holiday Testing, etc. Back filling & compaction Location, Brickwork, plaster of valve pit Top cover & Finish of valve pit SYSTEM COMPLETION Tie in joints Scrutiny of test packs for system testing (Refer Annexure-1) System testing INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

WC

WC

WC

WC

WC

WC *

WC

WC

WC

S

S

W

S

S

S *

Rw

HP

Rw

* For Tie-In, pl. refer ITP No.6648-00-19-43-2111




Page 5 of 5


N A F T E C . S P A

ANNEXURE – 1


Contractor Owner/

PMC A. 1. 1a 1b 2 3. 4.

MECHANICAL COMPLETION RECORD (U/G Piping) Clearance for flushing & testing Mechanical clearance - Conformity with drawing - Material as per Specification Welding & NDT clearance - Material as per Specification - Fit-up check record - Visual check of completed welds - PT/MT - Radiography - PWHT & hardness - RF pad testing Flushing & Pressure testing Coating & wrapping - Surface preparation - Primer application - Coating, wrapping & peel test - Holiday check Laying - Trench leveling - Lowering & checking for damages in wrapping & coating, their repair, Holiday testing, etc. - Backfilling

WC

WC WC


WC

WC WC WC WC

WC WC

WC

Rw

Rw Rw

Rw Rw Rw Rw Rw Rw Rw

HP

Rw Rw Rw Rw

Rw Rw

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

PLAIN CEMENT CONCRETE (PCC)


Contractor Owner/

PMC


WC Rw


WC W

2. Checking of layout and materials, compaction of sub -grade WC S

3. Mix proportion WC S

4. Check for shuttering, dewatering if any. WC S

5. Concreting with proper compaction WC S

6. Checking of top level of PCC WC S

7. Curing WC S






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR REINFORCED CEMENT CONCRETE (RCC)

(SUB-STRUCTURE)


Contractor Owner/

PMC


WC Rw

b) Field calibration, if any WC W

2. Checking of layout & condition of PCC/ leveling course WC S

3. Checking/ testing of materials WC S

4. Design of mix WC Rw

5. Inspection of concrete delivered by batching plants/ transit mixers/ concrete mixers

WC S

6. Check for line & level of shuttering including its condition, quality and rigidity.

WC S

7. Check for sub-soil water & dewatering arrangement, if any WC S

8. Reinforcement & covers to reinforcement WC W

9. Inserts, Anchor bolts and pipe sleeves, pockets, dowels, etc.

WC S

10. Pour Card WC HP

11. Check for obstacles encountered (Electrical conduits, pipe lines, etc.)

WC S

12. Concreting, testing, compaction & finishing WC S

13. Casting of cubes WC W

14. Curing WC S

15. Testing of cubes WC W

16. Removal of shuttering WC S

17. Check for water tightness, rendering, if any WC S

18. Preparation of As-built drawings WC Rw






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR REINFORCED CEMENT CONCRETE (RCC) (SUPER STRUCTURE)


Contractor Owner/

PMC 1. a) Calibration certificates of instruments/ testing

equipments WC Rw

2. b) Field calibration, if any WC W

3. Checking of layout WC S

4. Checking/ testing of materials WC W/Rw

5. Design of mix WC Rw

6. Inspection of concrete delivered by batching plants/ transit mixers/ concrete mixers

WC S

7. Check for line & level of shuttering and scaffolding/ vertical bracing including hoisting arrangements.

WC S

8. Reinforcement & covers to reinforcement WC W

9. Inserts, bolts, pipe sleeves, MS rungs, concealed electrical conduits, fan hooks, dowels, etc. including welding if any

WC S

10. Pockets/ openings WC S

11. Expansion joints, if any WC S

12. Pour Card WC HP

13. Concreting, testing, compaction & finishing WC S

14. Casting of cubes WC W

15. Curing WC S

16. Testing of cubes WC W

17. Removal of formwork/ stayings WC S

18. Verification of dimensions viz AFC drawings and tolerances WC S

19. Check for water tightness, rendering, if any WC S

20. Preparation of As built drawings WC Rw






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

FLOORING/PAVEMENT


Contractor Owner/

PMC



WC HP


WC W

3. Layout checking/ excavation of all new foundations WC S

4. Checking/ testing of materials WC S

5. Mix proportion/Design Mix WC W

6. Check for proper back filling/compaction/ completion of sub - Structure works

WC Rw

7. Check for edges of shuttering, alternate panels WC S

8. Check for slopes, thickness of flooring WC S

9. Shuttering, reinforcement (if any) WC S

10. Check for expansion joints/ Construction joints WC S

11. Check for concealed pipe embedment, earthing, if any WC S

12. Check for dividing strips, if any WC S

13. Concreting, testing, finishing, test cubes WC W

14. Checking for line, levels, slopes, joints, thickness of flooring viz. AFC drawings

WC S

15. Curing WC S

16. Grinding & polishing, if applicable WC S

17. Testing of concrete cubes (as applicable) WC W

18. Preparation of “As Built Drawings” including underground facilities if any

WC Rw






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

BRICK MASONRY


Contractor Owner/

PMC

1. Checking/ testing of bricks (as applicable)

WC W

2. Cleaning of surface

WC S

3. Wetting of bricks

WC S

4. Cement mortar proportion

WC S

5. Staging & scaffolding

WC S

6. Hacking of concrete surface

WC S

7. Check for bond/closers, thickness of joints .

WC S

8. Line, level & plumb

WC S

9. Raking out joints, keys in brick work, if any

WC S

10. Check for RCC bonds/Reinforcement/PCC flooring, in case of partition brick work

WC S

11. Embedment of fixtures

WC S

12. Curing

WC S

13. Preparation of 'As Built' Drawings

WC Rw






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

STRUCTURAL WORKS

S. NO ACTIVITY EPCC

CONTRACTOR OWNER/

PMC A PRE – FABRICATION ACTIVITIES 1. a) Review of calibration certificates of instruments/ testing equipments WC HP

b) Field calibration, if any WC W

2. Checking of structural steel material supplied by the Contractor/ Manufacturers test certificate/ testing (as applicable)

WC Rw

3. Welding Filler material approval/ qualification

a) Manufacturing test certificates/ documents WC Rw

b) Testing, if any WC Rw

4. WPS/ PQR WC W

5. Welders performance qualification WC W

6. Layout checking WC S

7. Welding equipment and accessories WC S

8. Preparation and approval of Fabrication drawings WC Rw

B FABRICATION ACTIVITIES

1 Materials as per design drawing WC Rw

2 Check straightness and non-warping of members WC S

3 Dimensional and fit-up checks including provision of slopes for deflection wherever required

WC S

4 Visual check for welding WC S

5 Grinding including surface preparation for painting and application of primer

WC Rw

6 Checking paint as per specs, shelf-life, etc. WC S

7 Application of specified paint, painting thickness, etc. WC W

C FIELD ERECTION ACTIVITIES

1 Lifting arrangements including test certificates of lifting tackles WC S/Rw

2 Correctness of location WC S

3 Orientation of bracing, lugs WC S

4 Alignment & levels WC S

5 Field welding (if any) WC W

6 Grouting WC S

7 Finishing coat of paint, thickness of paint etc. WC W

8 Preparation of As-built drawings WC Rw






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

PLASTERING


Contractor Owner/

PMC

1 Check for completeness of all hidden jobs like piping, conduiting, etc.

WC S

2. Check for grading of sand, Mix proportion

WC S

3 Sample preparation for finish and its approval

WC W

4 Neeru application on plaster (as applicable)

WC S

5. Hacking and cleaning the surface, removing loose particles, wetting the surface

WC S

6. Checking of plaster thickness, plumb & even surface

WC S

7. Check for grooves, openings, rounding off the corners, hollowness in plaster

WC S

8 Curing WC S






Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

ROOFING ACCESSORIES


Contractor Owner/

PMC

1. Check for material including Manufacturers test certificate (as applicable) and sequence of sheeting

WC W

2. Check for mitring, overhang, laps, etc.

WC S

3. Slopes line, level of sheets, barge boards, ridges & gutters, over hang of sheets

WC S

4. Bolting by drilling only, length of bolts, nos., anodizing and type of washers

WC W

5 Check for slopes of rain gutters, down take pipes, north lighting curves/ supports for gutters

WC S

6 Check for leakage/ passing of light WC S



NOTE : Fixing arrangement need to be reviewed with respect to contract specifications.




Page 1 of 2


N A F T E C . S P A

INDICATIVE


ELECTRICAL WORKS



Page 2 of 2


N A F T E C . S P A

INDEX

S.NO


1.

Installation/ Erection & Testing of Power Transformer

6648-00-19-43-2801 0

2.

Installation/ Erection & Testing of Motor

6648-00-19-43-2805 0

3.

Installation/ Erection & Testing of Generator

6648-00-19-43-2810 0

4.

Installation/ Erection & Testing of Switch Gears/ PCC/ MCC/ EMCC

6648-00-19-43-2815 0

5.

Installation/ Erection & Testing of EHT/ HT Main Bus & Allied Equip.

6648-00-19-43-2820 0

6.

Cable Laying

6648-00-19-43-2825 0

7.

Lighting System

6648-00-19-43-2830 0

8.

Earthing System

6648-00-19-43-2835 0

9.

Installation of Bus duct

6648-00-19-43-2840 0

10.

Cable Termination

6648-00-19-43-2845 0



Page 1 of 3


N A F T E C . S P A

INDICATIVE ITP FOR

INSTALLATION/ERECTION & TESTING OF POWER TRANSFORMER


Contractor Owner/

PMC 1. 2. 3. 4. 5. 6. 7. 8. 9.

Incoming Material inspection at site a) Owner supplied b) EPCC CONTRACTOR supplied including check testing, if

any Check foundation, its cleanliness, level and centre lines, Anchor bolts/insert plates, their position & straightness, flatness of contacting surface for transformer skid. In case of Rail mounted type, check centre line and levels of rails. Check the Transformer no. and rating as per drawings and purged gas/ air pressure & oil leakage, physical damage etc. Check availability of all accessories and Transformer oil Check sequence of installation e.g. main tank first + radiators + accessories + internal check as per installation flow chart. Ensure the cleanliness of connecting part e.g. flange parts and maintenance of duly tight Blank flanges until just before commencement of assembly Check bushing cracks, chips or presence of paint or dirt. Bushing should be cleaned as per vendor’s instruction. Check explosion vent assembly & healthiness of diaphragm Ensure the internal check is done by vendors’ supervisor and he submits the reports to OWNER/ PMC duly signed by him and EPCC CONTRACTOR After completing assembly of all parts, filling of tank and OLTC to be performed, prior to filling the Transformer oil, each drum must be tested against di-electric strength for minimum as per specifications

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N A F T E C . S P A


Contractor Owner/

PMC 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Check & ensure bus duct connection at both ends. Ensure cable connection at the cable and box their colour coding & tightness (if required, use of spring and flat washers on the appropriate faces to be confirmed) and cleanliness of lapping surfaces. For multiple cable connection, check for correctness of R.R., YY, BB grouping If specified, fill the cable end box with tested transformer oil and ensure oil levels Check the use of proper size conductors/ cables for HV/LV, neutral connection and their connection to NGR or earth grid/ earth point. Measure earth resistant of earth points Check equipment earthing, connections, tightness and earth resistance value Ensure earthing of tertiary winding Check leakage and oil level Check proper installation of Dessicauts (Reactivate the silica gel to blue; oil traps to be filled up) Measure winding resistance at each tap a. Test insulation resistance & PI b. Assure heat run/ dehydration of transformer c. Check final IR value after dehydration and temp. Vs IR curve to ensure drying Test vector group polarity, magnetizing current, magnetic balancing

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N A F T E C . S P A


Contractor Owner/

PMC 21. 22. 23. 24. 25. 26. 27. 28. 29.

Test transformation ratio at each tap points (injecting 3 phase, 415 V at primary) Assure laying, terminating & connection of all control cables Check Bucholtz's relay operation by air injection for both transformer & OLTC, MOG alarm and trip contacts’ function Check setting of Fan control (auto & manual), OTI, WTI- alarm and trip Check tap changer control/operation-both auto & manual – without energizing the transformer. Ensure master/ followers’ correct functioning Final residual check to confirm removal of all temporary supports/ spacers, tags, accumulation of air in Buchhelz relay, oil, if any, etc., which might have been used as protection/ and identification during transportation and erection Check operation of cooling system Check transformer protection relay settings as per Relay Setting diagram Mechanical Acceptance Test INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

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Page 1 of 2


N A F T E C . S P A

INDICATIVE ITP FOR

INSTALLATION/ERECTION & TESTING OF MOTOR

Sl. No.

Activity EPCC Contractor

Owner/ PMC

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Check for foundation, its level & centre line markings, ensure the depth of anchor grouting pockets and straightness of anchor bolts. Foundation should be thoroughly cleaned before placement of motor Check motor name plate, identify the equipment referring to vendor’s shop floor test certificate and construction drawing Check motor as per area classification drgs duly approved by CCE Check for installation of motor, its leveling, alignment and coupling with driven equipment (before coupling magnetic centering must be ensured) Ensure fixing of all accessories, temperature indicators, cooling system, lubricating pumps, etc. Ensure pedestal insulation Check lubrication of bearings, their suitability and level. For lubricants, vendor instructions and specifications to be followed Assure sealing of all exposed outlets during erection/ assembly Ensure Air-gap as per vendor instruction (for big machines assembled at site) Ensure all spacers and blockings used for transportation and erection have been removed Check proper earthing of the motor and earth connection.

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N A F T E C . S P A


Contractor Owner/

PMC 12. 13. 14. 15. 16. 17. 18.

a. Check IR and PI for the motor and IR for auxiliary

circuits like heaters and Thermal detectors, excitor (for system motor only), etc.

b. In case of low IR/PI, dehydrate the motor by suitable

method as per vendors’ recommendation. Measure winding Resistance (if specified) Inspect space heater and control cable connections. Ensure the tightness of connection, proper glanding and earthing of armour, correct phase sequence of supply cable as per hire mark and closing the covers of terminal boxes. Check for de-coupling of motor for no-load run and ensure the re-coupling of the motor after verification of original alignment. Set the temperature indicators (alarm/ trip) and vibration monitors (if any) Check motor protection relay settings as per Relay Setting diagram Mechanical Acceptance Test INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

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Page 1 of 3


N A F T E C . S P A

INDICATIVE ITP FOR

INSTALLATION/ERECTION & TESTING OF GENERATOR


Contractor Owner/

PMC 1. 2. 3. 4. 5. 6. 7. 8. 9.

Check for foundation, its level & centre line markings, ensure the depth of anchor grouting pockets and straightness of anchor bolts. Foundation should be thoroughly cleaned before placement of equipment Check equipment name plate, identify the equipment referring to vendor’s shop floor test certificate and construction drawing Check equipments as per approved area classification drawings Assure sealing of all exposed outlets during erection/ assembly Check for installation of equipment, its leveling, alignment and coupling with driven equipment (before coupling magnetic centering must be ensured) Ensure fixing of all accessories, temperature indicators, cooling system, lubricating pumps, etc. Ensure pedestal insulation Check lubrication of bearings, their suitability and level. For lubricants, vendor instructions and specifications to be followed Ensure Air-gap as per vendor instruction (for big machines assembled at site)

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N A F T E C . S P A


Contractor Owner/

PMC 10. 11. 12. 13. 14. 15. 16.

Ensure all spacers and blockings used for transportation and erection have been removed Check earthing of the equipment and earth connection including NGR. Ensure earth resistance a. Check IR and PI for the equipment and IR for auxiliary circuits like heaters and Thermal detectors, excitor PMG, etc. b. In case of low IR/PI, dehydrate the equipment by suitable method as per vendors’ recommendation. Measure winding Resistance (if specified) Inspect exciter control panel/ space heater and control cable connections. Ensure the tightness of connection, proper glanding and earthing of armour correct phase sequence of supply cable as per hire mar mark and closing the covers of terminal boxes. Set the temperature indicators (alarm/ trip) and vibration monitors Check the generator P.T.

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N A F T E C . S P A

Sl. No.


Owner/ PMC

17. 18. 19. 20. 21. 22. 23. 24.

Check generator control panel , its wiring as per drg. Relay & their calibration & setting, functional checks, etc. Perform relay testing and operations a. Diff. relay operation b. Over Current (O/C) relay operation c. Short circuit O/C relay operation. Draw short CRT curve &

compare with shop test results. Perform Negative phase sequence test & confirm the operation of the relay Perform Earth Fault (E/F) test & see the operation of E/F relay Perform open circuit test & draw the open CRT curve for comparison Check for synchronizing & manual excitation behavior Check AVR operation & setting Mechanical acceptance test INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

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NOTE : Activity pertaining to Sl. No. 5 will be checked by Mechanical group.




Page 1 of 3


N A F T E C . S P A

INDICATIVE ITP FOR

INSTALLATION/ERECTION & TESTING OF SWITCH

GEARS/PCC/MCC/EMCC Sl. No. Activity EPCC

Contractor Owner/

PMC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Check the layout of base channels/frames and assure the correct provisions for grouting/welding and cable entry openings Ensure level and centre lines are within the prescribed limits and they match with the requirements of incoming Bus-ducts, if any Assure proper grouting/welding of the base channels/frames Ensure proper handling of the panels Check sequence wise (starting from centre or Bus-duct panel) installation final leveling and bolting up Check main bus bar connection at all shipping sections and shrouding at all tap-off points Check inter panel wiring after fixing of loose accessories and wiring Assure the level of flooring for smooth opening of panel doors and drawing out and in operation of Breaker Trolleys Check interchangeabilities of circuit breakers Check equipment earthing & continuity of earth bus

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N A F T E C . S P A


Contractor Owner/

PMC 11. 12. 13. 14. 15. 16. 17. 18.

Ensure thorough cleaning, removal of temporary spacers, supports, any foreign materials and dusting the panels Verify the correctness, in accordance with the drawings, of all type of relays, test blocks, control switches, meters and instruments, motor starters, fuses, space heaters, etc. Check name plate for each breaker, inspect and test the operating mechanics (Mechanically), interlocks, contacts, arc chutes, auxiliary devices and adjustments as required Visually check all relays and meters for removal of shipping blocks and for mechanical damage. Ensure their range against approved drawings, inspect calibration, testing and setting for each relay and meter. Visually check name plates of CT’s and PT’s and ensure their ratio accuracy, class and proper grounding against approved drawings. Test their polarity knee point and ratio. Primary injection tests at three points on the characteristics curve submitted by the manufacturer’s Test and witness I.R. value of the power and control bus Test and witness high pot tests, if specified Ensure tightness of connection of control wiring

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N A F T E C . S P A


Contractor Owner/

PMC 19. 20. 21. 22. 23.

Inspect secondary injection test and ensure tripping of C.B. through protection relays Inspect primary injection & check the breaker tripping through protective relays, check ammeter indications Switch on AC & DC control supply. Check the sequence of operation of breakers electrically, local and remote interlock; ensure proper alarm and announciation and indications in SW/GR/MCC/Control Panel. Auto Change- over should be ensured. Verify tripping of breakers at 70% of nominal control voltage Measure contact resistance and ensure simultaneous closing and making of breaker contacts, if specified Mechanical Acceptance Test INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

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N A F T E C . S P A

INDICATIVE ITP FOR

INSTALLATION/ERECTION & TESTING OF EHT/HT MAIN BUS &

ALLIED EQUIP. Sl. No.


Owner/ PMC

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Check the insulators wall bushing for any damage like chips or cracks. Ensure proper installation of the insulators & bushing Check the clearance between conductor to ground & conductor to floor level. Ensure minimum clearance between two conductor Bus Check the anchoring of the conductor bus and terminal/ Tap. Off connections Ensure correctness of phase sequence Check earth connections and measure earth resistance of the supporting structures of insulators Check IR value of the conductor bus phase to phase and each phase to earth Check high voltage tests keeping all the CB’s and isolators closed but PT’s should be disconnected Check hot line insulator washing equipment and system-Nozzle position & resistivity of water Check type and class of lighting arrestor, its earth connection and earth resistance Mechanical Acceptance Test INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

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N A F T E C . S P A

INDICATIVE ITP FOR

CABLE LAYING Sl. No. Activity EPCC

Contractor Owner/

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

Survey the cable route as per AFC drawings, identify any possible obstruction like road/pipe rack crossing, heat sources etc. and finalize the cable route Complete all road/pipe crossings etc. as per drawing Prepare cable drum schedule to avoid wastage and minimize cable joints. Ensure entire route is available for cable trench Ensure availability of cables of required size and length Verify and ensure the dimensions of buried trench as per AFC drawings (in case of buried cables) Ensure readiness of cable trays and installation of GI pies (for cable protection) wherever required. Ensure the initial bed of sand is provided as per standard and its thickness Lay cables as per the cable schedule, minimizing criss-crossing of cables within the trench (1st layer) Provide cable tags at specified locations Record IR value of cables of first layer after sand filling. Provide second layer of sand, and ensure proper clearance between HT/LT cables (wherever applicable) Complete layer wise laying of cables and sand filling Record IR value of cables of each layer after sand filling Provide final layer of sand Ensure cable trenches in hazardous areas are filled with sand

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N A F T E C . S P A


Contractor Owner/

PMC 17. 18. 19. 20. 21.

Provide bricks/slabs for cable protection in buried trenches. Back fill the trenches with earth and compact properly after ensuring the completion of earthing works if any as per earthing layout drawings. Install cover slabs and seal the trenches in plant/offsite areas after ensuring the completion of earthing works if any. Remove surplus earth generated as per provisions in the contract. Provide cable markers as per the specifications at identified locations INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

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Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR LIGHTING SYSTEM


Contractor Owner/

PMC 1 The lighting fittings are checked for damage/ lack of

accompanying documents (for specialised items). The items usually include lighting fixtures, control gear box, glands, flameproof/ non-flameproof equipment/ fittings, lighting poles/ accessories, lighting mast, fans, receptacles, certificates from recognized authorities for Class IIA, IIB, IIC explosion proof/ flameproof fixtures/ plugs/ sockets.

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ensure that the lighting fixtures during installation are not interfering with any other plant equipment. In case of any fouling, a change of location is to be suggested & OWNER approval to be taken to proceed.

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receptacles will be mounted as per the drawings & standards.

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on walkways, platforms & outdoor areas, lighting fixtures will be located nearer to landing of stairs/ ladders, gauges, flow meters etc.

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plugs for spare entry/ sockets to be provided (especially in hazardous areas). lighting poles/ fixtures shall be erected manually on concrete foundations as per the drawings.

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earth continuity for all individual sockets/ outlets as well as for the complete lighting system will be checked.

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the lighting circuit numbers shall be maintained as indicated in the drawing.

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luminaries for emergency purpose shall carry identification marks.

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For Outdoor Lighting

9

the poles are welded or bolted to the base/ foundation. The verticality of the poles are checked and alignment adjusted accordingly.

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10

cable termination, earthing, etc are done and the JB sealed.

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11

touch-up painting or galvoseal application to be done at affected areas to arrest corrosion.

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INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

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N A F T E C . S P A

INDICATIVE ITP FOR EARTHING SYSTEM


Contractor Owner/

PMC

1.

2.

3.

4.

5.

6.

7.

8

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10.

11.

12.

Ensure that all the materials to be used for earthing are in accordance to the contract specifications and inspected & cleared by the OWNER/ consultant representatives before putting in use. Ensure the earthing layouts are surveyed & confirmed before commencement of excavation to avoid re-works/ interference/ fouling with other underground installations. Ensure the electrodes have a clean surface, free from non-conducting materials like paint, grease etc. Check the earth pit are backfilled by using alternate layers of charcoal & common salt and will be individually numbered for identification. Check the top level of the earth pit is matched to the finished grade level. Check earthing grids are installed as per the pre-determined layout & earthing conductors will be at a depth specified in the specifications from the grade level. Ensure the weld joints made are by overlapping of the strip equivalent to double the width of the strip and three sides being continuously welded. Check all joints for the conductors below the grade level are welded & suitably protected by application of two coats of bitumen & rapping with Jute. The earthing strips laid above ground shall be welded and will be protected by applying two coats of bitumen. Ensure the joints are inspected before the coat application & backfilling. Ensure from every earth electrode two distinct connections are made to the main earth grid. Ensure all the risers are protected against mechanical damage & are clamped to the walls, columns, etc. Ensure all the MV & HV electrical equipment are doubly earthed by connecting two points on the equipment to the earth grid. Rest of the structural, mechanical, piping shall be connected to the earth grid as per the contract specifications & drawings.

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Page 2 of 2


N A F T E C . S P A


Contractor Owner/

PMC

13.

14.

15.

16.

all process pipelines shall be bonded & earthed at entry & exit points of battery limit of hazardous area. Ensure lightning protection grid is connected to individual electrode and are bonded to the main earth grid by two or more points as per the drawings. Ensure each lighting fixture & receptacle are earthed through the extra core provided in the lighting cable. ( Normally, the third core of a 3 core cable) Remove surplus earth generated as per provisions in the contract. INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

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Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR INSTALLATION OF BUS DUCT Sl. No. Activity EPCC

Contractor Owner/

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

Incoming Material a) Owner supplied b) EPCC CONTRACTOR supplied including check testing, if any Ensure that the PCCC terminal box & the transformer terminal boxes are inspected & cleared to proceed with the bus duct installation. Check the equipment no. and rating as per drawings, physical damage etc. Check availability of all accessories Inspect the bus duct insulators for any physical damage, which may have occurred during transit. Check bushing cracks, chips or presence of paint or dirt. Bushing should be cleaned as per vendor’s instruction. Ensure the various sections of the bus duct enclosures are coupled together by using proper gaskets & bellows as specified. Ensure the bus bars are properly fixed & coupled on the insulator and ensure that the correct phases are connected at both ends. Ensure the bus bar bolts are tightened to the required torque values (preferably between 60 to 70 N Mtr) using calibrated torque wrench. Ensure the bus bar joints are insulated using manufacturers recommended materials, wherever required. Prior to closing of the bus duct cover, ensure that the bus duct enclosures are cleared of tools/ loose materials and debris. Ensure the enclosure of bus duct & support structures should be earthed to the earthing grid as per the drawing. Check touch up painting wherever necessary on completion of installation. Ensure the wall sealing is done & sun shields provided as per the drawings. Verify the bus bar joints are clean/ polished & not oxidised before bolt-up connection. INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

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N A F T E C . S P A

INDICATIVE ITP FOR CABLE TERMINATION

(The cables covered in this section are multi-core as well as single core HT & LT cables.)


Contractor Owner/

PMC 1.

2.

3.

4.

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6.

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8.

9.

10.

11.

12.

13.

14.

Ensure proper tagging of the cable at both ends. Ensure that the cables are laid separately for HT & LT system.

Ensure cables are properly dressed, clamped & glanded using suitable sizes of cable glands.

Ensure sufficient cable length is kept on both ends for future Re-termination if need arises. Ensure proper bending radius while laying to avoid twisting. Ensure cable segregation, spacing & depths maintained are as per the specifications Ensure usage of correct sizes of lugs shall be used for termination. Ensure all cores are firmly terminated to terminals provided in individual feeders. Ensure earthing of armour is done properly. Ensure continuity & IR value checks are done on the cable from panels to equipments. Ensure that unused entries are plugged tightly in panels, motor terminal boxes, JB’s, etc Ensure each underground cable is properly tagged as per the Instruction of Engineer In charge Ensure on completion of cable termination, the cable trenches are backfilled & trench covers put back in position. Ensure all cable openings & GI conduit entries are properly sealed. INSPECTION & TEST DOCUMENTS Review Test and Inspection Documents

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Page 1 of 2


N A F T E C . S P A

INDICATIVE


PIPELINE WORKS



Page 2 of 2


N A F T E C . S P A

INDEX S.NO


PIPELINE WORKS

1. Handing Over/Taking over of line pipe at Dump Yard

6648-00-19-43-2901 0

2. Receipt, Handling & Storage of Line pipes and other free issue materials

6648-00-19-43-2902 0

3. Procurement, Receipt & Storage of EPCC Contractor supplied materials

6648-00-19-43-2903 0

4. Row Survey, Clearing & Grading 6648-00-19-43-2904 0

5. Trenching 6648-00-19-43-2905 0

6. Blasting 6648-00-19-43-2906 0

7. Pipe taking over, handling, hauling & stringing

6648-00-19-43-2907 0

8. Cold Field Bending of Pipes 6648-00-19-43-2908 0

9. Concrete Coating 6648-00-19-43-2909 0

10. Main Line welding 6648-00-19-43-2910 0

11. Repair of ARC burns on pipes/Arc strikes 6648-00-19-43-2911 0

12. Field joint coating & repair 6648-00-19-43-2912 0

13. Lowering of main line & OFC cables 6648-00-19-43-2913 0

14. Back filling 6648-00-19-43-2914 0

15. Cased crossings 6648-00-19-43-2915 0

16. Open cut crossings 6648-00-19-43-2916 0

17. Major Water crossings 6648-00-19-43-2917 0

18. Hydro Testing of strings for crossings 6648-00-19-43-2918 0

19. Installation of pipeline markers 6648-00-19-43-2919 0

20. Hydrostatic Testing & De-watering 6648-00-19-43-2920 0

21. Main line sectionalizing valve (SV) installation 6648-00-19-43-2921 0

22. Final clean UP & restoration 6648-00-19-43-2922 0

23. Calibration of instrument 6648-00-19-43-2923 0

24. OFC Laying 6648-00-19-43-2924 0

25. OFC Jointing & Testing 6648-00-19-43-2925 0



Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

HANDING OVER/TAKING OVER OF LINE PIPE AT DUMP YARD


Contractor Owner/

PMC

1

Submission & approval of work procedure

WC

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Grading and stripping of dumpsites

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S

3 Checking of coating material, pipe dia., cleaning, heat nos. & other markings, bevel edges, correlating with Release Note by laying contractor

WC W

4 Stacking of pipes in a pyramid fashion with proper packing.

WC S

5 Segregation of defective pipes having beveled end defects, damaged coatings, improper cleaning, etc.

WC S

6 Repairs, if any

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7 Signing of Joint Record for handing over/ taken over

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INSPECTION & TEST DOCUMENTS Review test and inspection documents

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The above activities will be under EIL if warehousing is in EIL scope of work




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

RECEIPT, HANDLING & STORAGE OF LINE PIPES AND

OTHER FREE ISSUE MATERIALS


Contractor Owner/

PMC

1


WC

Rw

2

Material Issue Voucher

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3

Visual check for damages of coating, bevel & other damages, inside cleaning, and re-fixing of end caps

WC

W

4

Identification of correct grade, type, specification, heat no., pipe no., etc. of materials

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5

Holiday test of pipes

WC

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6

Storage/stacking of line pipes as per specs

WC

S

7

Drum testing of OFC

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8

Loading & transportation as per spec.

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9

Electrical items

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* wherever damage reported before taking over




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

PROCUREMENT, RECEIPT & STORAGE OF EPCC CONTRACTOR SUPPLIED MATERIALS


Contractor Owner/

PMC

1.


WC

Rw

2.

Receipt of all PO & PR/MR

WC

HP

3.

Physical verification of materials with PO for any damage

WC

S

4. Verification of batch no./specification/Inspector's hard stamp, etc.

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5

Verification of test certificates/ Release Notes & correlation with the materials received at site.

WC

HP

6.

Field testing, if any as required

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Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

ROW SURVEY, CLEARING & GRADING


Contractor Owner/

PMC

1

Taking over ROU from client/owner

WC

Rw

2

Calibration/testing of survey equipments a) Review of certificates b) Rechecking , if any

WC WC

Rw HP

3 Submission & approval of work procedure WC Rw

4

Staking markers for IPs, TPs, Km thickness change and others

WC

S

5 Availability of approved AFC alignment sheets WC HP

6 Recording of level before & after ROW grading WC S

7

Centre line of pipeline and location/width of turning points

WC

W/S *

8

Setting of reference line and TBM

WC

S

9

Establishment of width of ROW with reference to the existing pillars as per alignment sheet

WC

S

10

Existence of structure/obstruction

WC

W/S *

11

Restricted ROW

WC

W/S *


WC

Rw

* W : In case ROU is in Owner’s Scope S : In case ROU is in EPCC contractor’s scope Pl. refer document No. 6648-00-19-43-2000 for definition of WC, Rw, HP, W and S



Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

TRENCHING


Contractor Owner/

PMC

1

Submission and approval of work procedure

WC

Rw

2

Center line/dimensions of trench w.r.t established markers & stacks or existing U/G line (in case of existing ROW)

WC

S

3

Measurement of trench depth

WC

S

4

Detail of under-ground structures encountered and its safety

WC

S

5

Provision of warning signs & safety regulation

WC

S

6

Maintenance of motorable road

WC

S

7

Preservation of aerable soil

WC

S

8

Level and width of excavated trenches

WC

S

9 Bottom padding in trench, if required WC S

10

Restricted ROW WC W

11 Profile survey of trench at TP/crossing WC W


WC

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

BLASTING


Contractor Owner/

PMC

1 Submission & approval of work procedure

WC

HP

2

Centre line of trench / dimension

WC

W

3

Notice to all concerned authorities

WC

S

4

Removal of super structures

WC

W

5

Submit details of all explosive materials for approval & license for blasting

WC

HP

6

Availability of qualified supervisor

WC

Rw

7

Examine blasting material before use

WC

S

8

Trial blast & vibration recording for each rock and trench type

WC

HP

9

Ensure area is clear of human beings and animals

WC

S

10

Ensure firing of all spots, misfires to be brought to notice

WC

Rw

11

Recording of all safety regulations

WC

Rw

12

Fuses, inflammable materials, insertion of cartridge

WC

S

13

Firing

WC

S

14

Details of underground utilities encountered

WC

W

15

Bottom padding in trench, if required

WC

W

16

Profile of trench to suit vertical and horizontal bends

WC

S


WC

Rw Pl. refer document No. 6648-00-19-43-2000 for definition of WC, Rw, HP, W and S



Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

PIPE TAKING OVER, HANDLING, HAULING & STRINGING


Contractor Owner/

PMC

1


WC

Rw

2

Verification of pipe dia./ length/ ovality/ inside cleanliness, damage during transportation/ pipe no./ heat no./ yard coating no., holiday checking etc. & its documentation during taking over of pipes from dump yards

WC

S

3

Presence of bevel protector (Metal guard )

WC

S

4

Proper stacking & tieing of pipe on trailor

WC

S

5

Stringing of correct dia./thickness of pipes in ROW on sand bags

WC

W

6

Repair of damaged coating

WC

S

7

Use of proper slings

WC

S

8

Proper angular placement/TP

WC

S


WC

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

COLD FIELD BENDING OF PIPES


Contractor Owner/

PMC

1


WC

Rw

2

Bending procedure qualification and approval including performance test of bending machine

WC

HP

3

Survey check

WC

S

4

Setting up of pipe orientation for L-Seam

WC

S

5

Bending operation; degree/pull etc.

WC

S

6

Visual check after bending incl. radius angle etc.

WC

S

7

Gauge check

WC

W

8

Holiday checking

WC

W

9

Disbondment check

WC

W

10

Availability of straight length on ends

WC

W

11 Numbering for identification w.r.t. TP WC S


WC

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

CONCRETE COATING


Contractor Owner/

PMC

1


WC

Rw

2 Coating procedure approval WC Rw

3 Logging of activities WC S

4 Holiday test of pipes before placing of reinforcement wires etc./ repair

WC

W

5

Raw material inspection & testing wherever required

WC

HP

6

Wire mesh application

WC

S

7

Approval of concrete mix design

WC

HP

8

Preparation of concrete mix & pouring

WC

S

9

Visual check of coated pipe

WC

S

10

Repairs

WC

S

11

Water curing/ curing with compound

WC

S

12

Cube testing

WC

S

13

Megger checking

WC

HP

14

Marking of completed pipes, cleaning & fixing of end caps

W C

HP


WC

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

MAIN LINE WELDING


Contractor Owner/

PMC 1

Submission & approval of work procedures

WC

Rw

2

Filler material a) Approval of Make b) Review of manufacturer’s test certificates/documents c) Testing, as required

WC WC WC

HP HP HP

3

WPS/PQR a) Review of proposed WPS b) Procedure Qualification Test c) Approval of final WPS & PQR

WC WC WC

HP HP HP

4

Welders a) Performance qualification test b) Review of radiographs of qualification test piece c) Final approval of welders

WC WC WC

W HP HP

5 NDT Procedure Qualification a) Review of proposed procedure b) Procedure Qualification Test

WC WC

HP W

6 Bevel inspection & inside cleaning of pipes

WC S

7

Line-up/pre heating & root welding WC S

8 Lowering of pipe on sand bags & removal of line-up clamp

WC S

9 Weld visual & writing welder nos. beside completed welds

WC S

10 Placement of night caps/end caps

WC S

11 Interpretation of weld radiographs

WC HP

12 Other NDT’s

WC W/Rw

13 Visual check of repaired welds

WC S

14 Destructive Testing of production welds

WC HP

15 All weld tensile test and bend tests for each batch of electrodes (used for other than root pass welding )

WC HP

16

Confirmation check of radiography of weld joints WC W

INSPECTION & TEST DOCUMENTS Review inspection & test documents

WC




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

REPAIR OF ARC BURNS ON PIPES/ARC STRIKES


Contractor Owner/

PMC

1


WC

Rw

2

Visual check for arc burns on pipe surface

WC

S

3

Removal of arc burns by grinding

WC

S

4

DP/MP test on the ground area (arc burn area)

WC

W

5

Wall thickness check of arc burn repair area

WC

W

6

UT on the arc burn area, if required

WC

W


WC

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

FIELD JOINT COATING & REPAIR


Contractor Owner/

PMC

1


WC

Rw

2

Approval of coating procedure

WC

HP

3

Approval of coating materials

WC

HP

4

Qualification of insulators/application

WC

HP

5

Surface preparation/preparation at shop coating (chamfering etc.)

WC

S

6

Heating of pipe surface and mixing & application primer

WC

S

7

Temperature measurement prior to application

WC

S

8

Application of sleeves/tapes

WC

S

9

Visual check for irregularities, thickness etc.

WC

S

10

Holiday check

WC

W

11

Peel test, wherever required

WC

HP

12

Repairs and Holidays

WC

W


WC

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

LOWERING OF MAIN LINE & OFC CABLES


Contractor Owner/

PMC

1

Submission and approval of work procedure

WC

Rw

2

Clearance for lowering

WC

HP

3

Inspection of trench for depth , debris etc.

WC

S

4

Soft soil/sand padding , if required

WC

W

5

Holiday check prior/during Lowering after removing end caps

WC

HP

6

Calibration of Holiday detector

WC

W

7

Location of pipe center line w.r.t. trench center & fixing of end caps

WC

S

8

Tests on optical fibre cable/HDPE duct as applicable (before laying)

WC

Rw

9

Lowering of optical fibre cable/HDPE duct

WC

W

10

Checking of levels

WC

S

11

Post padding

WC

S


WC

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

BACK FILLING


Contractor Owner/

PMC

1


WC

Rw

2

Post padding by soft soil/sand, if required

WC

S

3

Placement of warning tape over OFC/HDPE duct

WC

S

4

Field concrete coating, if required

WC

S

5

Proper backfilling with crown

WC

S

6

Compaction of backfilling at crossings etc.

WC

S

7

Replacement of aerable soil, if required

WC

S


WC

Rw




Page 1 of 2


N A F T E C . S P A

INDICATIVE ITP FOR

CASED CROSSINGS


Contractor Owner/

PMC

1 Submission & approval of Work Procedure

WC

Rw

2

Approval from competent authority to start the work

WC

S

3 Preparation of constn. drg. and schedule for boring as per contract/specs.

WC Rw

4 Approval of construction drg. from competent authority for length & depth of casing pipe in case of boring in EPCC contractor’s scope

WC S

5 Preliminary survey & marking of P/L centre line WC W

6 Preparation of boring pit & level check WC S

7 Fitness check of casing pipe (out of roundness, dent etc.)

WC S

8 Welding of casing pipe WC S

9 Visual checks of casing pipe after welding WC W

10 Visual check of inside of the casing pipe & carrier pipe WC S

11 Boring operation WC S

12 Installation of casing vent and drain pipes WC S

13 Coating/Painting of vent and drain pipes WC S

14 Fabrication of carrier Pipe string WC *

15 Pre hydrotest of carrier pipe WC HP

16 NDT WC *

17

Field joint coating & holiday check WC *




Page 2 of 2


N A F T E C . S P A


Contractor Owner/

PMC 18 Approval of insulation material, spacing of insulator &

tightness etc. WC Rw

19

Installation of insulators

WC

W

20

Welding of nose piece to carrier pipe

WC

S

21

Insertion of Carrier Pipe

WC

W

22

Installation of end seals

WC

W

23

Electrical circuiting & resistance checks before backfilling

WC

W

24

Boring completion reports & preparation of As Built Drgs.

WC

Rw

25

Obtaining/submission of NOC from competent authority

WC

S


WC

Rw

* as per Main Line Welding ITP No. 6648-00-19-43-2910



Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

OPEN CUT CROSSINGS


Contractor Owner/

PMC


WC

Rw

2

a) Approval from competent authority, if required

to start the work

WC

S

b) Crossing drawings, wherever required WC Rw

3 Fabrication of crossing string

WC

*

4

NDT

WC

*

5

Hydro test of the crossing string, if applicable & reqd.

WC

HP

6

Field joint coating

WC

*

7

Survey, marking centre line of P/L

WC

W

8

Holiday testing while lowering in the trench & fixing of end caps after lowering

WC

HP

9

Concrete coating, if required

WC

*

10

Laying of HDPE pipe for OFC or MS conduit for HDPE pipe

WC

*

11

Paddings & backfilling with selected soil as required

WC

S

12

Crossing completion report

WC

Rw

13

Excess earth disposal

WC

S

14

Installation of warning markers

WC

W

15

Obtaining & submission of NOC from competent authority

WC

Rw


WC

Rw * as per Main Line welding ITP No. 6648-00-19-43-2910




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

MAJOR WATER CROSSINGS


Contractor Owner/

PMC


WC

Rw

2 Approval of competent authority to start the work

WC S

3 Preliminary survey, marking reference line & TBM WC S

4 Crossing drawings duly approved by Engg. or statutory approvals, wherever required

WC Rw

5 Fabrication of string WC *

6 NDT WC *

7 Trenching WC S

8 Hydro test of the crossing string WC HP

9 Field joint coating WC HP

10 Holiday testing of the entire string WC W

11 Lowering / pulling WC W

12 Concrete coating , if required WC **

13 Laying of HDPE pipe for OFC WC W

14 Paddings & backfilling WC S

15 Gauging & Post - hydro test WC HP

16 Bank protection WC S

17 Post laying survey/As Built Drgs WC W

18 Crossing completion report WC S

19 Warning marker WC S


* As per Main Line Welding ITP No. 6648-00-19-43-2910 ** As per Concrete Coating ITP No. 6648-00-19-43-2909




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

HYDRO TESTING OF STRINGS FOR CROSSINGS


Contractor Owner/

PMC


WC

Rw

2 Fabrication of string WC *

3 NDT clearance WC HP

4 Inside cleaning of pipe string/gauging WC HP

5 Calibration certificate for pressure / temperature gauges WC Rw

6 Welding of test headers WC S

7 Water filling & venting WC S

8 Pressurization WC S

9 24 hour hold-up period - recording pressure / temperature for every hour

WC W

10 Visual inspection of weld/ pipe, wherever feasible WC W

11 Post hydro testing of major water crossings WC HP

12 Compilation of test records WC S

13 Draining of hydrotest water from the pipeline & fixing of end caps

WC W


WC

Rw

* as per Main Line welding ITP No.6648-00-19-43-2910




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

INSTALLATION OF PIPE LINE MARKERS


Contractor Owner/

PMC

1


WC

Rw

2

Approval of " Sample " markers

WC

Rw

3

Fabrication of pipe line / OFC markers as per drawing

WC

S

4

Surface preparation & primer application

WC

S

5

Pre -casting of markers ( ROU boundary marker )

WC

S

6

Installation of correct type marker at correct location as per drawing

WC

W

7

Primer touch-up, finish painting & stenciling

WC

S


WC

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR HYDROSTATIC TESTING & DE-WATERING


Contractor Owner/

PMC 1 Submission & approval of work procedure WC Rw

2 Mechanical clearance of the pipe section (Part “B” of pipe book)

WC HP

3 Submission of water test laboratory report including recommendations for corrosion inhibitor and its testing (if reqd.), oxygen scavengers and bactericides

WC Rw

4 Calibration certificates for dead weight tester, pressure gauges, pressure/temperature recorders temp. sensor, water meter etc.

WC Rw

5 Installation of temporary piping, equipments, filters, provisions for launching and receiving pigs etc.

WC S

6 Installation of water holding devices or piping from WC S water sources etc.

7 Ensuring communication system WC S

8 Ensuring safety requirements WC S

9 Review of filling pump & pressurizing pump data WC W

10 Cleaning by air pigging WC W

11 Gauging pig run and gauge plate inspection WC HP

12 Flushing by water driven pigs WC S

13 Installation of temperature sensors WC S

14 Installation of launching and receiving WC S headers and pigs

15 Filling operations and chemical dosing a) Filling rate WC S b) Chemical injection rate as approved WC S c) Back pressure control to avoid air entrapment WC S

16 Thermal stabilization WC HP 17 Air volume confirmation test WC HP 18 Pressurization

a) Rates as per approved procedure WC S b) Recording of temperature & pressure at every two hours

during 24 hours hold period WC HP

c) Bleed off water measurement WC W 19 Detection of leaks if any and extension of hydro test duration WC HP 20 Rectification & stocking/marking of damaged pipes WC W 21 Acceptance and evaluation of recorded data WC HP 22 Depressurization and de-watering to the WC W

accepted point 23 Swabbing operation WC S 24 Acceptance after swabbing operation and drying WC HP 25 Reinstatement WC W


WC




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

MAIN LINE SECTIONALIZING VALVE (SV) INSTALLATION


Contractor Owner/

PMC

1


WC

Rw

2

Approval of WPS

WC

Rw

3

Pup piece welding & pre fabrication of valve assembly

WC

W

4

NDT clearance

WC

HP

5

Hydro test

WC

HP

6

Valve installation & tie-in

WC

W

7

NDT clearance after tie-in welding

WC

HP

8

Field coating/Holiday inspection

WC

W

9

Concrete foundation with insulation sheet on top

WC

W

10

Holiday checking, padding, backfilling

WC

HP

11

Miscellaneous Civil / Structural works as per drawing

WC

S

12

Painting of above ground structures

WC

S


WC

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

FINAL CLEAN UP & RESTORATION


Contractor Owner/

PMC

1


WC

Rw

2

Restoration of water ways, roads, land structures, ecology etc.

WC

S

3

Restoration of river banks and check protections as per approved drawings

WC

S

4

Sorting and grouping of surplus piping material for returning to the owner and for scrapping

WC

S

5

Transporting all scrap and disposable from ROW

WC

S

6

Inspect restoration of ROW to the condition as per spec.

WC

S

7

Installing all markers on the ROW and verify the activity with respect to As Built Drawings

WC

W

8

Obtaining signature of land owners / statutory authorities on final restoration document

WC

Rw


WC

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

CALIBRATION OF INSTRUMENT


Contractor Owner/

PMC

1


WC

Rw

2

Physical verification of instruments

WC

W

3

Review of calibration certificates for test equipments

WC

Rw

4 Field calibration of instruments wherever required WC W


WC

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

OFC LAYING


Contractor Owner/

PMC

1


WC

Rw

2 Review and approval of alignment sheets WC Rw

3 Review of manufacturer test certificate of HDPE & cable WC Rw

4 Trench inspection WC S

5 HDPE pipe installation WC S

6 C.S. piping installation (boring) WC S

7 Cable laying/blowing WC S

8 Padding / warning mat WC S

9 Route markers – Mechanical & Electronic and joint pit markers

WC S

10 Joint pit WC W

11 As-Built drawings WC Rw


WC

Rw




Page 1 of 1


N A F T E C . S P A

INDICATIVE ITP FOR

OFC JOINTING & TESTING


Contractor Owner/

PMC

-


WC

Rw

1

Drum Testing

1a

Physical inspection

WC

S

1b

Measurement of fibre attenuation

WC

W

2

Jointing

2.1

Before splicing (after laying)

a)

Record fibre attenuation of both the fibre being spliced

WC

W

2.2

Measurement of splice loss

WC

W

3

Link Testing

3.1

Measurement of link loss from either side OFC between two stations after jointing

WC

W


WC

Rw




Page 1 of 2


N A F T E C . S P A

INDICATIVE FORMATS

FOR REPORTING

INSPECTION & TEST RESULTS



Page 2 of 2


N A F T E C . S P A

INDEX

S.NO


1. Indicative Formats for Mechanical works 6648-00-19-43-5100 0

2. Indicative Formats for Instrumentation works 6648-00-19-43-5600 0

3. Indicative Formats for Civil works 6648-00-19-43-5700 0

4. Indicative Formats for Electrical works 6648-00-19-43-5800 0



Page 1 of 2


N A F T E C . S P A

INDICATIVE

FORMATS

FOR

MECHANICAL WORKS



Page 2 of 2


N A F T E C . S P A

INDEX

S.NO


1.

Daily Material Traceability Report (For Piping/Heater)

6648-00-19-43-5101 0

2.

Daily Fit-up Inspection Report (For Piping/Heater)

6648-00-19-43-5102 0

3.

Daily Weld Visual Inspection Report (For Piping/Heater)

6648-00-19-43-5103 0

4.

Radiography Interpretation Report (For Piping/Heater)

6648-00-19-43-5104 0

5.

Line Wise Record (History Sheet) (For Piping/Heater)

6648-00-19-43-5105 0

6.

Flushing Completion Report

6648-00-19-43-5106 0

7.

Execution Scheme for Foundations

6648-00-19-43-5107 0

8.

Tie-In

6648-00-19-43-5108 0



Page 1 of 1


N A F T E C . S P A

DAILY MATERIAL TRACEABILITY REPORT

(FOR PIPING/HEATER)

Contract No. : Report No. : EPCC Contractor : Date :

Verified S.

No. Line/

Heater No.Area No.

Dia. Joint No.

Spool No.

Component Manufacturer Heat/Batch No.

Colour Code Contractor

* PMC/Owner*

Remarks

NOTE : A sketch of the spool may be enclosed. * As per approved Inspection & Test Plans (ITPs)



Page 1 of 1


N A F T E C . S P A

DAILY FIT-UP INSPECTION REPORT

(FOR PIPING/HEATER) REPORT NO : ______________ DATE : ____________________

Sl. No.

Line/Heater No. Area No. Dia Joint

No. Type

(*) A/R

Inspection Clearance

Remarks

A : Accepted R : Rejected (*) G - BUTT WELD S - SOCKET WELD B - BRANCH WELD __________________ M - MITRE WELD EPCC CONTRACTOR



Page 1 of 1


N A F T E C . S P A

DAILY WELD VISUAL INSPECTION REPORT

(FOR PIPING/HEATER) REPORT NO : ______________ DATE : ____________________

Sl. No.

Heater/Line No./ Drawing NO.

Area No. Dia

Weld Joint No.

Type (*)

Welder No.(s)

Acceptance Yes/No Remarks

(*) G = BUTT WELD S = SOCKET WELD TOTAL IN DIA. = B = BRANCH WELD PREVIOUS = M = MITRE WELD TILL DATE =



Page 1 of 1


N A F T E C . S P A

RADIOGRAPHY INTERPRETATION REPORT

(FOR PIPING/HEATER) RADIOGRAPHY TECHNIQUE : SWSI/DWSI/DWDI PROJECT :___________ SOURCE IR 192, X RAY, COBALT OWNER : ____________ FILM TYPE & NAME : __________________________ REPORT NO : ________ IQI : _________________________ DATE : ______________ RADIOGRAPHY PROCEDURE NO. Sl. No.

Heater/ Line No.

Area No.

Dia JointNo.

WelderNo.

Radio- Graphy No.

Segment Results Joint Status A/R/H

SWSI - SINGLE WALL SINGLE IMAGE, DWDI - DOUBLE WALLL DOUBLE IMAGE DWSI - DOUBLE WALL SINGLE IMAGE A - ACCEPTED, R - REPAIR H - HOLD



Page 1 of 1


N A F T E C . S P A

LINE WISE RECORD (HISTORY SHEET)

(FOR PIPING/HEATER) HEATER/LINE NO. ……………………. % RADIOGRAPHY ____________

Sl. No.

Area No. Dia.

(**) Joint No.

(*) Type

Welder No.

Visual Inpn.

Report No.

Radio- graphy Accep- tance

Report. Date

Stress Release

Chart No.

Hard- ness

PMI Weld ACC Date

Base Metal

Comp- onent

Manuf- acturer

Heat/ Batch

No.

PMI Accep- tance Date

(Material)

Remarks

(*) G - BUTT WELD S - SOCKET WELD (**) Joint No are to be posted from the dalily B - BRANCH WELD fit up reports M - MITRE WELD Where ever lsos are not available



Page 1 of 1


N A F T E C . S P A

FLUSHING COMPLETION REPORT

PROJECT : ______________________ REPORT NO: __________________ PLANT : ________________________ DATE : ________________________ EPCC CONTRACTOR : _________________

System Loop Nos. Ref. P&ID No.

Area Unit Test Reports – Enclosed

The above system has been cleaned/flushed/tested as per the

requirement of drawings and specifications and cleared for

operation.



Page 1 of 1


N A F T E C . S P A

REMARKS :

PROJECT :

FORMAT :

PLANT : SHEET NO: EPCC CONTRACTOR :

EXECUTION SCHEME

FOR FOUNDATIONS DATE OF CHECKING :

FDN NO:

DRG NO:

PCD / BCD ______________ GROUT THK ____________ ( ) TOP OF BOLT ( ) TOP OF CONCRETE PCO BOLT HT. P C D BOLT HT.

DESCRIPTION AS PER DRG ACTUAL DEVIATION REMARKS

N C/L CO ORDINATES E

EL. TOP OF CONCRETE NO. OF BOLTS & SIZE HEIGHT OF BOLTS POD OF BOLTS POCKET CLEARING F D N. ROUGHENING EL. TOP OF GROUT



Page 1 of 1


N A F T E C . S P A

TIE-IN POINT INSPECTION Unit Job No.

Tie-in Point No. Line No.

P&ID No.

Line Size Material

Chkd by Chkd by

S.No. Activity EPCC Contractor Sign./date

OWNER/PMC Sign./date

Remarks

1.

Bevel/Thickness

2.

Fit up Check material, thk, root gap etc.

3.

Root run welding

4.

DP check of root run

5.

Final Welding

6.

PWHT (if applicable)

7.

DP check of final welding

8.

Radiography check

9.

Hydrostatic test (if applicable)

* Details attached separately

TIE-IN POINT IS ACCEPTED _______________ _________________ EPCC Contractor OWNER/PMC



Page 1 of 2


N A F T E C . S P A

INDICATIVE

FORMATS

FOR




Page 2 of 2


N A F T E C . S P A

INDEX

S.

NO


1.

Cable/ Tube Drum Cutting Plan

6648-00-19-43-5601

0

2.

Calibration Report for Control Valves/On/Off Valves/ Shut Down Valves

6648-00-19-43-5602

0

3.

Fit-up Inspection Report

6648-00-19-43-5603

0

4.

Instrument Cable Laying Report

6648-00-19-43-5604

0

5.

Instrument Cable Megger Report

6648-00-19-43-5605

0

6.

Junction Box/LCP Installation Report

6648-00-19-43-5606

0

7.

Instrument Air Line/Pneumatic Tube Erection Report

6648-00-19-43-5607

0

8.

Level Instrument Installation Report

6648-00-19-43-5608

0

9.

Installation Report for Test T/W, TG, TC, RTD

6648-00-19-43-5609

0

Pl. refer document No.6648-00-19-43-5100 for Impulse piping formats.



Page 1 of 1


N A F T E C . S P A

CABLE/TUBE DRUM CUTTING PLAN REPORT NO : ______________________________ DATE : ______________________________ LOCATION : ______________________________ AREA : ______________________________

Sl. No.

Cable/Tube Size From To Drum

No. Drum

Length Length as per

Cable/Tube Schedule

Actual Length Balance Test

Reports Remarks

___________________ _____________ (EPCC CONTRACTOR) (OWNER/PMC)



Page 1 of 1


N A F T E C . S P A

CALIBRATION REPORT FOR CONTROL VALVES/ON/OFF VALVES/SHUT DOWN VALVES

REPORT NO: _____________________________ DATE : _____________________

Instrument details : Master calibration instrument details: Tag No. Type : Model No.: Model No.: Sl.No.: Sl.No. : Manufacturer : Testing agency : Range : T/C No.: Ref. Data Sheet : Validity upto : Calibration date :

Valve Position Indicator Input With Positioner Without Positioner

% Actual

E/P Positioner

Output INC DEC DIFF INC DEC DIFF Stroke Action Remarks

0 25 50 75

100 Acceptance criteria : As per CV/SDV/instrument data sheet (a) Hysteris with Positioner (Within + 1% FS) …….….. Yes/ No (d) Shutdown Valve Stroke Speed ……………….…. (b) Hysteris without Positioner (within + 5% FS)……… Yes/No (e) Air Fail Action checked ……………. Open/Close (c) Linearity Checked ……………………………………. Yes/No (f) Solenoid Power Supply …………………………….

(g) Solenoid Valve OP Checked …………… Yes/No REMARKS ___________________ _____________ (EPCC CONTRACTOR) (OWNER/PMC)



Page 1 of 1


N A F T E C . S P A

FIT UP INSPECTION REPORT

REPORT NO. : ________________________ DATE : _____________________

Inspection clearance Sl. No.

Line No./ Isometric

No. Area No.

Spool No.

Joint No.

Heat No.

Joint dia (Inch)

Thickness (mm)

Type of Joint

Material Traceability R.No. & Date

EPCC Contractor

Owner/ PMC

Remarks

No. of Joints Inch Dia. Today Previous Cumulative Today Previous Cumulative ___________________ _____________ (EPCC CONTRACTOR) (OWNER/PMC)



Page 1 of 1


N A F T E C . S P A

INSTRUMENT CABLE LAYING REPORT

REPORT : ________________________________ DATE : _______________________________

Verification by Sl. No.

Cable Tag From To

Act. Length

(m) Cable Type Dressing Clamping Gland

Type Gland Size Glanding Ferruling Termination EPCC

Contractor Owner/

PMC Remarks




Page 1 of 1


N A F T E C . S P A

INSTRUMENT CABLE MEGGER REPORT

REPORT NO : ________________________________ DATE : ___________________ Details of Megger instrument: Sl. No. Make : Test certificate No. : Model No. : Validity uoto :

Insulation Resistance (IR) Test Sl. No. Cable Identification Tag ** Cable Length

Test voltage Core to core Core to Earth Remarks

Remarks : Acceptance criteria : As per cable data sheet ** Cable identification tag details with From-To type ___________________ _____________ (EPCC CONTRACTOR) (OWNER/PMC)



Page 1 of 1


N A F T E C . S P A

JUNCTION BOX/LCP INSTALLATION REPORT

REPORT NO : _____________________________ DATE : _________________________

Verification by Sl. No. Tag no. Type Location Support Instln Alignment Earthing Gland

type Plugging Painting EPCC Contractor

Owner/ PMC

Remarks




Page 1 of 1


N A F T E C . S P A

INSTRUMENT AIR LINE/PNEUMATIC TUBE ERECTION REPORT REPORT NO : ___________________________ DATE : _______________________________ REF. DRAWING : _________________________ REV. : ________________________________

Check for Test Gauge details Test Pr. Verification by Sl. No.

Tag No.

Hook Up

STD From To Union/

Loop Drain Vent BOM Support Painting Flushing Sl/

Model No.

Range (Kg\Cm2)

Cal report

No.

Valid Upto Kg\Cm2

Joint Tightening

Joints Leak Test

EPCC Contractor

Owner/ PMC

Remarks : ___________________ _____________ (EPCC CONTRACTOR) (OWNER/PMC)



Page 1 of 1


N A F T E C . S P A

LEVEL INSTRUMENT INSTALLATION REPORT REPORT NO.: _____________________________________ DATE : ____________________________ REF. DRAWING : __________________________________ REV. : _____________________________

Check for correctness of Test Gauge details Verification by Sl. No.

Tag No.

Model No.

Serial No. Location PMS

Class Flange Rating Flanges Gasket Stud/

nut Verti- cality

Orien- tation

Instln. Check for

Float/ Displacer

Sl/ Model

No.

Range (Kg/Cm2)

Cal Report/ Validity

Hydro Test

Result EPCC

Contractor Owner/

PMC

Acceptance criteria: Instrument Installation Standard Remarks: ___________________ _____________ (EPCC CONTRACTOR) (OWNER/PMC)



Page 1 of 1


N A F T E C . S P A

INSTALLATION REPORT FOR TEST T/W, TG, TC, RTD REPORT NO:. ______________________________________ DATE : __________________________

Verification by Sl. No.

Tag No. Location Range

Deg C PMS Class

Flange Rating

Immersion Length (mm)

TappingSize

Orien- tation Gasket Stud/

Nut Tightness

of stud/ Nut

Plugging EPCC Contractor

Owner/PMC

Remarks




Page 1 of 2


N A F T E C . S P A

INDICATIVE

FORMATS

FOR

CIVIL WORKS



Page 2 of 2


N A F T E C . S P A

INDEX

S.NO


1.

Calibration of Instruments

6648-00-19-43-5701 0

2.

Determination of Dry Density and Moisture Content

6648-00-19-43-5702 0

3.

Sieve Analysis

6648-00-19-43-5703 0

4. Cement Testing

6648-00-19-43-5704 0

5.

Pour Card

6648-00-19-43-5705 0

6.

Crushing Strength of Cubes

6648-00-19-43-5706 0

7. Bricks Testing

6648-00-19-43-5707 0



Page 1 of 1


N A F T E C . S P A

FORMAT FOR CALIBRATION OF INSTRUMENTS Project : Job No. : OWNER : EPCC CONTRACTOR : Name of Work :

Accepted Sl. No.

Name of Equipment/ Apparatus

Model No.

Certificate No.

Calibrated By

Calibration Date

Next Calibration

Due on Remarks EPCC

Cont-ractor

PMC/OWN-

ER



Page 1 of 1


N A F T E C . S P A

FORMAT FOR DETERMINATION OF DRY DENSITY AND MOISTURE CONTENT

Project : Job No : OWNER : EPCC CONTRACTOR : Name of Work : Location : Layer No :

Test Nos: S. No. Description Relation

1 2 3 4 5 6 Remarks

1. Wt. of mould + wt. of wet soil

W1 gm

2. Wt. of mould W2 gm 3. Wt. of wet soil (W1 – W2) gm 4. Volume of mould V cc 5. Density of wet soil Dw = (W1 – W2)/V gm/cc 6. Wt. of wet sample taken Ww gm 7. Wt. of sample after drying Wd gm 8. Moisture Content Mc = (Ww – Wd)/wdx100% 9. Dry density Dd = Dw/(1+Mc) gm/CC 10. Laboratory Max dry

density gm/cc

11. Degree of Compaction % 12. Required degree of

compaction %

13. Optimum Moisture Content (OMC)

%

_____________________________ ____________________ ______________ ( TESTED BY/LAB-IN-CHARGE ) ( EPCC CONTRACTOR ) ( PMC/OWNER ) Date :



Page 1 of 1


N A F T E C . S P A

FORMAT FOR SIEVE ANALYSIS Project : Job No : OWNER : EPCC CONTRACTOR : Name of Work : Wt. of Sample taken : Date on which sample taken : FINE AGGREGATE

S. No.

Sieve Size

Weight Retained (gm)

Percentage Retained

Cumulative % Retained

% Passing

Fineness Modulus

Zone

Remarks

1. 4.75mm 2. 2.36mm 3. 1.18mm 4. 600 u 5. 300 u 6. 150 u 7. Pan COARSE AGGREGATE Wt. of Sample taken : 1. 20mm 2. 10mm 3. 4.75mm 4. 2.36mm

_________________________ ___________________ _____________ (TEST BY/LAB-IN-CHARGE) EPCC CONTRACTOR) (PMC/OWNER) Date :



Page 1 of 1


N A F T E C . S P A

CEMENT TEST RESULTS

Project : Job No : Owner : PMC : EPCC Contractor : Name of Work : Brand of Cement : Consignment No. : Wt. of sample taken : Sample Collected on: Room Temperature : A. CONSISTENCY

Trial No.

Wt. of Cement

(gm)

Wt. of Water Added (gm)

% of Water Reading on

Indicator (mm)

Consistency Remarks

B. SETTING TIME

Trial No.

Wt. of Cement

(gm)

Wt. of Water Added (gm)

W/C Ratio

Time Recorded

when Water Added

Time Recorded

at set

Initial Set

Final Set

Setting Set

Remarks

C. FINENESS

Trial No. Wt. of Cement Sample used

Retained on 90 µ sieve

in gm

% Retained Remarks

D. COMPRESSIVE STRENGTH Cube Size : 7.06X7.06X7.06 cm

Date of Trial No.

Mix Proportion Casting Testing

Age of Specimen

Crushing Surface

Area (Cm2)

Crushing Load (Kg)

Crushing Strength (Kg/Cm2)

Remarks

______________________________ ___________________ ____________

( TESTED BY )/LAB-IN-CHARGE ( EPCC CONTRACTOR ) ( OWNER/PMC)

Date:



Page 1 of 2


N A F T E C . S P A

FORMAT FOR POUR CARD

Programme of concreting

EPCC CONTRACTOR : OWNER : Name of work : 1. Reference document : 2. Type of structure : Location : 3. Levels From : To : 4. Grade of concrete/ Approved Design Mix 5. Brand name, Grade and Consignment no. of cement 6. Estimated volume of concrete : 7. Quantity of cement required : 8. Reinforcement checking details : No. Dia. Length a) Laps b) Separators c) Chairs d) Any other Remarks

9. Pre pour inspection details Checked NA a) Survey/ Layout b) Sub soil compaction c) Completion of underground works d) Cleanliness e) Cover to reinforcement f) Anchor bolts g) Sleeves/ pockets h) Water stops i) Formwork j) Slopes k) Construction/ Expansion joints l) Admixtures m) Any other Remarks

10. Clearance for Electrical/ Mechanical works required/ not required :

Electrical Mechanical

11. The above structure is finally inspected on at AM/PM and found/ not found satisfactory for concreting.

Remarks, if any

(EPCC CONTRACTOR) (PMC) (OWNER) Name Name Name Designation Designation Designation Date Date Date



Page 2 of 2


N A F T E C . S P A

FORMAT FOR POUR CARD

Observation during concreting

EPCC CONTRACTOR : OWNER : Name of work : 1. a) Quality of coarse aggregates

Satisfactory Not satisfactory b) Quality of fine aggregates Satisfactory Not satisfactory c) Bulkage of sand taken into account Yes No

2. Quality of water Satisfactory Not satisfactory

3. Machinery mobilization Nos. Stand by a) Mixture machine b) Ready mixed concrete dumpers c) Vibrators d) Pumps e) Hoists 4. Pour start time : AM/PM ; Date : 5. Slump 6. W/C Ratio 8. Type of weather

Normal Abnormal Details of abnormality : (Precautions taken for <50C and >400C, rainy season)

10. Number of cubes taken : 11. Quantity of concrete poured : 12. Pour completion time : AM/PM ; Date : 13. Curing method :

Traditional Curing compound Blankets/ foils/ gunny bags Others (specify)

14. Period for removal of form work : 15. Any defect(s) observed during concreting :

(EPCC CONTRACTOR) (PMC) (OWNER) Name Name Name Designation Designation Designation Date Date Date



Page 1 of 1


N A F T E C . S P A

FORMAT FOR CRUSHING STRENGTH OF CUBES Project : Job No : OWNER : EPCC CONTRACTOR : Name of Work : Grade of Concrete : Type of Cement : W/C Ratio : Max. size of Aggregate :

Date Of

Dimensions of Cube

Cube No.

Id. Mark

on cube

Type & Location of Struc.

Cast Test

Age (days)

L (m)

B (m)

H (m)

Vol. of

Cube (m3)

Wt. of

Cube (Kg)

Unit WT.

(Kg/m3)

Sur-ace Area (m2)

Crus-hing Load (Kg)

Crushing Strength (Kg/Cm2)

Remarks

_____________________________ ________________ _____ ( TESTED BY)/LAB-IN-CHARGE (EPCC CONTRACTOR ) ( PMC )



Page 1 of 1


N A F T E C . S P A

WATER ABSORPTION, CRUSHING STRENGTH & EFFLORESCENCE TESTS FOR BRICKS

Project : Job No : OWNER : PMC : EPCC Contractor : Name of Work :

S. No.

Frog Mark

Wt. of oven Dried Brick (gm)

Absorption Period

(hr)

Wt. of wet

Brick (gm)

% of Water

Absorption

Efflore-scence

Observed After

Drying

Av. Size of Brick

(LXBX H) Cm3

Crushing

Rem-arks

Surface Area

(Cm2)

Load (Kg)

Stren-gth

(Kg/Cm2)

___________________________ __________________ ___________ (TESTED BY/LAB-IN-CHARGE) EPCC CONTRACTOR OWNER/PMC Date :



Page 1 of 2


N A F T E C . S P A

INDICATIVE

FORMATS

FOR

ELECTRICAL WORKS



Page 2 of 2


N A F T E C . S P A

INDEX

S.NO


1.

HV Switch Board

6648-00-19-43-5801 0

2.

Transformers

6648-00-19-43-5802 0

3.

ON Load Tap Changer

6648-00-19-43-5803 0

4.

Neutral Grounding Resistor

6648-00-19-43-5804 0

5.

MV Switch Board

6648-00-19-43-5805 0

6.

Battery Set and Charger

6648-00-19-43-5806 0

7.

HV Motor

6648-00-19-43-5807 0

8.

MV Motor

6648-00-19-43-5808 0

9.

DG Set

6648-00-19-43-5809 0

10.

Cable Installation

6648-00-19-43-5810 0

11. Electrical Heat Tracing System

6648-00-19-43-5811 0

12. Lighting Installation

6648-00-19-43-5812 0

13. Earthing Installation

6648-00-19-43-5813 0



Page 1 of 6


N A F T E C . S P A

TEST PROFORMA

HV SWITCHBOARD Project : Job No. : Name of Work : EPCC CONTRACTOR : Tag No. 1.0 Voltage : Manufacture : Current : Type of Breaker : VCB/SF6/MOCB Fault level : Section 1 fed from : Section 2 fed from : Control supply : 2.0 GENERAL CHECKS : (Put tick ( ) if satisfactory, otherwise give details) 2.1 Installation

General cleaning of panels and assembly

Cleaning & Inspection of insulators

Earthing of the panel (Double earthing)

Floor level

Busbar alignment and connections

Bus trunking and tightness of nut and bolt connections

Glands, termination & spacing of cables

Sealing of cable entries and Vermin proofing

Taping of exposed portion of cables (if required)

Tightness of cable connections

Tagging of ferruling of cables

Leakage of oil if any

Pressure of SF6 gas

Dielectric strength of oil

CB closing & tripping mechanism

Circuit breaker-Main contacts alignment

Auxiliary contacts change over

Control switches & keys

Drive & limit switches functioning

Rating of fuse as per approved drg.

Relay cleaning & operation

Indication lamps

Meters ranges Danger board



Page 2 of 6


N A F T E C . S P A

2.2 Circuit Checking :

CT & current circuits

PT & PT circuits

Control circuit

Alarm & signaling circuit

Meters & metering circuit

Interlocks

2.3 Pre-Commissioning Checks

Control, protection and signaling circuit operation

Bus shrouds and safety features

Operation of manual Auto transfer circuit and interlocks

Insulation resistance of main bus and control

Settings of relays & timers as per drawings (Attach Relay setting details with this format for Incomers, Bus couples, DG incomes (if available))

Interlocks & inter tripping

External interface with ECS/DCS/ Annunciation panel

3.0 TEST RESULTS 3.1 Insulation, Resistance Measurement Megger used: Ambient Temp:



Page 3 of 6


N A F T E C . S P A

INSULATION RESISTANCE (I.R.) IN MEGA OHMS

RY YB BY RE YE BE

a. Busbars Section-1

Section-2

b. Busduct/Cables Section-1

(Incomer) Section-2

c. Outgoing feeders (Panel no./ Feeder Designation

3.2 Current Transformer Panel No. : Feeder Designation : 3.2.1

Protection Manufacturer's Data Metering

Core 1 Core 2 Core 3 Ratio

VA rating

Accuracy Class

Serial nos.

3.2.2 Tests & Checks: (Put tick ( ) if satisfactory)

a.

Polarity check (inconformity with the drawing)

b.

Check CT earthing

c. Wiring correctness & continuity check and tightness of connections



Page 4 of 6


N A F T E C . S P A

d. Test results:

Protection Tests Metering

Core 1 Core 2 Core 3 i) Ratio measurement

ii) Insulation Resistance (Measured)

Primary to Earth

Secondary to Earth

Primary to secondary

3.3 Potential Transformer Panel No.: 3.3.1 Manufacturer's Data Ratio : VA rating : Class : Type : Serial Nos. : 3.3.2 Tests and Checks a) Ratio Measurements b) Polarity check : c) Wiring correctness & tightness of connections : d) Check PT earthing : e) Insulation resistance measured : Primary to earth : Secondary to earth : Primary to earth : f) Check fuses rating :



Page 5 of 6


N A F T E C . S P A

3.4 Relays 3.4.1 Protective current relays

S. No. NEMA Code

Component code as per

vendor drawing Type and

Range

Test conducted and found satisfactory

as per field test report

(Put ' ' mark) 1.

2.

3.

3.4.2 Voltage, Auxiliary relays and timers

S. No. Circuit Symbol NEMA Code Type and

Range

Test conducted and found satisfactory

as per field test report

(Put ' ' mark) 1.

2.

3.

Note : 1. For each relay, site pre-commissioning checks and tests shall be carried out in

accordance with manufacturer’s instructions manual and test readings are recorded.

2. IDMTL, and instantaneous relays and other protective relays shall be checked for proper operation at minimum of 3 settings which shall include relay protection co-ordination setting values for IDMTL & instantaneous relays.

3. Correctness of CT polarity and connections for differential protection circuit shall be ensured through 3 phase primary injec5tion transformer kits for in zone & out zone.

4. Enclose Relay Test reports along with the report 4.0 COMMISSIONING

Clearance from all agencies

Electrical Inspector’s clearance

Operation of breaker in test position

Tripping of breaker thro’ protective relays



Page 6 of 6


N A F T E C . S P A

Meggar results of cable (Attach format E-10 For H.T. Cables & Enclose Megger value taken before commissioning).

Meggar readings of equipment being charged (busbar, transformer or motor) (Attach format E-2/ET depending upon equipment being charged if it is other than H.V. Switchboard).

Pre commissioning test results of equipment to be charged (transformer/motor etc.

Relays settings done as required (Enclose Relay Setting details with this Format)

5.0 OPERATIONAL CHECKS

Condition of equipment after energisation

Magnetisining/starting current

Phase matching of two sections

(in case of incomer breaker)

Auto transfer ckt, operation

Time :

Manual transfer ckt. Operation

6.0 REMARKS (if any)



Page 1 of 5


N A F T E C . S P A

TEST PROFORMA TRANSFORMERS

Project : Job No. : Name of Work : EPCC CONTRACTOR : 1.0 MANUFACTURER’S DATA

Type

S.No.

Year of Manufacture

Kva rating

Primary voltage

Primary current

Frequency

Secondary voltage

Secondary current

Vector group

% impedance

No. of taps

2.0 GENERAL CHECKS : tick ( ) if found satisfactory correct otherwise give details. 2.1 Installation

Installation of transformer

Transformer Earthing

Neutral earthing

Oil level

Leakage of oil

Tap changer Position

Condition of bushings

Cable box, glands, lugs terminations

Winding and Oil

Breather/sillicagel

Temperature indicator-settings

Oil level indicator

Size of the Primary/Secondary cable as per schedule

Thermometer pocket filled with oil

Position of valves

Wiring for auxiliaries



Page 2 of 5


N A F T E C . S P A

Marshalling box

Buchholz Relay mounting

Explosion vent

Fuse rating for circuits

Cooling fan

Stopper provided

Fire extinguisher (Provided in sub station)

Danger boards

2.2 Value of Earth Resistance : Date of Measurement : Neutral earth Electrodes : Electrodes for transformer body earthing : 3.0 DIELECTRIC STRENGTH OF THE OIL :

Withstand voltage Breakdown

Top sample

Bottom sample

4.0 INSULATION RESISTANCE

TEMPERATURE AT THE TIME OF TESTING

H.V. winding to earth L.V. winding to earth H.V. to L.V. winding

Meggar Range used Meggar Range used Meggar Range used

R15 R60 K=R60/R15 R15 R60 K R15 R60 K



Page 3 of 5


N A F T E C . S P A

5.0 MEASUREMENT OF WINDING RESISTANCE:

Temperature at the time of testing:

H.V. Winding L.V. Winding

Tap 1 Tap 2 Tap 3 Tap 4 Tap 5 Current injected

Voltage Drop

Resistance

A-B

a-b

B-C

b-c

C-A

c-a

6.0 VECTOR GROUP SHORT A-a HV Terminals A B C LV Terminals a b c

Voltage group on HV side Voltage measured on LV side VAB VBC VCA VBb VBC VCb VCc Remarks

Vector Group: 7.0 VOLTAGE RATIO

TAP : Voltage applied on H.V. Side Voltage on L.V. Side Av Ratio

A-B B-C C-A a-b b-c c-a

Tap1

Tab2

Tab3

Tab4

Tab5



Page 4 of 5


N A F T E C . S P A

8.0 OPERATION OF BUCHHOLZ RELAY : Alarm at; Tripping at: 9.0 OPERATION OF COOLING PUMP & FAN

Control circuit

Overall relays

Direction of Rotation

Interlocks

Temperature at which fans start

10. CHECKING OF EXTERNAL CIRCUITS

Operation of protection relays

Signaling circuit

Alarm/blinkers

Breaker tripping through relays

Meters & metering ckt.

LV section isolation

11.0 OPERATION CHECKS Vibrations : Any abnormal noise : Magnetization current :



Page 5 of 5


N A F T E C . S P A

Temperature reading :

Load Current Load Current Load Current

Time Interval

30’ 60’ 120’ 240’ 30’ 60’ 120’ 240’ 30’ 60’ 120’ 240’

Temp

12.0 REMARKS : a) b) c)



Page 1 of 1


N A F T E C . S P A

TEST PROFORMA

ON LOAD TAP CHANGER Project : Job No. : Name of Work : EPCC CONTRACTOR : 1.0 MANUFACTURER’S DATA

Type

:

Name of manufacturer

:

Sl.no.

:

Voltage

:

Current

:

No. of steps

:

Step voltage

:

Motor rating

:

2.0 GENERAL CHECKS : (Put tick ( ) if satisfactory otherwise give details).

Installation of OLTC

:

OLTC earthing

:

Installation of associated (Remote control panel & earthing)

:

3.0 TEST 3.1 I.R. value of Motor : I.R. value of cables : 3.2 Scheme checking of OLTC and : remote control panel in manual, auto mode for correct operation 3.3 Tap change time between successive : steps 3.4 Master/follower operation : 4.0 REMARKS 3.5 AVR setting =



Page 1 of 1


N A F T E C . S P A

TEST PROFORMA

NEUTRAL GROUNDING RESISTOR

Project : Job No. : Name of Work : EPCC CONTRACTOR : 1.0 MANUFACTURER’S DATA Type : Name of manufacturer : Rated resistance : Voltage : Current and time : 2.0 GENERAL CHECKS : (Put tick ( ) if satisfactory, otherwise give details)

Installation of NGR

:

General cleanliness

:

Condition of bushings

:

NGR Cubicle earthing

:

Incoming and outgoing cable/earth

:

3.0 TEST

Insulation resistance with respect to earth

:

Megger used

:

Ambient temperature

:

Resistance value measured

:

4.0 REMARKS



Page 1 of 6


N A F T E C . S P A

TEST PROFORMA MV SWITCH BOARD

Project : Job No. : Name of Work : EPCC CONTRACTOR : 1.0 SWITCHBOARD DETAILS TAG No. Manufacturer : Type : Bus rating : Fault level : Section 1 fed from : Section 2 fed from : 2.0 GENERAL CHECKS : (Put tick ( ) if satisfactory, otherwise give details) 2.1 Installation

Switchboard leveling and grounting Assembly of panels & cleaning

Vermin proffing and - )

Busbar alignment & connections

Unused cable entries covering )


Glands termination and spacing of cables

Floor level

Taping of exposed portion of cable

Tagging & ferruling cables

Tightness of cable connections

Cleaning and inspection of insulators, bushings

Control switches, keys and indication lamps

Earthing of panel and cables

Danger Board

Nomenclature of various feeders

Alignment of power and auxiliary contacts

Switchfuse units and door interlocks

Circuit breaker closing & tripping mechanism




Page 2 of 6


N A F T E C . S P A

Glands termination and spacing of cables



Earthing of panel and cables

Switch fuse units and door interlocks

Safety interlocks of breaker

Fuses, bimetal relays, ranges matching with load

Inspection of arc chutes

Circuit breaker release/relays – ranges matching with load

2.2 Circuit Checking :


PT circuits

Shorting link provided for unused terminals

Control circuit



Interlocks


Control, protection & signaling circuit operation

Operation of manual/auto transfer circuit & interlocks

Insulation resistance of main bus and control circuit

Settings of relays & timers interlocks & inter tripping



Page 3 of 6


N A F T E C . S P A

3.0 TEST RESULTS 3.1 Insulation, Resistance Measurement Megger used: Amb. Temp:;

INSULATION RESISTANCE (I.R.) IN MEGA OHMS RY YB BY RE YE BE RN YN BN

a. Busbars Section-1

Section-2

b. Busduct/ Cables

Section-1

(Incomer) Section-2

c. Outgoing feeders (Panel no./Feeder Designation

3.2 Current Transformer Panel No. : Feeder Designation : 3.2.1

Manufacturer's Data Metering Protection

Ratio

VA rating

Accuracy Class

Serial nos.



Page 4 of 6


N A F T E C . S P A

3.2.2 Tests & Checks: (Put tick ( ) if satisfactory)

a.

Polarity check (inconformity with the drawing)

b.

Check CT earthing

c.

Wiring correctness & continuity check and tightness of connections

d. Test results:

Tests Metering Protection

i) Ratio measurement

ii) Insulation Resistance (Measured)

Primary to Earth

Secondary to Earth

Primary to secondary

3.3 Potential Transformer Panel No.: 3.3.1 Manufacturer's Data Ratio : VA rating : Class : Type : Serial Nos. : 3.3.2 Tests and Checks a) Ratio Measurements b) Polarity check : c) Wiring correctness & tightness of connections : d) Check PT earthing :



Page 5 of 6


N A F T E C . S P A

e) Insulation resistance measured : Py-G : Sy-G : Py-Sy : f) Check fuses rating : 3.4 Relays/Releases

S. No. NEMA Code

Component code as per

vendor drawing Type and

Range Test conducted and found satisfactory

(Put ' ' mark) 1.

2.

3.

3.4.2 Voltage, Auxiliary relays and timers

S. No. NEMA Code Component code

as per vendor drg. Type and

Range Test conducted and found satisfactory

(Put ' ' mark) 1.

2.

3.

Note : 1. Site precommissioning checks and tests shall be carried out in accordance with

manufacturer’s instructions manual and test readings are recorded. 4.0 COMMISSIONING

Clearance from all agencies

Electrical Inspector’s clearance

Operation of breaker in test position

Tripping of breaker thro’ protective relays

Meggar results of cable

Meggar readings of equipment being charged (busbar, transformer or motor)

Test results of equipment to being charged (transformer/motor etc.

Relays, Releases settings done as required



Page 6 of 6


N A F T E C . S P A


Phasing of bus sections

:

Auto transfer circuit operation & time

:

Manual transfer circuit operation for incomers and bus tie

:

6.0 REMARKS



Page 1 of 2


N A F T E C . S P A

TEST PROFORMA BATTERY SET AND CHARGER

Project : Job No. : Name of Work : EPCC CONTRACTOR : Tag No. 1.0 Manufacture : Type of battery : Equipment No. : No. of cells : Name plate details : (Charger) 2.0 GENERAL CHECKS : (Put tick ( ) if satisfactory, otherwise give details)

CHARGER PANEL

BATTERY SET

Levelling and grouting

Batteries and racks installation

Vermin proofing and blanking of spare holes

Level of electrolyte in each cell

Leakage of electrolyte in cell if any

Earthing of panel

Specific gravity

Control switches, meters, fuses, indication lamps functioning O.K.

Number plates of cells and connection links

All circuit cards are firmly seated in their sockets

General cleaning & tightness of all cables connection

Termination, glands & spacing of all cables

Battery connection and Polarity

Anticorrosive coating (Vaseline) provided on terminals



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3.0 INSULATION RESISTANCE TEST (CABLES) Megger used Input Phase to phase : _________________ Power supply cable phase to earth : _________________ Battery cables Positive to negative : _________________ Positive to earth : _________________ Negative to earth : _________________ 4.0 CIRCUIT CHECKING & WIRING VERIFICATION :

Float/boost chargers

:

Rectifier and output circuit

:

Alarm circuits, indication lights

:

Interlocks

5.0 COMMISSIONING CHECKS AC input voltage : DC output voltage, variation : Operating temperature in cabinet : (No hot spot) Battery voltage : Battery trickle charge current : Abnormal noise if any : 6.0 TEST READINGS OF CHARGE/DISCHARGE CYCLE OF BATTERY SET(TO BE

ATTACHED SEPARATELY) 7.0 REMARKS (if any)



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TEST PROFORMA H.V. MOTOR

Project : Job No. : Name of Work : EPCC CONTRACTOR : Tag No. 1.0 MANUFACTURER’S DATA Motor Tag No. : Make : S.No. : Enclosure : Ex(d)/Ex(e)/ Ex(n) Rotor/voltage : RPM : Stator Current : Rotor current : Power factor : Connections : Class of insulation : Type of coupling : Type of mountg : Applicable code : Duty : Method of starting : 2.0 GENERAL CHECKS : (Put tick ( ) if satisfactory, otherwise give details) 2.1 Motor

Bushigs/insulators

Lubrication & Greasing

Condition of bearings

Ventilation/cooling system

Slip rings-brush gear and bedding

External inspection

Polarity of windings

External inspection Provided/not provided

Bearing/windings temp. Indicator

Bearing oil level indicator

Insulation resistance of windings



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2.2 Installation

Motor enclosure protection appropriate to area classification of location

Levelling of motor

Alignment and coupling

Earthing of motor and cable box

Tightness of foundation Bolts

Pedestal insulation

Heaters and heater circuit

2.3 Supply Cables And Connections

Suitability of cables box for required size of cable Bushings/insulators

Cable laying, tagging

Termination of armour

Cable gland suitability and tightness

Blanking of holes

Condition of epoxy

Suitability of lugs

Termination connection tightness

Taping of exposed portion of cable

Gaskets of terminal lease for IP55 and for outdoor boxes suitability

2.4 Push Button Station

FLP/industrial

Meters & indication lamsp

Earthing

Name plates

Cable laying, ferruling, termination

Cleaning of contracts, switches, push buttons

Operation of control ckt



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2.5 External Circuits/Equipments

Local Panel/control room interface connections

Feeding Circuit breaker at sending end tested and found ready for commissioning

Cooling fan/lubrication pump

Interlocks

3.0 INSULATION RESISTANCE : Temperature oC Megger range: 3.1 Power Cable & Motor :

Stator Rotor Meggar Supply cable

Quantity RE YE BE Wegs-E RE YE BE RY YB BR

Remarks

R15

R60

K

3.2 Control Cable : 4.0 MEASUREMENT OF RESISTANCE :

Description Stator Rotor Remarks

Between Terminals

U-V

V-W

W-U

Resistance



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5.0 COMMISSIONING

Clearance from other concerned agencies

Test results

Tripping of breaker on protections

Interlocks

Operation of control and signaling ckt.

5.1 operational checks (Repeated starts to be avoided)

Direction of Rotation

Starting current kick

No load current of all phases

Full load current of all phases

Bearing condition/ temperature after 4 hours run

Temperature of windings after 4 hrs. run

Vibrations

Any abnormal sound

Cooling air flow direction

5.2 V-Characteristics of Motor (For Synchronous Motor)



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N A F T E C . S P A

TEST PROFORMA M.V. MOTOR

Project : Job No. : Name of Work : EPCC CONTRACTOR : 1.0 MANUFACTURER’S DATA Make : S.No. : Type : Voltage : Current : Speed : Frame size : KW : Connections : Sq.cage/slipring : Enclsoure : Mounting type : 2.0 GENERAL CHECKS : (Put tick ( ) if satisfactory, give details) 2.1 Motor

Installation of motor

Size of Power and Control Cables same as given in schedule

Free hand rotation

Cable glanding and termination

Lubrication and greasing

Weather proofing to terminal box

Ventilation/cooling system

Any visible external damage

Type of PB Station FLP/ Industrial

Area classification of location and Motor suitability

Ammeter range and CT ratio

Motor suitability

Earthing of motor & PB station

Tagging of cables

Connections Star/Delta

Starting Star/Delta/Soft start



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B. STARTER MODULE

EPCC CONTRACTOR Feeder

Matching of fuse with motor rating

Matching of OLR with the motor rating

Matching of switch motor rating

Matching of EPCC CONTRACTOR with motor rating

Cleanliness and tightness of all connections

(in the case of breaker feeder the thermal, magnetic release ranges (and/or other protective devices), breaker rating etc. shall be checked with motor rating.

3.0 TESTING 3.1 Insulation Resistance Megger Range :

UE VE WE UV VW VW Power cable : Motor : Control cable between line to line:

3.2 Thermal Relay Checking Relay range : Tripping time at twice rated current of motor : 4.0 COMMISSIONING

Clearance from concerned agencies obtained

:

Wiring schematic operation verified

:



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4.1 Operational Checks : (Repeated start to be avoided) ‘At no load’

Starting current

:

Stating time

:

Direction of rotation

:

Current of all phases

:

Vibration

:

Voltage

:

Any abnormal sound

:

Cooling fan operation

:

Temperature rise after 4 hours run:

Load run R Phase Y Phase B Phase Current of all phases

:

Voltage

:

Vibration

:

RY =

YB =

BR =

Bimetal relay set at : (after load run) No load run: Load run: 5.0 REMARKS



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TEST PROFORMA D.G. SET

Project : Job No. : Name of Work : EPCC CONTRACTOR : 1.0 MANUFACTURER’S DATA Engine Alternator Rating : Type Designation : Fuel tank capacity : Battery : Charging system : Excitation type : Method of start : Air/battery 2.0 GENERAL

Installation, alignment & grouting

:

General cleanliness

:

Cable termination & tightness of all connection

:

Earthng of DG set and control panels (Enclose Earthing Values taken) (Enclose Relay Test Reports)

:

Generator neutral earthing grouting

:

Fuelling connection & valves in correct position

:

Fuel leaks, (if observed, shall set right)

:

Lube oil circuit and oil level

:

Radiator filled up with clean soft water

:



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Instruments & control devices installation

:

Battery sets, charger and control panel

:

3.0 INSULATION RESISTANCE TEST I. ALTERNATOR MEGGAR USED: Winding to earth R15 R60 K = R60 ------ R15

II. FIELD WINDING

III. POWER CABLE RE RY RN YE YB YN BE BR BN NE

4.0 WINDING RESISTANCE

Stator

:

Rotor

:

5.0 COMMISSIONING

Tripping of breaker on protections

:

Operation of excitation, control & signaling ckt.

:

Interlocks

:



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N A F T E C . S P A

Operation of all protective devices and setting

:

Operation of AVR circuit

:

Auto and manual transfer circuits

:

Starting circuit functioning

:


All instruments reading on engine operating panel

:

Voltage frequency excitation current

:

Bearing condition/temp. After 4 hrs. run

:

Any abnormal sound

:

Vibrations

:

Fuel, lubrication and cooling circuits

:

AMF Feature

:

Paralleling of DG sets (if available)

:

Radiator filled up with clean soft water

:



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7.0 LOAD RUN

Voltage

:

Current of all phases

:

Excitation current

:

Frequency

:

Power factor

:

Winding temperature rise

:

Bearing condition

:

8.0 REMARKS



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TEST PROFORMA

CABLE INSTALLATION Project : Job No. : Name of Work : EPCC CONTRACTOR : 1.0 CABLE DETAILS Make : Type : Cable tag : From : To : Size : Voltage : Length : No. of runs : No. of straight through joints if any : 2.0 GENERAL CHECKS : (Put tick ( ) if satisfactory, otherwise give details)

Laying

:

Lugs (size, material and crimping)

:

Earthing of armour/Screen

:

Phasing/continuity

Cable support

:

Cable gland (size & proper fixing)

:

Cable entry cutout sealing

:

Inspect cable protective measures

:

Cable Gland plate Non magnetic/Aluminium

:

(Applicable for Single core cables)

Earthing of armour (as per job spec)

:



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3.0 HIGH POT TEST AND INSULATION RESULTS 3.1 Insulation, Resistance before the Hipot Test: Megger used: Ambient Temp:

Description R to E Y to E B to E RY YB BR

R15

R60

K = R60 R15

3.2 High Pot Test ** :

Leakage current in mA Voltage applied value kV

30 sec. 1 minute 5 minutes

* Between Red and Earth

* Between Yellow and Earth

* Between Blue & Earth

** With other cores connected to earth ** Applicable for H.V. Cables and for those M.V. Cables where st-through joints are made. 3.3 Insulation Resistance After The High Pot Test : Megger used : Ambient temp. :

Description R to E Y to E B to E RY YB BR R15

R60

K = R60 R15

4.0 REMARKS



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TEST PROFORMA ELECTRICAL HEAT TRACING SYSTEM

Project : Job No. : Name of Work : EPCC CONTRACTOR : PART-I : TRACER 1.0 TRACER DATA Circuit no. : LDP No./FDR No. : Heater type : Heater cable length : Drawing no. : Spiraling details, if any : Area : Line no. : Maintenance temperature : Heat loss/mt. : 2.0 GENERAL CHECKS

- Laying and covering of tracer complete length

:

- Heater continuity

:

- Power cable continuity

:

- Tightness and cleanliness of connections at

a. FLP JB

:

b. Thermostat

:

- Number of splice connectors (if used)

:

- Tag plates

:

- Warning plates online

:



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3.0 TEST RESULTS Insulation in M Ω

Megger used

:

Ambient temperature

:

3.1 Ph. To Earth N1 to Earth Set Ph. No.1

(Load disconnected) Circuit power cable 3.2 Line 1 to earth Line 2 to earth Heater cable 4.0 COMMISSIONING CHECKS - Heater cable input resistance value measured at pipe temp. : - Control circuit functional checks and operation : - Calibration check at the temperature controller set point : - Thermostat set at : oC - Commissioning clearance obtained : 5.0 AFTER COMMISSIONING 5.1 Inrush current value : Duration : 5.2 At stready state conditions Voltage V : Load current I : Pipe temperature : Power output (V X I) : Watts Calculated value from guaranteed curve (at the pipe temp.) : Watts



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Project : Job No. : Name of Work : EPCC CONTRACTOR : PART-II : LOCAL DIST. PANEL 1.0 SWITCHBOARD DETAILS Manufacturer : Bus rating : Section fed from : Feeder rating (Amb.) : No. of outgoing switchfuse : feeders with contactor (used) No. of outgoing spare feeders type : Indoor/outdoor Fault level : LDP no. : Location : 2.0 GENERAL CHECKS : (Put tick if satisfactory, otherwise give details) 2.1

Assembly of panels and cleaning

:

Vermin proof

:

Bus bar arrangement and connection

:

Unused cable holes covering

:

Bus trunking and tightness of nuts and bolts connection

:

Gland termination and spacing of cables floor level

:

Tapping of exposed portion of cables

:

Tagging and ferruling of cables

:



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N A F T E C . S P A

Tightness of cable connection

:


:


:

Earthing of panel & cables

:

Danger Board

:

Nomenclature of various feeders

:

Switchfuse units and door interlocks

:

Alignment of power and auxiliary contacts

:

Earth leakage circuit breaker

:

Fuses

:

Door covers all bolts are provided properly

:

2.2 Circuit Checking


:

Control circuits

:


:


:

Interlocks

:



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N A F T E C . S P A


Control, protection and Signaling circuit operation

:

Insulation resistance of main bus & control circuit

:

ELCB operation

:

3.0 TEST RESULTS Megger used : Amb. Temp. : I.R. in M Ω

RE YE BE NE RY YB BR RN YN BN

a. Bus bars: b. Incoming :

Cables 4.0 COMMISSIONING Clearance from all agencies Checking all outgoing switch fuse feeders kept off) before energization of panel 5.0 AFTER COMMISSIONING 5.1 Voltage V : 5.2 Load current IR = IY = IB = I Neutral = 6.0 REMARKS



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TEST PROFORMA LIGHTING INSTALLATION

Project : Job No. : Name of Work : EPCC CONTRACTOR : 1.0 MANUFACTURER’S DATA : MLDB/LIGHTING PANEL/POWER PANEL Rated voltage : Rated current : Incomer rating : Rating of branch circuit feeders : and connected load Panel tag no. : 2.0 GENERAL CHECKS : (Put tick ( ) if satisfactory, otherwise give details) 2.1

Panel Installation Check Mark Remarks

Check general cleaning of panels and assembly

Inspect earthing of panel

Inspect glands termination and spacing of cables

Check tightness of all connections including cable connection

Check circuit numbering and

Check dust vermin proofing

Check explosion prot3ction of field equipment in hazardous area

LPs, PPs : FLP

Jbs : FLP/Ex(e)

Sockets : FLP

Gas Group : IIA IIB or IIC



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2.2

Lighting Installation Check Mark Remarks

Check the operation and setting of time switches, photo-electric cells, EPCC CONTRACTORs (wherever provided)

Check lamp fittings for neatness of connections, suspension, weatherproofness

Spot check wall sockets, test the voltage of each socket test the earthing continuity

Insert all lamps and measure illumination level

3.0 INSULATION RESISTANCE TEST 3.1 Panel R Phase to Earth : Between R Y : Y Phase to Earth : Between YB : B Phase to Earth : Between B R : Neutral to earth : R, Y, B to N : 3.2 Incoming Cable RE : RY : YE : YB : BE : BR : NE : R, Y, B to N : 3.3 OUTGOING CIRCUITS Phase to Neutral : Size : Phase to Earth : (Without lamps being in place)



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4.0 MEASURE LOAD CURRENT IN EACH PHASE ARE RECORD: IR : IY : IB : IN : (If required adjust circuit loads for load balancing in each phase) 5.0 REMARKS



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TEST PROFORMA EARTHING INSTALLATION

Project : Job No. : Name of Work : EPCC CONTRACTOR : 1.0 EARTH SYSTEM DATA Type of electrode : Total number of electrodes : Main grid size : Material : 2.0 GENERAL CHECKS Put tick if satisfactory otherwise give details.

Construction of electrodes as per PMC/OWNER standard

:

Size of earth conductor for various equipment satisfactory as per layout drawing

:

Cleanliness and tightness of connector

:

Inspect bolted and clamped connectors, at all earth plates.

:

3.0 TESTS 3.1 Measured earth resistance of each electrode in ohms

Electrode No. Measured Resistance in ohms

1.

---------------------

2.

---------------------

3.

---------------------

4.

---------------------

5.

---------------------



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3.2 Measurement of Earth Grid Resistance (With all electrodes connected to grid) a. At system neutral earth : b. At one point on each earthing system used to earth electrical equipment enclosure : c. At one point on each earthing system usedto earth wiring system such as metal conduits etc. : d. At one point on each fence enclosing electrical equipment : 4.0 REMARKS



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N A F T E C . S P A

REQUIREMENTS

FOR

POSITIVE MATERIAL IDENTIFICATION (PMI)

AT

CONSTRUCTION SITES



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TABLE OF CONTENTS

_________________________________________________________________________ CLAUSE NO. TITLE PAGE NO. _________________________________________________________________________ 1.0 SCOPE 3 2.0 DEFINITIONS 3 3.0 SPECIFIC APPLICABILITY 3 4.0 REFERENCES 4 5.0 GENERAL REQUIREMENTS 4 6.0 EXTENT OF PMI 5 7.0 PMI IN WAREHOUSE 5 8.0 PMI OF PIPING AND HEATER COIL COMPONENTS 5 9.0 TESTING METHODOLOGY 6 10.0 CHARACTERISTIC ELEMENTS 6 11.0 CALIBRATION 6 12.0 SITE VERIFICATION OF ANALYZER 7 13.0 PERSONNEL QUALIFICATION 7 14.0 ACCEPTANCE CRITERIA 7 15.0 REJECTION CRITERIA 7 16.0 DOCUMENTATION 8 ATTACHMENT (REPORTING FORMAT) I. FORMAT FOR PMI TEST REPORT - 6-82-0002-F1 (1 SHEET) _______________________________________________________________________



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1.0 SCOPE 1.1 This specification applies to metallic alloy materials used in piping, heater coils, storage

tanks, vessels etc. at construction sites. Positive Material Identification (PMI) is to be carried out on owner supplied material as well on materials purchased by the EPCC contractor.

1.2 Any deviation from this specification must be approved by Owner/PMC in the prescribed

format. 1.3 Carbon steels are excluded from the scope of this specification. 2.0 DEFINITIONS 2.1 Positive Material Identification (PMI)

The term Positive Material Identification (PMI) refers to determination/verification of alloy type or its composition using portable or mobile spectrometer/alloy analyzer. Chemical spot checking, resistivity testing, eddy current testing, electromagnetic alloy sorting, thermoelectric testing shall not be considered as PMI for the purpose of this specification.

3.0 SPECIFIC APPLICABILITY 3.1 The following items require PMI unless specifically exempted through a Waiver/Deviation

permit by Owner/PMC. 3.1.1 All pressure containing piping components including, thermowells instrument manifolds,

RTJ gaskets, fasteners etc.. 3.1.2 Tubular products used in the fabrication of heaters. 3.1.3 Pressure - containing instrument housings (e.g. gauge glass housings, orifice meter tubes). 3.1.4 Internal metallic linings/cladding, and weld overlay, done at site, used for protection against

corrosive environments. 3.1.5 Tubing 3.1.6 Stud, bolts and nuts 3.1.7 Plates 3.1.8 All pressure containing welds. 3.1.9 Any other components or materials specifically designated for PMI on the purchase

order/contract.



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3.2 Exclusions

The following items are exempted unless specifically designated for PMI in the purchase order/contract.

3.2.1 Gaskets (spiral wound or carbon steel only). 3.2.2 Internal instrument parts. 3.2.3 Internal machinery parts. 3.2.4 Internal non pressure - containing baffles, trays, tray clips, supports, pall-rings, support

rings, etc. 3.2.5 Electrical components. 3.2.6 Non pressure - containing welds, including seal welds, piping supports welds, structural

parts. 3.2.7 Internal valve components. 3.2.8 Compression-type ferrules and fittings for use with 3/4 inch (19mm) outside diameter and

smaller tubing. 4.0 REFERENCES American Society of Mechanical Engineers (ASME) BPV Code Section-II Part A,B,C and D ASME B 31.3 American Society for Testing and Materials (ASTM): As applicable Material Verification Program for New and Existing Alloy Piping Systems : API RP 578 Any other material specification referenced by the Purchase Order/Contract. 5.0 GENERAL REQUIREMENTS 5.1 The test methods outlined in this specification are intended to identify the nominal

composition of alloy materials. These test methods are not intended to establish the conformance of a material to a particular alloy specification.

5.2 PMI shall not be considered as a substitute for required mill test reports listing chemical

composition. In addition, mill test reports shall not be considered as confirming alloy verification.

5.3 The PMI activity shall be included in the overall quality plan and Inspection & Test Plan for

warehouse and fabrication/erection. The EPCC contractor shall submit to PMC/Owner, a procedure for PMI to comply with the requirements of this specification. Approval of PMI procedure shall be obtained from Owner/PMC prior to commencement of fabrication/erection as the case may be.



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5.4 A copy of daily PMI records shall be submitted to owner/PMC . 5.5 After installation, but prior to hydrostatic testing/painting/insulation, the EPCC contractor

shall examine all components requiring PMI for proper compliance to this specification. A record of this final check, as specified below, shall be submitted to PMC/Owner and made part of the permanent inspection records.

5.5.1 Owner supplied material : Records signed by EPCC contractor and duly certified by PMC/Owner. 5.5.2 EPCC contractor supplied material : Records signed by EPCC contractor and certified by an approved third party inspection

agency. 5.6 After acceptance, all components shall be marked with a suitable paint mark. Markings

must be permanent and readily visible. These markings are in addition to markings required by other codes/specifications/Technical Notes.

5.7 Controls shall be established to keep the non conforming items identified till proper

resolution of non conformity. 5.8 PMC/Owner shall have the right to witness the performance of any PMI test. 6.0 EXTENT OF PMI PMI shall be done on each component (100 percent PMI inspection) including welds,

unless specifically exempted by Owner/PMC. However, one stud & nut assembly for each flange joint shall require PMI. All studs & nuts

in a piping hydro test loop shall require PMI, if any non conformity is detected. 7.0 PMI IN WAREHOUSE PMI testing to be performed as part of the receiving inspection at warehouse. The extent of PMI shall be as specified in 6.0. However, if PMI testing has been carried out

at vendor/manufacturer’s shop and relevant certified records and correlation with incoming material is available, PMI testing at warehouse need not be done.

PMI testing done as a part of receiving Inspection shall not be regarded as an alternative to

PMI testing of the installed system. 8.0 PMI OF PIPING AND HEATER COIL COMPONENTS PMI testing (irrespective of PMI done at earlier stages) shall be carried out when piping

loops/heater coils have been cleared for hydrostatic testing by PMC/Owner. Hydrostatic Testing shall be carried out only when non conforming components have been



Page 6 of 9


N A F T E C . S P A

replaced with conforming components and subsequent Non Destructive Testing, Post Weld

Heat-Treatment, Hardness checking etc., as required by specifications have been completed. PMI records shall form a part of piping/heater inspection records. EPCC contractor shall demonstrate to PMC that each & every component of the piping system and heater coils has been subjected to PMI by providing line wise records of PMI.

9.0 TESTING METHODOLOGY In general, portable X-Ray Fluorescence (XRF) type alloy analyzers such as Oxford

Instruments’ X-Met 3000 TX, X-Met 2000 Metal Master, NITON’s XLt or NITON II or similar analyzer shall be used for carrying out PMI. Identification of characteristic alloying elements (see 10.0 for examples), which distinguishes the material from other materials, will be sufficient. However, in case of doubt, Owner/PMC may insist on complete analysis.

The surface of the component to be subjected to PMI shall be free from grease, oil, paint or

oxides. Testing shall be done after proper surface cleaning and other requirements outlined by the manufacturer of the portable alloy analyzer. Modification, if any, of these procedures must be approved by Owner/PMC.

10.0 CHARACTERISTIC ELEMENTS

Material Specification Characteristic Elements ASTM A 335

Gr P11

Gr P5 Gr P22 Gr P9

Cr, Mo

ASTM A 312 Type 304 Cr, Ni Type 316 Cr, Ni, Mo Type 321 Cr, Ni, Ti Type 347 Cr. Ni, Columbium, Tantalum

Characteristic elements for materials not listed above shall be proposed by the EPCC

contractor for approval of the owner/PMC 11.0 CALIBRATION 11.1 Instruments used for PMI shall have the sensitivity to detect the alloying elements in the

specified ranges. Instruments or methods used for examination shall be of the type that will provide quantitative, recordable, elemental composition results for positive identification of the alloy elements present.

11.2 Each alloy analyzer shall be calibrated using known alloy standards for intended materials

to be checked by PMI. A calibration certification from the Manufacturer or his authorized agency shall be submitted to PMC/Owner for records. As such, calibration at site is not envisaged.

11.3 PMC/Owner shall review the procedure and qualification and witness sample alloy

verification tests to confirm that the procedures, equipment and personnel are capable of providing consistent and accurate results.



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12.0 SITE VERIFICATION OF ANALYZER Verification using Standard samples supplied by institutes such as ASM (American Society

of Metals) for the intended materials type and grade shall be performed each day before using the analyzer. Such a verification shall be done again if PMI test is to be performed on different grade or type of material.

13.0 PERSONNEL QUALIFICATION The persons performing the PMI test should be knowledgeable about properties of

material, all aspects of operation of PMI equipment including the method of testing. Qualification/experience documents of the person performing the PMI test including his training and experience shall be submitted to PMC/owner for review and approval.

14.0 ACCEPTANCE CRITERIA 14.1 Base Metal PMI test results showing presence of characteristic elements upto 10% less than the

minimum specified value in the material specification or upto 10% more than the maximum specified value in the material specification shall be acceptable.

14.2 Deposited Weld Metal For deposited weld metal between base metals of the same specification using matching

consumables, the recorded presence of characteristic elements upto 12.5% less than the minimum specified value in the welding consumables specification and upto 12.5% more than the maximum specified value in the welding consumable specification shall be acceptable.

15.0 REJECTION CRITERIA 15.1 If the PMI test results fall outside the acceptable range as given in 14.0 above, the EPCC

contractor shall obtain a quantitative check analysis performed by a laboratory acceptable to PMC/owner for a complete chemical analysis. Results of this analysis shall be submitted to PMC/Owner, with EPCC contractor’s recommendation, for final decision.

Decision of PMC/Owner shall be final in this regard. 15.2 If any material component or weld is found unacceptable all other represented materials (

e.g. in case of fasteners, supports ) or weld shall be considered suspect. The EPCC contractor has the following options.

15.2.1 Scrapping all those represented materials and components and replacing with new

components or welds. 15.2.2 Performing 100% examination of the remainder of the represented materials/ components

and replacing each item that fails the PMI check.. 15.2.3 If the performance of any verification activity is unacceptable to PMC/Owner or if any

material has been incorrectly identified, all further tests shall be subject to PMC/Owner approval until the problem is corrected.



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N A F T E C . S P A

16.0 DOCUMENTATION 16.1 Print out from alloy analyzer, in original, duly certified by the EPCC contractor. 16.2 PMI report as per format No. PMI-F1 16.3 Basis and action for resolving and documenting PMI non conformances . 16.4 EPCC contractor shall demonstrate to PMC/owner that all components requiring PMI have

been subjected to PMI testing and accepted.



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N A F T E C . S P A

(Format No. PMI-F1 Rev 0)

REPORT NO: ______

POSITIVE MATERIAL IDENTIFICATION TEST REPORT

EPCC contractor _____________________ Date of PMI_____________________ Project __________________________ Inspection Agency ________________ Location ________________________ PMI Equipment model ____________ Line No. /ISO Drg. No_____________ Make & Serial No. _______________ /Heater No./Drawing No

Sr. No. Part Identification Material

As per Drg./spec Material

as per PMI Result

(Accepted/Rejected/Retest)

___________________ ________________ ______________ (EPCC CONTRACTOR) (PMI AGENCY) (PMC/OWNER )