Attachment 9.

2
INDICATIVE INSPECTION & TEST PLAN**

SHEET 1 OF 3

PROJECT : 44NC-4600 : CPCL MANALI REFINERY, CHENNAI : RESID

UPGRADATION PROJECT

EQUIPMENT/ITEM DESCRIPTION: UTILITY BOILER

PACKAGE
EQUIPMENT / ITEM TAG NO. :
TEST & INSPECTION AS PER:
(CODES & SPECIFICATIONS) :

EQUIPMENT INSPECTION CODE : A

A
C
T
I
V
I
T
Y

VENDOR :
P.O. NO. :

PR/PS NO.
DRG. NO.

WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY OWNER / JE

2

1
2
3

R
R
W/R

H
H
H

W/R

W/R

WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY VENDOR / THIRD

PARTY INSPECTION AGENCY (TPIA) / STATUTORY AUTHORITY

3 CERTIFICATES / DATA TO BE SUBMITTED BY VENDOR FOR APPROVAL /

REVIEW BY TPIA / OWNER / JE

FABRICATED ITEMS:- BOILER ASSEMBLY, STEAM DRUM, WATER
DRUM, EONOMIZER ASSEMBLY, SUPER HEATER ASSEMBLY, AIR PREHEATER, RISER & DOWN COMERS, HEADERS, BLOW DOWN & FLASH
DRUM/ TANK, COOLERS, KNOCK OUT DRUM, PRESSURE
VESSELS,STORAGE TANKS(CS,SS,FRP), MEMBRANE PANEL, STACK,
DUCTING, STRUCTURAL & COLUMN BEAMS, GIRDERS, SILENCER,
FURNACE CONVECTIVE & SUPERHEATIVE SECTION, FILTERS, ETC
X WPS/PQR/WELDER QUALIFICATION
X MATERIAL TEST CERTIFICATES FOR IBR & NON-IBR ITEMS.
X RAW MATERIAL & CONSUMABLE CERTIFICATE REVIEW. IN PROCESS
INSPECTION (DISHED END INSPECTION, SHELL , DISHED END &
NOZZEL FIT UP, WELDING INSPECTION), NDT, PWHT, HYDRO TEST,
FINAL VISUAL, DIMENSIONAL INSPECTION & ASSEMBLY INSPECTION,
SPARES VERIFICATION,

MACHINERY ITEMS:- AGITATORS, PUMP, STEAM TURBINE, DAMPERS,
BLOWER , ID, FD FAN, DE-AERATOR, ON OFF POWER CYLINDER, FUEL
OIL TRAIN, GAS SEPERATOR SYSTEM, BURNERS ASSEMBLY, BUNKER
ISOLATION GATES, CONVEYER SYSTEM, ROTARY AIR LOCK VALVES,
MANUALY OPERATOR ISOLATION GATE, CHEMICAL DOSING SYSTEM,
AIR POLLUTION CONTROL SYSTEM, FUEL FEEDING SYSTEM,
ATTEMPERATOR SYSTEM, LEVEL MONITORING SYSTEM, CRANE,
HOIST/CHAIN PULLY BLOCKS WITH TROLLY, DEDUSTING SYSTEM,
EYE WASH & SAFETY SHOWER SYSTEM, ESP , ETC.
X MATERIAL CERTIFICATE REVIEW (IBR & NON-IBR)
, ROTOR
BALANCING, PERFORMANCE & MECHANICAL RUN TEST, FUNCTIONAL
TEST, HYDROSTATIC TEST, NDT, DIMENSIONAL & VISUAL INSPECTION ,
PAINTING, SPARES VERIFICATION, FIRST FILL OF LUBRICANTS AS
APPLICABLE, ETC .

PIPING ITEMS- IBR & NON-IBR PIPES, VALVES, PIPE FITTINGS,
BOLTING MATERIAL, EXPANSION BELLOW(Metallic & Non-Metallic),
FLANGES, GASKETS, STRAINERS, STEAM TRAPS, SPRING SUPPORTS,
ETC
X RAW MATERIAL CERTIFICATE REVIEW (IBR & NON-IBR), HYDROTEST
FOR VALVES, EXPANSIONBELLOW, DIMENSIONAL INSPECTION, FINAL
DOCUMENT REVIEW.

INDICATIVE INSPECTION & TEST PLAN**

SHEET 2 OF 3

PROJECT : 44NC-4600 : CPCL MANALI REFINERY, CHENNAI : RESID

UPGRADATION PROJECT

EQUIPMENT/ITEM DESCRIPTION: UTILITY BOILER

PACKAGE
EQUIPMENT / ITEM TAG NO. :
TEST & INSPECTION AS PER:
(CODES & SPECIFICATIONS) :

EQUIPMENT INSPECTION CODE : A

A
C
T
I
V
I
T
Y

VENDOR :
P.O. NO. :
PR/PS NO.
DRG. NO.

WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY OWNER / JE

2

W/R

W/R

W/R

10

11

12

13

14

15

WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY VENDOR / THIRD

PARTY INSPECTION AGENCY (TPIA) / STATUTORY AUTHORITY

3 CERTIFICATES / DATA TO BE SUBMITTED BY VENDOR FOR APPROVAL /

REVIEW BY TPI A / OWNER / JE

ELECTRICAL ITEMS:- LV/HV SWITCH GEAR (PCC, MCC), HT & LT
SWITCH BOARDS, PLC PANEL, LOCAL OPERATING PANEL,
ELECTRICAL CONTROL SYSTEM/MAN MACHINE INTERFACE, D.G.SET,
HT&LV MOTORS, VFD, HIGH & MEDIUM VOLTAGE CABLES, JUNCTION
BOX, FIRE ALARM SYSTEM, BATTERY & BATTERY CHARGER,
TRANSFORMERS, ETC
X VISUAL & DIMENSIONAL, FUNCTIONAL TEST, ROUTINE TEST, FAT, HV/IR
TEST, IP REQUIRMENT, ETC AS APPLICABLE.
X TYPE TEST FOR ITEMS LIKE TRANSFORMERS, LV SWITCH GEAR,
GENERATOR, MOTORS, BUS DUCTS ETC AS APPLICABLE.

INSTRUMENTATION ITEMS:- ANALYZER, CONTROL VALVE, CONTROL
PANEL, PRESSURE REDUCING & DESUPER HEATING STATION, FLOW
INSTRUMENTS, INSTRUMENT CABLES, SOOT BLOWERS, , LEL
DETECTOR,
PRESSURE,
LEVEL
&
TEMPERATURE
TRANSMITTERS/GAUGES, ORIFICE PLATE & ASSEMBLIES, SAFETY
VALVES, ROTOMETERS, VIBRATION MONITERING SYSTEM, JUNCTION
BOX ,ETC.
X VISUAL & DIMENSIONAL, FUNCTIONAL TEST, ROUTINE TEST, FACTORY
ACCEPTANCE
TEST,
PRESSURE
TEST,
HV/IR
TEST,
IP
REQUIRMENT,ETC AS APPLICABLE.

MISCELLANEOUS ITEMS:-REFRACTORIES, INSULATION MATERIALS,
CABLE TRAYS, FOUNDATION BOLTS,ETC.
X
MATERIAL TEST CERTIFICATES, COMPRESSIVE TEST, LINEAR CHECK,
CONE TEST ETC.TESING & VISUAL , DIMENSIONAL INSPECTION.UT
TEST OF FOUNDATION BOLTS MORE THAN 20MM DIAMETER.

COMMON REQUIRMENTS FOR ALL ITEMS
X PRE-INSPECTION MEETING TO BE CONDUCTED BY PACKAGE VENDOR
AFTER ISSUE OF PO/PR/PS. JE, CPCL & VENDOR SHALL ATTEND THE
PRE-INSPECTION MEETING.
X INSPECTION CATEGARIZATION PLAN SHALL BE SUBMITTED AFTER
PLACEMENT OF P.O./PR/PS.
X DETAILED INSPECTION & TEST PLAN AFTER ISSUE OF PO/PR/PS SHALL
BE SUBMITTED FOR FABRICATED ITEMS/EQUIPMENT, MECHANICAL
ITEMS, ELECTRICAL & INTRUMENT, PIPING ITEMS AS PER INSPECTION
CATEGARIZATION PLAN & SPECIFICATION.
X INSPECTION & TEST PROCEDURE INCLUDING NDT, PWHT,
HYDROSTATIC TEST, PERFORMANCE & MECHANICAL RUN TEST, FAT
(FOR PLC, DCS, ANALYZER SHELTER, ETC.), PMI, PAINTING, PACKING
PROCEDURE / SHIPPING DRAWING OF COMPLETED EQUIPMENT. ETC.
X SUMMARY OF ALL SUPPLIMENTARY REQUIREMENTS AS SPECIFIED IN
THE ORDER PR/PS.
X SUB-VENDOR APPROVAL OF BOUGHT OUT ITEMS.

INDICATIVE INSPECTION & TEST PLAN**

SHEET 3 OF 3

PROJECT : 44NC-4600 : CPCL MANALI REFINERY, CHENNAI : RESID

UPGRADATION PROJECT

EQUIPMENT/ITEM DESCRIPTION: UTILITY BOILER

PACKAGE
EQUIPMENT / ITEM TAG NO. :
TEST & INSPECTION AS PER:
(CODES & SPECIFICATIONS) :

EQUIPMENT INSPECTION CODE : A

A
C
T
I
V
I
T
Y
16

VENDOR :
P.O. NO. :
PR/PS NO.
DRG. NO.

WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY OWNER / JE

2

17
18

A
R

H
H

19

WITNESS INSPECTION AND / OR DOCUMENT REVIEW BY VENDOR / THIRD

PARTY INSPECTION AGENCY (TPIA) / STATUTORY AUTHORITY

3 CERTIFICATES / DATA TO BE SUBMITTED BY VENDOR FOR APPROVAL /

REVIEW BY TPI A / OWNER / JE
X REVIEW OF STATUTORY CERTIFICATES (IBR, CIMFR, CCOE, IP
REQUIRMENT, ATEX, FM, ASME, ETC. AS APPLICABLE.)
X CONTENT LIST OF FINAL DOSSIER
X FINAL DOSSIER OF BOILER PACKAGE
AS PER VENDOR DATA
REQUIRMENT
ISSUE OF IRC FOR ALL ITEMS BY JE.

LEGENDS : H HOLD, W - WITNESS, R - REVIEW, A APPROVAL, I INFORMATION, X SUBMIT

PO PURCHASE ORDER, PR PURCHASE REQUISITION, PS PURCHASE SPECIFICATION

** NOTE : THIS IS AN INDICATIVE INSPECTION AND TEST PLAN IDENTIFYING SCOPE OF

INSPECTION /REVIEW OF DOCUMENTS AS A MINIMUM REQUIREMENT, DETAILED INSPECTION
AND TEST PLAN INDICATING ALL SPECIFIED REQUIREMENTS AFTER ISSUE OF PO / PR TO BE
GENERATED BY VENDOR AND SAME TO BE SUBMITTED TO JE/CPCL FOR APPROVAL.
JE/CPCL RESERVES RIGHT TO WITNESS INSPECTION OF ANY ITEM AT ANY STAGE WHICH
SHALL BE INDICATED ON QAP / INSPECTION & TEST PLAN AT THE TIME OF APPROVAL AND
SAME TO BE COVERED AS PART OF PURCHASE ORDER CONDITION ISSUED BY CONTRACTOR.