02 Mechanical

HPCL, Visakh
INDICATIVE INSPECTION &

TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261
TOYO ENGINEERING INDIA LTD.
DOC.No. 6261-CD-303 DHT PROJECT Sheet 1

INDEX

Indicative Inspection & Test Plans

SL.
No.
DESCRIPTION
B. MECHANICAL WORKS
I Under Ground Piping
II Above Ground Piping/ Heater Coils
III Storage Tanks
IV Equipment Erection (Static)
V Equipment Erection (Rotary)
VI Crane (EOT/ HOT)
VII Column Internals
HEATER WORKS
I Fired Heaters
II
Refractory & Insulation Works
Fired Heaters

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

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

W : WITNESS POINT.
An activity which requires witnessing by Owner/ Consultant when activity is performed.
Suppose, after proper notification has been provided, the contractor not obliged to
hold further processing, if Owner/ Consultant is not available to witness the activity or
does not provide the comments before the date notified.

Rw : REVIEW of contractors documentation.

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

WC : 100% Examination by CONTRACTOR.

NDT : NON DESTRUCTIVE TESTING.

PWHT : POST WELD HEAT TREATMENT.

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

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

I UNDER GROUND PIPING

A PRIOR TO FABRICATION

1 Incoming Material WC W

2 Welding Filler Material Approval/ Qualification. WC HP

3 WPS/ PQR WC HP

4 Welder Performance Qualification. WC HP

5 a NDT Procedure Qualification WC HP

b PWHT Procedures Qualification (if any) WC HP

6 Preparation of Sketches. WC S

7 Joint Numbering. WC S

8 Material traceability & transfer of heat nos. WC S

B FABRICATION (SHOP & FIELD)

1 Material as per piping class (check w.r.t. approved WC S
Colour coding procedure).

1 a Fit-up check WC S

b Dimensional check WC S

2 Pre-heat (if any). WC S

3 Check for purity of purging/ shielding gas WC Rw/S

4 Purging (if any) WC S

5 Shielding rate (if any) WC S

6 Basking of Electrodes WC S

SL.
NO.
ACTIVITY CONTRACTOR PMC

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

7 Interpass cleaning & temperature check WC S

8 Visual check of completed welds WC S

9 Monitoring of PWHT Cycle WC S

10 Hardness Check WC S

11 PT/MT WC S

12 Radiography marking (for Random Radiography) WC W

13 Radiography Interpretation WC HP

14 Check shot for Radiography WC W

C PROOF TESTING

1 Procedure WC HP

2 Correctness of Testing arrangements WC S

3 Calibration of Pressure Gauges WC Rw

4 R.F. Pad testing, if any WC W

5 Positive Material Identification as per WC HP
Specification after completion.

6 Scrutiny of test packs for Mechanical WC HP
& NDT Clearance(As per Annexure A)

7 Air / Water Flushing (preliminary) WC W

8 Pneumatic/ Hydro testing WC P

9 Draining of Water & Air drying WC S

D LAYING

1 Trench excavation and levels WC S

2 Cleaning of pipe surface WC S

3 Approval of wrapping/ coating material manufacturers WC HP

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

4 Approval of agency for wrapping & coating WC HP

5 Sample test of coating materials in approved laboratory WC Rw

6 Procedure qualification for wrapping & coating WC HP

7 Application of primer WC S

8 Coal tar temperature WC S

9 Coating and wrapping WC S

10 Calibration of Holiday tester WC HP

11 Holiday testing WC HP

12 Thickness of coating WC HP

13 Peel test WC HP

14 Lifting arrangement WC S

15 Lowering (levels & orientation of branches) WC S

16 Checking of wrapping and coating for damages during WC HP
lowering, their repair, holiday testing, etc.

17 Back filling WC S

18 Location, Brickwork, Plaster of valve pit WC S

19 Top cover & finish of valve pit WC S

E SYSTEM COMPLETION

1 Tie in joins (As per Annexure - B) WC W

2 Scrutiny of test packs for system testing
(As per Annexure - C) WC W

3 System testing WC W

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

Inspection & Test Documents

Review Test and Inspection Document HP Rw

Abbreviations:

NDT : Non Destructive Testing

WPS : Welding Procedure Specifications

U/G : Under Ground

PT : Penetrant Testing

MT : Magnetic Particle Testing

PWHT : Post Weld Heat Treatment

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

Plant: Report:
Contractor: Area :

Loop No.: Inch Metre
Sketch No.: From: ____________ To : ____________

Sr.No.

Activity Check
Clearance by
Contractorwith
Date & Sign
Clearance by
PMC with Date
& Sign

A MECHANICAL COMPLETION RECORD (U/G)
1 Clearance for flushing & testing.

1.a

Mechanical clearance
Conformity with drawing.

1.b

Welding & NDT clearance
Material as per piping class
Fit-up check
Visual check of completed welds
LPI checks
RF pad testing

2
Flushing & Pressure testing
Medium
Test pr. Kg /Sqcm

3
Coating and Wrapping
Surface preparation
Primer application
Coating, wrapping and peel test
Holiday check

4

Laying
Trench leveling
Lowering & checking for damages in
wrapping & coating, their repair, holiday
testing, etc.
Backfilling

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

Review by Area Co-ordinator

Sign. Date Name Designation

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

INSPECTION REPORT FOR TIE IN JOINT
(FOR UNDER GROUND PIPING)

JOINT NO. REPORT NO.
DATE
A TTIME AT THE TIME OF FIT UP
CLEARANCE BY
DATE CONTRACTOR PMC
B FIT UP
C ROOT RUN DP
D FINAL RUN DP
E WELDER NO
F RADIOGRAPHY
G PWHT HARDNESS
H RF PAD TESTING
I CLEANING & PRIMING
J COATING, WRAPPING & PEEL TEST
K HOLIDY CHECKING
L CHECKING FOR ANY DAMAGE IN
WRAPPING & COATING AFTER
LOWERING, THEIR REPAIR, HOLIDAY
TESTING, ETC.

M BACK FILLING

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

Contractor PMC Mechanical PMC Inspection

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

Plant: Report:
Contractor: Area:

Loop No.: Inch Meter
Sketch No.: From: ____________ To: ____________

Sr.No.

Activity Check
Clearance by
Contractorwith
Date & Sign
Clearance by
PMC with Date
& Sign

A MECHANICAL COMPLETION RECORD (U/G)
1 Clearance for flushing & testing.

1.a

Mechanical clearance
Conformity with drawing.

1.b

Welding & NDT clearance
Material as per piping class
Fit-up check
Visual check of completed welds
LPI checks
RF pad testing

2
Flushing & Pressure testing
Medium
Test pr. Kg /Sqcm

3
Coating and Wrapping
Surface preparation
Primer application
Coating, wrapping and peel test
Holiday check

4

Laying
Trench leveling
Lowering & checking for damages in
wrapping & coating, their repair, holiday
testing, etc.
Backfilling

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

Review by Area Co-ordinator

Sign. Date Name Designation

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

II ABOVE GROUND PIPING

1 Incoming Material WC W

2 Welding Filler Material Approval/ Qualification WC HP

3 WPS/ PQR WC HP

4 Welder Performance Qualification WC HP

5 a NDT Procedure Qualification WC HP
b PWHT Procedures Qualification WC HP

6 Joint numbering in Isometries (Big & Small Bore) WC S

7 Preparation of sketches for job in case of off sites WC S
A/G piping and Joint Numbering

8 Transfer of Heat Nos. & Traceability WC W

B FABRICATION (SHOP & FIELD)

1 Material as per piping class (check w.r.t. approved WC S
Colour coding procedure)

1 a Fit-up check WC S
b Dimensional checks WC S

2 Pre-heat (if any) WC S

3 Check for purity of purging/ shielding gas WC Rw/S

4 Purging WC S

5 Shielding rate (if any) WC S

6 Baking of Electrodes WC S

7 Interpass cleaning & Temperature check WC S

8 Visual check of completed welds WC S

9 Monitoring of PWHT Cycle WC S

10 Hardness Check

i) For C.S. Materials WC S
ii) For A.S. Materials Piping WC W
iii) For A.S. Material Heating Coil WC HP

SL.
NO.

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

11 PT/MT WC S

12 Radiography marking (for Random Radiography WC W
only)

13 Radiography Interpretation WC HP

i.For Carbon Steel Piping WC HP
ii.For Alloy Steel/SS Piping WC HP

14 Spool clearance WC HP

C ERECTION

1 Lifting arrangement WC S
2 Test Certificates for lifting tackles WC Rw

3 Location and orientation of branches WC S

4 Provision of Instrument Tappings WC S

5 Provision of vents and drains WC S

6 Correctness of type of supports, anchors, guides WC S

7 Correctness of gasket/ fasteners WC S

8 Correctness of valves (NRV, Gate, Globe, Control WC S
Valves), Steam traps and their direction of flow

9 Provision of cold pull WC HP

D PROOF TESTING (See enclosed checklist in Annexure-A)

1 Procedure WC HP

2 Correctness of testing arrangements WC S

3 All valves to be kept open and chek if testing done WC S
against closed valve position

4 Isolation of equipments, control valves, instruments, WC S
ellows, before testing. Removal of flappers from
check valves

5 Scrutiny of test packs for Mechanical and NDT WC HP
Clearance

6 Positive Material Identification as per specification WC HP
after completion of installation

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

7 Calibration of pressure gauges WC Rw

8 Preparation of check list WC S

9 Liquidation of check list WC S

10 Air/Water flushing (preliminary) WC W

11 Pneumatic / Hydrotesting (See Annexure - B) WC HP

12 Draining & drying WC S

13 Removal of temporary blinds/ supports WC W

14 Pickling of system, if required WC W

15 Boxing up including reinstallation of flappers WC W
of check valves

16 a. Check on fasteners & gaskets and record WC Rw
Thereof

b. Torque tightening of flange joints WC S

17 System testing WC W

18 Setting of spring supports WC W


Review Test and Inspection Documents HP Rw

Abbreviations:

A/G : Above Ground

For liquidation of Punch list. See Annexure - C.

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

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

Project: ___________________
Plant/Unit: ___________________
Contractor: ___________________
Loop No: ___________________

Report No: ___________________
Date : ___________________
Area : ___________________
INCH MTR ___________________
Line No (Isometric No.) Rev. GAD NO. Rev. P&ID No.

Sr.
No.
Items to be checked
Acceptance by
Contractor

Witness by
Owner/ PMC
as required by
ITP
1 Installation checked as per Isometric w.r.t.
CONFIGURATION : Route, plumb, elevation, clearance
for thermal expansion/ insulation
BRANCH: Location, angle, orientation, type, R.F. pad etc.
STEAM TRAP : Direction

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 and Field welds)
b) Spool numbering
c) As-built routing and dimensions

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

Gate valve
Globe valve
Check valve

Control valve Tag Nos.
Safety Valve Tag Nos.
5
Any other valves
FORMAT NO:_______________________________________ (Sheet 2/4)

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261


Sr.
No.
Items to be checked
Acceptance
by
Contractor
Witness by
Owner/ PMC
as required by ITP
6 Strainers: Check for clearance, flow direction, elements
Flanged joints
Total Nos.
Check for type of flange
Check for Rating
Check for Alignment, (Proper gap and parallelity)
Check for correct studs and nuts dia, length, material, uniform protrusion of
studs, anti seize compound

Check for correct gasket (type, size, spec., thickness, etc.)
7
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
Orifice flanges 11
Check for Tag. No. tapping orientation, tap valve, jack screw, straight run
length of upstream and downstream

12 Local Gauges: Check for accessibility
13 Slope (When applicable)
Supports
a) Guides, Cross Guides, Trunnion etc.
i) Check for correct type, material and dimension
ii) Check welding
iii) Check for vent hole on pads (if applicable)
iv) Check offset for thermal expansion
v) Check clearance of guide
vi) Check U bolt for slide support
b) Spring support
i) Verify tag no. and check details as per data sheet/ spring set
ii) Check for locking arrangement and any damage during transit, etc.
iii) Check for completeness of installation as per drg. Including welding of
mounting cleat/ bracket

iv) Check for locking during installation and pressure test
c) Bracket support and inserts with Anchor fasteners:
i) Check for members dimensions and materiall
ii) Check for welding
iii) Check for bolting
14
iv) Check for appearance damage
Vents/ Drains
As per Drg
Orientation of valve handles
Clearance for hose
15
Requirement of additional vents/ drains (highest/ lowest pt.)
FORMAT NO:_______________________________________ (Sheet 2/4)

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

Sr.
No.
Items to be checked
Acceptan
ce by
Contracto
r

Witness by
Owner/ PMC
as required by
ITP
16 Earthings:
a) Check for location
b) Check for dimension of lug welding
17 17 Joints History sheets enclosed for
17.1 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)
Checked for Removal Binding off of:
a. Control, Safety and Check valves
b. In-line instruments
c. Rupture discs
d. Equipment nozzles
18
e. Others
19 19 Supports and Weld/Flanged/ Screwed connections free from insulation or other
coverage

Checked installation of (Indicate location in Drawings)
a. Temporary Blinds, Spades
b. Temporary Strainers
c. Temporary Dummy-spools
d. Temporary Gaskets
20
e. Others
Expansion Bellows
a) Checks prior to installations
Physical damage
Transit locks are intact
Dimensions as per drgs.
b) Check during installations
Parallelity of mating flanges
Face to face dimensions of mating flanges
Concentricity of mating flanges
No stress on expansion bellows
Record
c) Isolation during pressure tests
Bellow manufacturers recommendations on isolation of
bellow during Pr. Test to be followed

21
If recommended expn, bellow to be dropped during pr. Test
22 Cleanliness internally and externally
23 Rotating equipment final alignment
checked with piping

FORMAT NO:______________________________________ (Sheet 3/4)

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261


Sr. No. Items to be checked
Acceptance by
Contractor

Witness by
Owner/ PMC
as required by
ITP
24 Removal of unwanted construction supports

25 Instrument tappings provided as per Drawing

26 Physical Walk Through The Line Checked for gross
irregularities including physical damages, unwanted tacks,
arc strikes, spatters and space for thermal expansion

Other

Remarks

Contractor :
Sign. :
Date :
Name : Designation :
PMC
Sign : Review by Area Co-ordinator (PMC)
Date : Sign :
Date : Date :
Name : Designation : Name : Designation :

FORMAT NO:_______________________________________ (Sheet 4/4)

HPCL, Visakh
INDICATIVE INSPECTION & TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

DAILY MATERIAL TRACEABILITY REPORT
(FOR ABOVE GROUND PIPING/ HEATER)
Contract No. : _______________________ Report No.: ______________
Contractor : ________________________ Date : ___________________

Verified Remarks Sl.
No.
Line / Heater No. Area
No.
Dia Joint No. Spool
No.
Piping Component Heat / Batch No. Colour Code
Contractor PMC

Contractor PMC

Note : A Sketch of the spool may be enclosed.

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

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

Project :

Report No:

Plant / Unit :

Date :

Contractor :

Area :

Loop No. :

REF P & ID No.

INCH MTR

From
______________
To _________________
Line No (s) Isometric No. (s) P & ID No.

Test Medium : Test Duration Design/ Test pressure
Test Pressure Gauge No. Range
Calibration
Certificate No.
Gauge Calibration Date

Items to check Accept Witness
Contractor PMC
Field installation Checklist prior to Hydrotest
Signed

Punch list prepared Yes/ No
Pre-Hydrotest Punch items cleared
Accessibility to inspection/ witness locations
Capacity of pressurising pump checked
Cordon off area for high pressure testing as
required

Pre-hydrotest flushing carried out
IBR/Others test Witnessing required Yes/ No
System released for Pressure Testing :

Contractor
PMC
Sign Name Sign Name
Date Date
Designation Designation

FORMAT NO:_______________________________________ (Sheet 1/ 2)

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

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

Activity

Date Time
Water Filling and Venting started at

Water Filling completed

Vents closed

Isolation of Pressurising pump

Test completed at :

- Water drained

- Air

- Temp Blinds Removed

- Checked for reinstallation of

a. Control & Safety valves

b. On line instruments

c. Rupture disks

d. Deblinding

e. Others

- Cold setting of spring supports carried out

Contractor PMC

Sign Sign

Date Date
Name Designation Name Designation

FORMAT NO:_______________________________________ (Sheet 2 / 2)

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

Punchlist

Project:

Report No:

Plant/Unit:

Date :

Contractor:

Area :

Loop No:

REF P&ID No.

Description :

Ref. Document :

Punc
h
Item
No
Priority

Description of
Punch
Items
Location Prepared
by

Action by Due Date

Completion
Acceptance

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

PMC

Sign Sign
Date Date
Name Designation Name Designation

FORMAT NO:_______________________________________

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.

III

STORAGE TANKS

1 Acceptance of the tanks foundation WC W
2 Materials WC W
3 Filler materials tests and approval WC HP
4 WPS/ PQR WC HP
5 Welders performance qualification WC HP
6 Radiography procedure WC HP
7 Joint numbering in drawings WC S
8 Welding equipment and accessories WC S
9 Tools and Tackles WC S
10 Baking ovens
- Portable WC
S
- Heavy WC S
11 Jig & Fixtures WC S
12 Suitability of plate bending machine WC S
B FABRICATION/ ERECTION BOTTOM
1 Plate size, marking and cutting WC S
2 Blast cleaning & painting of underneath
bottom plates
WC S
3 Plate layout, overlap and fitup WC S
4 Sequence of welding to follow WC S
5 Size and positioning of backing plate for
annular plates
WC S
6 Baking of electrodes/ interpass cleaning WC S
7 Visual check WC S
8 LPI/MPI/ Radiography of annular plate butt
welds and
bottom plate butt welds (if any)
WC HP
9 Vacuum/ MPI/ LPI of shell portion of the
bottom plates
WC HP
10 Vacuum box test for the bottom plate
welding
WC HP

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.
SHELL
1 Plate size, marking and cutting. WC S
2 Plate bending, curvature check, stacking. WC S
3 Shell course alignments and fitup of vertical
and
circumferential joints.
WC
S
4 Shell diameter, circularity, perpendicularity,
straightedge before welding.
WC
HP
5 Visual and Back chip check WC S
6 Second side visual. WC S
7 Location, size and alignment of nozzles and
other Openings
WC
HP
8 R.F.Pads fitup / welding. WC W
9 PWHT of RF pad. Nozzles & manhole, etc.
(As
applicable)
WC
HP
10 Radiography marking for Random
radiography only
WC
W
11 Curbangle and Wind girders fitup / welding WC S
12 MPI/LPI nozzles, wind girders fitup/welding WC W
13 RF Pads air test. WC HP
14 Shell to bottom fit-up WC W
15 Sheel to bottom I/S welding root run visual/
Oil chalk test
WC

HP
16 Sheel to bottom O/S welding visual and LPI
for toecracks
WC
HP
17 Fabrication and erection of stairways WC S
18 Cleates welding for insulation WC S
19a Radiography interpretation. WC HP
19b Extension marking for repair

WC HP

FIXED ROOF

1 Identification of Roof Structure members in
AFC drgs
WC
Rw
2 Blast cleaning and painting Roof Structure
underside of Roof plates

WC S

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.

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

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.
C
TESTING

1
Correctness of testing arrangements especially
size of blind flanges/ vents/ drains/ temporary
piping
WC
S
2
Mechanical / Inspection clearances WC
HP
3
Earthing of ladder and shell WC
W
4
Settlement readings during water filling WC W
5
Hammer test WC HP
6
Air pressure test WC HP
7
Vacuum test WC HP
8
Roof collapsability test in case of floating roof
tanks
WC HP
9
Calibration of tanks in case of floating roof
tanks
WC Rw
D
PAINTING AND INSULATION
1
Cleaning WC S
2
Painting WC W
3
Insulation WC W



HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.

IV

EQUIPMENT ERECTION (STATIC)

1 BEFORE ERECTION
A Execution scheme WC Rw
B Materials supply WC W
C Readiness of erection WC S
I Level of foundation (shims/ packing with
marking to be prepared & kept ready)
WC S
II No. & Size of bolts WC S
III Hole dia and no. of hole in base/ structure of
equipment and columns
WC S
IV Equipment base with actual foundation WC S
V Checking the threads of bolts & nuts WC S
VI Chipping & roughening of foundation WC S
VII C/L marking on equipment WC S
2 ERECTION SCHEMES FOR CRITICAL EQUIPMENTS
A Approval of Rigging procedure
(As per Annexure 1)
WC HP

3

SAFETY TEST

A Load test of cranes, lifting beams, slings and
shackles, length and dia. of sling &
condition of wire rope (Broken/ damaged
strands should not be there)
WC W
4

Cross checking if Data-sheet w.r.t.
orientation, base plate Deatails

WC S
5 DURING ERECTION
A Orientation to be checked

WC S
B Placement of packing as per marking

WC S
C Outside cleaning, coating/ wrapping,
painting for underground equipment
WC W

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.
6
AFTER ERECTION

A
Tightening of Bolts and providing washers WC
S
B
Levelling and alignment of equipments WC
HP
C
Corresponding requirement elevation and distance
between nozzles in special cases
WC
S
D
Cleaning of sleeves before grouting WC S
E
Grouting WC S
F
Final tightening of bolts WC S
G
Internals installation after PMI as required

i. Critical equipments WC HP

ii. Other equipments WC W

7
TESTS

As per specification WC W
8
Packing of column (As per Annexure 2) WC W
9
Final Boxing up WC W



HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.

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

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

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.

PACKING COLUMN

1
BEFORE INSTALLATION

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

2
DURING INSTALLATION
A
Degreasing and cleaning of packing material

WC S
B
Check packing su
pport plate
WC S
C
Check for stacked or dumped packing as per
Specifications
WC S
D
Check for nesting WC S
E
Check for packings are touching bed limiter
(when issued and top level)
WC S

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.

V

EQUIPMENT ERECTION (ROTARY)

1 BEFORE ERECTION
B Foundation check
I Level / centreline of foundation WC S
II No / Dia / Length of anchor bolts, Depth of
pockets, verticality of pockets
WC S
III Chipping, roughing and cleaning of pockets WC W

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

3

VISUAL INSPECTION OF EQPTS. TAG/ IDENTIFICATION NO.
A For any damage WC S
B Free shaft rotation WC S

4

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

a. Size/ Taps WC S

DURING ERECTION

A Level/ elevation of base frame WC W
B All foundation bolts to be checked WC S
C Grouting of base frame / pocket grouting WC W
D Orientation of eqpts. WC W
E Elevation/ Level of eqpts. WC HP
F Shimsize/ material/ thickness WC W
G Distance between couplings WC W
H No-load run of motors WC W

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.
I
Alignment readings
WC

- Without piping (Loose bolts) WC
HP

- With piping (After tightening the flange bolt) WC HP
J
Type of grout and grouting WC S
K
All protection and safety guards installation WC S

AFTER ERECTION
A
Curing of grout WC S
B
Auxiliary connections to be mounted on eqpts.
as per drawing
WC S
C
Final tighting of bolts WC S
D
Tests as per spec. WC W
E
Chemical Cleaning of equipments parts /
connected piping
WC S
F
Boxing up of equipment 7 connection piping WC S
G
Log book maintenance (For rotating of shaft,
lubrication Oil reservoir full, all plugs in
positions)
WC S
H
No load run of Motor WC W
I
Recoupling of motor & reconfirmation of
alighnment
WC W

INSPECTION & TEST DOCUMENTS

Review test and Inspection documents HP Rw

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.
VI CRANE (EOT/ HOT)
1 BEFORE ERECTION
B Materials supply (contractor) WC W
C Readiness for erection
I Structural steel girder span centre to centre and
elevation Difference
WC S
II Check centre to centre distance of rails, gaps,
elevations, crab wheels distances
WC S
III Check buffer stops WC S
2 A Erection and assembly of components like LT,
Crane Girders, Crab, Platforms, etc.
WC S
B Review of hoist ropes and assembly of hook
blocks
WC S
3 A Electrical installation, testing and no load test of
motor
WC S
B Coupling of motors to drives WC S
4 NO LOAD TEST
A. Winding & unwinding test WC W
B. Traversing test WC W
C. Travelling test WC W
5 LOAD TEST
A. Winding & unwinding test WC W
B. Traversing test WC W
C. Travelling test WC W
D. Load & Over load testing WC W
E. Deflection of girder WC W

Review test and Inspection Documents HP Rw

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.
VII INSTALLATION OF COLOUMS INTERNALS
A
Before Installation

1
Avalable of Venders representatives at site WC HP
2
Material Inspection

a) Manufactures Test Certificate WC Rw

b) Testing, If any WC S*

c) Positive Material Identification WC* Rw
3
Fabricated materials receipt WC Rw
4
Level check on TSRs WC S
5
Check for down corner clearance and Tray
clearance
WC S
6
Distance between TSRs WC S

B
After Installation

Check for
1
Exit weir height WC S
2
UDFC WC S
3
Tightness of bolts WC S
4
Orientation and tightness of clamps WC S
5
Provision of lock nuts / seal pates WC S
6
Correctness of installation of shimming / bolting
for top down corner
WC S
7
Correctness of gasketing (if any) WC S
8
Tray to tray distance and level of tray WC S
9
Leak testing of seal pans as applicable WC HP
10
Damaged, missing valves and valve movement
for valve trays
WC S

11

Fitting of proper valve combination

WC

S
12
Damage to deck components WC S

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

13
Level and alignment of inlet weir and exit weir WC S
14
Check for slots on tray components to be fully
covered
WC S
15
Gaps at down corner ends WC S
16
Removal of temporary plugs after testing WC S
17
Cleaning of all trays & inside of equipment WC S
18
Certification of installation by Vendors
representative and operation groups of PMC /
Owner
WC HP
19
Final boxing up and intertisation, if any WC Rw


Review test and Inspection documents HP Rw

NOTE:- All activities pertaining to material receipt, identification. Pre installation checks
checks and installation to be carried out in the presence of Vendors
representative and duly certified and documented for submission as final
document.

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.
I FIRED HEATERS (FABRICATION & ERECTION
A
PRIOR TO FABRICATION

1
Material Inspection

a) Manufacturing Test Certificate
WC
Rw

b) Testing, if any
WC S

c) Positive Material Identification for Alloy
Steel & Stainless Steel material by alloy
analyzer
WC S*/RW
2
WPS / PQR WC HP
3
Welders Performance WC HP
4
Welding Consumable WC HP
5
a) NDT Procedure Qualification WC HP

b) PWHT Procedure Qualification WC HP
6
Availability of AFC drawing (Reviewed by
PMC)
WC S
7
Joint Numbering for coils / pressure parts WC S/Rw
8
Structural members identification WC S/Rw
9
Layout Checking WC S/Rw

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.
B
FABRICATION

STEEL WORKS
1
Materials as per AFC drawing
WC
S
2
Dimensional check
WC S
3
Fit-up check
WC S
4
Weld Visual Inspection WC S
5
Radiography as Applicable

a) RT Marking (for random radiography only) WC HP

b) RT Interpretation WC HP
6
Completion of structures as per AFC
drawings
WC HP
7
Surface cleaning for primer painting WC S
8
Primer Coating as applicable

COIL WORK
1
Edge Preparation WC S
2
Fit-up of joints WC S
3
Weld Visual Inspection WC S
4
PT/MT Check as required WC S/Rw
5
PWHT & Hardness check as applicable WC S/Rw
6
a) RT Marking (for random radiography only) WC HP

b) RT Inspection WC HP
7
Check Short for Radiography WC HP
8
Clearance for Hydro testing WC HP
9
Hydro testing

WC HP

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.
C
ERECTION

1
Foundation check as per AFC drawing
WC
Rw
2
Lifting arrangements
WC Rw
3
Test certificates for lifting tools and tackles
WC Rw
4
Lifting of radiant section columns WC S
5
Bottom plate fit-up & welding WC S
6
Radiant shell course fit-up and welding WC S
7
Weld visual inspection WC S
8
Radiography as required WC HP
9
Cutout for burners in bottom / shell plate

a) Marking WC HP

b) Cutting WC S
10
Coil erection in Radiant section WC S
11
Erection of convection box & APH with all
sheet work & tube Supports

a) Erection Procedure WC HP

b) Erection WC S
12
Check Shot for radiography for coil field joints WC W
13
Clearance for Hydro test WC HP
14
Hydro test field joints WC HP
15
Erection fit-up & welding of stack

a) Erection Procedure WC HP

b) Erection WC S
16
Erection fit-up & Welding of ducts WC S
17
Radiography as required

a) RT Marking WC HP

b) RT Interpretation WC HP

18

FD & ID

19
Installation of soot blowers

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

a) Marking WC HP

b) Erection WC S
20
Erection of all Platforms, ladders, Hand rails &
miscellaneous structures
WC S
21
Final Painting


Review Test And Inspection Document WC Rw

Abbreviations:

RT : Radiography Testing

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.
II REFRACTORY & INSULATION WORKS (HEATERS)
A
RADIANT SECTION

1
Radiant shell

Fixing of Ceramic fiber blanket /

I. Material Inspection

Manufacturing Test Certificate
WC
Rw

Testing, if any
WC S

II. Clearance for hot work
WC* HP

III. Marking of studs WC S

IV. Welding of studs with approved PS&PQR WC S

V. Surface Cleaning WC S

VI. Check for individual layers of ceramic fiber
blankets and SS foils
WC W

VII. Check for overlap of ceramic blanket WC S

VIII. Fixing of speed fix washer and cup lock WC S

IX. Cleaning and final inspection WC HP

2
Arch Plate


WC
Rw

Testing, if any
WC S

WC* HP

III. Marking of studs / anchors WC S

IV. Welding of studs / anchors with approved
PS&PQR
WC S


VI. Check for individual layers of ceramic fiber
Blankets (CFB) modules and SS foils

WC

S

VII. Check for overlap of CFB and modules WC S

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

VIII. Cleaning and final inspection WC HP

3
Floor Plate

Laying of castable / fire bricks


WC
Rw

Testing, if any
WC S

WC HP

III. Surface Cleaning WC S

IV. Check Shelf life prior to application WC HP

V. Check for undulations on floor WC S

VI. Check for castable mix WC W

VII. Check for proper compaction WC S

VIII. Check for thickness of castable WC S

IX. Curing WC S

X. Cleaning after laying of castable WC S

XI. Check for cracks and repair WC W

XII. Fixing of tar paper, If applicable WC S

XIII. Cleaning and final inspection WC HP

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.
II
REFRACTORY & INSULATION WORKS
(HEATERS)
B
CONECTION SECTION

1
Convection Walls

Laying of castable


WC
Rw

Testing, if any
WC S

WC* HP


PS&PQR
WC S

V. Surface Cleaning WC W

VI. Check for undulations on wall WC S

VII. Check for castable mixing WC W

VIII. Check for proper compaction WC S

IX. Check for thickness of castable WC S

X. curing WC S

XI. Cleaning after laying of castable WC S

XII. Check for cracks and repair WC W


2
End tubesheets

Laying of Castable

i. Material Inspection

WC
Rw

Testing, if any
WC S

ii. Clearance for hot work
WC HP

iii. Marking of studs / anchors WC S

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

iv. Welding of studs / anchors with approved
PS&PQR
WC S

v. Surface Cleaning WC S

vi. Check for castable mixing WC W

vii. Check for proper compaction WC S

viii. Check for thickness of castable WC S

ix. curing WC S

x. Cleaning after laying of castable WC S

xi. Check for cracks and repair WC W

xii. Cleaning and final inspection WC HP

3
Breeching Plate

Laying of castable


WC
Rw

Testing, if any
WC S

WC* HP


PS&PQR
WC S


VI. Check for undulations on plate WC S




X. curing WC S

XI. Cleaning after laying of castable

WC

S



HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

4
Header box

Laying of castable

i. Material Inspection

WC
Rw

Testing, if any
WC S

ii. Clearance for hot work
WC* HP

iii. Marking of studs / anchors WC S

iv. Welding of studs / anchors with approved
PS&PQR
WC S

v. Surface Cleaning WC S

vi. Check for undulations on box WC S

vii. Check for castable mixing WC W

viii. Check for proper compaction WC S

ix. Check for thickness of castable WC S

x. curing WC S

xi. Cleaning after laying of castable WC S

xii. Check for cracks and repair WC W

xiii. Cleaning and final inspection WC HP

HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.

II

REFRACTORY & INSULATION WORKS (HEATERS)
C
STACK

Laying of castable


WC
Rw

Testing, if any
WC S

WC* HP


PS&PQR
WC S


VI. Check for undulations on stack shell WC S




X. curing WC S

XI. Cleaning after laying of castable WC S



HPCL, Visakh
TEST PLAN
ISSUED :01.06.2009 JOB NO. : 6261

SL.
NO.

II

REFRACTORY & INSULATION WORKS (HEATERS)
D
HOT AIR DUCT


WC
Rw

Testing, if any
WC S

II. Clearance for insulation
WC HP

III. External Surface cleaning WC S

IV. Provide spacer ring / anchors WC S

V. Check for thickness of the mineral wool
insulation
WC S

VI. Check for staggering of joints in insulation WC S

VII. Check for providing expansion joints WC W

VIII. Overlapping of metal sheet as per
specification
WC S

IX. Overlap on joints for aluminium sheets
as per specifications
WC S

X. Sealing alluminium sheets WC S

E
Final Inspection & Acceptance WC HP


Review Test and Inspection Documents WC Rw

02 Mechanical

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