Inspection and Test Plan (ITP) Document no.

:
Project No./Name : Job No./name : H=Hold Point Rev No. :
Customer/Client : Item-Description Name : Auxiliary Boiler R=Review Point Date :
Customer Project no. : Unit no. : Serial No. W=Witness Point
Manufacturer : Getabec Co.,Ltd. Drawing No./Rev. : SW=Spot witness D=Documented

Quality Surveillance

Document
GETABEC THIRD PARTY CUSTOMER
Reference Document/Drawings/
Item Area of activity Quality control activity Acceptance Criteria
Standard Code

Point

Point

Point

Point
Sign/Date Sign/Date Sign/Date Sign/Date

1 Design calculation and drawings

1.1 Design data/calculations Review design data and calculations Technical requirement ASME I & Project spec. D H -
Design code and standard
1.2 Drawing for approval Review drawing for approval Design calculations ASME I & Project spec. D H -
Design code and standard
1.3 Drawing for construction Review drawing for construction Design calculations D H -
Approved drawing

2 Material
2.1 Raw material for pressure part Verify material certificates and mfg. stencil marks Material certificates Material specification D H -
g reports
Material recieiving
2.2 Raw material for non-presure pt. Visual and dimensional inspection Drawing for construction Material specification - H -
Purchase order
2.3 Welding consumable material Verify and visual inspection WPS and purchase order Mfg. specification D H -
Material recieiving reports
2.4 Equipments and accessories Verify, visual and dimensional inspection Technical specification Mfg. specification - H -
P&I Diag, Purchase spec.
2.5 All alloy materials Positive material identification (PMI) Material specifications ASME section II Part A. D H
3 Welding
3.1 Welding Procedure Specification Review WPS Drawing for construction ASME IX D H -
(WPS)
3.2 Procedure Qualification Record Review test records (existing) WPS ASME IX D H -
(PQR) Witness PQR test (new) and review test records. Test records D H -
3.3 Welder Qualifiaction Test (WQT) Review welder certificates (existing) Welder certificates, WPS ASME IX D H -
Witness welder test (new) and review test records. Drawing for construction D H -
Test records

4 Drum fabrication
4.1 Outsourcing of head forming Manufacturer's (outsource) certification Manufacturer's certificate ASME I D R -
Raw material certificate (if supplied) Material certificates ASME II D R -
Material identification and transfering Material identification record PG-77 D R -
Dimensional inspection after forming Dimension report PG-80,PG-81 D R -
Visual inspection of appearance Visual inspection report PG-90 - H -
Review NDE report NDE reports PW-11 D R -
Review stress relieve (heat treatment) procedure Heat treatment procedure PW-49, PW-39ASME II D R -
and of heat treatment record (if required) and record
4.2 Layout marking and cutting Review cutting plan Cutting plan/ drawing for con Fabrication standard D R -
4.3 Material identification transfering Review cutting plan and stencil mark transfering Cutting plan/ drawing for con PG-77, PG-76 D R -
Material identification record D H -
Review material certificate Material certificates ASME II D H -
4.4 Shell plate rolling Dimensional inspection after forming
-out of roundness Drawing for construction PG-80 - H -
-minimun wall thickness design caculation design calculation - H -
4.5 Shell course longitudinal weld Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) after grinding PT.report A-270 D H -
4.6 Shell circumferential weld Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) after grinding PT. reports A-270 D H -
Radiography Test (RT) after cover layer RT. reports PW-51 D R -
Dimensional inspection of overall length Drawing for construction Fabrication standard D H -
4.7 Nozzles & manhole
4.7.1 material see also item 4.3
4.7.2 Flange and tube fit-up and weld Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) after grinding PT. reports A-270 D SW -
Radiography Test (RT) after cover layer RT. reports PW-51 D R -
Dimensional inspection of overall length Drawing for construction Fabrication standard D H -
4.7.3 Nozzles fit-up and weld to shell Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 - H -
and heads Penetration Test (PT) after grinding PT. reports A-270 D SW -
Ultrasonic Test (UT) after cover layer (if required) UT. reports PW-52 D R -
Dimensional inspection of overall length Drawing for construction Fabrication standard D H -
4.8 Inside component assembly Visual and dimensional inspection. Drawing for construction PW-29,31,33,34,36,38 - H -
(before fit-up heads to shell) NDE (if required) NDE reports PG-90 D R -
4.9 heads and shell assembly Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) after grinding PT. reports A-270 D H -
Radiography Test (RT) after cover layer RT. reports PW-51 D R -
4.10 ---end of drum fabrication process and ready to assembly to boiler main body fabrication item 5.12---

5 Boiler main body fabrication

5.1 Collectors preparation
5.1.1 Layout marking and cutting Review cutting plan Cutting plan/ drawing for con Fabrication standard D R -
Material identification transfering Review cutting plan and stencil mark tranfering Cutting plan/ drawing for con PG-77, PG-76 D R -
Material identification record D H -
Review material certificate Material certificates ASME II D H -
5.1.2 Collector tube extension weld Dimensional inspection of overall length Drawing for construction - H -
Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) after grinding PT. reports A-270 D H -
Radiography Test (RT) after cover layer RT. reports PW-51 D R -
5.1.3 Collector tube drilling/machining Dimensional inspection drilling center pitch Drawing for construction Fabrication standard - H -
Visual and dimensional inspection of holes after Drawing for construction PG-79 - H -
drilling - H -
5.2 Tube panels preparation
521
5.2.1 ttubes
b extension
t i ld
weld Di
Dimensional
i l inspection
i ti off overallll length
l th Drawing
D i for
f construction
t ti Fabrication
F b i ti standard
t d d - H -
Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) after grinding PT. reports A-270 D H -
Radiography Test (RT) after cover layer RT. reports PW-51 D R -
5.2.2 panel welding (tubes&flat bars) Witness of production panel welding Drawing for con, WPS PW-29,31,33,34,36,38 D H -
Visual inspection of tube surface after sandblasting Sandblasting specification SA 2.0 - H -
Visual and dimensional inspection of weld drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) PT. reports A-270 - SW -
5.2.3 panel bending (gang bending) Witness of production panel bending Drawing for construction D H -
 Inspection and Test Plan (ITP) Document no. :
Project No./Name : Job No./name : H=Hold Point Rev No. :
Customer/Client : Item-Description Name : Auxiliary Boiler R=Review Point Date :
Customer Project no. : Unit no. : Serial No. W=Witness Point
Manufacturer : Getabec Co.,Ltd. Drawing No./Rev. : SW=Spot witness D=Documented

Quality Surveillance

Document
GETABEC THIRD PARTY CUSTOMER
Reference Document/Drawings/
Item Area of activity Quality control activity Acceptance Criteria
Standard Code

Point

Point

Point

Point
Sign/Date Sign/Date Sign/Date Sign/Date

-Out of roundness panel welding and bending PG-80

-Min/Max wall thickness design caculation design calculation
5.2.4 panel ends cutting (for assembly) Dimensional inspection of fit-up length Drawing for construction Fabrication standard - H -
5.3 Single tube bending Dimensional inspection of fit-up length Drawing for construction - H -
-Out of roundness Drawing for construction PG-80
-Min/Max wall thickness design caculation design calculation
5.4 Evaporator preparation
5.4.1 Outsourcing of tube finning Manufacutring (outsource) certification Manufacturing certificate ASME I D R -
Raw material certificate (if supplied) Material certificates ASME II D R -
Material identification and transfering Material identification record PG-77, PG-76 D R -
p
Visual inspection pp
of appearance p
Visual inspection p
report PG-90 - H -
5.4.2 Fin-tubed fit-up and weld to Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
collectors (pre-assembly) Penetration Test (PT) after grinding PT. reports A-270 D H -
Pre-hydrostatic test Pressure test report PG-99 - H -
5.5 Panels fit-up to collectors
5.5.1 Main chamber (the first and Visual and dimensional inspection of weld joints drawing for con. , WPS PW-29,31,33,34,36,38 - H -
second flue gas pass) Dimensional inspection of overall length Drawing for construction D H -
Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Visual and dimensional inspection cover layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) PT. reports A-270 D H -
Visual and dimensional inspection of inserted drawing for con. , WPS - H -
flat bars
Pre-hydrostatic test Pressure test report PG-99 - H -
5.5.2 Reversing chamber Visual and dimensional inspection of weld joints drawing for con. , WPS PW-29,31,33,34,36,38 - H -
(the third flue gas pass) Dimensional inspection of overall length Drawing for construction D H -
Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Visual and dimensional inspection cover layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) PT. reports A-270 D H -
Pre-hydrostatic test Pressure test reoport PG-99 - H -
Visual and dimensional inspection of inserted drawing for con. , WPS - H -
flat bars
5.6 Evaporators fit-up to collectors Visual and dimensional inspection of weld joints drawing for con. , WPS PW-29,31,33,34,36,38 - H -
Dimensional inspection of overall length Drawing for construction D H -
Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Visual and dimensional inspection cover layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) PT. reports A-270 D H -
5.7 Base frame fabrication Dimensional inspection of overall length Drawing for construction - H -
Visual and dimensional inspection of weld joints drawing for con. , WPS PW-29,31,33,34,36,38 - H -
5.8 Lower & side collectors assemb. Dimensional inspection of overall length Drawing for construction D H -
Visual and dimensional inspection of weld joints drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Radiography Test (RT) after cover layer RT. reports PW-51 D R -
5.9 Lower collectors crossing weld Visual and dimensional inspection of weld joints drawing for con. , WPS D H -
(lower collectors and chamber Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
collectors) Visual and dimensional inspection cover layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) PT. reports A-270 D H -
5.10 Upper collectors crossing weld Visual and dimensional inspection of weld joints drawing for con. , WPS PW-29,31,33,34,36,38 D H -
(upper collectors and chamber Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
collectors) Visual and dimensional inspection cover layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) PT. reports A-270 D H -
5.11 Top collector assembly Dimensional inspection of overall length Drawing for construction D H -
Visual and dimensional inspection of weld joints drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Radiography Test (RT) after cover layer RT. reports PW-51 D R -
5.12 Drum assembly to boiler main Dimensional inspection of overall length Drawing for construction D H -
body Visual and dimensional inspection of weld joints drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Radiography Test (RT) after cover layer RT. reports PW-51 D R -
5.13 Front wall assembly Visual and dimensional inspection of weld joints drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Dimensional inspection of overall length Drawing for construction D H -
Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Visual and dimensional inspection cover layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) PT. reports A-270 D H -
Visual and dimensional inspection of inserted drawing for con. , WPS - H -
flat bars -
5.14 Rear wall assembly Visual and dimensional inspection of weld joints drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Dimensional inspection of overall length Drawing for construction D H -
Visual and dimensional inspection root layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Visual and dimensional inspection cover layer drawing for con. , WPS PW-29,31,33,34,36,38 D H -
Penetration Test (PT) PT. reports A-270 D H -
Visual and dimensional inspection of inserted drawing for con. , WPS - H -
flat bars
5.15 Pre-hydrostatic test Pre-hydrostatic test Pressure test reoport PG-99 - H -
(before closing of flat bars)
5.16 closing of flat bars and other Visual and dimensional inspection of weld joints drawing for con. , WPS PW-29,31,33,34,36,38 - H -
welding parts of pressure part Penetration Test (PT) PT. reports A-270 D SW -
(final wleding) Final inspection of pressure parts all data and reports of all concern spec. D R -
pressure
5.17 Main pressure test Hydrostatic Test Pressure test reoport PG-99 D H -
5.18 Non-pressure part & accessories Visual and dimensional inspection Drawing for construction, - H -
parts assembly technical data.
5.19 surface preparation (power brush) Visual inspection Painting specification D H -
5.20 Primer painting Visual inspection Painting specification D H -
5.21 Steel structural for insulation Visual and dimensional inspection Insulation and cladding spec. D H -
and cladding preparation
5.22 Burner mounting preparation Visual and dimensional inspection Mfg. technical data D H -

5.23 ---end of boiler main body fabrication process and ready to pre-assembly with other equipments ---

6 Economizer pre-assembly Review Economizer MDR Technical requirement D R -

(separated ITP) Design code and standard PG-90
Visual and dimensional inspection Drawing for construction, - H -
 Inspection and Test Plan (ITP) Document no. :
Project No./Name : Job No./name : H=Hold Point Rev No. :
Customer/Client : Item-Description Name : Auxiliary Boiler R=Review Point Date :
Customer Project no. : Unit no. : Serial No. W=Witness Point
Manufacturer : Getabec Co.,Ltd. Drawing No./Rev. : SW=Spot witness D=Documented

Quality Surveillance

Document
GETABEC THIRD PARTY CUSTOMER
Reference Document/Drawings/
Item Area of activity Quality control activity Acceptance Criteria
Standard Code

Point

Point

Point

Point
Sign/Date Sign/Date Sign/Date Sign/Date

7 Superheater pre-assembly Review Superheater MDR Technical requirement D R -

(separated ITP) Design code and standard PG-90
Visual and dimensional inspection Drawing for construction, - H -

---end of fabrication process and ready to site erection, start up, test run and pre-commisioning ---

Prepared by Approved by Accepted by Reviewed by Reviewed by

QA/AC Engineer QA/QC Manager ASME A.I. CUSTOMER