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INSPECTION AND TEST PLAN FOR HEAT EXCHANGERS

QAP. No. : HDO/QAP/8164-75 REV.01 DTD. 12.10.2010 CLIENT : TECHNIP KT INDIA LTD.(NOIDA)
HDO Ref No. : BYC 210968 PROJECT : HGU FOR DHT PROJECT
P.O.NO. : 00774 91 PO 0610 02 10588 R0 DT.05/05/2010 INSPECTION BY : M/S. TECHNIP/TPIA
INSPECTION CATEGORY - A
GENERAL APPLECABLE SPECIFICATION : 00774-91-SP-0610-02, E-102, D-123, O-301-A, D-102
SR.NO ITEM NO EQUIPMENT NAME HDO JOB NO SPECIFIC APPLICABLE SPECIFICATION
1 91-E-26 PROCESS BFW PREHEATER I 8164 (Refer Note-1)
2 91-E-27 CLEAN BFW PREHEATER I 8165 (Refer Note-1)
3 91-E-28 DEMIN WATER PREHEATER 8166 (Refer Note-1)
4 91-E-21 NAPHTHA VAPOURIZER 8167 (Refer Note-1)
5 91-E-01A/B SOUR NAPHTHA PREHEATER- I 8168A/B 00774-91-SP-0800-001,003 & 004 (Refer Note-1)
6 91-E-05A/B/C FEED PRODUCT EXCHANGERS 8169A/B/C 00774-91-SP-0800-001,003 & 004 (Refer Note-1)
7 91-E-06 STRIPPER REBOILER 8170 00774-91-SP-0800-001 & 004
8 91-E-08 SOUR NAPHTHA PREHEATER II 8171 00774-91-SP-0800-001 & 004 (Refer Note-1)
9 91-E-31A/B FUEL NAPHTHA VAPOURIZER 8172/73 ------
10 91-E-32 FUEL NAPHTHA SUPERHEATER 8174 ------
11 91-E-33 N2 HEATER 8175 (Refer Note-1)

SCOPE OF INSPECTION

S.R. INSPECTION CHARACTERISTICS QUANTUM REFERENCE ACCEPTANCE STD. FORMAT OF HDO TPI
TECHNIP TOYO
NO. ACTIVITY & COMPONENT OF CHECK DOCUMENT REPORT
1.0 MATERIALS INSPECTION
Visual & Dimensional PR/ASME SEC.IIA, PR/ASME SEC.IIA,
Pressure parts IIB/SEC.VIII DIV.1/ IIB/SEC.VIII DIV.1/
(Plates, Pipes) - Co-relation of markings with TEMA-R/APPD DRGS/ TEMA-R/APPD DRGS/
1.1 (To be procured from Approved Vendor test certificates. MANUFACTURER'S MANUFACTURER'S Inspn. Report W W
100%
list attached with MR) - Chemical and Physical TEST CERTIFICATES TEST CERTIFICATES
Inspection At HDO's works properties. EN 10204 EN 10204
- Transfer of identification TYPE 3.2/3.1 TYPE 3.2/3.1
marks, wherever required. Approved TPS Approved TPS
Bought out items (forgings, Tubes Chemical & Physical properities ASME Sec IIA / ASME Sec IIA /
1.2 Fittings,) inspection at Vendor's Works Review of test certificates / 100% VIII Div.I / TEMA-R / VIII Div.I / TEMA-R / Insp. Report W W
(To be procured from Approved Vendor ) PR/Spec/Drawings PR/Spec/Drawings
Fasteners and Gaskets Chemical & Physical properities ASME Sec IIA / ASME Sec IIA /
1.3 Inspection at HDO's Works Review of test certificates / 100% VIII Div.I / TEMA-R / VIII Div.I / TEMA-R / Insp. Report W R
(To be procured from reputed Mfgrs) PR/Spec/Drawings PR/Spec/Drawings
Non Pressure Parts (including internals, Chemical & Physical properities ASME Sec IIA / IIB / ASME Sec IIA / IIB /
1.4 supports, baffles, sliding plate etc.) Review of test certificates / 100% VIII Div.I / TEMA-R / VIII Div.I / TEMA-R / Insp. Report W R
Inspection At HDO's works Check test report. PR/Spec/Drawings PR/Spec/Drawings
2 WELDING BOOK
2.1 Weld Map Welding procedures 100% ASME Sec IX /Spec. ASME Sec IX /Spec. WPS W R
New-W
2.2 WPS/PQR/WPQ Welding parameters 100% ASME Sec IX /Spec. ASME Sec IX /Spec. WPS/PQR W
Old-R
Mock up Procedure for ASME Sec IX /Spec./ ASME Sec IX /Spec./ WPQ
2.3 Qualification Requirement 100% W R
tube-to-tubesheet joint (Note-2) Drawings Drawings

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INSPECTION AND TEST PLAN FOR HEAT EXCHANGERS
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SCOPE OF INSPECTION

S.R. INSPECTION CHARACTERISTICS QUANTUM REFERENCE ACCEPTANCE STD. FORMAT OF HDO TPI
TECHNIP TOYO
NO. ACTIVITY & COMPONENT OF CHECK DOCUMENT REPORT
3 INSPECTION DURING FABRICATION
Weld Edge preparation & set up of Visual & Dimensional W-FOR FIRST
Major pressure parts like L/S, C/S inspection,Marking, 100% Spec./Drawings Spec./Drawings Insp. Report W L SEAM or
3.1 (PTC to be provided if applicable as per WEP, Offset, Ovality,etc ASME SEC VIII Div.1 ASME SEC VIII Div.1 C-SEAM
CL. No. IN 42.0 of AXENS Spec. ) Sound metal after backchipping 100% Spec./Drawings ASME Insp. Report
W R
Sec V/ VIII-1 Sec V / Sec VIII-1
WEP, Dimensions, completeness Spec./Drawings Spec./Drawings Insp.
3.2 100% W R
Assembly of Nozzles of assembly Sec V/ VIII-1 Sec V / Sec VIII-1 Report
Inspection of Completed welds Visual inspection for Drawings/ Spec / Drawings/ Spec / Insp. Report
3.3 reinforcement, Undercuts, 100% ASME Sec VIII-1 ASME Sec VIII-1 W W
Weld bead, surface defects etc.
RADIOGRAPHY EXAMINATION OF WELDS Soundness of Full Weld As per Drg. Drawings/ Spec / Drawings/ Spec / NDT Report
3.4 (As per Approved Drgs.) ASME Sec VIII-1/ V ASME Sec VIII-1 / V Reviewe W FILM REVIEW
of RT films
Visual and Dimensional Insp.shell/ch.shell Dimensions, completeness 100% Drawings/ Spec / Drawings/ Spec / Insp. Report
3.5 W W
Assl.(Internals & externals) of assembly ASME Sec VIII-1/ V ASME Sec VIII-1/ V
positive Material Identification Alloying Element check in As per TOYO Spec./Drawings Spec./Drawings Insp. Report
3.6 (Applicable for SS Materials) Parent metal & weld spec. & Sec.II part 2a & Part C Sec.II part 2a & Part C W W
Ferrite check of SS welds Appd.Proc. Approved Procedure Approved Procedure
Heating Time
PWHT OF SHELL/CH. SHELL ASME SEC VIII Div.1 Drawing/ Insp.Report/
3.7 Cooling Time 100% W R
(As per approved drawings) Drawing/Spec ASME SEC-VIII-1 PWHT CHART
Soaking Time & Temp.
As per Drg./ Drawing/
3.8 NDE After PWHT (If Applicable) Note-5 Soundness of welds Drawing/Spec Insp.Report W W(10%)
NDE MAP ASME SEC-VIII-1
4 INSPECTION OF FORMED COMPONENT
Visual & Dimensional 100% Drawings/Spec. Drawings/Spec. Insp. Report
W W
inspection, Thickness & Profile check. ASME SEC.VII Div.1 ASME Sec.VIII-1
100% ASME Sec.VIII Div.1/ ASME Sec.V/ FILM
RT of weld seam (If applicable) RT Report W
SEC.V/Spec. Spec. REVIEW
4.1 Dished ends/ formed components PT Examination 100% ASME Sec.V ASME VIII Div.I
W W
On Inside & Out side KR,SF & EDGE Spec./Drawings & Sec.V. Spec./DRG Insp. Report
HT chart review ASME Sec.VIII-1 ASME Sec.VIII-1 HT Chart
W R
If applicable 100% /Spec./DRG/Appd.Drg. /Spec./DRG
Test Coupon (If applicable) 100% Spec./Drawings. ASME Sec.VIII Div.1 Insp. Report W R
5 INSPECTION OF TUBE BUNDLE
Tube sheet Maching/ Drilling Hole Dia/PPCD/Ligament/Layout 100% Drawings/ Spec / Drawings/ Spec /
5.1 Insp.Report W W
OTL/Steps/OD/Thk./Grooving/Hole Finish TEMA TEMA
Inspection of Tube To Tube Sheet joint % of expansion Drawings/ Spec / Drawings/ Spec /
5.2 Welding/expansion 100% PT for Root, First & Final layer 100% ASME Sec VIII-1 ASME Sec VIII-1 Insp.Report W RW
TEMA TEMA
Inspection of Tube Bundle before visual & Dimensional inspection 100% Drawings/ Spec / Drawings/ Spec / Insp.Report
5.3 W W
Instertion into the shell As per Approved DRG. TEMA TEMA
Main shell inside surface inspection Insde flush of nozzle conn & 100% Drawings/ Spec / Drawings/ Spec / insp. Report
5.4 W W
before tube Bundle instertion in to shell cleaniness of shell

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INSPECTION AND TEST PLAN FOR HEAT EXCHANGERS
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S.R. INSPECTION QUANTUM REFERENCE FORMAT OF HDO TPI


TECHNIP TOYO
NO. ACTIVITY & COMPONENT CHARACTERISTICS OF CHECK DOCUMENT ACCEPTANCE STD. REPORT
6 TESTINGS
Soap Suds test of RF PADS at Test Drawings/Spec. Drawings/Spec.
6.1 W W
Pressure as per Appd.Drg. Leak checking 100% ASME SEC VII Div.1 ASME SEC VII Div.1 Insp. Report
Leak test of Tube To Tube sheet Leak checking from TTS joint Drawings/Spec. Drawings/Spec.
6.2 joint weld/Expansion 100% ASME SEC VIII Div.1 ASME SEC VII Div.1 Insp. Report W W
Appd.Procedure Appd.Procedure
Hydrostatic test as per Appd Drg. leak Check 100% Drawings/Spec./ Drawings/Spec./ Insp.
6.3 Shell Side ASME Sec.VIII-1 ASME Sec.VIII-1 Report W H
Tube Side Appd.Procedure Appd.Procedure
Drying of equipment Cleanliness of Shell side Drawings / Spec. Drawings / Spec. Insp.
`7.0 W R
Shell Side/Tube Side Tube side Report
Pickling & Passivation of SS parts Visual inspection afer 100% Drawings / Spec. Drawings / Spec. Insp.
`8.0 W R
Pickling & Passivation Appd.Procedure Appd.Procedure Report
Surface preparation/cleaning Visual insp for Drawings./Spec. Drawings./Spec.
`9.0 W R
workmanship 100% Appd.Procedure Appd.Procedure Insp. Report
Painting Visual insp & DFT Measurement 100% Drawings./Spec. Drawings./Spec. Insp. Report
`10.0 W W
Spare Item Varification Mandatory spare varifed as per 100% Drawings./Spec. Drawings./Spec. Insp. Report
`11.0 W +
Spares shall include in IRN DRG.
Final Stamping of equipment and Verifying stamping details Name plate Name Plate/
`12.0 W H
marking etc. & Rub off Drawings / Spec. Drawings / Spec. Rub-Off
Nitrogen Filling N2 pressure & non return Full Drawings/Spec. Drawings/Spec. Insp.
`13.0 w R
( If required as per Drg.) valve. exchenger Report
DOCUMENTATION Verification & Compilation
`14.0 of inspection & test records 100% Spec. (VDR) Spec. Q.C. Dossier W H
and other documents with Index
NOTES : 1 ) For Above Mentioned items Hydrogen service is required. All requirement as per Clause no.3.8.10 of D-102 shall be followed.
2) In absence of old mock up procedure New mock up procedure shall be carried out under TPIA.
3) Where AXENS Spec. IN-042.0 Applicable and PWHT required in the job, Simulation Tensile shall be carried out after Actual PWHT cycle plus one additional cycle & Simulation Impact shall be carried out after Actual PWHT cycle
For major Bought out items such as plates,Pipes,Forgings, Tube sheet, Girth flanges and Fittings only as per Clause No.5.0(Inspection and Testing) of 00774 -91-SP-0610-02 Rev.0
4) Inspection of major bought out items like Plates, Tube sheet, Girth flanges and Fittings shall be carried out at sub vendor's work under TPIA
5) UT after PWHT required where thickness of butt weld is 50 mm (for CS) and 38mm (for SS).
6) After PWHT, hardness of base metal, weld metal & HAZ shall be checked (225 BHN Max.) except exchanger under HIC/H2S services (For HIC/H2S service, Hardness shall be 200 BHN Max.)
7) For Tag NO. E-01A/B. E-05A/B/C, E-06 & E-08, The Tests specimen, subjected to anticipated heat treatment cycle, are taken through the thickness and the said reduction shall not be less than35% of the initial cross section as pe ASTM A770
8) NDE Shall be performed as per Approved NDE MAP.
9) All areas where temporary attachment was welded and removed shall be examined by MT or PT.
10) Chloride content of water used for Hydro test shall have <100ppm for CS/LAS material and <30 ppm for austenitic stainless material.
11) Inspection Requirements of Appendix-B of E-102 shall be followed as applicable. Main dimensions of HE shall be checked after PWHT
12) welding surface shall be inspected by PT after hydrostatic test for all SS HE's and CS HE's ( base metal thk>38 mm or 100% RT is specified)
HOLD -H : MANDATORY INSPECTION POINT WORK SHALL NOT PROCEED FURTHER WITHOUT THE PRESENCE OF THE REPRESENTATIVE OF THE TPI.
WITNESS-W :I NSPECTION POINT OF THE HDO-QC IN CASE THE REPRESENTATIVE OF THE TPI DOES NOT ATTEND WITHIN AGREED PERIOD.
REVIEW-R : THE ENTAILS REVIEW OF APPROPRIATE DOCUMENTATION.

LEGENDS : H - HOLD H.T. - HEAT TREATMENT R/W - REVIEW OR WITNESS


W - WITNESS R.T. - RADIOGRAPHIC TEST RW - RANDOM WITNESS
R - REVIEW U.T. - ULTRASONIC TEST TPIA - THIRD PARTY INSPECTION AGENCY
A - APPROVAL T.C. - TEST CERTIFICATES
PREPARED BY REVIEWED BY APPROVED BY

P.V.CHAUDHARI R.R.SHARMA
SR. ENGINEER (HDO, A'BAD) SR. MANAGER (Q.C.) HDO, A'BAD TECHNIP

This document is electronically generated, Signature is not required.