Hindustan Urvarak and Rasayan Limited

Barauni & Sindri

PROJECT REFERENCE
Originator
Project N° Unit Number Doc. Type Material Code Serial Number Revision No. of Pages

LT 077625 C00 ITP 1330 5500 A 5

STANDARD INSPECTION AND TEST PLAN FOR CARBON STEEL FITTINGS (FORGED, SEAMLESS & WELDED)

STANDARD INSPECTION AND TEST PLAN FOR CARBON STEEL FITTINGS

(FORGED, SEAMLESS & WELDED)

DOCUMENT CATEGORY
☐ INFORMATION – Class 1
☒ REVIEW – Class 2
ISSUED FOR
☒ OWNER
☐ INTERNAL- CONSORTIUM
☐ INTERNAL-TECHNIP-FMC
☐ INTERNAL - LTHE

samadhan.aher@lar Digitally signed by

samadhan.aher@larsentoubro.com
Digitally signed by
jatin.gandevikar@larsentoubro.com
DN: cn=jatin.gandevikar@larsentoubro.com

sentoubro.com DN: cn=samadhan.aher@larsentoubro.com

Date: 2018.09.07 09:39:34 +05'30'
Date: 2018.09.07 10:22:04 +05'30'

A 07/09/18 ISSUED FOR REVIEW SAMADHAN AHER JATIN GANDEVIKAR JATIN GANDEVIKAR
Rev Date STATUS WRITTEN BY CHECKED BY APPROVED BY
DD/MM/YY (name & visa) (name & visa) (name & visa)

DOCUMENT REVISIONS

Sections changed in last revision are identified by a vertical line in the margin

CONFIDENTIAL INFORMATION –The information contained in this document belongs to LTHE. All IP rights relevant to this document are
expressly reserved.
 Page 1 of 4

STANDARD INSPECTION AND TEST PLAN FOR CARBON STEEL FITTINGS (FORGED,SEAMLESS & WELDED)

Purchaser : L&T Hydrocarbon Engineering Limited, Vadodara Item Description CS FITTINGS (FORGED, SEAMLESS & WELDED) (FOR OEM/Mill Only)

Project : Ammonia Urea Fertilizer Plant ITP Document No. LT-077625-C00-ITP-1330-5500 Rev.A

Client : Hindustan Urvarak & Rasayan Limited (HURL) MR/PR/Specification No. PDIL Spec:5003/E-01/P-II/5.2.3 Rev 0

PMC : Projects & Development India Limited (PDIL) Inspection Category C

Licensor : Haldor Topsoe A/S Name of TPIA Approved TPIA(BVIS/LR/TUV)
ITP approval by LTHE & PDIL/HURL
Form to record Inspection Agency
Sl. Extent of
Inspection Activity Reference Document Acceptance Criteria results of LTHE / PDIL/ Remarks
No. Check Vendor
compliance TPIA HURL
Codes, Standards & Codes, Standards &
1 Inspection and Test Plan 100% ITP H A A
Specifications Specifications
NDT Procedures are to be
NDT Procedures:MT,PT,RT ; Heat Treatment; Project Specifications; codes Project Specifications; codes approved by Level III Qualified
2 100% Approved Procedures H R
& Quality Procedures & standards & standards Personnel & submitted to LTHE
R*
& TPIA for review.
WPS/PQR/WPQ for welded fittings Approved WPS,PQR
3 100% ASME B31.3, ASME Sec.-IX ASME B31.3, ASME Sec.-IX H R / W* * W for new Qualification
(Approved under Reputed TPIA) & WPQ
Raw Material Identification and correlation with
MTC (Note 3) Project Specifications;codes Project Specifications;codes
4 100% RMTC H R R*
& standards & standards
RMTC Review & Heat Analysis
Manufacturing (In Process Inspection):
Forming,Forging,Machining, Welding, Visual & Manufacturer Internal
5 100% codes & standards codes & standards H - -
Dimension check before heat treatment Record
(Note 4)
Project Project Heat Treatment applied & it's
Heat Treatment Original Time Vs.
6 100% Specifications;Material Specifications;Material H R temperature range shall be
Temp Record/Chart
specifications specifications R* specified in the MTC.
As required by Project Specifications;codes Project Specifications;codes Material Identification
7 Stamping of Sample for Check Testing H W
Sl. No.: 8 & 9 & standards & standards Report
For carbon steel material, the
As per Material Project Project carbon content shall be ≤
8 Product Chemical Analysis Spec./Project Specifications;Material Specifications;Material Test Report / MTC H R R* 0.25%.
Spec.. specifications specifications

9 Mechanical Testing (Note 5)

Tensile Test (UTS,%age Elongation,Yield
9.1
Stress)
As per Material Project Project
Hardness Test including weld & HAZ MTC / Lab Test
9.3 Spec./Project Specifications;Material Specifications;Material H W R*
(As Applicable ) Reports
Spec. specifications specifications
9.4 Impact testing (As applicable)
 Page 2 of 4

STANDARD INSPECTION AND TEST PLAN FOR CARBON STEEL FITTINGS (FORGED,SEAMLESS & WELDED)

Purchaser : L&T Hydrocarbon Engineering Limited, Vadodara Item Description CS FITTINGS (FORGED, SEAMLESS & WELDED) (FOR OEM/Mill Only)

Project : Ammonia Urea Fertilizer Plant ITP Document No. LT-077625-C00-ITP-1330-5500 Rev.A

Client : Hindustan Urvarak & Rasayan Limited (HURL) MR/PR/Specification No. PDIL Spec:5003/E-01/P-II/5.2.3 Rev 0

PMC : Projects & Development India Limited (PDIL) Inspection Category C

Licensor : Haldor Topsoe A/S Name of TPIA Approved TPIA(BVIS/LR/TUV)
ITP approval by LTHE & PDIL/HURL
Form to record Inspection Agency
Sl. Extent of
Inspection Activity Reference Document Acceptance Criteria results of LTHE / PDIL/ Remarks
No. Check Vendor
compliance TPIA HURL

As per Material
Grain Size Measurement - As Applicable As per Material Spec./Project As per Material Spec./Project
9.5 Spec./Project Insp. Report H R R*
(ASTM E112) Spec. Spec.
Spec.
10 NDT
RT of all welds of welded fittings after Heat
10.1 100% NDT Reports H R# #- Review of RT Films
Treatment (Note 6)
R*
W
10.2 PT/MT of Bevel Edges 100% NDT Reports H
(10%)
PT/MPT on Fittings surface after heat Project specification; ASME Project specification; ASME W
10.3 100% NDT Reports H
treatment (As Applicalbe) Sec VIII Div.1; ASME Sec. V Sec VIII Div.1; ASME Sec. V (10%)
UT Thickness Gauging for all wrought elbows
R*
& bends of size ≥ 2" NPS (Note 7) :- Thickness W
10.4 100% H
At least five readings at different locations on Measurement Reports (10%)
extradose/outer radius of elbows
11 Final Inspection
11.1 Visual Examination (Note 8) 100% Insp. Report H W R*
W
11.2 Overall Dimensional Check (Note 9) 100% Insp. Report H R*
(10%)
Project Project Mass of Zinc coating and
W
11.3 Galvanizing (If applicable) (Note 10) 100% Specifications;Material Specifications;Material Insp. Reports H R* coating thickness to be
(10%)
specifications ;Applicable specifications;Applicable checked.
Procedures Procedures W
11.4 End Preparation & End Protection (Note 11) 100% Insp. Report H R*
(10%)
Verification of Marking & Colour Coding
11.5 100% IC / IRN H W R*
(Note 12)
Identification marking / stamping by TPIA
11.6 100% PO & Specification PO & Specification IC / IRN H W R*
(Note 13)
11.7 Verification of IBR Stamp for IBR items 100% - - IC / IRN H W R*
Project Project
MTC as per EN10204
12 Manufacturer's Test Certificate (Note 14) 100% Specifications;Material Specifications;Material H R R*
3.1
specifications; specifications;
13 Inspection Certificate / Release Note 100% PO & Specification PO & Specification IC / IRN H Issue R*
 Page 3 of 4

STANDARD INSPECTION AND TEST PLAN FOR CARBON STEEL FITTINGS (FORGED,SEAMLESS & WELDED)

Purchaser : L&T Hydrocarbon Engineering Limited, Vadodara Item Description CS FITTINGS (FORGED, SEAMLESS & WELDED) (FOR OEM/Mill Only)

Project : Ammonia Urea Fertilizer Plant ITP Document No. LT-077625-C00-ITP-1330-5500 Rev.A

Client : Hindustan Urvarak & Rasayan Limited (HURL) MR/PR/Specification No. PDIL Spec:5003/E-01/P-II/5.2.3 Rev 0

PMC : Projects & Development India Limited (PDIL) Inspection Category C

Licensor : Haldor Topsoe A/S Name of TPIA Approved TPIA(BVIS/LR/TUV)
ITP approval by LTHE & PDIL/HURL
Form to record Inspection Agency
Sl. Extent of
Inspection Activity Reference Document Acceptance Criteria results of LTHE / PDIL/ Remarks
No. Check Vendor
compliance TPIA HURL
Final Documentation / VDR Submission IRN / IC, MTC'S, PMI
14 100% PO & Specification PO & Specification H R R*
(Note 14) reports etc.
Legends: A - Approval ; H - Hold ; W - Witness ; R - Review ; M - Monitor ; RW - Random Witness ; IC - Inspection Certificate ; R*- Note 15(a) ; MTC - Material Test Certificate ; IRN - Inspection Release Note
Notes :
a) Fittings under purview of IBR shall be accompanied with IBR certificates in form IIIC, duly approved and countersigned by IBR authority.
b) For IBR Service, TPIA inspection shall be as per QAP Sl. No. 10,11,12,13 & 14 only.
1 c) All materials used on lines falling under IBR must be accompanied with IBR Inspection Certificate in original. Alternatively, photocopy of the original certificate duly countersigned and attested by local IBR
inspector is acceptable.
a) Supplier / Manufacturer to ensure that all the activities related to the product are taken care with respect to the Material Codes & Client, Licensor specifications.
2 b) Supplier / Manufacturer shall provide complete access to the End user / Client / Purchaser at all the stages of the related product or services.
a) All materials shall be new materials with all surfaces clean and free from weld repairs, defects, weld spatter, arc strike, rust, dirt, sand, scale, paint or any other foreign substance.
b) Steel made by Acid Bessemer process shall not be acceptable.
3 c) Thickness of starting material shall have positive tolerance only.
e) For fittings made out of welded pipe, the pipe itself shall be of double welded type, manufactured with the addition of filler material and made employing automatic welding only.
f) All pipes employed for manufacturing of fittings shall be required to have undergone Hydro test to ASTM A530 to the extent so as to produce wall stress of 75% of SMYS of the material.
a) All fittings shall be seamless in construction unless otherwise specified. Welded fittings shall not be acceptable in place of seamless fittings.
4 b) All welded fittings shall be double welded. Inside weld projection shall not exceed 1.6 mm. However, 25 mm from the ends shall be flush smooth.Welded tees shall not be of fabricated (Stub-in) type.
c) Elbows and tees shall not be machined direct from bar stock.Caps shall be of one piece material without welded seams.Seamless Stubends shall not have any weld in the body.
a) LTCS- material shall confirm the applicable standard specification and any supplementary requirement specified in Item decription.
5 b) Fittings shall be impact tested as per requirement of ASME B31.3.(Cl 323.3 Fig & Table 323.2.2A).
6 All welded fittings shall be normalised for CS and 100% radiographed by X-ray for all welds made by fitting manufacturer as well as for welds on the parent material.
a) All elbows within (-) 5% of nominal thickness only shall be accepted for clearance.
7 b) Ultrasonic Thickness Gauge calibration shall be rechecked at regular intervals during extended periods of checking to take care of any possible instrument drift.
a) Fittings shall be supplied free of scale,heavy oxide,dirt,grease, paint or other foreign material. The methods used for cleaning the surface shall not be detrimental to the base metal or the surface finish.
8 b) Excessive roughness or scratches are not allowed.
c) Each Fitting shall be visually examined over the entire external surface. The internal surface shall be visually examined from each Fitting end.
 Page 4 of 4

STANDARD INSPECTION AND TEST PLAN FOR CARBON STEEL FITTINGS (FORGED,SEAMLESS & WELDED)

Purchaser : L&T Hydrocarbon Engineering Limited, Vadodara Item Description CS FITTINGS (FORGED, SEAMLESS & WELDED) (FOR OEM/Mill Only)

Project : Ammonia Urea Fertilizer Plant ITP Document No. LT-077625-C00-ITP-1330-5500 Rev.A

Client : Hindustan Urvarak & Rasayan Limited (HURL) MR/PR/Specification No. PDIL Spec:5003/E-01/P-II/5.2.3 Rev 0

PMC : Projects & Development India Limited (PDIL) Inspection Category C

Licensor : Haldor Topsoe A/S Name of TPIA Approved TPIA(BVIS/LR/TUV)
ITP approval by LTHE & PDIL/HURL
Form to record Inspection Agency
Sl. Extent of
Inspection Activity Reference Document Acceptance Criteria results of LTHE / PDIL/ Remarks
No. Check Vendor
compliance TPIA HURL
a) Measuring Instruments used during inspection shall have valid calibration. This will be verified by TPIA during inspection.
b) Thickness/Schedule lower or higher than specified shall not be accepted.
c) Vendor to ensure that Final Dimension Report shall cover OD, ID, Thickness, Ovality ,length ,bevel angle and Circumference as a minimum.
d) Dimensional tolerances on fittings shall be within the limit specified in the applicable ASME/ ANSI or MSS standards, except that circumferential tolerance at the bevelled end in sizes NFS 26" and larger shall
be within the range of -0.2 to +0.3 % the nominal circumferential length.
9
e) Unless and otherwise specified in the requisition all socket weld and screwed fittings shall be in accordance with ASME B16.11 to the extent covered in the specification except for unions which shall be in
accordance with MSS-SP-83.
f)Special fittings like Weldolet, Sockolet, Sweepolet etc. which are not covered in ANSI , MSS-SP shall be as per Manufacturer‘s Std. Contours of these fittings shall meet the requirements of ANSI 31.3.
Manufacturer shall submit drawings/catalogues of these items along with the offer & also shall be submitted for approval before manufacturing
g) All welded fittings shall have maximum negative tolerance equivalent to pipe selected
a)Galvanized fittings shall be coated with zinc inside and outside by hot-dip process to ASTM A153 after all forming and heat treatment has been completed.
10
b) All beveling on galvanized fittings shall be made after galvanizing
a) All fittings shall be provided with provisions to prevent ingress of foreign particles and bevel edge protection.Threaded or beveled ends of fittings shall be protected with plastic, metal or wood covers.
b) Rust preventive on machined surfaces to be welded shall be easily removable with a petroleum solvent, and the same shall not be harmful to welding.
11
c) Bevel Ends shall be as per Figure 2a for wall thickness 22 mm and smaller, And Figure 3a for wall thickness greater than 22 mm in ASME B16.25.
d) Threaded ends shall have NPT taper threads in accordance with ASME B1.20.1 up to 1.5"NB & IS: 554 from 2" to 6" NB.
a) If die stamping is used, it shall be low stress stamping.Fittings covered under steam service shall be stamped/ marked as per I.B.R.
b) All items coming under the purview of "IBR", "CRYO"&"NACE" shall be painted in red strips, light purple strips & canary yellow strips (25 mm. width) respectively for easy identification.Paint or ink for marking
12 shall not contain any harmful metal or metal salts such as zinc, lead or copper which causes corrosive attack on heating.
c)After inspection and before dispatch, fittings shall be thoroughly dried and cleaned. All fittings except SS fittings shall be coated with hard film type of rust preventive to protect against rusting during transit and
storage
a) For Identification TPIA to do the double stamping on the items Inspected and single stamping on balance items. TPIA stampimg shall be done with low stress stamping.
13 b) Where the size of the fittings does not permit double / single stamping, random inspected and accepted fittings should be seperately packed and sealing tag duly identified with single / double stamping as
applicable.
a) Manufacturer shall mention results of all the tests carried out in detail in MTCs.
b) The fittings shall be supplied with 3 copies of the mill test certificates duly signed by the inspecting authority along with supply of materials. In addition 8 copies of these certificates shall be sent to Contractor for
14 final compilation.
(c) Fittings meant for steam service/IBR shall be supplied with 3 copies of I.B.R. certificates in Form IIIC duly signed by IBR inspecting authority along with supply of materials. In addition 8 copies shall be sent to
Owner / Contractor for final compilation.
a) R*- These documents shall be shared with PDIL/HURL as part of complete Dossier for verification.
15
B) PDIL/HURL reserve right to associate during any stage of inspection.
16 This ITP is not applicable to Stockist/Trader material.
In addition to the applicable codes and standards, following specifications shall also be complied:
PDIL Specification No. 5003/E-01/P-II/5.2.3 Rev 0
Inspection Requirement for Brought out LT-077625-C00-PP-0000-5604 Rev.A
it
Marking & Color Coding Procedure LT-077625-C00-PP-0000-5505