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QAP/ INSPECTION TEST PLAN (CHECK/HOLD POINTS ) FOR PIPING WORKS

Type or Method of Extent of Reference of Format of Inspection By
SR.NO Activity Characteristics Category Acceptance Norms SGE CLIENT TPI Remarks
check check Document Record
A. Fabrication of Piping
1 MATERIAL
Physical condition, Dimension &
Approved drawings / Approved drawings /
Pipes, Pipes fittings i.e. End condition, Chemical &
Customer specification Customer specification R / RW
1.1 bends, Tees, Reducer, Physical properties, Major V,M,R 100% SR / MTC P R
/ Relevant / Relevant
Flanges, Gaskets & Identification, Stacking
standard/MTC standard/MTC
Fasteners etc.
Relevant IS codes i.e. IS Relevant IS codes i.e. IS
Classification, Size, Batch no.,
814,AWS and ASME 814, AWS and ASME R / RW
1.2 welding consumables Storage, Chemical & Physical Major V, Ve, R 100% SR / BTC P R
Sec.II Part-C or as Sec.II Part-C or as
properties
applicable applicable
Approved Painting Approved Painting
Painting specification, Brand R / RW
1.3 Paints Major V, Ve, R 100% Specification/Relevant Specification/Relevant SR / BTC P R
name/Make, Batch no.,
Standard Standard
Storage
Grade, Brand
Tech. Specification / Tech.Specification/ R / RW
1.4 Bolts & Nuts name/Make, storage, Chemical Major V, Ve, R 100% SR / BTC P R
Relevant Standard Rele vant Standard
& Physical
2 WELDING & WELDER QUALIFICATION
Relevant IS codes (i.e. IS Relevant IS codes (i.e. IS
Welding Parameters, Chemical
2.1 WPS/PQR Major R, Ve, T 100% 7307,AWS and ASME 7307,AWS and ASME WPS,PQR P W/H R
& Mechanical test, NDE
Sec.IX) Sec.IX)
Relevant IS codes (i.e. IS Relevant IS codes (i.e. IS
Setup, technique,
Welder Qualification Test Major Vi, M & T 100% 7307,AWS and ASME 7307,AWS and ASME WQTR P W/H R
Surface Defects &
2.2 Sec.IX) Sec.IX)
Soundness of
Calibration certificate, CALIBERATIO
3 register for testing and Date of testing, validity Major R, Ve 100% Applicable N P R R
measuring equipment's CERTIFICATE
4 FABRICATION WORKS
Fit up of Pipe/Supporting
Physical condition,
structure/Fittings/Valves/ Tech. Specification / Tech. Specification /
4.1 Dimension, edge preparation, Major Ve & M 100% site Log Book P W,H R
Pipes Spools including Approved drawings Approved drawings
straightness, orientation,
bends, reducer etc.
ovality etc.
WELDING
Electrode, backing (as
applicable), position of job for WPS AND relevant
4.2 Before welding Major Vi,M 100% Approved WPS WPS P W R
welding, pre heat, inter pass standards
temperature(as applicable)
Technical specification / Technical specification /
Welding Parameters, Sequence
4.3 During welding Major Vi, Ve 100% Approved Approved --- P RW R
of Welding
drawings/WPS drawings/WPS
 Technical specification
Technical specification
After completion Weld size, Finish, soundness / Approved
4.4 Critical Vi, G, T 100% / Approved drawings / P W,H R
of welding of weld, Overall dimensions drawings/Relevant Site Log
Relevant Standards
Standards Book &
SR
5 SURFACE PREPARATION , PAINTING AND A/G PIPING AND COATING FOR U/G PIPING
A/G Piping:- Mechanical Profile of surface preparation, Profile, visual
Stage
Cleaning & application coverage, color shade, inspection, DFT Technical specification Technical specification
5.1 Major 100% Inspectio P w R
of primer, intermediate uniformity and Measurement by Elkometer & / Approved drawings / Approved drawings
n Report
and Final Painting of DFT Document
Review
U/G Piping:- Mechanical Profile of surface preparation, Profile, visual
5.2 Stage
Cleaning & application coverage, coating seat , inspection, & Technical specification Technical specification
Major 100% Inspectio P w R
of Coating & Wrapping uniformity Document / Approved drawings / Approved drawings
n Report
Review
Technical specification Technical specification
/ / Approved
5.3 Flushing of Pipe lines Cleanliness Major Visual inspection 100% P W,HP R
Approved Approved Format
drawings/Approved drawings/Approved
Procedure / Procedure /
Relevant Relevant
Technical specification Technical specification
/ Approved / Approved Approved
5.4 Pickling & Passivation Cleanliness Major Visual inspection 100% P W,HP R
Procedure/Relevant Procedure/Relevant Format
Standards Standards
6 INSPECTION & NDE
Technical Technical
Review/Interpretat As per
6.1 Radiography Testing Soundness of Weld Major Specification/Relevant Specification/Relevant RT Report P H R
ion tech Standards codes & Standards
spec
Technical specification Technical
Random
6.2 Root DPT and Final DPT Surface defects Major Visual & Testing / Approved drawings / Specification/Relevant RT Report P W R
Root=10
Relevant Standards codes & Standards
0
%
Visual,
Valves, Strainer, Technical specification Technical specification Site Log
Visual Inspection, Measurement, R/ RW
6.3 Flanges, Blinds, Major / Approved drawings / / Approved drawings/ book, P R
Inspection status & MTC etc Leak Test,
gaskets, pressure 100% MTC/IC Relevant Standard Test
body
gauges, RF Pads etc. Report
and Seat test
Technical specification
Technical specification
/ Approved W/ HP
6.4 Hydro Test and Flushing Leak Tightness, Pressure Drop Major Visual and Testing / Approved drawings/ Test Report P R
drawings/Approved
100% Relevant Standard
Procedure
Technical specification
Pneumatic Test for RF Pad, Measurement of Pressure, leak Visual and Technical specification R/ RW
6.5 Major / Approved drawings/ Test Report P R
(as Applicable) tightness Measurement / Approved drawings
100% Relevant Standard
7 ERECTION OF U/G AND A/G PIPING
Elevation, type of support Visual and Approved drawings & Approved drawings &
7.1 Pipe Support Major 100% SR P RW R
(anchor, guide, saddle etc) Measurement Project specification Project specification
Arrangement, location Erecting of pipes over rack Visual and Technical Specification/
7.2 Major Random Approved Drawings SR P W R
and orientation of and support as applicable Verification Approved Drawings
branches
LHS &
Technical specification Technical specification
7.3 Lifting and Placing LHS & Supporting Documents Major Visual and Review 100% Supporting P W R
/ Approved drawings / Approved drawings
Document
s
Provision of
Tapping point location Visual and Technical specification Technical specification
7.4 Instrument Tapping Major 100% Site Log book P RW R
for instrumentation Measurement / Approved drawings / Approved drawings
including vents
and drains
Pipes, Valves, Strainer,
Physical Condition, correctness
Flang es, Visual, Technical specification Site Log
of types of fittings, Dimensions, Technical specification
7.5 Blinds, gaskets, Major Measurements 100% / Approved drawings/ book/ P W R
Identifications, orientations, / Approved drawings
pressure gauges, RF , Leak Test Test Reports test
alignment, Level, Slope etc
Pads, Fittings report
etc.
8 BOX-UP
Preparation of loop file,
Mechanical clearance Verification, Technical specification Technical specification
8.1 Documentation(Test Pack) Major 100% Formats P R/HP R
including physical Measurement / Approved drawings / Approved drawings
verification and
Completeness of stage wise
Final Documentation Review/Verification Technical specification Technical specification
8.2 inspection reports, Test reports Major 100% Formats P R/HP R
and Commissioning n / Approved drawings / Approved drawings
& closing of NCR etc
LEGENDS
MTC-Manufacturer's Test V- View
P-Performer H-Hold Point T- Test
Certificates
MRR-Material Receiving Report M- Measure
W-Witness SC-Sub Contractor R- Report

Vi-Visual
RW- Random Witness R-Review SIR-Site Inspection Report
SIGN & DATE : SGE CLIENT TPI