Master Formats

NUBERG ENGINEERING LIMITED
Index for Mechanical Formats

Name of the Project : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations
Client : SPREA MISR, EGYPT
EPC Contractor : NUBERG ENGINEERING LIMITED
Dated:-20
Sl Rev.
Format Description Format No.
No. No.
1 WELDING PROCEDURE SPECIFICATION 9560/NBEL/FORM/MECH/01 0
2 PROCEDURE QUALIFICATION RECORD 9560/NBEL/FORM/MECH/02 0
3 WELDER QUALIFICATION TEST RECORD 9560/NBEL/FORM/MECH/03 0
4 WELDER IDENTIFICATION CARD 9560/NBEL/FORM/MECH/04 0
5 WELDER PERFORMANCE QUALIFICATION TEST RECORD 9560/NBEL/FORM/MECH/05 0
6 WELDING ELECTRODE RECORD 9560/NBEL/FORM/MECH/06 0
7 FIELD PAINTING INSPECTION REPORT 9560/NBEL/FORM/MECH/07 0
8 PIPING FIT UP INSPECTION REPORT 9560/NBEL/FORM/MECH/08 0
9 WELD VISUAL INSPECTION REPORT 9560/NBEL/FORM/MECH/09 0
10 LPT INSPECTION REPORT 9560/NBEL/FORM/MECH/10 0
11 RADIOGRAPHY OFFERING REPORT 9560/NBEL/FORM/MECH/11 0
12 RADIOGRAPHY INTERPRETATION REPORT 9560/NBEL/FORM/MECH/12 0
13 LINE HISTORY SHEET 9560/NBEL/FORM/MECH/13 0
14 CHECK SHOT CONTOL LOG 9560/NBEL/FORM/MECH/14 0
15 POSITIVE MATERIAL IDENTIFICATION REPORT 9560/NBEL/FORM/MECH/15 0
16 UG PIPING COMPLETION RECORD 9560/NBEL/FORM/MECH/16 0
17 PUNCH LIST 9560/NBEL/FORM/MECH/17 0
18 TAPE COATING REPORT (UG PIPING) 9560/NBEL/FORM/MECH/18 0
19 LAYING & BACKFILLING REPORT (UG PIPING) 9560/NBEL/FORM/MECH/19 0
20 PIPING HYDROSTATIC TEST ACCEPTANCE RECORD (UG PIPING) 9560/NBEL/FORM/MECH/20 0
21 MAGNETIC PARTICLE TESTING REPORT 9560/NBEL/FORM/MECH/21 0
22 CHECK LIST FOR MECHANICAL CLEARANCE -A/G PIPING 9560/NBEL/FORM/MECH/22 0
23 RECORD OF CALIBRATION OF MEASURING / TESTING EQUIPMENT 9560/NBEL/FORM/MECH/23 0
24 PIPING HYDRO RELEASE /ACCEPTANCE RECORD- A/G PIPING 9560/NBEL/FORM/MECH/24 0
25 PIPING PNEUMATIC TEST RELEASE /ACCEPTANCE RECORD- A/G PIPING 9560/NBEL/FORM/MECH/25 0
26 PROTOCOL DIMENSION REPORT 9560/NBEL/FORM/MECH/26 0
27 INSTALLATION OF PIPE SUPPORT 9560/NBEL/FORM/MECH/27 0
28 FIELD INSPECTION REPORT FOR INSULATION 9560/NBEL/FORM/MECH/28 0
29 HISTORY SHEET FOR FLANGE JOINTS 9560/NBEL/FORM/MECH/29 0
30 ORIFICE FLANGE INSIDE WELD FLUSHING 9560/NBEL/FORM/MECH/30 0
31 RADIOGRAPHIC PROCEDURE QUALIFICATION RECORD FOR PIPE WELDING 9560/NBEL/FORM/MECH/31 0
32 FIELD INSPECTION REPORT FOR FIRE PROOFING 9560/NBEL/FORM/MECH/32 0
33 POST WELD HEAT TREATMENT REPORT 9560/NBEL/FORM/MECH/33 0
34 PRE HEAT & POST HEATING REPORT 9560/NBEL/FORM/MECH/34 0
35 ULTRASONIC EXAMINATION 9560/NBEL/FORM/MECH/35 0
36 PIPE ERECTION REPORT 9560/NBEL/FORM/MECH/36 0
37 PROJECT PRESERVATION LOG 9560/NBEL/FORM/MECH/37 0
38 HARDNESS TEST REPORT 9560/NBEL/FORM/MECH/38 0
39 SUPPORT HISTORY SHEET 9560/NBEL/FORM/MECH/39 0
40 MPT PROCEDURE QUALIFICATION RECORD 9560/NBEL/FORM/MECH/40 0
41 BOX UP CLEARANCE 9560/NBEL/FORM/MECH/41 0
42 RF PAD PNEUMATIC TEST RECORD 9560/NBEL/FORM/MECH/42 0
43 INDEX FOR LOOP FILE 9560/NBEL/FORM/MECH/43 0
44 CHECKLIST FOR REINSTATEMENT 9560/NBEL/FORM/MECH/44 0
45 NDT OF ATTACHMENT WELD 9560/NBEL/FORM/MECH/45 0
46 NDT OF BRANCH WELD 9560/NBEL/FORM/MECH/46 0
47 NDT OF SOCKET WELD 9560/NBEL/FORM/MECH/47 0
48 NDT OF BUTT WELD 9560/NBEL/FORM/MECH/48 0
49 AUTHORISATION FOR MODIFICATION OF PIPING JOINTS 9560/NBEL/FORM/MECH/49 0
50 MATERIAL RECIEPT AND INSPECTION REPORT-MIR 9560/NBEL/FORM/MECH/50 0
51 INCOMING MATERIAL RECIEPT AND INSPECTION REPORT- IMIR 9560/NBEL/FORM/MECH/51 0
52 TANK BOTTOM/ANNULAR PLATE INSPECTION REPORT 9560/NBEL/FORM/MECH/52 0
53 MPT 9560/NBEL/FORM/MECH/53 0
54 TANK SHELL VERTICAL JOINTS INSPECTION REPORT 9560/NBEL/FORM/MECH/54 0
55 TANK SHELL HORIZONTAL JOINTS INSPECTION REPORT 9560/NBEL/FORM/MECH/55 0
56 TANK SHEEL/ROOF NOZZLES INSPECTION REPORT 9560/NBEL/FORM/MECH/56 0
57 TANK WIND GIRDER/COMPRESSION RING INSPECTION REPORT 9560/NBEL/FORM/MECH/57 0
58 TANK SHELL TO BOTTOM JOINTS INSPECTION REPORT 9560/NBEL/FORM/MECH/58 0
59 TANK STRUCTURAL INSPECTION REPORT 9560/NBEL/FORM/MECH/59 0
60 TANK ROOF PLATE INSPECTION REPORT 9560/NBEL/FORM/MECH/60 0
61 INSPECTION REPORT OF TANK SHELL/ROOF APPURTENANCES 9560/NBEL/FORM/MECH/61 0
62 TANK VACUUM BOX TESTING REPORT 9560/NBEL/FORM/MECH/62
63 TANK MECHANICAL CLEARANCE REPORT 9560/NBEL/FORM/MECH/63
64 TANK WATER FILLL TEST REPORT 9560/NBEL/FORM/MECH/64
65 TANK PNEUMATIC TEST REPORT 9560/NBEL/FORM/MECH/65
66 TANK INTERNAL SHELL CLEANING INSPECTION REPORT 9560/NBEL/FORM/MECH/66
67 PLUMBNESS OF SHELL COURSES INSPECTION REPORT 9560/NBEL/FORM/MECH/67
68 STATIC EQUIPMENT ELEVATION REPORT (HORIZONTAL TYPE) 9560/NBEL/FORM/MECH/68
69 STATIC EQUIPMENT ELEVATION REPORT (VERTICAL TYPE) 9560/NBEL/FORM/MECH/69
70 FIELD INSPECTION REPORT GROUTING 9560/NBEL/FORM/MECH/70
71 EQUIPMENT ERECTION REPORT 9560/NBEL/FORM/MECH/71
72 ROTARY EQUIPMENT ALIGNMENT INSPECTION REPORT 9560/NBEL/FORM/MECH/72
73 COUPLING ALIGNMENT INSPECTION REPORT 9560/NBEL/FORM/MECH/73
Dated:-20.07.2021
Remarks
FORMAT NO.:9560/NBEL/FORM/MECH/01, REV.0

WELDING PROCEDURE SPECIFICATION
Name of the Project :500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT
Client :SPREA MISR
EPC Contractor :NUBERG ENGINEERING LIMITED
( QW - 482 AS PER ASME SECTION IX )
Welding Procedure Specification No : Date :
Supporting PQR No : Date :
Welding Process(es) : Types :
Automatic,Semi-automatic,
manual,machine
JOINTS (QW - 402 )

Type of joint
Joint Design :
Backing (Yes/No ) :
Root opening :
Groove angle :
Backing gouging : Yes / No
BASE METAL (QW - 403)

P.No : Group No: to P.No : Group No:
Specification Type & Grade : to Specification Type & Gra :
Thickness & Dia of test coupon :
Qualified thickness range :
Qualified dia range :
FILLER METALS (QW - 404 )

SFA Specification :
AWS Specification :
Filler Metal F No :
Weld Metal Analysis A No :
Size of filler metal :
Weld Metal Analysis A No :
Deposited weld metal :
Brand name/make :
POSITION ( QW - 405 )
Position of groove :
Weld progression :
(Uphill/Downhill ) :
PREHEAT ( QW - 406 ) POST WELD HEAT TREATMENT (QW - 407 )
Preheat Temperature : Temperature range :
Interpass Temperature : Rate of Heating :
Pre-heat method : Rate of cooling :
: Soaking time :
Temperature measuring method,if any
: Others :
Page 5 of 93
GAS (QW - 408 ) ELECTRICAL CHARACTERISTICS ( QW - 409 )
Percenatge Composition (Amps&volts
Current : range should be recorded
Polarity : for each
electrode size,position and thickness.This
Gas(es) Mixture Flow rate information may be listed in a tabular form similar to
Tungsten
that shownelectrode
below ) size :
Shielding : Mode of metal transfer :
Trailing : for GMAW :
Electrode Wire feed
Backing : :
speed range
TECHNIQUE (QW - 410 )
Stringe or weave bead :
Orifice or gas cup size :
Intial and interpass cleaning :
Method of back gouging :
Oscillation :
Contact tube to work distance :
Multiple or single pass (per side ) :
Multiple or single electrode :
Travel speed range :
Peening :
Others :
Filler metal Current Travel
Weld Layer(s) Process speed Remarks
Class / Dia Type Polarity Amps range range
Sign
Name
Date
SUBCONTRACTOR NBEL/SPREA MISR
Prepared and Checked By Reviewed and Approved By

AKS AKT
Page 6 of 93
Format No:-9560/NBEL/FORM/MECH/02, REV.0

PROCEDURE QUALIFICATION RECORD
Client :SPREA MISR
QW - 483 FORMAT FOR PROCEDURE QUALIFICATION RECORD ( PQR )
(See- OW- 200.2 Section IX,ASME Boiler & Pressure Vessel Code )
Procedure Qualification Record No : Date :

Welding Procedure Specification No : Date :
Welding Process(es) : Types :
JOINTS (QW - 402 )
Joint Design :
Backing :
Method of preparation :
BASE METAL (QW - 403) POST WELD HEAT TREATMENT (QW - 407 )
Material specification : Temperature :
Type of grade : Time :
Chemical analysis : Others :
Thickness of test coupon: Others :
Diameter of test coupon : Rate of Heating :
Others : Rate of cooling :
FILLER METALS (QW - 404 ) GAS (QW - 408 )
SFA Specification :
AWS Specification : PERCENT COMPOSITION
Filler Metal F No : Gas(es) Mixture Flow rate
Weld Metal Analysis A No : Shielding :

Size of filler metal : Trailing :
:
Weld Metal Analysis A No Backing :
POSITION ( QW - 405 ) ELECTRICAL CHARACTERISTICS ( QW - 409
Position of groove : Current :
Polarity :
Weld progression : Amperes : Volts
(Uphill/Downhill ) : Others :
:
Tungsten electrode size
Others Others :
PREHEAT ( QW - 406 ) TECHNIQUE ( QW - 410 )
Preheat Temperature : Travel speed :
String/weave bead :
Interpass Temperature : Oscillation :
Multi/single pass per side :
Other : Single/Multiple electrode :
Other :
Page 7 of 93
QW - 483 ( BACK )
TENSILE TEST ( QW - 150 )
Ultimate
Ultimate
Width Thickness in Tensile
Specimen No Area in SQ.MM Total Load in Type of failure and Location
in MM MM Stressin
KN
N/MM2
GUIDED BEND TEST ( QW - 160 )

TYPE & FIGURE NO RESULT REMARKS
TOUGHNESS TEST ( QW - 170 )

Speimen Test Impact Value Drop Weight
Specimen No Notch Location
size Temperature Ft Lbs % Shear Mils Y/N
FILLET WELD TEST (QW - 180 )

Result : Penetration into parent metal :
Macro result :
OTHER TESTS
Type of test :
Deposite Analysis :
Other :
Welder's name : Clock No :

Test Conducted by : Laboratory Report No :
We certify that the statement in this record are correct and the test welds prepared,welded and tested in accordance
with the requirements in Section IX of the ASME code.
Manufacturer :
By :
Sign
Name
Date

AKS AKT
Page 8 of 93

WELDER QUALIFICATION TEST RECORD
Client : SPREA MISR Report No:-
EPC Contractor :NUBERG ENGINEERING LIMITED Date:-
Welder's Name : Dimension of test coupon
Reference WPS No :
Base material ro be :
welded
Position :
Backing : Yes / No
Filler Metal Redrying of Current Travel
Weld Layer Process Remarks
AWS class Dia in mm Review of TC electrode Type Polarity Amps Average Volts Average Speed
Visual Inspection :
Clearance given for Radiography :
Test to be conducted : Macro/Mechanical/Radiography
Sign :
Name :
Date :

AKS AKT
Page 9 of 93

500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT
WELDER'S IDENTIFICATION CARD
WELDER NAME
WELDER NO
WELDING PROCESS
VALIDITY
Qualification
Range Date Signature
SL WPS Posi- Filler
Meterial of SUB
NO NO. tion Dia Thk metal NBEL SPREA MISR
Test CONTRACTOR
REMARKS:

AKS AKT
Page 10 of 93

QW - 484A FORMAT FOR WELDER PERFORMANCE QUALIFICATION TEST ( WPQ )
QW -301 SEC- IX ASME BOILER & PRESSURE VESSEL CODE
Client :SPREA MISR
Welder's name : : Clock no : Photo

Welding process(es) used : Type :
Identification of WPS followed by welder during welding of test :
Base material(s) welded : Thickness :
Actual values used in

Manual or Semi-automatic variables for each process ( QW - 350 ) Range Qualified
Qualification
Backing (metal,weld metal,welded from both sides,flux etc ) (QW - 402 ) :
ASME P No: to ASME P No: (QW - 403 ) :
( ) Plate ( ) Pipe (Enter diamter/thickness,if pipe :
Filler metal specification __________________ Classification (QW - 404 ) :
Filler metal F No :
Consumables insert for GTAW of PAW :
Weld deposit thickness for each welding process :
Welding position ( 1G,5G etc ) ( QW - 405 ) :
Progression ( Uphill/downhill ) :
Guided Bend Test Type ( ) QW - 462.2( Side ) Results ( ) QW - 462.3 ( a) ( Trans - R & F Type ( ) QW - 462.3 ( b) ( Long R & F results )
GMAW transfer mode ( QW - 409 ) :
Welding current - Type /Polarity :
Machine welding variables for the process used ( QW - 360 ) :
GUIDED BEND TEST RESULTS
Guided Bend Test Type ( ) QW - 462.2( Side ) Results ( ) QW - 462.3 ( a) ( Trans - R & F Type ( ) QW - 462.3 ( b) ( Long R & F results )
Visual examination result ( QW - 302 ) :

Radiographic test results ( QW - 304 & QW - 305 ) :
Fillet weld- Fracture test : Length and percentage of defect:
Macro test fusion : Fillet leg size : Concavity/Convexity:
Welding test witnessed by :
Mechanical test conducted by : Laboratory Test Report No :
We certify that the statement in this record are correct and the test coup[on were prepared, welded , and tested in accordance with the requirements of Section IX of ASME
code
As the welder has completed the performance qualification test and the result were found satisfactory
Hence , the welder is QUALIFIED

Organisation
By
Date :
Sign:
Name:
Date : SUBCONTRACTOR NBEL/SPREA MISR
Checked and Prepared By Review and Approved By

AKS AKT
Page 11 of 93

WELDING ELECTRODE DRYING RECORD
Client : SPREA MISR
Report No : Date :
AWS IMIR DRYING TIME
BRAND TEMP.
DATE MANUFACTURER SIZE CLASSIFICATIO BATCH NO CLEARED,IF Remarks.
NAME 0
C START FINISH
N YES ,IMIR NO
Sign :
Name:
Date :
Sub-Contractor NBEL/SPREA MISR
Prepared and Checked By Reviewed and Accepted

AKS AKT
Page 12 of 93

FIELD PAINTING INSPECTION REPORT
Name of the Project : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT
Client : SPREA MISR Report No:
EPC Contractor :NUBERG ENGINEERING LIMITED Date:
Environment Surface Preparation(Avg.) Primer Coat(Avg.) Intermediate Coat(Avg.) Finish Paint(Avg.)

Total DFT
Drawing no/Line No./Equipment No/Structure Spool /Item
S.No. Reqd. Remarks
Mark No./Tank No Mark No Profile
Humidity Temp. Amb. Surface (In Microns)
Readings First Second First Second First Second Third
(%) (0 C ) Finish
(microns )
Description Primer Intermediate Paint Finish paint

Specification
Shade/Colour
Manufacturer
Batch No/Date
Sign :
Name :
Date :
Subcontractor NBEL/SPREA MISR
Prepared and Checked By Reviewed and Accepted By

AKS AKT
Page 13 of 93

PIPING FIT - UP INSPECTION REPORT
Spool JOINT DESCRIPTION
Joint
No /Tag
SL. NO DRG NO. / LINE NO REV. DIA Joint Joint Comb. Accept/ Remarks
No/ Nozzel SW / FW Joint No. THK. TYPE * Heat No Heat No
(inch) Comb.1(**) 2(**) Reject
No
LEGEND * G - BUTT WELD, S - SOCKET WELD, B - BRANCH WELD, M - MITER WELD , ( ** ) - PIPE, ELBOW, REDUCER, FLANGE etc,SW - Shop Weld, FW-Field Weld..
Sign:
Name:
Date:

AKS AKT
Page 14 of 93

WELD VISUAL INSPECTION REPORT
REPORT NO:
Client : SPREA MISR
EPC Contractor :NUBERG ENGINEERING LIMITED DATE :
JOINT
SL. Sp. No FIT-UP REPORT WELDER OBSERVAT
LINE NO /DRG NO REV. REMARKS
NO /Tag NO SW / FW NO DIA THK TYPE * No NO. ION
LEGEND * G - BUTT WELD, S - SOCKET WELD, B - BRANCH WELD, M - MITER WELD , SW - SHOP WELD , FW - FIELD WELD
Sign :
Name:
Date :

AKS AKT
Page 15 of 93
Format No:-9560/NBEL/FORM/MECH/010,REV.0

LPT INSPECTION REPORT
Client : SPREA MISR
REPORT NO: DATE:
SURFACE TEMP :
PENETRANT TYPE : BATCH NO: DWELL TIME:
DEVELOPER TYPE : BATCH NO:
CLEANER TYPE : BATCH NO:
Drg. No./Line No/Str Mark No Joint Welder ACC / REJ

S. No. Type Dia. Remarks
/Tank No No. No Root Final
LEGENDS:
G : For Butt Joints S : For Socket joints B : For Branch Joints MT :For Miter Joints
Comments:-
Sign :
Name :
Date :
Prepared and Checked BY Reviewed and Approved By

AKS AKT
Page 16 of 93

RADIOGRAPHY OFFERING REPORT
Report No: DATE:
Client : SPREA MISR
Joint Welder % Radiography
S.No. Line No./Tank No Dia Thickness Remarks
No. No. Radiography No
Comments:-
Sign :
Name:
Date:
Page 17 of 93

AKS AKT
Page 18 of 93

RADIOGRAPHY INTERPRETATION REPORT
Client :SPREA MISR
Report No : Date :
ACCEPTANCE CRITERIA : ASME SEC-IX RADIOGRAPHY PROCEDURE NO:934-201-PP-1300-Rev-01
DESCRIPTION OF ITEM EXAMINED:Alloy steel MATERIAL :Alloy steel
SENSITIVITY: 2% GAMMA RAY
FILM TYPE: D7 Ir-192
FILM MAKE: AGFA ISOTOPE Source Strength: 8Ci
DENSITY: 2%-3%
PENETRAMETER TYPE: DIN-61SO12 PENETRAMETER PLACEMENT: Flim side
RADIOGRAPHY TECHNIQUE: SWSI /DWSI /DWDI
Joint Welder
Sl no. Line No/Tank No/Str Dia Thk. X-Ray No. Segment Observation Result REMARKS
No. No.
NSD No Significant Defect Rep : Repair

RS Re-shoot CRW :Cut & Re -weld
RT Re-take C/S : Check Surface
Sign:
Name:
Date:
Page 19 of 93
AKS AKT
Page 20 of 93
Format No.:-9560/NBEL/FORM/MECH/013,REV.0

LINE HISTORY SHEET
%age of Radiography-
%age of MPT /LPT- LOOP NO.:
Line No. : Piping Class- Date :
Fit Up Weld Visual RADIOGRAPHY MPT DPT PWHT HARDNESS PMI

Sl.N Joint Joint Dia THK.
Welder No WPS No Remarks
o No. Type (inch) (mm)
Report No Date Report No Date XR No Report No Date Report No Date Report No Date Report No Date Report No Date Report No Date
SIGN WITH DATE:
NAME :

AKS AKT
Page 21 of 93

CHECK SHOT CONTROL LOG
CHI Report Matching/Not

Sl. No CHS No. Line No Area Joint No Dia W/No XR No. Report No Date Date EIl Sign.
No Matching
1
2
3
4
5
6
7
8
9
10
11
12
Sign
Name
Date

AKS AKT
Page 22 of 93

POSITIVE MATERIAL IDENTIFICATION REORT
Report No: DATE:
Client : SPREA MISR
Equipment Make/Model No :
Serial No :
Caibration Date/Validity :
Drg No/ISO No./Line No :
Location :
Material as per Material as per
S.No PMI S.No Description of Material Result Remarks
spec. PMI
Sign
Name
Date
PMI Operator Subcontractor NBEL/SPREA MISR

AKS AKT
Page 23 of 93
Format No:9560/NBEL/FORM/MECH/016,REV.0

UG PIPING COMPLETION RECORD
Report No:
CLIENT :SPREA MISR
LOOP NO / TEST PACK NO.:
LINE NO: REF P & ID Nos. :
CLEARANCE
SL NO. ACTIVITY CHECK Subcontractor NBEL/SPREA
Sign Date Sign Date
1.1 Mechanical Clearance
a Mechanical clearance conformity with drawings
b Material as per Piping Class and PMS
c Fit up Check
1.2 Coating and Wrapping
a Surface preparation
b Primer application
c Coating, wrapping and peel test
d Holiday Check
1.3 Laying
a Trench Leveling
b Lowering
c Spacing ,alignment, slope of pipe line
Checking for damages in wrapping and coating,
d
their repair, Holiday testing, etc.
e Backfilling
1.4 Welding and NDT clearance
a Visual checks of completed welds
b DPI Checks
c Radiography clearance
d PWHT and Hardness clearance
2 Testing medium
a Pressure …………………………Kg/Cm2
3(a) Preparatory arrangement for flushing / testing
3(b) Clearance for flushing and testing
4 Hydro Test witnessing
5 Draining and Drying
6 Box Up
7 Manhole / Catch basin location
8 Bottom slab top level
9 Surface preparation manhole at pipe inlet & Outlet
10 Others
Signature:
Name:
Date:

AKS AKT
Page 24 of 93

CLIENT :SPREA MISR
PUNCH LIST (Mechanical)

REPORT NO: DATE :
LOOP NO.:
REF. P & ID NO.:
Remedial Acceptance
S. No. Line No. Description Priority Punch Issued By Remarks
SUBCONTRACTOR NBEL/SPREA
Priority : A - Before Pressure test, B- Before pre-commissioning, C - Before start up
Sign
Name
Date
Page 25 of 93

3LPE COATING/TAPE COATING REPORT (UG PIPING)
CLIENT :SPREA MISR REPORT NO.:
EPC Contractor :NUBERG ENGINEERING LIMITED DATE:
Surface Preparation coating Inspection By Adhesion Inspection By

Final
Tape Test
Visual
Length
(Mtrs.)
Area Pipe Primer overlap on (after
Sl. No. Line No. Profile 1st 2nd Check &
No. Dia Surface DFT Edges 72hrs.)
Readings Coat Coat SUBCONTRA NBEL/
(mm)
Holiday
Observatio
SUBCONTRA NBEL/
Finish CTOR SPREA Test CTOR SPREA
(microns ) Layer Layer n
Sign
Name
Date
Page 26 of 93

LAYING & BACKFILLING REPORT (UG PIPING)
Name of the Project :500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT Report No:-
CLIENT :SPREA MISR

Level as per site Manholes SUBCON
SL. Length in Back-Filling NBEL/
Line No. TRACTO Remarks
NO Meter Inlet/Outlet From To Date SPREA
R
Sign:
Name:
Date:
Page 27 of 93

PIPING HYDROSTATIC TEST ACCEPTANCE RECORD (UG PIPING)
Client : SPREA MISR Report No:-

P & ID No. GA Drg No.
Isometric No.
Test medium:- Test Duration :- Design / Test Pressure:-
Test pressure gauge Range Calibration certificate No Gauge Calibration Date
S.No Activity Date Time
1 Cordon off area for high pressure testing, as required
2 Water filling started at
3 Water filling Completed & venting started at
4 Vents Closed
5 Isolation of Pressurising Pump/Required pressure attained at
6 Test Completed at
7 Water drained at
Sign
Name
Date
Page 28 of 93

MAGNETIC PARTICAL-TEST REPORT
REPORT NO.
Client :SPREA MISR
Method:
Technique :Electro Magnetic Yoke Type of Current:-
Surface condition : Surface Temperature:
Acceptance Criteria : ASME Sec-VIII Div.1 Appendix-VI Pole Spacing:
Equipment Make : GL NO:-
Joint Detail
SL No Line No: Area Zone W.No Observation Result
NO Size Type
Abbreviations
L : Linear Indication ACC : Accept
A:Found Indications Rep : Repair
MSD :MG Significent defect CO: Cut out
Sign
Name
Date
Page 29 of 93

CHECKLIST FOR MECHANICAL CLEARANCE - A/G PIPING
Name of the Project :500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT Date:
Client :SPREA MISR Area:
EPC Contractor : NUBERG ENGINEERING LIMITED Loop No:
LineNo(Isometric No.) Rev. GAD No. Rev. P & ID No. Rev
Sl no. Items to be checked Observation SUBCONTRACT NBEL/SPREA

OR MISR
1 Installation checked as per Isometric w.r.t.
CONFIGURATION. Route,Plumb,Elevation, Clearence for Thermal
expansion/Insulation
BRANCH
Location,angle.orientation type.RF pad,etc.
STEAM TRAP Direction

2 Installation checked as per GAD w.r.t.
CONFIGURATION .
Route, Clearence for Thermal expansion /Insulation
3 Installation Checked as Per P & ID
4 Isometrics Completed for (enclosed):
a.Joint Numbering (Shop & Field Welds)

b.Spool Numbering
c. As-built Routing & dimensions
Valves ( Check Ratings, Gaskets, Flow Direction, Sheet No.,Tag No.,Spindle
Direction,CSO,LO/LC Damage etc.
Gate Valves - ( Nos)
Globe Valves - ( Nos)
Check Valves - ( Nos)
5
Control Valves Tag Nos.
SafetyValves Tag Nos.
Any Other Valves
6 Strainers: check for clearance,flow direction elements

7 Flanged Joints
Total Nos.
Check For Type of Flange

Check For Rating
Check for alignment(Proper gap &Parallelity)
Check for Correct Studs & nuts-dia.,length,Material, Uniform Protrusion of Studs,Anti Seize
Compound
Check for correctr gasket(type,size,spec,thickness,etc

Torque values Used for Tightening
Page 30 of 93


OR MISR
8 Seal Welding Of Screwed conections(if required)
Page 31 of 93


OR MISR
Vents/Drains as per Dwg and Provision of Additional High Point Vents and/or Low Point
9
Drains.If Reqd.
10 Reinforcement Pads As Per Piping Class
11 Orifice Flanges
Check for Tag No. Tapping Orientation,Tap Valve,Jack Screw, Straight Run Length of
upstream & Downstream
12 Local Gauges: Check For accessibility
13 Slope(When Applicable)
14 Supports
a) Guides,Cross Guides,Trunnion,etc.
i) Check for correct type,Material & 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 data as per data sheet/spring set
ii) Check for locking arrangement and any damage durring transit,etc.
iii) Check for completeness of installation as per drg. Including welding of mounting
cleat/bracket
iv) Check for locking durring installation and pressure test
c) Bracket support & Inserts with Anchor Fasteners
i)Check for members dimensions and materials
ii)Check for welding
iii)Check for bolting
iv)Check for appearance/damage
15 Vents/Drains
As per drg.
Orientation of valve handles
Clearance for hose
Requirement of additional vents/drains(highest/lowest pt.)
16 Earthing:
a) Check for location
b) Check for dimensions of lug welding

17 Checked for Removal/Blinding-off of :
a. Control,Safety And Check valves
b.In-Line Instruments
c.Rupture Discs
Page 32 of 93


OR MISR
d. Equipment Nozzles
e. Others
Page 33 of 93


OR MISR
18 Support and Weld/Flanged/Screwed connections free from insulation or other coverage
19 Checked Installation of (Indicate location in drg.)
a. Temporary Blinds/Spades
b. Temporary strainers
C. Temporary dummy-Spools
d. Temporary Gaskets
e. Others
20 Expansion Bellows-
a) Check priro to installations
Physical damages
Transit locks are intact
Dimensions as per drgs.
b) Check durring installation
Parallelity of mating flangs
Face to face dimensions of mating flanges
Concentricity of mating flanges
No stress on expansion bellows

Record
c) Isolation durring pressure tests
Bellow mfg. recommendations on isolation of below durring pr. Test to be followed
If recommended expn. Below to be dropped durring pr. test.
21 Cleanliness Internally And Externally
22 Rotating Equipment Final Alignment Checked with piping
23 Removal of temporary/unwanted construction supports
24 Instrument taping as per instrument drawing
Physical-Walk-Through -The -Line,checked for gross irregularitites including physical
25
damages, unwanted tacks, arc strikes, spaters and space for thermal expansion
26 Cold Pull If Any
Remarks
Sign
with
date
Name:
27 Joist History sheets enclosed for:
Page 34 of 93


OR MISR
27.1 Material traceability as per procedure
27.2 Fit ups checked
27.3 NDT Complete (Radiography, MT,PT)
27.4 Stress reliving & Hardness check complete

27.5 Positive Material Identification ( PMI )
Sign
with
date
Name:
Page 35 of 93

RECORD OF CALIBRATION OF MEASURING / TESTING EQUIPMENT
Name of the Project : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT REPORT NO.:
Client : SPREA MISR DATE:

Calibration Due Date of
S.No Name of the Equipment Model No. Certificate No Calibrated by Remarks
Date Calibration
Sign :
Name:
Date:
Page 36 of 93

PIPING HYDRO TEST RELEASE/ACCEPTANCE RECORD - A/G PIPING
Client : SPREA MISR Report No.:
EPC Contractor : NUBERG ENGINEERING LIMITED Date:

Loop No.: REF P & ID No.:
Inch Mtr : From To
Line NO. (s) Isometric No. (s) P & ID No. (s)
Test Medium: Test Duration: Design/Test Pressure:

Test Pressure Gauge No. Range Caliberation Certificate No. Gauge Caliberation Date
Accept
S.No Items to check
1 Field Installation Checklist Prior to Hydrotest Signed
2 Punch list prepared
3 Pre-Hydrotest Punch items Cleared
4 Accessibilty to Inspection/Witness Locations (Weld Joint etc)
5 Capicity of pressurizing pump checked
7 Pre-hydrotest flushing carried out
8 IBR/Others test Witnessing Required
9 System Released for Pressure Testing:
ACTIVITY Date Time
10 Water Filling and Venting startred at
11 Water Filling Completed
12 Vents Closed at:
13 Isolation Of Pressurizing pump
14 Test Completed
15 Water drained
16 Air flushing
17 Temp Blinds Removed
18 Checked for reinstallation of
19 a.Control & Safety valves
20 b. Online Instuments
21 c. Rupture disks
22 d. Deblinding
23 e. Others
24 Cold setting of spring supports carried out
Remarks:-
Sign:
Date:
Name:
Page 37 of 93

PIPING PNEUMATIC TEST RELEASE/ACCEPTANCE RECORD - A/G PIPING
Client : SPREA MISR Report No.:

Loop No.: REF P & ID No.:
Inch Mtr : From To
Line NO. (s) Isometric No. (s) P & ID No. (s)
Test Medium: Test Duration: Design/Test Pressure:

Test Pressure Gauge No. Range Caliberation Certificate No. Gauge Caliberation Date
Accept
Sl no. Items to check
1 Field Installation Checklist Prior to Pressure test
2 Punch list prepared
3 Pre-Pneumatic test Punch items Cleared
4 Accessibilty to Inspection/Witness Locations (Weld Joint etc)
5 Capicity of pressurizing compressor checked
7 Pre-pneumatic test flushing carried out
8 IBR/Others test Witnessing Required
9 System Released for Pressure Testing:
ACTIVITY Date Time
10 Air Filling and Venting startred at
11 Air Filling Completed
12 Isolation Of Pressurizing compressor
13 Test Completed
14 Air released
15 Temp Blinds Removed
16 Checked for reinstallation of
17 a.Control & Safety valves
18 b. Online Instuments
19 c. Rupture disks
20 d. Deblinding
21 e. Others
22 Cold setting of spring supports carried out
Remarks:-
Sign:
Date:
Name:
Page 38 of 93

PROTOCOL DIMENSION REPORT
Client :SPREA MISR
ITEM DESCRIPTION : REPORT NO.:
DRAWING No. : DATE:
Sign
Name
Date
Page 39 of 93

INSTALLATION OF PIPE SUPPORT
Name of the Project : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT Report No:-
Client : SPREA MISR Date:-
QUANTITY ERECTION INSPECTION

ZONE/ TYPE OF SUPPORT
SL NO. LINE NO. REV. OF WEIGHT FIT UP ALLIGNMENT AND REMARKS
AREA SUPPORTS DETAILS SUBCONTRA NBEL/SPREA
SUPPORTS WELDING
CTOR MISR
Sign:
Name:
Date:
Page 40 of 93

FIELD INSPECTION REPORT FOR INSULATION
Client :SPREA MISR
ITEM DESCRIPTION : Report No.:-
DRAWING No. : DATE:-
LINE/EQUIPMENT NO. :
ISOMETRIC DRAWING NO. :
DESIGN TEMPERATURE :
TYPE OF INSULATION /THICKNESS :
NBEL/
SUBCONTRAC
S.NO ACTIVITIES/DESCRIPTION OBSERVATION SPREA Remarks
TOR
MISR
Clearance for insulation from mechanical, painting etc and
1
hydro test
2 Cleaning of surface
3 Application of Heat Transfer cement for IT Pipe lines
4 Fixing of spacer ring, where ever required
5 Installation of insulation material 1 st layer / thk.
6 Installation of insulation material 2 nd layer /thk.
Installation of insulation material 3 rd layer where ever
7
applicable / thk.
8 Thickness of insulation ( Total)
9 Check Securement of insulation ( Aluminium / SS bands)
10 Installation of Aluminium / SS jacket
11 Overlapping of vertical & horizontal joints ( 50mm)
Securement of Aluminium / SS jacket with Screws and
12
Bands, Putty.
13 Total insulation areas/ length
Sign
Name
Date
Page 41 of 93

HISTORY SHEET FOR FLANGE JOINTS
Report No:
Client :SPREA MISR
Counsltant :NUBERG ENGINEERING LIMITED Date:

Flange Parallelism Gasket Studs Nuts Flange Joint Acceptance
Bolt
Flange Flange Dia Torque Identify
Spec as Accepted/ Tension
Joint No. & Rating Total OK/NOT Value FJNHT/FJHT
Up Stream Down Stream per OK/NOT OK Size Spec. Not SPEC. Value SUBCONTRACT NBEL/SPREA MISR
Nos OK OR
Drawing Accepted
Special care to be taken for tapped hole and it is to be certified by contractor that full engagement of stud is there to tapped hole. FJHT-Flange Joint Hydrotested FJNHT-Flange Joint Not Hydrotested
Sign :
Name :
Date :
Page 42 of 93

ORIFICE FLANGE INSIDE WELD FLUSHING
Client :SPREA MISR
Report No: Date:
INSPECTION BY
ORIFICE
SL NO LINE NO JOINT NO DIA SUBCONTRAC NBEL/SPREA REMARKS
FLANGE NO
TOR MISR
Sign
Name
Date
Page 43 of 93
Format No.:9560/NBEL/FORM/MECH/031,REV.0

Client :SPREA MISR Report No:
RADIOGRAPHIC PROCEDURE QUALIFICATION RECORD FOR PIPE WELDING
1 LOCATION / IDENTIFICATION NUMBER
2 DATE OF TESTING
3(A) NAME OF THE SUB-CONTRACTOR
3(B) NAME OF THE RT AGENCY
4 MATERIAL
4A TECHNIQUE
5 DIAMETER & THICKNESS
6 TYPE OF WELD JOINT
7 RADIATION SOURCE
8 INTENSIFYING SCREENS/LEAD SCREENS
9 GEOMETRIC RELATIONSHIP(ug)
10 LIMIT OF FILM COVERAGE
11 FILM TYPE AND MAKE
12 EXPOSURE TIME
13 PROCESSING
14 DENSITY
15 SENSITIVITY
16 TYPE OF PENETRAMETER(SOURCE SIDE)
17 TYPE OF PENETRAMETER(FILM SIDE)
Approval of OWNER/PMC's Inspector

*Ref. Para regarding recommended practice on placement of penetrameters Article 22, SE 142,ASME Sec. V.
* For "Random Radiography" lines placement of penetrameters as per Article 2, ASME,Sec. V is permitted.
Sign :
Name :
Date :
Page 44 of 93

FIELD INSPECTION REPORT - FIRE PROOFING
Name of the Project :500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT REPORT NO:
Client :SPREA MISR DATE:
STRUCTURE: EQUIPMENT: OTHER:
NBEL/
S.NO ACTIVITY/DESCRIPTION OBSERVATION SUBCONTRACTOR REMARKS
SPREA MISR
1 Surface check
2 Primer application
a) Welding of Nut / Stiffner
b) Placing of Cover block.
c) Fixing of Metal fibre / Wire fabric.
d) Protection to Adjacent Structure/Equip.
e) Vermiculite Application as per approved Procedure

3 Curing
4 Surface finish
5 Thickness Check
6 Sealant Coat
7 Finish Coat
8 Hardness Check
Comments:-
Sign:
Name:
Date:
Page 45 of 93

POST WELD HEAT TREATMENT REPORT
Client : SPREA MISR REPORT NO:-
EPC Contractor : NUBERG ENGINEERING LIMITED DATE:

BHN OVER WELD BHN OVER HAZ
No of BHN on
SR Date of
S. No. Line / Isometric Drg. No./Tank No Joint No. Dia. Thickness Thermoco Parent Observation Remarks
uples Chart No. SR
Top Bottom Top Bottom Material
NOTE : SR chart to be enclosed wih this format
BASE MATERIAL SPECIFICATION:

THICKNESS:
RATE OF SOCKING RATE OF

HEATING TIME COOLING
( ⁰C/HR) (HR) ( ⁰C/HR)

Sign:
Name:
Date:
Page 46 of 93

PRE HEAT & POST HEATING REPORT
Client :SPREA MISR REPORT NO:-
Pre Heating Temp. Interpass Temp.

Preheat/ Date of
No of
Post Preheat/ Post heat Post heat
S. No. Line / Isometric Drg. No./Tank No Joint No. Dia. Thickness Thermoco Remarks
uples heating Post temp. time
Chart No. heating Req. Act. Max. Act.
NOTE : Chart to be enclosed wih this format
BASE MATERIAL SPECIFICATION:

THICKNESS:
Sign:
Name:
Date:
Page 47 of 93

Field Inspection Report -
ULTRASONIC EXAMINATION
Name of the Project :500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT REPORT NO:
Client :SPREA MISR DATE :
Acceptance Criteria: ASME Sec - VIII, Div-1 App- 12 Technique: PULSE ECHO CONTACT
Equipment: EINSTEIN OF MODSONICS Calibration Block: IIW-V2 Surface Condition/ Temperature: SMOOTH & AMBIENT
Reference Reflector: 38 mm SDH BLOCK, BWERT; 80% FSH Couplant : GREASE

Path Length: :NA Sensitivity Setting : 48 & 56 dB Probe & Frequency : 1 8X9MM ANGLE; 2MHz
Transfer Correction ( If any):NA Sizing Method : 6dB drop method Angle : 45 & 60
Welder Dia. Thk Observat Defect Size

Sl No Drg. No. / Line No. / ISO No./Equipment No. Rev. No Joint No Result
No. (Inch) ( mm) ion Ref. Point
Length Depth
Sign :
Name:
Date:
Page 48 of 93

PIPE ERECTION REPORT
SR. SHT. JOINT NO. SPOOL RUNNING INCH NO. OF

LINE NUMBER REV. CLASS AREA MATERIAL SIZE REMARKS
NO. NO. FROM/TO NOS METER METER VALVES
Sign:
Name:
Date:
Page 49 of 93

PROJECT PRESERVATION LOG
Name of the Project : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT Report No.:-
SL No. DISCIPLINE DESCRIPTION FREQUENCY ACTIVITY TAG NO DATE OF INSP REMARKS
Sign
Name
Date
Page 50 of 93

HARDNESS TEST REPORT
BHN OVER WELD BHN OVER HAZ BHN on

Observatio
Sl no. Line / Isometric Drg. No./Tank No Joint No. Dia. Thickness Parent Remarks
Top Bottom Top Bottom n
Material
Sign:
Name:
Date:
Page 51 of 93

SUPPORT HISTROY SHEET
Name of the Project : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT Loop No.: Report No.:
Client : SPREA MISR System No.: Date:
EPC Contractor : NUBERG ENGINEERING LIMITED Ref. P & ID No.: Area:
FIT UP CHECKED WELDING CHECKED

SL NO. LINE NO. ZONE REV. SUPPORT TYPE SUPPORT NO. REMARKS
SUBCONTRACTOR
NBEL/SPREA MISR
SUBCONTRACTOR
NBEL/SPREA MISR
Sign:
Name:
Date:
Page 52 of 93
Format No.:9560/NBEL/FORM/MECH/040,REV.0

MPT PROCEDURE QUALIFICATION RECORD
1 NAME OF THE NDT AGENCY
2 DATE OF TESTING
3 MATERIAL
4 YOKE MACHINE SERIAL NO
5 BLACK LIGHT SERIAL NO
6 MAGNETIC PARTICLE MATERIALS
7 BATCH NO
8 MAGNETISING METHOD
9 DIAMETER & THICKNESS
10 TYPE OF WELD JOINT

11 SURFACE CONDITION
12 MAGNETISING TECHNIQUE
13 MEDIUM
14 MAGNETISING CURRENT
15 POLE SPACING
16 LIFTING CAPACITY
OBSERVATIONS:
Sign :
Name :
Date :
AGENCY SUBCONTRACTOR NBEL/SPREA MISR
Page 53 of 93

BOX-UP CLEARANCE
Name of the Project :500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT Loop No.: Area:
Client :SPREA MISR System No.: Report No.:
EPC Contractor : M/sLIMITED
:NUBERG ENGINEERING Engineers India Limited Ref. P & ID No.: Date:
COMPLIANCE ATTENDED
SL.NO. LINE NO. / DRAWING NO. FOLLOWING CHECKING PERFORMED RESULT NBEL/SPREA REMARKS
SUBCONTRACTOR
MISR
Sign
Name
Date
Page 54 of 93

RF PAD PNEUMATIC TEST RECORD
Report No.:
Client :SPREA MISR
Test Medium: Test Duration: Gauge Calibration Date:
Test Pressure Gauge No.: Range: Calibration Certificate No.
Applied Pressure in
Sl no. Tank No./Line No. Joint No. Check for leaks by Soap Bubble Test Remarks
PSI / Kg/Cm2
Sign:
Name:
Date :
Page 55 of 93

INDEX FOR LOOP FILE (AG)
REPORT NO.:
Client :SPREA MISR
Counsltant :NUBERG ENGINEERING LIMITED DATE:

Area: Loop No: System No.:
Attachment
No. of
SL NO. Description REMARKS
Yes No Sheets
1 Isometric Index
2 Loop Marked Up P&ID
3 Line Schedule
4 Isometric Drawing
5 Punch list for Mechanical Clearance
6 Punch list for NDT Clearance
7 Punch list For Instrumentation Clearance
8 Checklist for Mechanical Clearance
9 Line History Sheet
10 NDT Summary
11 PMI Report
12 History Sheet for Flange joint
13 Support History Sheet
14 Pipe Support Drawings
15 RF Pad Pneumatic Test Record
16 Orifice Flange Weld Internal Grinding Report
17 Piping PressureTest Release/Acceptance Record
18 Modification After Hydrotest
19 Calibration Certificate/Reports
20 Checklist for Reinstating of Piping System
Sign:
Name:
Date :
Page 56 of 93

CHECKLIST FOR REINSTATEMENT
Name of the Project : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT System No./Loop No.:-
ACCEPTED BY
SL No. ITEMS TO CHECK
SUBCONTRACTOR NBEL/SPREA MISR REMARKS
1 Temperory Test Blinds and Dummy Spools Removed
2 Orifice Low Indicator,Spade,Spacer ring etc installed
3 Safety Relief Valves Installed
4 Control Valve Installed(Flow direction Checked)
5 Check Valve Installed(Flow direction Checked)
6 Rupture Installed(Flow direction Checked)
7 Inline Instrumentations Installed

All temperory Gaskets Replaced With permanent gaskets
8
as per specification
9 Flange Connection Bolts Tightened
10 Equipment dressing completed where applicble
11 Temperory Strainers Removed
12 Suction Line Strainers Installed
13 Extension Stems Installed
14 Dresser Couplings Completed
15 Spring hanger/Supports setting checked

Flow direction checked forGlobe Valves,NeedlleValves
16
etc.
17 Post Hydro Punch Points Closed
18 Exception Items agreed and listed in Punch List
19 PMI Of Stud/Bolts as per PMS(If applicable)
Sign
Name
Date
SUBCONTRACTOR NBEL SPREA MISR
Page 57 of 93

NDT OF ATTACHMENT WELD
Client : SPREA MISR
Line Class: Type of NDT & % Lot No:
NOS. OF SIGNATURE
TOTAL NO
SL NO. LOOP NO. ATTACHMENT NDT REQUIRED LINE NO JOINT NO REPORT NO. DATE RESULT REMARKS
OF JOINTS SUBCONTRA
WELD JOINT NBEL
CTOR
Sign:
Name:
Date:
SUBCONTRACTOR NBEL
Page 58 of 93

NDT OF BRANCH WELD
Client : SPREA MISR
NOS. OF SIGNATURE
TOTAL NO NDT
SL NO. LOOP NO. BRANCH LINE NO JOINT NO REPORT NO. DATE RESULT REMARKS
OF JOINTS REQUIRED SUBCONTRA
WELD JOINT NBEL
CTOR
Sign:
Name:
Date:
SUBCONTRACTOR NBEL
Page 59 of 93

NDT OF SOCKET WELD
Client : SPREA MISR
NOS. OF TOTAL NDT SIGNATURE

SL NO. LOOP NO. SOCKET NO OF REQUIRE LINE NO JOINT NO REPORT NO. DATE RESULT REMARKS
WELD JOINT JOINTS D SUBCONTRACTO
NBEL
R
Sign:
Name:
Date:
SUBCONTRACTOR NBEL
Page 60 of 93

NDT OF BUTT WELD
Client : SPREA MISR
NOS. OF SIGNATURE
BUTT TOTAL NO NDT
SL NO. LOOP NO. LINE NO JOINT NO REPORT NO. DATE RESULT REMARKS
WELD OF JOINTS REQUIRED SUBCONTRA
JOINT NBEL
CTOR
Sign:
Name:
Date:
SUBCONTRACTOR NBEL
Page 61 of 93
Format no.:-9560/NBEL/FORM/MECH/049,REV.0

AUTHORISATION FOR MODIFICATION OF PIPING JOINTS
Client : SPREA MISR
Indicative format for Authorisation/Recording of Modification of Piping Joints after Mechanical clearance/NDT
Clearance/Hydrotest/Pneumatic testing of Pressure Test Packages/Loops in Piping jobs
Report No:- Date:-
Loop No/Pressure Test Package No:

System Name & No:-
Previous Hydrotest Date:-
Drawing No:- Line No:-
Joints Nos to be Modified (Attach sketch):- New Joints No:-
Deleted Joints No:- Modification Joint No:-
Reason for Modification:-
A Proposed checks/NDT/Testing after Modification
1.Fit up and Traceability: 2.Weld Visual inspection Report:
3.PMI Checks : Mark "√" in box as necessary
4.MPI TEST : DPT (Root/Final): RT:
5.PWHT/HARDNESS : Required : Not Required :
6.Hydrotesting : Not Required :
Clearance/Acceptance after modifications (All Supporting Documents enclosed)
Mechanical Clearance: DEE/KKSEPL- Mech. Sign: TPIL/BPCL- Mech. Sign:
NDT Clearance : DEE/KKSEPL- QA/QC Sign: TPIL/BPCL- Welding/NDT Sign:
Testing Acceptance : DEE/KKSEPL- Mech Sign: TPIL/BPCL- Mech Sign:
Sign:
Date:
Name:
Page 62 of 93
Format No:-9560/NBEL/FORM/MECH/050, Rev-0

MATERIAL RECEIPT AND INSPECTION REPORT
Name of the Project : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT Mumbai
Client : SPREA MISR REPORT NO:
Quantity
SI No. Material Description P O . No./Date Reference Invoice No./Challan No. MTC No. Heat/Batch No. Date of Receipt Remarks
UOM Received Accepted
1.Quantity verified and found in order 2. Material condition appears to be good 3.Heat/Batch/Tag No. mentioned on the material
4.Color coding done as applicable 5. Site identification marks on material 6.Correlation w.r.t. IRN/MTC/Lab Tests report
7.TC verification w.r.t. IRN/Spec/QAP,etc.
Sign :
Name:
Date:
Page 63 of 93
Format No: 9560/NBEL/FORM/MECH/051,REV.0

INCOMING MATERIAL RECEIPT AND INSPECTION REPORT
Name of the Project : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT REPORT NO:
Client : SPREA MISR DATE:
MIR NO./IRN Quantity
SI No. Material Description P O . No./Date Reference Invoice No./Challan No. MTC No. Heat/Batch No. Date of Receipt Remarks
NO. UOM Received Accepted
1
2
1.Quantity verified and found in order 2. Material condition appears to be good 3.Heat/Batch/Tag No. mentioned on the material
4.Color coding done as applicable 5. Site identification marks on material 6.Correlation w.r.t. IRN/MTC/Lab Tests report
7.TC verification w.r.t. IRN/Spec/QAP,etc. 8.Col. NO. 3,4,5,6 is not applicable (N.A.) for fabricated structurals, fabricated Reinforcement steel,Piping Spools,Heater Items
Sign :
Name:
Date:
Page 64 of 93

TANK BOTTOM / ANNULAR PLATE INSPECTION REPORT
Client :SPREA MISR
TANK NUMBER : TANK SIZE : PRODUCT : REPORT NO :

DRAWING NUMBER : REV NO. : Date:
Sl. FIT UP Welder WELD VISUAL VACUUM TEST
Description Joint No. Remarks
No. SUBCONTRACTOR NBEL No. SUBCONTRACTOR NBEL SUBCONTRACTOR NBEL
Sign :
Name:
Date:
Page 65 of 93

MAGNETIC PARTICAL-TEST REPORT
Client :SPREA MISR
REPORT NO.: DATE:
Method:
Technique :Electro Magnetic Yoke Type of Current:-
Surface condition : Surface Temperature:
Acceptance Criteria : ASME Sec-VIII Div.1 Appendix-VI Pole Spacing:
Equipment Make : GL NO:-
Joint Detail
Sl No. Line No Area Zone W.No Observation Result
NO Size Type
Abbreviations
L : Linear Indication ACC : Accept
A:Found Indications Rep : Repair
MSD :MG Significent defect CO: Cut out
Sign
Name
Date
Page 66 of 93
KKS ENGINEERS PVT. LTD.

TANK SHELL VERTICAL JOINTS INSPECTION REPORT
Client :SPREA MISR

Tank Number : Tank Size : Report No :
Drawing No. : Rev No : Date:
Sl. Fit-Up Acceptance Back Gouging Peaking Weld Visual Acceptance
Description Joint No. Date Welder No. Date Remarks
No. SUBCONT. NBEL SUBCONT. SUBCONT. NBEL SUBCONT. NBEL
B-Bottom, M-Middle, T-Top

SIGN :
NAME :
DATE :
Page 67 of 93

TANK SHELL HORIZONTAL JOINT INSPECTION REPORT
Client :SPREA MISR

Tank Number : Tank Size : Report No :

Drawing No. : Rev No : Date:
FIT UP Back Gouging Weld Visual
Banding & Welder
Sl No. Ref. Points Joint No. Remarks
Plub reading No.
SUBCONT. NBEL SUBCONT. SUBCONT. NBEL
SIGN :
NAME :
DATE :
Page 68 of 93

TANK SHELL/ROOF NOZZLES INSPECTION REPORT
Client :SPREA MISR
Tank Number : Tank Size : Report No:-

Drawing No. : Rev No : Date:-
Sl. NOZZLE MARK Fit-Up Acceptance Weld Visual Acceptance RF PAD TESTING
ORIENTATION ELEVATION RF PAD Date Welder No. Date Remarks
No. NUMBER SIZE SUBCONT. NBEL SUBCONT. NBEL SUBCONT. NBEL
SIGN:
NAME:
DATE:
Page 69 of 93

TANK WIND GIRDER / COMPRESSION RING INSPECTION REPORT
Client :SPREA MISR

TANK NUMBER : TANK SIZE : REPORT NO :
DRAWING NUMBER : REV NO. : DATE:
Fit-Up Check Welder Weld Visual
Sl no. Description Joint No. Orientation Remarks
SUBCONT. NBEL Date No. SUBCONT. NBEL Date
Sign :
Name :
Date :
Page 70 of 93

TANK SHELL TO BOTTOM JOINT INSPECTION REPORT
Client :SPREA MISR

Tank No. : Tank Size : Product :
Drawing No. : Rev No. : Report No : Date:-
Inside Outside (Final Welding)
Orientatio Fit-Up Check
Sl. Welder Oil Chalk Test(1st Run ) Weld Visual (Final ) Liquid Penetrant Exam. Welder Weld Visual Remarks
n
No. SUBCONT. NBEL Date No. SUBCONT. NBEL Date SUBCONT. NBEL Date SUBCONT. NBEL Date No. SUBCONT. NBEL Date
0 to 90
1
Deg.
90 to 180
2
Deg.
180 to
3
270 Deg.
270 to
4
360 Deg.
SIGN :
NAME :
DATE :
Page 71 of 93

TANK STRUCTURAL INSPECTION REPORT
Client :SPREA MISR
Tank Number : Tank Size : Report No:-

Drawing No. : Rev No : Date:-
MARK Fit-Up Accept/Alignment Weld Visual Acceptance
SL NO. DESCRIPTION ORIENTATION Date Welder No. Date Remarks
NUMBER SIZE SUBCONT. NBEL SUBCONT. NBEL
SIGN :
NAME :
DATE :
Page 72 of 93

TANK ROOF PLATE INSPECTION REPORT
Client :SPREA MISR

TANK NUMBER : TANK SIZE : REPORT NO :
DRAWING NUMBER : REV NO. : Date:
Sl. Fit-Up Check Welder Weld Visual Pneumatic Test
Description Joint No. Remarks
No. SUBCONT. NBEL No. SUBCONT. NBEL Date Report no Date
SIGN :
NAME :
DATE :
Page 73 of 93

INSPECTION REPORT OF TANK SHELL/ ROOF APPURTENANCES
Client :SPREA MISR
Drawing No.: Rev No : Report No : Date:

Orientation in Deg. Elevation Fit-up Clearence Weld Visual Pneumatic test
Size in Welder
Sl.No Mark No. Report Remarks
inches Reqd. Actual Reqd. Actual SUBCONT. NBEL No. SUBCONT. NBEL Date Date
No.
SIGN :
NAME :
DATE :
Page 74 of 93

TANK VACCUM BOX TESTING REPORT
Client :SPREA MISR
Tank No :- Report No: Date :
SL.NO. Of vacuum gauge/ identification no Range Calibrated Date Calibration due date
Vacuum Gauge Reading (Average)

S.No. Area Description Item no. Remarks
PRESSURE RESULT
SIGN:
NAME:
DATE:
SUBCONTRACTOR NBEL/MISR
Page 75 of 93

TANK MECHANICAL CLEARENCE REPORT
Client :SPREA MISR

TANK NO : DRAWING NO : Report No:-
CHECK
DIA : REV NO : Date:-
SL. CLEARED BY
ACTIVITY REMARKS
NO SUBCONT. NBEL
1 Dimentional Clearance
YES / NO
APPURTENANCES OF SHELL / ROOF
2
( As Per Drawing )
3 NDT CLEARANCE
a). Visual Check
b). Nozzle Pad Test Check
c). Radiography Clearance
d). L.P.T Check
e). Oil Chalk Test
f). Vaccum Box Test
SIGN :
NAME :
DATE :


TANK WATER FILL TEST REPORT
Client :SPREA MISR

Report No:- Date:-
TANK NO : DRAWING NO : GAUGE RATIO :
DIA : REV NO : CALIBRATION DATE :
SL. CLEARED BY
ACTIVITY OBSERVATION REMARKS
NO SUBCONT. NBEL
A. SHELL TESTING (WATER FILL TEST)
1) 1st stage water filling (……….mtr)
a) Start date & time
b) End date & time
c) Stabilisation period (………hrs)
d) Settelment
2) 2nd stage water filling (……….mtr)
b) End date & time
d) Settelment
3) 3rd stage water filling (………mtr)
b) End date & time
d) Settelment
4) 4th/final stage water filling (……..mtr)
b) End date & time
d) Settelment
B)
FIXED ROOF TESTING (PNEUMATIC)
1 Closing of all roof opening
2 Location of manometer / pressure gauges
3 Test pressure required …………
4 Testing with soap soln & status of roof plate
leakages
C) DEWATERING
1 1st stage of dewatering (………mtr)
a) Opening of all roof nozzle
b) Start date & time
Page 77 of 93

TANK WATER FILL TEST REPORT
Client :SPREA MISR

Report No:- Date:-
TANK NO : DRAWING NO : GAUGE RATIO :
DIA : REV NO : CALIBRATION DATE :
SL. CLEARED BY
ACTIVITY OBSERVATION REMARKS
NO SUBCONT. NBEL
c) End date & time
d) Stabilisation period (……….hrs)
2) 2nd stage of dewatering (………mtr)
b) End date & time
c) Stabilisation period (……….hrs)
3) 3rd stage of dewatering (………mtr)
b) End date & time
c) Stabilisation period (……….hrs)
4) PARTIAL VACUUM TESTING(if
applicable) with one mtr of water in tank.
a) Vacuum reading in U tube (…25…….mm of
WC)
b) Result of vacuum test
D. FINAL DEWATERING & CLEANING
OF TANK
SIGN :
NAME :
DATE :
Page 78 of 93
TECHNIP INDIA LIMITED
TANK WATER FILL TEST
Name of the Project:ONSHORE TERMINAL FOR VA&S1 DEVELOPMENT PROJECT
: M/s ONGC
Client
Tank Size:-
TPI :M/s VCS QUALITY SERVICES PVT LTD
Contractor
Sub-contractor : M/s ARUN FABRICATORS
BENCH
SL.NO WATER LEVEL C1 C2 C3 C4 C5 C6 C7
MARK
BEFORE
WATER
FILL TEST
1 CLEAT
INITIAL
LEVEL
2 1 mtr
3 2 mtr
4 2.750 mtr
24 HOURS
5 HOLDING
6 3 mtr
7 4 mtr
P
8 5.55 mtr
mtr
M
9
SA
24 HOURS
10 HOLDING
11 6 mtr
12 7 mtr
8 mtr
13
14 8.25 mtr
24 HOURS
15 HOLDING
16 9 mtr
17 10 mtr
18 11 mtr
24 HOURS
19 HOLDING
Note:-Water Level & Level Cleat Nos has been changed as per API 650 &Tank Height/Circumference.
SIGN :
NAME:
DATE :
ARUN FABRICATORS TPIL
Prepared and Checked By
TPIL
CHNIP INDIA LIMITED
TER FILL TEST REPORT
TANK No:-
VCS/
C8 C9 C10 C11 DATE TIME AF TPIL REMARKS
ONGC
25%
PL E
AM
50%
75%
100%
Circumference.
VCS/ONGC
Reviewed and Approved By
VCS/ONGC

TANK PNEUMATIC TEST REPORT
Name of the Project 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT
Client :SPREA MISR

Gauge No. Validity: Report No. : Date:
Nozzle Part Test Holding Gauge Accepted

Sl. No. Tank No Remarks
No. Description Pressure Time No. SUBCONT. NBEL Date
SIGN :
NAME:
DATE :
Page 84 of 93

TANK INTERNAL SHELL CLEANING INSPECTION REPORT
Client :SPREA MISR
Tank No. : Tank Size : Report No. :
Drawing No. : Rev. No. : Date:-
Accepted by Date Remarks

Sl. No. Description
SUBCONT. NBEL
Sign:
Name:
Date:
SUB-CONTRACTOR NBEL/SPREA MISR
Page 85 of 93

PLUMBNESS OF SHELL COURSES INSPECTION REPORT
Client :SPREA MISR
DRG NO.- REV NO.- REP NO.
TANK HT.-
TANK NO.- TANK DIA.- DATE:
Shell Reading Plumb Reading before Welding Roundness &
SUBCONT. NBEL Remarks
Course No Point Individual Overall Diameter
0º TO 90º
90º TO 180º
180º TO 270º
270º TO 360º
SIGN.:
NAME:
DATE:
Page 86 of 93

STATIC EQUIPMENT ELEVATION REPORT(HORIZONTAL TYPE)
EQPT. NO. : MANUFACTURER :

EQPT. NAME : WEIGHT :
TYPE OF EQPT : VENDOR DWG NO :
LENGTH / HEIGHT : LOCATION / AREA/UNIT:
HORIZONTAL TYPE
ELEVATION OF CENTRE LINE

ELEVATION OF REF. NOZZLE OF EQUIP. AT SLIDE END &
ORIENTATION REF. NOZZLE NO. FIXED END REMARKS
As per drg. As Actual As per drg. As Actual
TIGHTENING OF BOLTS:- ACC/REJ

RELEASE FOR GROUTING:-
REMARKS
Sign
Name
Date
Page 87 of 93

STATIC EQUIPMENT ALIGNMENT REPORT(VERTICAL TYPE)
Client :SPREA MISR
REPORT NO:
VERTICAL EQUIPMENT ALIGNMENT REPORT
DATE:
Drawing Reference of Inspection,
Equipment Name Equipment No. Equipment Wt. Area
No: Measuring and Test Equipment
VERTICALITY ALIGNMENT REPORT
POSITION BOTTOM TOP

0O
0O
90O
180O
NORTH
270O
NOTE : ALL DIMESIONS ARE IN MM
270O 90O
180O
Nozzle No. Size Drg. Elv. Actual Elv. Orientation
Bottom of skirt Elevation:

Required Actual Deviation
EL + ……
Check description Result

Levelness and Anchor bolts tightness
Orientation and verticality
Tightening of Bolts:-
Release for Grouting:-
Signature :
Name :
Date :


FIELD INSPECTION REPORT - GROUTING
REPORT No.: DATE:
Client :SPREA MISR
STRUCTURE / EQUIPMENT:-
Sl no. Activity Description Observation DEE/KKSEPL TPIL/BPCL REMARKS
1 Availability of material with TC
2 Mechanical clearence of the
3 Structure/Equipment
Surface Check
4 FORMWORK
a) line
b) level
c) support with water tight
5 Placement
a) water added (cement
based grout)
b) Air temperature
6 No of Cubes & ID
7 Curing
8 7/28 days cube test
Comments:
Sign :
Name:
Date:
Page 89 of 93

EQUIPMENT ERECTION REPORT
Name of the Project :500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT REPORT NO:-
Client :SPREA MISR
TYPE OF EQPT
LOCATION / : VENDOR DWG NO :
AREA/UNIT :

1.Job Procedure/JSA YES NO
2.Material Inspection YES NO
3.Foundation Release YES NO
4.Pad Plate Elevation check YES NO
5.Name Plate Checking YES NO
6.Oroentation Checking YES NO
Remarks:-
Sign
Name
Date
Page 90 of 93

ROTARY EQUIPMENT ALINGMENT INSPECTION REPORT
Name of the Project
:500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations,EGYPT REPORT NO:
Client :SPREA MISR

LENGTH / HEIGHT :
LOCATION /
AREA/UNIT :
Signature
Sl. No. Check Item Result Date
SUBCONT. NBEL SPREA MISR
1 Foundation Coordinates checked
Foundation lacking and cleaning

2
of pockets
3 Anchor Bolt & Nuts
4 Visual Inspection of Equipment
5 Erected on
6 Preliminary / First Alignment
7 Pocket Grouting
8 Level Checking
9 Final Grouting
10 Free Shaft Rotation
a. Alignment without piping Hook
11
up Axial and radial
b. Alignment with piping Hook up
Axial and radial.
12 Aux. Installation for flushing oil
Installation of coupling spacer
13
and coupling guard.
14 Oil filling in oil cup.
15 Final box – up.
Nozzle No. Size Orientation DWG. ELE. Actual ELE. Remarks
SUCTION NOZZLE
DISCHARGE NOZZLE
Remarks
Sign
Name
Date
Page 91 of 93

ROTARY EQUIPMENT ALIGNMENT INSPECTION REPORT
REPORT NO:-
Client :SPREA MISR
DATE:
LENGTH / HEIGHT :
LOCATION /
AREA/UNIT :
0
) ( ) (
)
( )
TOG ( )
Orientation of Nozzles Elevation

Nozzle No
As per DWG Actual Variation As per DWG Actual Variation Levelness Verticality
Suction Nozzle NA
Discharge Nozzle As Per sketch
REMARKS:
Sign
Name
Date
Page 92 of 93

COUPLING ALIGNMENT INSPECTION REPORT

LENGTH / HEIGHT : LOCATION / AREA/UNIT:
Face
ALIGNMENT WITHOUT PIPE CONNECTION AS PER DRAWING ACTUAL FACE
0 0
) ( ) ( A ) (
) ( R
) ( ) (
R – Redial
ALIGNMENT WITH PIPE CONNECTION
0 A – Axial
0
) ( A ) (
) ( R ) (
) (
) (
REMARKS
Sign
Name
Date
DEE/KKSEPL TPIL/BPCL

DEE/KKSEPL TPIL/BPCL
Page 93 of 93

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NUBERG ENGINEERING LIMITED

Index for Mechanical Formats

NUBERG ENGINEERING LIMITED

JOINTS (QW - 402 )

BASE METAL (QW - 403)

FILLER METALS (QW - 404 )

SUBCONTRACTOR NBEL/SPREA MISR

Prepared and Checked By Reviewed and Approved By

NUBERG ENGINEERING LIMITED

Procedure Qualification Record No : Date :

JOINTS (QW - 402 )

Filler Metal F No : Gas(es) Mixture Flow rate

Weld Metal Analysis A No : Shielding :

GUIDED BEND TEST ( QW - 160 )

TOUGHNESS TEST ( QW - 170 )

FILLET WELD TEST (QW - 180 )

Welder's name : Clock No :

Prepared and Checked By Reviewed and Approved By

NUBERG ENGINEERING LIMITED

SUBCONTRACTOR NBEL/SPREA MISR

Prepared and Checked By Reviewed and Approved By

NUBERG ENGINEERING LIMITED

SUBCONTRACTOR NBEL/SPREA MISR

Prepared and Checked By Reviewed and Approved By

NUBERG ENGINEERING LIMITED

Welder's name : : Clock no : Photo

Actual values used in

Visual examination result ( QW - 302 ) :

Hence , the welder is QUALIFIED

Date : SUBCONTRACTOR NBEL/SPREA MISR

Checked and Prepared By Review and Approved By

NUBERG ENGINEERING LIMITED

Sub-Contractor NBEL/SPREA MISR

Prepared and Checked By Reviewed and Accepted

NUBERG ENGINEERING LIMITED

Environment Surface Preparation(Avg.) Primer Coat(Avg.) Intermediate Coat(Avg.) Finish Paint(Avg.)

Description Primer Intermediate Paint Finish paint

Prepared and Checked By Reviewed and Accepted By

NUBERG ENGINEERING LIMITED

Subcontractor NBEL/SPREA MISR

Prepared and Checked By Reviewed and Approved By

NUBERG ENGINEERING LIMITED

Prepared and Checked By Reviewed and Approved By

NUBERG ENGINEERING LIMITED

Drg. No./Line No/Str Mark No Joint Welder ACC / REJ

Prepared and Checked BY Reviewed and Approved By

NUBERG ENGINEERING LIMITED

Prepared and Checked By Reviewed and Approved By

NUBERG ENGINEERING LIMITED

NSD No Significant Defect Rep : Repair

Subcontractor NBEL/SPREA MISR

Prepared and Checked By Reviewed and Approved By

NUBERG ENGINEERING LIMITED

Fit Up Weld Visual RADIOGRAPHY MPT DPT PWHT HARDNESS PMI

SIGN WITH DATE:

Subcontractor NBEL/SPREA MISR

Prepared and Checked By Reviewed and Approved By

NUBERG ENGINEERING LIMITED

Client : SPREA MISR Report No:

EPC Contractor :NUBERG ENGINEERING LIMITED Date:-

CHI Report Matching/Not

Subcontractor NBEL/SPREA MISR

Prepared and Checked By Reviewed and Approved By