INSPECTION & TEST PLAN for VALVE (Low Temperature Application)

AR : Approval Required
W : Witness Inspection
Work Description :
R : Review of Documentation
T/C : Test Certificate Required
H : Hold Point
Description : Forging & Casting Material Manufacture/Vendor and/or Sub Vendor's
M :
Inspection/Implementation
Figure No. : -
Tag Code : All tag code

PHASE PROCESS DESCRIPTION or

REFERENCE DOCUMENT VERIFIED DOCUMENT ACCEPTANCE CRITERIA Sample Size
No. QUALITY ACTIVITIES Vendor Kontraktor
Pertamina / Third
Party
Note
1.0 Administration Requirement
1.1 Contract Review & Technical Issue of Quotation and
Purchase Order Record Review Purchase Order M R R -
Specification
1.2 Drawings and Procedure Purchase Order/ - Drawings, Manuf Spec & Purchase Order
Customer Data Sheet Procedure. Customer Data Sheet
-Testing Procedure Related Std.
- Manuf. Data Sheet
M AR AR -
- General Assy Drawing
- Inspection & Test Plan Related Std.
- QC Manual
- Coating Procedure
1.3 Pre Inspection Meeting MOM H H H

Procurement of Material Inspection and Testing at Supplier

2.1 Material Inspection

if failed, double the

Material spec based on Material Test Certificate EN Material spec based on 3 ea every heat sample for re-testing. Both
2.1.1 Chemical Composition Test M R R
Customer Data Sheet 10204 (Type 3.2) Customer Data Sheet number the sample need to be
success
 if failed, double the
sample for re-testing. Both
Mechanical Requirement: Charpy the sample need to be
Material Test Certificate EN Material spec based on 3 ea every heat success.
2.1.2 impact test (body, body cover, ASTM A370 M R R
10204 (Type 3.2) Customer Data Sheet number
bonnet, disc, yoke and bolt)
especially for LCB / LF2
Class.1 materials, must
undergo charpy impact
test in -50°F (-46°C)

Hardness Test (stem, ball, seat, if failed, double the

2.1.3 body (forging), bonnet (forging),
body cover (forging) and bolt)
Tensile Test: Tensile, Yield,
Elongation, Reduction of Area
2.1.4 (body, bonnet, body cover, ball
(forging), seat (forging), yoke,
disc, bolt and stem)
Marking and Traceability (as
2.1.5
appropriate)
Material spec based on Material Test Certificate EN Material spec based on 3 ea every heat sample for re-testing. Both
M R R
Customer Data Sheet 10204 (Type 3.2) Customer Data Sheet number the sample need to be
success
Material spec based on Material Test Certificate EN Material spec based on 3 ea every heat if failed, double the
M R R
sample for re-testing. Both
Customer Data Sheet 10204 (Type 3.2) Customer Data Sheet number
the sample need to be
success
Traceability List (Set-Out
Manufacturing Procedure As per stamping requirement M R R 100%
Report)

2.2 Fire-Tested Design

API 607 API 607

API 6FA API 6FA
2.2.1 Fire Test Fire Type-Test Certificate M R R
API 6FD API 6FD
ISO 10497 ISO 10497

2.3 NDT (Non-destructive Test)

-Purchase Order
-MSS SP 55
Material Test Certificate EN Applicable Standard
2.3.1 Visual Inspection -Drawing M W W 100%
10204 (Type 3.2) MSS SP - 55
-ASME VIII div 1 UF45.UF46

2.3.2 Dimensional Inspection Purchase Order

Dimensional Inspection
Dimensional Report As per parts drawings M W W 100%
Procedure
Drawing
Material Test Certificate EN
UT for forging body, closure, body ASME B16.34 / ASTM ASME VIII Div 1, ASME
2.3.3 10204 (Type 3.2), NDE M W W
cover,ball, seat, stem and disc A388 B.16.34, ASTM A388
Report
Material Test Certificate EN
RT for casting body, bonnet, yoke ASME VIII Div 1, ASME
2.3.4 ASME B16.34 10204 (Type 3.2), NDE M W W
and disc B.16.34 100%
Report
accessible
internal /
external surface
 100%
accessible
Surface NDE (PT/MT) for body,
Material Test Certificate EN internal /
bonnet, closure, ball, seat, stem ASME Section V, Article 6 ASME VIII Div 1, ASME
2.3.5 10204 (Type 3.2), NDE M W W external surface
yoke and disc after final & article 7 B.16.34
Report
machining
Material Test Certificate EN
Surface NDE (PT/MT) for welding
2.3.6 ASME Section V, Article 6 10204 (Type 3.2), NDE ASME VIII Div 1, appendix 8 M W W
(overlay/hardfacing) if applicable
Report
2.4 PMI (Positive Material Identification)

PMI of mettalic alloy with methods

X-Ray Flourescence (XRF) or Material Test Certificate EN
2.4.1 Optical Emission Spectrometry PMI Procedure 10204 (Type 3.2), NDE Project spec, ASME II M W W 10% if failed, double the
sample for re-testing.
(OES) (hardfacing, body, bonnet, Report
All the sample need to be
disc, stem)
success
2.5 Material Receiving, Assembly & Testing Quality Requirements

- No damage, deep scratches

- COC -
Receiving of: etc - Correct
Material Test Certificates
marking -
- Raw Materials - - Relevant Inspection
2.5.1 Manufacturing Procedure Dimension within spec - M R R 100%
Machined Components - & Test Report
As per Purchase Order -
Buy Out Components - Material Test Certificate EN
Full documentation package
10204 (Type 3.2)
receive

- No damage, deep scratches

- COC -
Visual Inspection on Body, etc - Correct
Material Test Certificates
marking -
Closure, Trim, Bolts & Nuts and - Relevant Inspection
2.5.2 Manufacturing Procedure Dimension within spec - M R R 100%
non metallic material (Gasket & & Test Report
As per Purchase Order -
Seal) - Material Test Certificate EN
Full documentation package
10204 (Type 3.2)
receive

Dimensional Verification - Body, Dimensional within Spec ;

2.5.3 Manufacturing Procedure Dimensional Report M R R 100%
Closure, Trim Components Drawing

Components traceability prior Traceability List (Set-Out

2.5.4 Manufacturing Procedure As per stamping requirement M R R 100%
assembly Report)

2.5.5 Valve Assembly BOM, Approved GA Drawing - Correct Assembly M R R 100%

2.6 Valve Factory Acceptance Tests (FAT)

 High Pressure Hydrostatic Shell
2.5.1
Test
2.5.2 Torque Test Approved FAT Procedure (Refer
High Pressure Hydrostatic Seat Approved FAT Procedure FAT Report to API 6D, API 598, ASME M W W 100%
2.5.3 B.16.34, etc)
Test

2.5.4 Low Pressure Pneumatic Seat Test

2.6 Suplementary Test Requirement

Approved FAT Procedure (Refer

High Pressure Gas Test (Shell and
2.6.1 Approved FAT Procedure FAT Report to API 6D, API 598, ASME M W W 100%
Seat) B.16.34, etc)

Approved FAT Procedure (Refer

2.6.2 Functional Test (where applicable) Approved FAT Procedure FAT Report to API 6D, API 598, ASME M W W 100%
B.16.34, etc)

no defect on material
(crack on body, gate, disc
and stem)
10% of valve
total population if failed, double the
- Project spesification sample for re-testing.
& min 1 sample
Valve Low Temperature Testing - MESC SPE 77/306, 2005 All the sample need to be
2.6.3 Approved FAT Procedure FAT Report M W W for every lot
(LTT)* - BS 6364,1984 success
(type, model,
size & pressure before LTT, the valve shall
rating) be thoroughly cleaned,
degreased and dried. The
valve assembly shall not
be painted.

NDE Procedure, NDE

ASME VIII Div 1, ASME every sample
2.6.4 NDE after LTT ASME Section V, Article 5 Qualification Personnel, M R H
B.16.34 that undergo LTT
NDE Report

2.7 Blasting and Painting Requirement

2.7.1 Blasting and Painting Approved Painting Procedure Painting Inspection Report Approved Painting Procedure M R R 100%

2.7.2 Painting Inspection Approved Painting Procedure Painting Inspection Report Approved Painting Procedure M R R 100%
 Testing at Workshop (Indonesia)
3.0 Visual Check

3.0.1 Visual Inspection Purchase Order Visual Inspection Report Applicable Standard M R R
GA Drawing MSS SP - 55

Dimensional Inspection
3.0.2 Dimensional Inspection Purchase Order ASME B 16.34, etc M R R
Report
GA Drawing

3.1 Pressure Test

High Pressure Hydrostatic Shell

3.1.1
and Seat Test

High Pressure Gas Shell and Seat

3.1.2
Test (if applicable)

After Pressure Test, all

3.1.3 Low Pressure Pneumatic Seat Test Approved Testing Procedure API 6D, API 598, ASME valve must be cleaned
Testing Report M W W 100%
B.16.34, etc and free from
contamination.
Functional Test & Torque Test (if
3.1.4
applicable)

4.1 Final Inspection Requirement

Correct Assembly as per

Final Inspection and Issue Final & Visual Inspection
4.1.1 Manufacturing Procedure drawing, BOM, Approved GA H R R 100%
Inspection Release Note (IRN) Report, Certificate of IRN Drawing

5.0 Presevation & Packaging

5.1 Tagging requirements Purchase Order Purchase Order

5.2 Identification Plate Data Sheet MSS SP - 25 Apply rust-protective agent

for internal valve & Flange
Preservation & Packaging
5.3 Protection ASME B 16.34 M W W - End then Flange End must
Procedure
be protected with Flange
5.4 Final Inspection Vendor report Project Spec Cap

Sea Packing Waterproof

5.5 Packing Vendor report
suitable for all transportation
6.0 MDR
Drawing, Data Sheet
 COO, COC, MTC, PTR,

Related Procedure, ITP,

Inspection Release Note,
Fire Safe Certificate,
MDR Purchase Order Project Spec M R R -
Certificate of non metallic
material (seals, gaskets)

Calibration Certificate
PMI Report
Testing Report

*: applicable for low temperature valve