BRIDGE & ROOF CO.

(INDIA) LTD Document Type: Inspection & Test Plan

A GOVERNMENT OF INDIA ENTERPRISE Document No: B&R/70909/MECH/ITP/001
Rev 0

PROJECT: PHASE - II EXPANSION PROJECT AT NALCO, DAMANJODI

NAME OF WORK: BALANCE PIPING WORK
JOB NO: 70909

INSPECTION TEST PLAN FOR ABOVE GROUND PIPING

Records to be
Sl.
Activity Contractor EIL submitted/
No
Format No.
A. PRIOR TO FABRICATION
1 Incoming Material
a) Owner's supply WC Rw Format M2/ F12
b) Contractor's supply including check testing WC Rw Format M2/ F12

2 Welding Filler Material Approval / Qualification

a) Manufacturing Test Certificate/ Documents WC* Rw Yes
b) Testing if any
i) Carbon Steel WC W Format M2,F12
ii) Alloy Steel / Stainless Steel WC W Format M2,F12

3 WPS/PQR
a) Review of proposed procedure WC Rw Format M5/ F25
b) Testing
i) Carbon Steel WC HP
ii) Alloy Steel / Stainless Steel WC HP
c) Approval of final WPS/PQR WC HP Format M6/ F26

4 Welder Performance Qualification Test WC W Format M7/ F22

5 Certification & approval of welders WC HP Format M8/ F23

6 NDT Procedure Qualification

a) Review of proposed procedure WC Rw
b) Witnessing of Proposed Procedure Testing WC HP
c) Approval of Qualified Procedure WC HP Format F24

7 Review of Joint numbering in Isometrics (Big & Small

bore) WC Rw Yes

8 Lines where Isometrics not available

a) Preparation of sketches WC Rw Yes
b) Joint Numbering in sketches WC Rw Yes

9 Material traceability & Transfer of Heat Nos.

- C.S. piping above 600# rating WC W Format M9/F05
- A.S. Piping, S.S Piping, NACE piping, H2 service
piping WC HP Format M9/F05

* Notwithstanding any other tests/documentation required for qualification/approval of filler metals

i) For Alloy Steel & Stainless Steel welding filler metals, chemical analysis to be carried out for very
batch

Page 1 of 5
 BRIDGE & ROOF CO. (INDIA) LTD Document Type: Inspection & Test Plan
A GOVERNMENT OF INDIA ENTERPRISE Document No: B&R/70909/MECH/ITP/001
Rev 0

PROJECT: PHASE - II EXPANSION PROJECT AT NALCO, DAMANJODI

NAME OF WORK: BALANCE PIPING WORK
JOB NO: 70909

INSPECTION TEST PLAN FOR ABOVE GROUND PIPING

Records to be
Sl.
Activity Contractor EIL submitted/
No
Format No.
ii) For LTCS welding filler metals, Impact test to be carried out for very batch
iii) For NACE filler metals, corrosion tests like HIC, SSCC, etc. to be carried out for every batch.
B. FABRICATION (SHOP & FIELD)

1 Material as per piping class (check w.r.t. approved

colour coding procedure) WC W Format M10/F01

1a. Dimensional Checks WC S -----

1b. Fit-up check for butt joints and socket joints WC W Format M10/F01

1c. Fit-up checks for branch joints WC W Format M10/F01

2 Pre-heat(if any) WC S -----

3
Certificate of purity of purging / shielding Gas (if any) WC Rw Yes

4 Purging rate (if any) and arrangement WC S ----

5 Shielding rate (if any) WC S ----

6 Baking of Electrodes WC S ----

7 Inter-pass cleaning & Temperature check WC S ----

8 Visual check of completed welds having WC S Format M11/F02

Procedure qualification of PWHT WC W Format F27

9 Monitoring of PWHT Cycle WC S ----

10 Review of Time - Temperature graph WC HP Yes

11 Hardness Check

a) For C.S. Materials WC S Format M12/F03

b) For A.S. Materials Piping WC W Format M12/F03

12 PT/MT WC W Format M13/F04,

M14/F18

Page 2 of 5
 BRIDGE & ROOF CO. (INDIA) LTD Document Type: Inspection & Test Plan
A GOVERNMENT OF INDIA ENTERPRISE Document No: B&R/70909/MECH/ITP/001
Rev 0

PROJECT: PHASE - II EXPANSION PROJECT AT NALCO, DAMANJODI

NAME OF WORK: BALANCE PIPING WORK
JOB NO: 70909

INSPECTION TEST PLAN FOR ABOVE GROUND PIPING

Records to be
Sl.
Activity Contractor EIL submitted/
No
Format No.
13 Radiography marking (for Random Radiography only) WC Rw Format M15/F06

14 Radiography Interpretation/ Review

a) For Carbon Steel Piping WC HP Format M16/F07

b) For Alloy Steel / SS Piping WC HP Format M16/F07

15 Check Shot for Radiography WC W Format M16/F07

16 Surface cleaning and primer application WC S Format M17/F15

C. ERECTION

1 Lifting arrangement (for critical piping only) WC Rw Yes

2 Test certificates for lifting tackles WC Rw Yes

3 Location and orientation of Branch connections WC Rm Format F10

4 Provision of Inst. Tappings WC Rm Format F10

5 Provision of vents and drains WC Rm Format F10

6 Correctness of type of supports, Anchors, Guides WC HP Format F10

7 Correctness of gaskets/fasteners

- C.S. piping WC Rm Format F10

- A.S. Piping, S.S. Piping, NACE piping WC W Format F10

8 Correctness of valves
(NRV, Gate, Globe, control Valves etc), steam traps
and their direction of flow

- C.S piping WC HP Format F10

- A.S. Piping, S.S. Piping, NACE$ Piping WC HP Format F10

Page 3 of 5
 BRIDGE & ROOF CO. (INDIA) LTD Document Type: Inspection & Test Plan
A GOVERNMENT OF INDIA ENTERPRISE Document No: B&R/70909/MECH/ITP/001
Rev 0

PROJECT: PHASE - II EXPANSION PROJECT AT NALCO, DAMANJODI

NAME OF WORK: BALANCE PIPING WORK
JOB NO: 70909

INSPECTION TEST PLAN FOR ABOVE GROUND PIPING

Records to be
Sl.
Activity Contractor EIL submitted/
No
Format No.
9 Provision of cold pull, if any WC HP Format F10

D PROOF TESTING

1 Procedure Review WC HP Format F19

2 Correctness of Testing arrangements WC W Format F10

3 Check all valves kept open and confirm that testing is

not done against closed valve seat WC W Format F10

4 Isolation of equipments, control valves, Instruments,

bellows, Removal of flappers from check valves WC W Format F10

5
Scrutiny of test packs for Mechanical & NDT Clearance WC HP Format M21/F09

6 Positive Material Identification as per specification after

completion of installation WC HP Format M18/F08

7 a) Review of Calibration certificates of pressure Gauges WC Rw Format M1

b) Field Calibration, if any WC W Yes

8 Preparation of check list (Punch list) WC HP Format F17

9 Liquidation of check list WC HP Format F17

10 Air/Water Flushing (preliminary) WC W ----

11 Visual inspection of all weld joints for leak during

Pneumatic / Hydroatesting WC HP ----

12 Draining of Water & Air Drying WC S Format F19

13 Removal of temporary blinds / supports WC S Format F19

Page 4 of 5
 BRIDGE & ROOF CO. (INDIA) LTD Document Type: Inspection & Test Plan
A GOVERNMENT OF INDIA ENTERPRISE Document No: B&R/70909/MECH/ITP/001
Rev 0

PROJECT: PHASE - II EXPANSION PROJECT AT NALCO, DAMANJODI

NAME OF WORK: BALANCE PIPING WORK
JOB NO: 70909

INSPECTION TEST PLAN FOR ABOVE GROUND PIPING

Records to be
Sl.
Activity Contractor EIL submitted/
No
Format No.

14 Pickling of system, if required WC W Format M19/F20

15 Boxing up including reinstallation of flappers of check

valves WC W Format F19

16 Review of Records of fasteners & gaskets WC S Format F10

17 Torque tightening / tensioning of flange joints,

wherever applicable WC S Format F10

18 System testing WC HP Format M20/F21

19 Setting of spring supports WC HP Format F19

INSPECTION & TEST DOCUMENTS

Completeness of Inspection and Test Records WC Rw Format F21

NOTES:

i) For painting works, refer ITP for Painting works No. 6-82-1501

Page 5 of 5