Project N° Unit Doc. Type Mat. Code Serial N° Rev.

Page

202180C 000 ITP 1320 0002 0 1 of 4

INSPECTION AND TEST PLAN FOR VALVES

PROJECT : PRODUCT RECOVERY IMPROVEMENT PROJECT LPG UNIT

LOCATION : GAIL, VIJAIPUR, MADHYA PRADESH

OWNER EPCM

TECHNIP INDIA LTD. (T.EN)

GAIL INDIA LTD. (GAIL)

INSPECTION AND TEST PLAN FOR VALVES

Document Category Document Review Status (by Client)

(Use “X” Mark)

Approval Review

Information

Pages Modified under this revision: None

Aditya Singh Bisht Tarun Relhan   Tarun Relhan

2022.01.31 13:40:03  
2022.01.31   2022.01.31
 
13:40:47 +05'30' 13:40:54 +05'30'
 
+05'30'
 
Written By  Checked By  Approved By 

0 26/01/2022 ISSUED FOR INQUIRY ADITYA S. BISHT TARUN RELHAN TARUN RELHAN

Rev Date STATUS WRITTEN BY CHECKED BY APPROVED BY

DD/MM/YYYY (name & visa) (name & visa) (name & visa)

DOCUMENT REVISIONS

This document developed by TECHNIP India Limited and the information it contains are property of GAIL India Ltd. It shall not be
used for any purpose other than for which it was supplied.

CONFIDENTIAL – Not to disclose without Authorization

 INSPECTION AND TEST PLAN CLIENT : GAIL INDIA LTD. (GAIL)

FOR PROJECT : PRODUCT RECOVERY IMPROVEMENT PROJECT

VALVES DOC NO : 202180C-0 00-IT P- 13 20 -0 0 02

CONFIDENTIAL PROPERTY OF TECHNIP INDIA LIMITED Page 2 of 4

INSPECTION BY

MANUFACTURER
SL. NO. STAGE DESCRIPTION TYPE OF CHECK REFERENCE DOCUMENT ACCEPTANCE CRITERIA VERIFYING DOCUMENT REMARKS

TECHNIP

Review of Material Test
Material Identification
Certificates for raw material drawings
and bought outs (body, bonnet,
1 disc, stem, body ring, trim,
fasteners, gaskets
etc)Physical, chemical, Impact
(As Applicable)
Purchase Requisition/ Approved Purchase Requisition / Material Test Certificate
Applicable Material Code EN10204-3.1 for pressure
parts / EN 10204 2.2 for non
pressure bearing parts.
RECORD
OWNER
TPIA
H R OR Heat Treatment of Pressure containing parts as specified in Purchase
Requisition.
Stabilized Austenitic Stainless Steels shall be provided with stabilization heat
treatment subsequent to solution annealing.
IGC Testing for all austenitic steel valves as per ASTM A262 practice B for
Castings with acceptance criteria of “60 mils/year (max.)” & Practice E for
Forgings at 20X & 250X.
C<= 0.25 & CE<= 0.43 %

Review of WPS/PQR/WPQ for

WPS / PQR / WPQ
2 Weld overlay, Stelliting, Purchase Requisition / ASME IX Purchase Requisition / ASME IX WPS / PQR / WPQ H R/W* R OR * W - For new procedures, R - For existing procedures
Hardness

Review of Heat Treatment Purchase Requisition/ Applicable Purchase Requisition/ Applicable

3 PWHT (if applicable) Heat Treatment Chart H R OR
record code / code

Non Destructive Examination Radiographic Examination, Purchase Requisition / Approved For Radiographic examination, RT films to be reviewed by TPIA.
Purchase Requisition/ Approved
4 for valves (castings/forgings) Dye Penetrant Examination, Drawings / ASME sec VIII / RT Reports / PT reports H R OR For bypass installations, 100% PT for fillet and 100% RT for butt welds shall be
Drawings / ASME Sec V
& bypass installations. Magnetic Particle Examination ASTM E446/E186 carried out.

Verification of Special service Purchase Requisition / Purchase Requisition /

Helium leak test, Hardness, Bend Test, Magnetic Particle Examination, PT, RT,
5 Special Service Requirements required viz. Hydrogen, IBR Applicable material standard Applicable material standard Test Report H W OR
Tensile, Charpy Impact test, etc. as per Purchase Requisition
etc.

Hardfacing/stelliting if PT of the surface after PT reports for

6 ASME V ASME VIII Div1 H R OR
applicable hardfacing/stelliting/ hardfacing/stelliting

Body , Seat and back seat
7 Body and Seat Hydrotest
Hydrotest
For shell hydrotest, minimum witness - 10% witness for Forged Valves
- 100% witness for Cast Valves.
Approved drawings/ Valve
Applicable API For bidirectional valves, Seat leakage test shall be done from both upstream and
specification / Applicable API Hydrotest Report H H OR
standard/Purchase Requisition downstream positions.
standard /Purchase Requisition
The chloride content shall not exceed 30ppm and minimum pH 6,5 for stainless
steel, duplex, nickel alloy and titanium valves

Approved drawings/ valve Min 10% witness by TPIA

Applicable API standard/
8 Pneumatic seat leak test Pneumatic seat leak test specification/ Purchase Test Report H H OR For bidirectional valves, Seat leakage test shall be done from both upstream and
Purchase Requisition
Requisition downstream positions.

Strip check is required for 1 % of total ordered quantity of gate & globe valves
Strip Test for Gate and Globe Strip Test & PMI of SS/AS
9 Purchase Requisition no visual abrasion Inspection Report H W OR (min. 1No.) for each valve. PMI of SS Internals shall be done on valves subject
valves internals
to strip test.

Functional / Operational Test

10 Functional / Operational Test (For Motor Operated/Actuator Purchase requisition Purchase requisition Inspection Report H W OR
Operated/Gear operated)
 CLIENT : GAIL INDIA LTD. (GAIL)
INSPECTION AND TEST PLAN
PROJECT : PRODUCT RECOVERY IMPROVEMENT PROJECT
FOR
DOC NO : 202180C-0 00-IT P- 13 20 -0 0 02
VALVES
CONFIDENTIAL PROPERTY OF TECHNIP INDIA LIMITED
Page 3 of 4

INSPECTION BY

MANUFACTURER
SL. NO. STAGE DESCRIPTION TYPE OF CHECK REFERENCE DOCUMENT ACCEPTANCE CRITERIA VERIFYING DOCUMENT REMARKS

TECHNIP

RECORD
OWNER
TPIA
Review of Fire Safe Test(for
11 Fire Safe Test ball valves/ soft seated valves Purchase Requisition Applicable specification Fire Safe Test Certificate H R OR
only)

Visual & Dimensional

Dimensional -10% witness by TPIA
12 Visual & Dimensional Check examination and Functional Approved drawings Approved drawings Inspection Report H W OR
Visual Inspection -10% witness by TPIA
test

Applicable material code/

Positive Material Identification Chemical Analysis for body , Purchase Requisition/
13 Purchase PMI Report H W OR Extent as per 202180C-000-PP-509
(for SS and AS) bonnet, stem and welds 202180C-000-PP-509
requisition/202180C-000-
PP-509

Pickling and Passivation for SS ASTM A380 / Purchase ASTM A380 / Purchase
14 Pickling and Passivation Valves, Ti Valves (as Requisition Requisition Inspection Report H R OR Minimum pickling temperature shall be 21°C (70°F) .
applicable)

Ferroxyl test on 300 series SS Purchase Requisition/ ASTM Purchase Requisition/ ASTM
15 Ferroxyl test fittings, Ti fittings (as A380 A380 Inspection Report H R OR
applicable)

Painting check Checks on Final painting / Purchase Requisition / Approved Purchase Requisition / Approved Painting report H W OR
16 pickling & passivation Drawings Drawings

Verification of marking ,
Purchase Requisition/ Applicable Full compliance to Purchase
stamping , color coding, Flow
17 Traceability Verification code/ Requisition/Applicable code/ Inspection report H W OR
direction, Gear orientation and
100% stamping by TPIA
End Protection

Purchase Requisition/ Approved Full compliance to Purchase Preservation Report and Check of lifting arrangement, cleanliness, protection, End Caps, marking, name
18 Preservation & Packing Preservation & Packing H R OR
Procedure Requisition Packing list plate, packing condition and quantity

Review of Inspection Record Purchase Requisition/ Approved Confirmation of completion of all

19 Inspection Record Book Inspection Record Book H R OR
Book Procedure required inspection

Confirmation of completion of all

20 Issue of Release Note Issue of Release Note Purchase Requisition IRN H H R OR Separate IRN shall be issued for IBR Items
required inspection

Notes 1) Requirements of Purchase Requisition shall govern, wherever more stringent than this ITP. All the Raw material of the Valves shall technically comply with PR .
2) Client/ PMC comments, if any, shall be provided later to the vendor for implementation.
3) All valves in vacuum service shall be tested for vacuum.-Extent shall be 1 no. per size/type/metallurgy.
4) IBR items shall be supplied with applicable IBR certificates in Original. TPIA shall perform Visual Inspection, Verification of Form III and Issuance of IRN apart from IBR Inspection.

5) Vendor shall ensure that all test and measuring instruments are duly calibrated and calibration shall be valid at the time of inspection. calibration procedure & records shall be reviewed by TPIA.
 CLIENT : GAIL INDIA LTD. (GAIL)
INSPECTION AND TEST PLAN
PROJECT : PRODUCT RECOVERY IMPROVEMENT PROJECT
FOR
DOC NO : 202180C-0 00-IT P- 13 20 -0 0 02
VALVES
Page 4 of 4
CONFIDENTIAL PROPERTY OF TECHNIP INDIA LIMITED

INSPECTION BY REMARKS

MANUFACTURER
SL. NO. STAGE DESCRIPTION TYPE OF CHECK REFERENCE DOCUMENT ACCEPTANCE CRITERIA VERIFYING DOCUMENT

PMC/OWNER
TECHNIP

RECORD
TPIA
6) All material shall only be procured from the GAIL / T.EN approved Vendor List(AVL)
7) NDE procedure shall be approved by TPIA during the Inspection at Vendor workshop.
8) NDE procedure shall be approved by vendor ASNT Level III personal
9) NDT to be performed after heat treatment.

Reference Code/ Standard: 1) ASME SEC II Part A, latest edition

2) ASME B16.34 Edition 2020, ASME B16.10 latest edition
3) API 598 Edition 10th 2016 , API 6D Edition 24th, API 6FA latest edition
4) INDIAN BOILER REGULATION 1950, Edition 2017

LEGEND: H - HOLD POINT; W - WITNESS; IW - INITIAL WITNESS;

R - REVIEW OF DOCUMENTS; S – SURVEILLANCE,
OR - OFFICIAL RECORD; IR - INTERNAL RECORD;

REF.DOC.: QUALITY CONTROL SURVEILLANCE (QCS) Doc No. 202180C-000-PP-502