INDICATIVE INSPECTION TEST PLAN FOR MECHANICAL WORKS TAN GOPALPUR

CHECK / INSPECTION CATEGORY/ PERFORMED BY REMARKS

TYPE OF
S.NO ACTIVITY / DESCRIPTION REFER STD.DOC./ NORMS OF ACCEPTANCE CONTRAC
TYPE SCOPE/ EXTENT STL/TCE/TPI PMC/CLIENT RECORD Rev R0
TOR
1 EQUIPMENT ERECTION
A STATIC EQUIPMENT : (PRE-FABRICATED)
Scrutiny of relevant calibration
Calibration of testing & measuring
1 certificates including their 100% Those issued by STL/TCE recognised laboratories/agencies S H H TC
instruments
validity
1. Conformity to as-built /
approved drawings and other RPT
To the extent required 1. As- built approved drawings. - P,RPT -
2 Equipment to be erected documents
to facilitate erection 2. Inspection release notes/ other documents
2. Transit Damage RPT STL/DEC
3. Match erection marks P,RPT W - NR
WPS
Conformity to Specification & Approved WPS & PQR and manufacturer's test &
3 Consumables 100% S R - PQR
validity certificate
TC
Check of dimensions / level/
Take Over of foundation jointly with civil Approved drawing / equipment layout/ orientation
4 centre line CO.ORD/ Pockets/ 100% P,RPT W R RPT
contractor and DEC drawing/ template
Foundation bolts
Adequacy of resources

A. Manpower 1. Site Organogram

5 Management/ Supervisory Staff skilled/ Physical/ Visual 100% 2. Daily manpower Report RPT R - NR
unskilled labour 3. Erection Scheme / Schedule

B. Plant & Machinery

Adequacy of site infrastructure Plot Plan, Equipment layout, Erection data sheet , Load
Feasibility/ Safety 100% S R R RPT
Erection Scheme for critical Equipment Chart
Adequacy for erection Space for
Physical , by actual
receiving/ Hoisting the equipment, 100% Plot Plan, Equipment layout, Erection Scheme P R - -
measurement
placing main/ trailing
1. Scrutiny of Crane's
1. Fitness certificate
documents including their
2.Load chart and appropriate derating commensurate with
Adequacy of Crane's capacity validity 100% S,P,RPT R,W - RPT
the age of the crane/ Safety Factor
2. General appearance
3. Erection Scheme
3.Trial Load test , if required
1. Scrutiny of soil investigation
6 report
2. Confirmation from civil
Adequacy of soil condition at the 1.Soil investigation report
contractor on load bearing 100% R,P R,W - NR
erection point 2.Data from Civil Contractor
capacity etc.
3.Trial loading using moving
loads if required
Adequacy of access at the erection front
to permit free manoeuvrability of crane/ Physical verification at the Plot plan/ Equipment layout / Erection data sheet /
100% P R - NR
equipment without any hindrance from erection site erection Scheme
neighbouring structures

Availability of construction power and Physical verification at the 1. erection scheme

100% P R - NR
water within close proximity etc erection site 2. layout drawing for construction power & water

ITP 1 OF 8
 INDICATIVE INSPECTION TEST PLAN FOR MECHANICAL WORKS TAN GOPALPUR

CHECK / INSPECTION CATEGORY/ PERFORMED BY REMARKS

TYPE OF
S.NO ACTIVITY / DESCRIPTION REFER STD.DOC./ NORMS OF ACCEPTANCE CONTRAC
TYPE SCOPE/ EXTENT STL/TCE/TPI PMC/CLIENT RECORD Rev R0
TOR
Installation of equipment Orientation level, Vertically
bolting / Anchoring grouting 100% As per Drawing / Scheme P,RPT W R RPT
7
Correct Positioning alignment etc.
Install internals/ mountings Dimensional / Visual 100% As per Drawing / Scheme P,RPT W - RPT
Testing

1. Check quality of water used

for testing like pH value,
8 Hydrostatic, pressure/ vacuum/ chloride content in ppm etc.
P,RPT W W RPT
Pneumatic 2. Visual check of water level As per equipment data sheet/ Approved testing
100%
monitoring pressure gauges/ procedure/ Civil drawing & Load data
manometers etc.
3. Reading of foundation
P,RPT M,R R,RAN RPT
settlement
9 Cleaning / Flushing/ Drying Visual 100% As per process Spec P,RPT W R,RAN RPT
Safety
Quantity/ Quantity by physical
100% Relevant Indian standards as per annexure Yes R,RAN R,RAN NR
Personal protective Equipment and verification
Gadgets
Ensuring good quantity erection aids , Visual/ Scrutiny of test Test Certificate, Section -29 of the factorises sct,1948 (
100% for Major items S R R,RAN TC
Wire ropes Slings etc Certificate Latest Edition)
Safe Load carrying capacities of crane, Scrutiny of test/ fitness Fitness certificate, load charts etc. Section -29 of the
100% S R - CERT.
winches, derricks etc. certificates & Validity factories act,1948 ( latest edition)
10
Fire extinguishers Type/ Quantity/ Expiry date 100% IS 2190 Yes R,RAN - -
Scrutiny of medical fitness
Crane Operators vision, hearing ability, ANSI/ ASME B 30.5 Latest edition
certificate 100% S R - RPT It is a Statutory requirement
driving licence etc.
Review of driving licence Motor Vehicle Act & Motor Vehicle rules

Prevent unauthorized entry of personnel Critical erection to be scheduled on holidays or

Physical/ Visual As applicable - Yes RAN - -
at the erection venue during erection before 9.am
Any other like fair whether etc Yes RAN - -
Mark -up of As built dimensions on
11 Yes R - DRGS
related drawings
B ROTARY EQUIPMENT
Scrutiny of relevant calibration
Calibration of testing & measuring
12 certificates including their 100% Those issued by STL/TCE recognised laboratories/agencies S H H TC
instruments
validity
1. Conformity to as-built /
approved drawings and other RPT
To the extent required 1. As- built approved drawings. - P,RPT -
13 Equipment to be erected documents
to facilitate erection 2. Inspection release notes/ other documents
2. Transit Damage RPT STL/DEC
3. Match erection marks P,RPT W - NR
Conformity to Specification &
14 Consumables 100% Manufacturer's Technical Specification/ Test certificates S R - TC
validity
Check of dimensions / level/
Take Over of foundation jointly with civil Approved drawing / equipment layout/ Manufacturers
15 centre line CO.ORD/ Pockets/ 100% P,RPT W R RPT
contractor and DEC installation manual, Orientation drawing
Foundation bolts

ITP 2 OF 8
 INDICATIVE INSPECTION TEST PLAN FOR MECHANICAL WORKS TAN GOPALPUR

CHECK / INSPECTION CATEGORY/ PERFORMED BY REMARKS

TYPE OF
S.NO ACTIVITY / DESCRIPTION REFER STD.DOC./ NORMS OF ACCEPTANCE CONTRAC
TYPE SCOPE/ EXTENT STL/TCE/TPI PMC/CLIENT RECORD Rev R0
TOR
Adequacy of resources

A. Manpower 1. Site Organogram

16 Management/ Supervisory Staff skilled/ Physical/ Visual 100% 2. Daily manpower Report RPT R - NR
unskilled labour 3. Erection Scheme / Schedule

B. Plant & Machinery

Adequacy of site infrastructure
Plot Plan, Equipment layout, Erection data sheet , Load
Erection Scheme for critical Equipment Feasibility/ Safety 100% S R R RPT
Chart
Like turbine compressor etc.

1. Scrutiny of Crane's 1. Fitness certificate

documents including their 2.Load chart and appropriate derating commensurate with
Adequacy of Crane's capacity validity 100% the age of the crane/ Safety Factor (ref. SEC-29 of the S,P,RPT R,W - RPT
2. General appearance factories act,1948)
3.Trial Load test , if required 3. Erection Scheme
1. Scrutiny of soil investigation
report
17 2. Confirmation from civil
Adequacy of soil condition at the 1.Soil investigation report
contractor on load bearing 100% R,P R,W - NR
erection point 2.Data from Civil Contractor
capacity etc.
3.Trial loading using moving
loads if required
Adequacy of access at the erection front
to permit free manoeuvrability of crane/ Physical verification at the Plot plan/ Equipment layout / Erection data sheet /
100% P R - NR
equipment without any hindrance from erection site erection Scheme
neighbouring structures

Availability of construction power and Physical verification at the 1. erection scheme

100% P R - NR
water within close proximity etc erection site 2. layout drawing for construction power & water
Orientation level, bolting /
Anchoring assembling
Installation of equipment Plot Plan/ Equipment layout/ Orientation drawing ?
alignment without piping,
18 100% Installation manual/ Drawing for motor frame giving P,RPT W R RPT
alignment with piping,
Correct Positioning overall dimensions
grouting, no load run of prime
mover etc.
Safety
Quantity/ Quantity by physical
100% Relevant Indian standards as per annexure Yes R,RAN R,RAN NR
Personal protective Equipment and verification
Gadgets
Test Certificate, in accordance with the requirements spelt
Ensuring good quantity erection aids , Visual/ Scrutiny of test
100% for Major items out under Section -29 of the factorises sct,1948 ( Latest S R R,RAN TC
Wire ropes Slings etc Certificate
Edition)
Safe Load carrying capacities of crane, Scrutiny of test/ fitness Fitness certificate, load charts etc in accordance with the
winches, derricks EOT cranes, Monorails, certificates including their 100% requirements spelt out under Section -29 of the factories S R - CERT.
19
Hoist etc. Validity act,1948 ( latest edition)
Fire extinguishers Type/ Quantity/ Expiry date 100% IS 2190 Yes R,RAN - -

ITP 3 OF 8
 INDICATIVE INSPECTION TEST PLAN FOR MECHANICAL WORKS TAN GOPALPUR

CHECK / INSPECTION CATEGORY/ PERFORMED BY REMARKS

TYPE OF
S.NO ACTIVITY / DESCRIPTION REFER STD.DOC./ NORMS OF ACCEPTANCE CONTRAC
TYPE SCOPE/ EXTENT STL/TCE/TPI PMC/CLIENT RECORD Rev R0
TOR
Scrutiny of medical fitness
Crane Operators vision, hearing ability, ANSI/ ASME B 30.5 Latest edition
certificate 100% S R - RPT It is a Statutory requirement
driving licence etc.
Review of driving licence Motor Vehicle Act & Motor Vehicle rules

Prevent unauthorized entry of personnel Critical erection to be scheduled on holidays or

Physical/ Visual As applicable - Yes RAN - -
at the erection venue during erection before 9.am
Any other Yes RAN - -
Mark -up of As built dimensions on
20 Yes R - DRGS
related drawings
C SITE FABRICATED TANKS
Scrutiny of relevant calibration
Calibration of testing & measuring
21 certificates including their 100% Those issued by STL/TCE recognised laboratories/agencies S H H TC
instruments
validity
1. Approved Drawings
1. Conformity to as-built /
2. Inspection release notes/ Manufacturer's test
Materials/ Accessories approved drawings and other 100% P,RPT P,RPT - RPT
22 Certificate
(Jointly with STL/TCE) documents
3. Bill of materials
2. Transit Damage RPT By TCE/STL
WPS
Conformity to Specification &
23 Consumables 100% Approved WPS & PQR &Manufacturers test certificate S R - PQR
validity
TC
Check of dimensions / level/ Approved drawing / equipment layout/Erection data
Take Over of foundation jointly with civil
24 centre line CO.ORD/ Pockets/ 100% sheet, code for construction of tanks to check foundations P,RPT W R RPT
contractor and DEC
Foundation bolts tolerances
Adequacy of resources

A. Manpower 1. Site Organogram

25 Management/ Supervisory Staff skilled/ Physical/ Visual 100% 2. Daily manpower Report RPT R - NR
unskilled labour 3. Erection Scheme / Schedule

B. Plant & Machinery

Adequacy of site infrastructure
Erection Scheme for critical Equipment.
Feasibility/ Safety 100% Plot Plan, Equipment layout, Erection data sheet S R R RPT
1. By conventional method
2. By Jacking Method
Adequacy of erection space around
Physical by actual
foundations for free movement of crane 100% Plot Plan, Equipment layout, Erection Scheme P R - -
measurement
etc
1. Scrutiny of Crane's 1. Fitness certificate
documents including their 2.Load chart and appropriate derating commensurate with
Adequacy of Capacities of erection
validity 100% the age of the equipment/ Safety Factor (ref. SEC-29 of the S,P,RPT R,W - RPT
equipment like Cranes , Jacks etc.
2. General appearance factories act,1948)
3.Trial Load test , if required 3. Erection Scheme
26

ITP 4 OF 8
 INDICATIVE INSPECTION TEST PLAN FOR MECHANICAL WORKS TAN GOPALPUR

CHECK / INSPECTION CATEGORY/ PERFORMED BY REMARKS

TYPE OF
S.NO ACTIVITY / DESCRIPTION REFER STD.DOC./ NORMS OF ACCEPTANCE CONTRAC
TYPE SCOPE/ EXTENT STL/TCE/TPI PMC/CLIENT RECORD Rev R0
TOR
26 1. Scrutiny of soil investigation
report
2. Confirmation from civil
Adequacy of soil condition at the 1.Soil investigation report
contractor on load bearing 100% R,P R,W - NR
erection point 2.Data from Civil Contractor
capacity etc.
3.Trial loading using moving
loads if required
Adequacy of access at the erection front
to permit free manoeuvrability of crane/ Physical verification at the Plot plan/ Equipment layout / Erection data sheet /
100% P R - NR
equipment without any hindrance from erection site erection Scheme
neighbouring structures

Availability of construction power and Physical verification at the 1. erection scheme

100% P R - NR
water within close proximity etc erection site 2. layout drawing for construction power & water
1. Material identification/
Stamp transfer 1. Approved Fabrication drawings
Site fabrication and erection 100% P,RPT W,RAN R,RAN RPT
2. Dimensions 2. Manufacturer's test Certificate
3. Profile
1. Dimensions RAN
2. Fit-up H
1. Approved fabrication drawing
Erection 3. Profile 100% P,RPT RAN - RPT
2. Code for construction
4. Verticality RAN
5. Orientation W
1. Identical PQR Established earlier under agencies
27 acceptable to STL/TCE
Establish WPS/PQR 100% 2. Laboratory reports on NDT/ DT carried out on coupon S,P H R,RAN RPT
welded at site
3. ASME SEC. IX latest edition
Welder qualification Test 100% WPS/PQR/ASME SEC.IX ( Latest Edition) P H R,RAN RPT
Welding
Root pass ( Weld finish/ 1. ASME SEC.IX ( Latest Edition)
100% P R,W,RAN - RPT
Penetration)- Visual 2. WPS/PQR
Back chip: Visual /DP 100% WPS/PQR/ASME SEC.IX ( Latest Edition) P H - RPT
Visual - 100% ASME SEC.IX (Latest Edition)/ Code for construction/
Finished Weld: Visual from
Other NDT as per DRG./ STL/TCE weld test plan/ approved procedure for various P W - RPT
both sides/ other ND tests
as applicable ND tests
Testing Procedure Review S R R,RAN
Vacuum Box testing
Hydrostatic
Witness the test as per tank
Pressure/ Vacuum As per approved drawing/ code of construction RPT
specifications/approved 100% P,RPT W W,RAN
28 Fixed/ Floating roof testing
testing procedure
Safety Valve setting
Pressure/ Vacuum
Reading of foundation
Settlement Reading 100% P,RPT M,R R,RAN RPT
settlement
As per contract, certified documents like calibration chart
29 Statutory approval like calibration etc. Review of final documents 100% P H R RPT
etc
30 Cleaning/ Box-up Visual 100% P W W RPT
31 Painting
32 Insulation LATER

ITP 5 OF 8
 INDICATIVE INSPECTION TEST PLAN FOR MECHANICAL WORKS TAN GOPALPUR

CHECK / INSPECTION CATEGORY/ PERFORMED BY REMARKS

TYPE OF
S.NO ACTIVITY / DESCRIPTION REFER STD.DOC./ NORMS OF ACCEPTANCE CONTRAC
TYPE SCOPE/ EXTENT STL/TCE/TPI PMC/CLIENT RECORD Rev R0
TOR
33 Rubber Lined
Safety
Quantity/ Quantity by physical
100% Relevant Indian standards as per annexure Yes R,RAN R,RAN NR
Personal protective Equipment and verification
Gadgets
Test Certificate, in accordance with the requirements spelt
Ensuring good quantity erection aids , Visual/ Scrutiny of test
100% for Major items out under Section -29 of the factorises sct,1948 ( Latest S R R,RAN TC
Wire ropes Slings etc Certificate
Edition)
Scrutiny of test/ fitness Fitness certificate, load charts etc in accordance with the
Safe Load carrying capacities of crane,
certificates including their 100% requirements spelt out under Section -29 of the factories S R - CERT.
winches, derricks etc.
Validity act,1948 ( latest edition)
Fire extinguishers Type/ Quantity/ Expiry date 100% IS 2190 Yes R,RAN - -
Scrutiny of medical fitness
Crane Operators vision, hearing ability, ANSI/ ASME B 30.5 Latest edition
certificate 100% S R - RPT It is a Statutory requirement
driving licence etc.
Review of driving licence Motor Vehicle Act & Motor Vehicle rules

Prevent unauthorized entry of personnel Critical erection to be scheduled on holidays or

Physical/ Visual As applicable - Yes RAN - -
at the erection venue during erection before 9.am
Any other Yes RAN - -
Mark -up of As built dimensions on
Yes R - DRGS
related drawings
2 PIPING
Scrutiny of relevant calibration
Calibration of testing & measuring
2.1 certificates including their 100% Those issued by STL/TCE recognised laboratories/agencies S H H TC
instruments
validity
1. Availability as per / 1. Approved Drawings
conformity to approved 2. Inspection release notes/ Manufacturer's test RPT Statutory approval, wherever applicable
2.2 Material/Accessories 100% P,RPT P,RPT,R -
drawings/ Other documents Certificate
3. Bill of materials
2. Transit Damage RPT By TCE/STL
WPS
Conformity to Specification &
2.3 Consumables 100% Approved WPS & PQR &Manufacturers test certificate S R - PQR Statutory approval, wherever applicable
validity
TC
Scrutiny of relevant
2.4 Statutory approval, wherever required 100% Contract documents, approval from statutory authorities S H R RPT
documents
Check of dimensions / level/
Take over of civil/ structural work jointly
2.5 centre line CO.ORD/ Pockets/ 100% Approved drawings, piping layout P,RPT W R,RAN RPT
with civil contractor and TCE/STL
Foundation bolts
Adequacy of resources

A. Manpower 1. Site Organogram

2.6 Management/ Supervisory Staff skilled/ Physical/ Visual 100% 2. Daily manpower Report RPT R - NR
unskilled labour 3. Erection Scheme / Schedule

B. Plant & Machinery

Adequacy of site infrastructure
Feasibility 100% Overall Schedule S R - NR
Review of construction Schedule
2.7 Adequacy of erection space / access Physical/ Visual 100% Overall Schedule P R - NR

ITP 6 OF 8
 INDICATIVE INSPECTION TEST PLAN FOR MECHANICAL WORKS TAN GOPALPUR

CHECK / INSPECTION CATEGORY/ PERFORMED BY REMARKS

TYPE OF
S.NO ACTIVITY / DESCRIPTION REFER STD.DOC./ NORMS OF ACCEPTANCE CONTRAC
TYPE SCOPE/ EXTENT STL/TCE/TPI PMC/CLIENT RECORD Rev R0
TOR
Adequacy of capacities /quantities of Scrutiny of relevant
RAN Construction Schedule P R - NR
erection equipment documents, Name plates etc
Site fabrication and erection 1. Material identification/ 1. Drawing duly approved for construction
2.8 Stamp transfer For critical lines 2. manufacturers Test certificate P W,RAN R,RAN RPT Statutory approval, wherever applicable
Fabrication 2. Fit-up 3. Piping Specification
Erection

Correct positioning
alignments / levels
Supporting - Primary / Secondary 1.Piping layout
Online fittings , valves, traps, filters, Physical/ Visual 100% 2.P&ID P W,RAN - RPT Statutory approval, wherever applicable
Safety valve, NRV, orifice plates etc. 3.isometric drawing
Flow direction
provision of platforms & Ladders
Provision for cold pull, if any

1. Identical PQR Established earlier under agencies

acceptable to STL/TCE
Establish WPS/PQR 100% 2. Laboratory reports on NDT/ DT carried out on coupon S,P,RPT H R,RAN RPT Statutory approval, wherever applicable
welded at site
Welding 3. ASME SEC. IX latest edition
Welder qualification Test 100% WPS/PQR/ASME SEC.IX ( Latest Edition) P,RPT H R,RAN RPT Statutory approval, wherever applicable
Weld finish- root/Final passes 1. ASME SEC.IX ( Latest Edition)
100% P,RPT W,RAN - RPT Statutory approval, wherever applicable
visual 2. WPS/PQR
Non- Destructive Test As applicable Piping Spec/ Code, Approved procedures P,RPT W,RAN R,RAN RPT Statutory approval, wherever applicable
Monitor temp/ Review of SR
Stress relieving As applicable Approved procedure for Stress relieving P,RPT W,R - RPT Statutory approval, wherever applicable
Charts
Monitor using temperature
Pre-heating / Post-heating As applicable Approved WPS/PQR P R - NR Statutory approval, wherever applicable
crayons
2.9 Pickling & Passivation Visual 100% Piping Spec/ Code, Approved procedures P,RPT W - RPT
2.10 Process Checks Physical/ Visual 100% P&ID Assist W,RPT W,RAN RPT By Process Engineer
Testing
Procedure giving details of isolation
Review 100% Piping Spec/ Isometrics/ P&ID S,P R - RPT
plans, sequence of testing, preparation
2.11 of test loops, testing pressure etc
Carry out air/ water flushing Witness/ Visual 100% Good Engineering Practice P,RPT W W,RAN RPT
Carry Out pneumatic/ Pressure test Monitor/ witness 100% Piping Spec/ Code, Approved procedures P,RPT W W RPT
Drain the testing medium Visual 100% P W - NR
Flushing with water, air, cardboard
2.12 blasting etc., and Box-upas per process Visual 1005 Process Spec P,RPT W - RPT
requirement
Safety
Quantity/ Quantity by physical
100% Relevant Indian standards as per annexure Yes R,RAN R,RAN NR
Personal protective Equipment and verification
Gadgets

ITP 7 OF 8
 INDICATIVE INSPECTION TEST PLAN FOR MECHANICAL WORKS TAN GOPALPUR

CHECK / INSPECTION CATEGORY/ PERFORMED BY REMARKS

TYPE OF
S.NO ACTIVITY / DESCRIPTION REFER STD.DOC./ NORMS OF ACCEPTANCE CONTRAC
TYPE SCOPE/ EXTENT STL/TCE/TPI PMC/CLIENT RECORD Rev R0
TOR
Test Certificate, in accordance with the requirements spelt
Ensuring good quantity erection aids , Visual/ Scrutiny of test
100% for Major items out under Section -29 of the factorises sct,1948 ( Latest S R R,RAN TC
Wire ropes Slings etc Certificate
Edition)
Scrutiny of test/ fitness Fitness certificate, load charts etc in accordance with the
Safe Load carrying capacities of crane,
certificates including their 100% requirements spelt out under Section -29 of the factories S R - CERT.
2.13 winches, derricks etc.
Validity act,1948 ( latest edition)
Fire extinguishers Type/ Quantity/ Expiry date 100% IS 2190 Yes R,RAN - -
Scrutiny of medical fitness
Crane Operators vision, hearing ability, ANSI/ ASME B 30.5 Latest edition
certificate 100% S R - RPT It is a Statutory requirement
driving licence etc.
Review of driving licence Motor Vehicle Act & Motor Vehicle rules

Prevent unauthorized entry of personnel Critical erection to be scheduled on holidays or

Physical/ Visual As applicable - Yes RAN - -
at the erection venue during erection before 9.am
Any other Yes RAN - -
Mark -up of As built dimensions on
2.14 Yes R - DRGS
related drawings

LEGENDS
H - HOLD POINT( Further steps shall commence only after clearance from STL/TCE- as applicable)
M - MONITOR
NR - RECORDS OPTIONAL
P - PERFORM
R - REVIEW & APPROVE
RAN - RANDOM
RPT - REPORT
S - SUBMIT
TC - TEST CERTIFICATE
W - WITNESS & APPROVE
TPI - THIRD PARTY INSPECTION AGENCY

ITP 8 OF 8