Third Party Inspection for Fire Tube Boiler - Procedure

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The Third Party Inspection for Fire Tube Boiler article provides a sample inspection and test
procedure for fire tube boiler in manufacturing shop. This might be reviewd with fire tube boiler
inspection and test plan.

This content guides you about all necessary stages in the production of the fire tube boilers from
the examination of certification of procurement sources to the final inspection, preservation and
packing to despatch to site.

You need to take this point in account this article is written for a typical Fire Tube Boiler and might
not be complete for special cases.

All Fire Tube Boiler inspections and tests are carried out against the approved drawings, purchase
order specifications, purchasers or company standards, and within the practices and rules of the
country, state or province and any government decrees, laws, ordinance or regulation as may
apply.

The applicable codes and specifications for the Fire Tube Boiler which is under construction
process are:

Design code
Purchase order specification
Purchaser's standards
Approved drawings

And the applicable codes and standards are:

ASME I
ASME V
ASME IX

The applicable codes and standard may be based other international standards such as BS 2790
and etc. This content is general and can be useful if even the design code is different from ASME
Code.

Required Documents for Third Party Inspector Review:

The list of documents normally is agreed in the Pre-Inspection meeting which is hold several weeks
before actual commencement of inspection work. The parties which are participated in this meeting
are manufacture, purchaser and third party inspection agencyrepresentatives.

These are the list of documents which are normally agreed to be presented to the inspector:

Fire Tube Boiler Manufacture Quality Control Plan

Fire Tube Boiler Inspection and test plan
Fire Tube Boiler Data Sheet
Fire Tube Boiler Approved Drawings
Fire Tube Boiler Strength calculation sheets
Fire Tube Boiler Material Test Reports
 Fire Tube Boiler Welding Specification Procedures (WPS) and Procedure Qualification
Records(PQR)
Fire Tube Boiler Welding Map
Fire Tube Boiler Repair Procedure
Fire Tube Boiler Welders Qualifications Reports
Fire Tube Boiler NDE procedures (Radiographic test, ultrasonic test, dye penetration
test, magnetic particle test and positive material identification test)
Fire Tube Boiler NDE Personnel qualifications Reports
Fire Tube Boiler Heat treatment procedure
Fire Tube Boiler Calibration Certificates for Test Equipment
Fire Tube Boiler Hydrostatic Testing Procedure and Water Quality Document
Fire Tube Boiler Preparation and Painting Procedure
Fire Tube Boiler Preservation, Packing and Shipping Procedure
Fire Tube Boiler Packing List

Third Party Inspection for Fire Tube Boiler- Material Inspection

The first actual inspection work in the Fire Tube Boiler is the materials inspection. Based the ASME
Code providing material test reports for Fire Tube Boiler plates is mandatory, for other components
only the marking inspection will be enough.

But if purchase order has mandated the MTR to be provided for all components such as tubes,
nozzle pipes, fittings and etc. then the manufacture provides them as well.

As mentioned in above, the original or authenticated copies of mill certificates for plates normally
are available at manufacturer's premises.

The third party inspector examines these certificates for compliance with specifications and where
appropriate, drawings.

The review includes checks on:

Certificate No.
Heat or cast No.
Chemical composition.
Mechanical properties.
Heat treated condition.
NDE applied and results.

Then inspector witnesses the plate material identification on the certificates against plate marking.
It is also necessary to check with Fire Tube Boiler drawing datasheet, material list and other
specification as appropriate.

The transfer identification to cut off plates also is checked.

Visual inspection for surface finish and probable defects are done and dimensional compliance
with specification need also to be controlled.

When third party inspector carried out the material inspection, then provides inspection visit report,
the report contains following items:

Confirmation of satisfactory document review

Record of the endorsement of certification reviewed/witnessed
Record of all non-conformities
 Record of any tests witnessed and the result

Third Party Inspection for Fire Tube Boiler-Fabrication

When Fire Tube Boiler material inspection carried out and result was satisfactory or non-
conformities closed by remedial action, then Fire Tube Boiler manufacture will be authorised to
start fabrication.

The third party Inspector checks following points on Fire Tube Boiler based on the inspection and
test plan (ITP) which is already agreed between purchaser and Fire Tube Boiler manufacture.

The inspection scope is determined in ITP, some clients prefer to have stringent control and put the
TPI inspector in more “hold points or witness points” in fabrication activities and some others may
take lesser “hold points” and put TPI much more in the review document.

This depend to the inspection budget which client assign for inspection, much more inspection will
have much more costs and less risks and conversely less more inspection will have less costs but
more risks.

The fire tube boiler third party inspector checks following:

Review weld procedure approval test and welder competency test records to ensure both are
qualified in accordance with the code requirements.

Check plate identities and compare with mill certification details.

Witness the marking of test plates for identification before they are cut from the parent plate.

Inspect weld preparations in shell plates and end plates after forming. Ensuring that correct
test plates have been attached.

As applicable to the welding method used in accordance with the boiler manufacturers quality
plan visually inspect, Root runs on principal seams and plates, Completion of first side and
back-gouged groove and After completion of all welding

Examine results of non-destructive testing and review radiographs.

Witness required tests on previously selected test plates.

Visually inspect tacked weld set ups on standpipes and similar attachments and review after
completion of welding.

Final visual examination after completion of all work including witness of hydrostatic test and
internal/external examination. Review of heat treatment records.

Third Party Inspection for Fire Tube Boiler-Post Hydrostatic Test

After depressurisation, boiler spaces are drained and where necessary dried.

Third Party Inspection for Fire Tube Boiler - Final Assembly

The fire tube boiler is checked by third party inspector for completeness and dimensionally
examined to ensure that all attachments/supports are in the correct orientation.

Third Party Inspection for Fire Tube Boiler - Marking

Identification marks is checked by third party inspector and information stamped using low stress
type stamps on pressure parts.

Third Party Inspection for Fire Tube Boiler - Name Plate Checking

The third party inspector checks the Fire tube boiler name plate and makes sure:

Material is compatible.
Contents of marking are in accordance with approved drawing and specifications and
authority stamped as required.
Name plate is mounted on a bracket welded to a specified area of boiler, in accordance with
the code requirement.

Third Party Inspection for Fire Tube Boiler - Painting and Coating Inspection

Surface preparation for painting is checked for the following points, according to specification by
third party inspector:

Cleaning method (White metal cleaning or near-white metal cleaning)

Preparation grades /surface profile or roughness
Freedom from weld spatter, blow-holes and other defects
Cleanliness test after blasting(surface dust test)
Dry film thickness is checked according to specification

It is necessary surface condition to be free from pin-holes, runs damage and other discontinuity

Third Party Inspection for Fire Tube Boiler - Spares, Loose Items, Tools and Accessories:

The third party inspector controls spares, loose items, tools and accessories and makes visual and
dimensional inspection for materials, workmanship and quantity according to purchase order
specification and packing list.

Marking and/or Tag is checked for identification.

Third Party Inspection for Fire Tube Boiler - Reporting:

Third party inspector provides Inspection Visit Report (IVR) after each visit as well as a final report
summarising the activities carried out during the vessel production in accordance with the contract
requirements and circulated within the time limits specified in the contract.

The report is in the format required by the client and clearly indicates final acceptance or rejection
of the Fire tube boiler.

Third Party Inspection for Fire Tube Boiler - Release Note:

When required by the contract or purchase order a release note is issued by third party inspection
agency and given to the manufacturer when the fire tube boiler have been finally accepted.

Third Party Inspection for Fire Tube Boiler - Packing, Marking and Shipping:

The following points are checked by the third party inspector:

 Cleanliness and dryness of Fire tube boiler
Rust prevention for all machined surfaces
Protection for cover for all opening and protruding parts
Packing style and suitably for overseas transportation
Shipping marks and other markings and notification of welding prohibited, etc.

Third Party Inspection for Fire Tube Boiler -Final Book (Dossier)
The following final documents are reviewed and signed off by third party inspector:

As built, drawings if required, Manufacturer's data reports, Material certificate or certified mill test
reports for all pressure parts, Material list or map, Heat treatment records (Temperature-time record
chart during PWHT), NDE records, Hydrostatic test record, Hardness test record, Post weld heat
treatment NDE, if specified, Name plate or other marks, Packing list and Spare parts and tool list