08. inspection & test plans.pdf
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This Inspection and Test Plan covers the minimum testing requirements of Orifice plates & Flanges, Meter Run assemblies, Flow Straightner
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Material Inspection
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Procedures
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Chemical , Mechanical Properties, Heat Treatment
Chemical , Mechanical Properties, Heat Treatment.
Welding procedure Qualification for welding
involved in Multistage orifice
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Calibration for multi element temperature sensor.
Calibration for water interface probes.
Functional test for RIU (Remote Interface Units)
Pressure test on float
Load driving capability check on transmitter
Certificate from approving authority like BASSEFA, FM, PTB, UL, CMRI, etc. for use in specified hazardous area.
BIS approval for explosion proof construction of instruments enclosure manufactured indigenously.
Statutory approval certificates for transmitter and electronic indicator from PESO for use in specified hazardous area.
Degree of protection certificate (IP) for
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Electromagnetic compatibility certificate
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STAGE/ ACTIVITY
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Hydro test on snubbers/gauges savers(as a licable)
Calibration, Overpressure, Hysteresis, Accuracy
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Reviews of Intemal Test Reports
Degree of protection certificate for enclosure
IC issuance
Type tests:
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Shock test
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Supplier's Test Records and
NDT reports /
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Supplier's Test Records
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Material Test Certificates / Test Lab Certificates
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Review of Intemal Test Reports &MTC
Bought out items/accessories TC
IC issuance.
Special cleaning and packing for oxygen and
chlorine services
Pre treatment, primer and final paint, shade, thickness.
Capacity Test as per ASME
Blow Down
Cold Bench Set Pressure
Seat Leakage Test
Valve Lift test
Reclosing pressure test
Helium Leak test (if specified)
CHARACTERISTICS
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Inspection Witness Record
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3 20.09.13 Revised and Reissued MJ RS
2 22.03.12 Revised and Reissued MJ GS
1 09.05.08 Revised and Reissued RB SKD
0 09.12.02 Issued for implementation RG AKC
Rev. No. Date Purpose
Prepared by
Checked by
SCG
AKC DM
SKP VC
AKB GRR
Standards Committee Standards Bureau Convenor Chairman
Approved by
,r..1 ENGINEERS
$4fgar ta5ie-G INDIA LIMITED
are, torOtennundivi/ (A Govt of India Undenakingi
INSPECTION AND TEST PLAN FOR
CONTROL VALVES
STANDARD SPECIFICATION NO.
6-81-2031 Rev. 3 Page 1 of 6
cprOd iViuur atrtaTur z1)79-1
INSPECTION AND TEST PLAN FOR
CONTROL VALVES
Copyright EIL All rights reserved Format No. 8-00-0001-F7 Rev. 0
Page 3337 of 3574
-
ei INSPECTION AND TEST ENGINEERS PLAN STANDARD SPECIFICATION NO.
6-81-2031 Rev. 3 Page 2 of 6
FOR OgZ1T f615tes iire71 ,ecnre ,ros.)
INDIA LIMITED (A Govt of India Undertaking) CONTROL VALVES
Abbreviations AS Alloy Steel MRT Mechanical Run Test BASEEFA British Approval Service for Electrical Equipment in Flammable MPT/MT Magnetic Particle Testing
Atmospheres MTC Material Test Certificates BIS Bureau of Indian Standards MOC Material of Construction CCE or CCOE Chief Controller of Explosives NPSH Net Positive Suction Head CEIL Certification Engineers International Limited NDT Non Destructive Testing CIMFR Central Institute of Mining & Fuel Research NEMA National Electrical Manufacturers Association CE Carbon Equivalent PO Purchase Order DFT Dry Film Thickness PESO Petroleum Explosive Safety Organization DT Destructive Testing PQR Procedure Qualification Record DP or DPT Dye Penetrate Testing PR Purchase Requisition ERTL Electronics Regional Test Laboratory PMI Positive Material Identification FCRI Fluid Control Research Institute PTB Physikalisch-Technische Bundesanstalt FM Factory Mutual QC Quality Control FLP Flame Proof RT Radiography Testing HART Highway Addressable Remote Transducer SS Stainless Steel HV High Voltage TC Test Certificate ITP Inspection and Test Plan TPI or TPIA Third Party Inspection Agency IP Ingress Protection UT Ultrasonic Testing IC Inspection Certification UL Under writer Laboratories IR Insulation Resistance VDR Vendor Data Requirement IEC International Electro technical Commission WPS Welding Procedure Specification JEC Japanese Electro technical Committee WPQ Welders Performance Qualification LPT Liquid Penetrate Testing XLPE Cross Linked Poly Ethylene
Inspection Standards Committee
Convenor : Mr. S C Gupta
Members: Mr. R.K. Singh
Mr. Rajeev Kumar Mr. Himangshu Pal Mr.Neeraj Mathur Mr. T Kamalakannan
Mr. Deepak Gupta (Project) Mr. Mayank Jain
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL All rights reserved
Page 3338 of 3574
-
STANDARD SPECIFICATION NO.
2.reaVU 07 6-81-2031 Rev. 3
Page 3 of 6
INSPECTION AND TEST PLAN FOR
CONTROL VALVES
k_111i tel ENGINEERS
1::g-af Of&leg INDIA LIMITED IA Govt of India UndellakIng)
1.0 SCOPE
This Inspection and Test Plan covers the minimum inspection and testing requirements for Control valve.
2.0 REFERENCE DOCUMENTS
PO/PR / Standards referred there in /Job specifications / Approved documents.
3.0 INSPECTION AND TEST REQUIREMENTS
SL NO. STAGE/ ACTIVITY CHARACTERISTICS
QUANTUM OF CHECK RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER EIL/TPIA
1.0 Procedures -- -- -- -- -- --
1.1 WPS/PQR/WPQ Welding procedure Qualification for welds,
overlays as applicable 100% WPS PQR WPQ
-- H W (New)
R (Existing)
2.0 Material Inspection
2.1
Incoming Material like Forgings & casting for body/ bonnet, wetted parts like plug, Seat, cage, Stem.
Accessories such as Positioners, I/P Converters, Solenoid valves, Limit Switches and Air filter Regulators etc.
Chemical & Mechanical Properties, HT
Make, model no, functional check.
100% Material Test Certificates / Test Lab Certificates
H H R
3.0 In process Inspection
3.1 Stellited & Hardened Trim (As specified ) D P Test
100% Supplier's Test Records H R
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL All rights reserved
Page 3339 of 3574
-
L31 ENGINEERS
1=g-ar iatit'dg INDIA LIMITED
etrwtrJn :Igo.), (A Govt of India Undertaking)
INSPECTION AND TEST PLAN FOR
CONTROL VALVES
STANDARD SPECIFICATION NO.
6-81-2031 Rev. 3 Page 4 of 6
SL NO. STAGE/ ACTIVITY CHARACTERISTICS
QUANTUM OF CHECK RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER EIL/TPIA
4.0 Final Inspection
4.2 NDT , Post Weld Heat Treatment (PWHT) ( If specified)
Radiography for weld joints Dye Penetration test. Post Weld Heat Treatment of welds,
100% NDT reports / PWHT chart - H R
4.1 Final Inspection on assembled Valve
Visual / Dimensional check Hydrostatic test. Helium leak test ( if specified). Check for valve characteristics like stroke,
Linearity & Hysteresis, etc. Functional tests including :
i) Seat leakage test, lift characteristics. ii) Test on smart positioners. iii) Control valve dynamic response and response time verification.(If specified) iv) Test on Accessories.
Interoperability test for Field bus positioners. Pneumatic test on actuator on representative
samples. Type test for valves in cryogenic service.(if
specified) Partial stroke test / valve signature capability of smart and field bus transmitters
to accept multimeters and check for
configuration, calibration, diagnostics through Hand Held terminal.
100% Inspection Witness Record - H RW
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL All rights reserved
Page 3340 of 3574
-
STANDARD SPECIFICATION NO.
1.171 21,1Tre 0,1 JVCASO 6-81-2031 Rev. 3
Page 5 of 6
INSPECTION AND TEST PLAN FOR
CONTROL VALVES ENGINEERS
ig- r INDIA LIMITED (A Govt of India Undertakngi
SL NO. STAGE/ ACTIVITY CHARACTERISTICS
QUANTUM OF CHECK RECORD
SCOPE OF INSPECTION SUB
SUPPLIER SUPPLIER EIL/TPIA
4.3 Submission of certificates/document
Certificate from testing agency like BASEEFA, FM, PTB, CIMFR etc. for accessories like solenoid valves, FP converters, Limit switches etc. for use in specified hazardous area.
BIS approval for explosion proof construction of above accessories manufactured indigenously.
Statutory approval certificates for instruments from CCOE/PESO for use in specified hazardous area.
Degree of protection certificate (IP) for instrument housing.
Fire Safe Certification as applicable.
Prototype for each model
Statutory Approval
Certificates / Type Test
Certificates
- H R
5.0 Painting
5.1 Packing
Cleaning for oxygen and chlorine services. Suitable protection to prevent entry of
foreign material. Lubrication for valves, which require
external lubrication.
100% Test Records - H -
6.0 Documentation and IC
6.1 Documentation and IC Review of Internal Test Reports, MTC Issuance of Inspection Certificate 100%
/ Supplier Test Records / IC - H H
6.2 Final Document submission Compilation of Inspection reports ,drawings, etc as per VDR / PR 100%
Final data folder /Completeness
certificate - H H
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL All rights reserved
Page 3341 of 3574
-
STANDARD SPECIFICATION NO.
IsTrrn riemrc' 131 6-81-2031 Rev. 3
Page 6 of 6
INSPECTION AND TEST PLAN FOR
CONTROL VALVES
raeit-s ENGINEERS
5fgar fai,les INDIA LIMITED IA Govt of Incha Unclettakng)
Legends: H- Hold (Do not proceed without approval, R- Review, RW-Random witness (As specified or 10 % - Samples must include min 1 No of each type), W- Witness (Give due notice, work may proceed after scheduled date). NOTES :-
1. This document describes the generic test requirements. Any additional test or inspection scope if specified in contract documents shall also be applicable. (Unless otherwise agreed upon).
2. Acceptance Norms for all the activities shall be as per PO/PR/ Standards referred there in/ Job specifications /Approved documents
Format No. 8-00-0001-F7 Rev. 0 Copyright EIL All rights reserved
Page 3342 of 3574
-
STANDARD SPECIFICATION NO.
6-81-2032 Rev. 3
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Revised and Reissued 22.03.2012
Issued for implementation
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,
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STAGE/ ACTIVITY
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In process Inspection
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g)
Detection of plugged impulse lines & output configuration (for fieldbus transmitter)
h)
Display of inbuilt control algorithm (fieldbus transmitter)
PID operation check for controllers.
Transmitter power supply check for receiver instruments.
Response Time check
Protection against short circuit & reverse voltage.
Zero elevation /suppression test for level transmitter
Bump less transfer check for controllers from manual to auto mode and vice-versa.
PID operation check for controllers.
Accessories check including air filter regulators, mounting accessories etc.
Certificate from testing agency like BASSEFA, FM, PTB, CMIFR, etc. for instruments for use in specified hazardous area/ fisco approval for fieldbus transmitter.
BIS approval for instruments manufactured
indigenously for use in specified hazardous area.
Statutory approval certificates for instruments from /PESO for use in specified hazardous area.
De ree of I rotection certificate for
STAGE/ ACTIVITY
Submission of certificates / Documents
a c:3 z (--, 4 1
Page 3347 of 3574
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STANDARD SPECIFICATION NO.
6-81-2032 Rev. 3
En c/) A z
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Packing list / Supp lier ' s Records
Supplier's Test Records / Inspection Certificate
Final data folder /Completeness
certificate
QUANTUM OF CHECK
.
.
.
. .
.
CHARACTERISTICS
instrument housing.
Interoperability test certificate for field bus transmitter
Certificate for electromagnetic compatibility and transient protection as per IEC 61000-4 Certified values of failure rates, probability of failure
on demand (PFD) and test intervals for safety Inte:ri level (SIL) analysis.
Special cleaning and packing for oxygen and chlorine services
Review of Internal Test Reports, MTC
Device Description files
IC issuance.
Compilation of Inspection reports ,drawings, etc as per VDR / PR
STAGE/ ACTIVITY
Painting
.
_
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Documentation and IC
Documentation and IC
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Certificate from testing agency like BASEEFA, CSA, FM/UL, PTB, CIMFR etc. for compliance to applicable hazardous areas for electrically operated items.
Statutory approval certificates for instruments from PESO for use in specified hazardous area.
Cryogenic service test certificate as per applicable specification, if specified.
Fire safe test certificates for fire safe valves as per applicable specification, if specified
NDT as applicable
Visual and Dimensional checks.
Hydrostatic test on all valve bodies.
Pneumatic test on actuators.
Valve stroke Test / functional test
Manual Valve test
Partial Stroke Test / Valve Signature
Seat leakage test
Open-Close operation time
Cryogenic test if specified
Helium leak test if s secified
Check for hardness
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Pre treatment, primer and final paint, shade, thickness.
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High Voltage Spark test Conductor resistance.
Armour resistance test. (for mining cables).
Mutual capacitance and capacitance between any core or screen.
Inductance and L/R ratio.
Dimension checks, Laying of cores, Pair twisting, Shield overlap.
Conductor Resistance, Drain Wire Resistance.
Insulation resistance .
High Voltage.
Armour resistance test (for mining cables).
Test for rodent and termite repulsion.
Mutual capacitance and capacitance between any core or screen.
Inductance & L/R ratio.
Thickness of insulation and sheath.
Tests on Insulation and Sheath as per IS/IEC *
Uniformity of Zinc coating on armour.
Oxygen and Temperature Index
FR test as per IS 10810 part 61.
Acid .eneration test as er IEC ( for fire
STAGE/ ACTIVITY
Final Inspection
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resistance cable)
Smoke density test ( for fire resistance cable)
Overall finish and Drum length check.
Fire survival test (if applicable )
FR test as per IS-10810 part 62.
Fire resistance test as per IEC 331 (If applicable).
Electrostatic Noise Rejection.
Visual, Packing list.
Proper packing to avoid any damage during transportation.
Review of Internal Test Reports (Routine, acceptance, type), MTC.
IC issuance.
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Painting
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Statutory approval certificates for instruments from PESO for use in specified hazardous area.
Degree of protection certificate for instrument housing.
Visual, dimensional, clearance & Paint shade check for all items.
Verification of Terminal Nos., sizes and no. of entries
Bill of material verification.
Warning plate for junction boxes and marking on cable glands, Adapters, Plugs etc.
Pressure test on casting for flameproof junction boxes.
High Voltage and insulation resistance test.
Air leak test report on pneumatic JBs.
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3.0 INSPECTION AND TEST REQUIREMENTS:
PO/PR / Standards referred there in /Job specifications / Approved documents.
This Inspection and Test Plan covers the minimum inspection and testing requirements for Instrument Tube Fittings.
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Sampling as per
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Performance test and supplementary test as per ASTM
Examination of Specimen
Pneumatic proof test
Hydrostatic proof test
Impulse test
Flexure fatigue test
Tensile test
Burst test
Repeat Assembly
Rotary Flexure test
Mecurous Nitrate test (if applicable)
Thermal Cycling test
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Torsion Test
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Fire test
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6-81-2068 Rev. 3
STANDARD SPECIFICATION NO.
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Product markings on tubes / label.
Hardness/ Tension test for SS tube.
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