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QAP. No. : HDO/QAP/8164-75 REV.01 DTD. 12.10.2010 CLIENT : TECHNIP KT INDIA LTD.(NOIDA)

HDO Ref No. : BYC 210968 PROJECT : HGU FOR DHT PROJECT

P.O.NO. : 00774 91 PO 0610 02 10588 R0 DT.05/05/2010 INSPECTION BY : M/S. TECHNIP/TPIA

INSPECTION CATEGORY - A

SR.NO ITEM NO HDO JOB NO

1 91-E-26 8164

2 91-E-27 8165

3 91-E-28 8166

4 91-E-21 8167

5 91-E-01A/B 8168A/B

6 91-E-05A/B/C 8169A/B/C

7 91-E-06 8170

8 91-E-08 8171

9 91-E-31A/B 8172/73

10 91-E-32 8174

11 91-E-33 8175

S.R. INSPECTION CHARACTERISTICS QUANTUM REFERENCE ACCEPTANCE STD. FORMAT OF HDO TPI

NO. ACTIVITY & COMPONENT OF CHECK DOCUMENT REPORT

1.0

Visual & Dimensional PR/ASME SEC.IIA, PR/ASME SEC.IIA,

Pressure parts IIB/SEC.VIII DIV.1/ IIB/SEC.VIII DIV.1/

(Plates, Pipes) - Co-relation of markings with TEMA-R/APPD DRGS/ TEMA-R/APPD DRGS/

1.1 (To be procured from Approved Vendor test certificates. MANUFACTURER'S MANUFACTURER'S Inspn. Report W W

list attached with MR) - Chemical and Physical TEST CERTIFICATES TEST CERTIFICATES

Inspection At HDO's works properties. EN 10204 EN 10204

- Transfer of identification TYPE 3.2/3.1 TYPE 3.2/3.1

marks, wherever required. Approved TPS Approved TPS

Bought out items (forgings, Tubes Chemical & Physical properities ASME Sec IIA / ASME Sec IIA /

1.2 Fittings,) inspection at Vendor's Works Review of test certificates / 100% VIII Div.I / TEMA-R / VIII Div.I / TEMA-R / Insp. Report

(To be procured from Approved Vendor ) PR/Spec/Drawings PR/Spec/Drawings

Fasteners and Gaskets Chemical & Physical properities ASME Sec IIA / ASME Sec IIA /

1.3 Inspection at HDO's Works Review of test certificates / 100% VIII Div.I / TEMA-R / VIII Div.I / TEMA-R / Insp. Report

(To be procured from reputed Mfgrs) PR/Spec/Drawings PR/Spec/Drawings

Non Pressure Parts (including internals, Chemical & Physical properities ASME Sec IIA / IIB / ASME Sec IIA / IIB /

1.4 supports, baffles, sliding plate etc.) Review of test certificates / 100% VIII Div.I / TEMA-R / VIII Div.I / TEMA-R / Insp. Report

Inspection At HDO's works Check test report. PR/Spec/Drawings PR/Spec/Drawings

2 WELDING BOOK

2.1 Weld Map Welding procedures 100% ASME Sec IX /Spec. ASME Sec IX /Spec. WPS W R

New-W

Old-R

ASME Sec IX /Spec./ ASME Sec IX /Spec./ WPQ

Drawings Drawings

of 3

INSPECTION AND TEST PLAN FOR HEAT EXCHANGERS

GENERAL APPLECABLE SPECIFICATION : 00774-91-SP-0610-02, E-102, D-123, O-301-A, D-102

EQUIPMENT NAME SPECIFIC APPLICABLE SPECIFICATION

PROCESS BFW PREHEATER I (Refer Note-1)

CLEAN BFW PREHEATER I (Refer Note-1)

DEMIN WATER PREHEATER (Refer Note-1)

NAPHTHA VAPOURIZER (Refer Note-1)

SOUR NAPHTHA PREHEATER- I 00774-91-SP-0800-001,003 & 004 (Refer Note-1)

FEED PRODUCT EXCHANGERS 00774-91-SP-0800-001,003 & 004 (Refer Note-1)

STRIPPER REBOILER 00774-91-SP-0800-001 & 004

SOUR NAPHTHA PREHEATER II 00774-91-SP-0800-001 & 004 (Refer Note-1)

FUEL NAPHTHA VAPOURIZER ------

FUEL NAPHTHA SUPERHEATER ------

N2 HEATER (Refer Note-1)

MATERIALS INSPECTION

100%

W W

SCOPE OF INSPECTION

2.2 WPS/PQR/WPQ Welding parameters 100% ASME Sec IX /Spec. ASME Sec IX /Spec.

Qualification Requirement 100% W

W R

W R

R

WPS/PQR W

2.3Mock up Procedure for

tube-to-tubesheet joint (Note-2)

TECHNIP TOYO

This document is electronically generated, Signature is not required.

S.R. INSPECTION CHARACTERISTICS QUANTUM REFERENCE ACCEPTANCE STD. FORMAT OF HDO TPI


3

Weld Edge preparation & set up of Visual & Dimensional W-FOR FIRST

Major pressure parts like L/S, C/S inspection,Marking, 100% Spec./Drawings Spec./Drawings Insp. Report L SEAM or

(PTC to be provided if applicable as per WEP, Offset, Ovality,etc ASME SEC VIII Div.1 ASME SEC VIII Div.1 C-SEAM

CL. No. IN 42.0 of AXENS Spec. ) Sound metal after backchipping 100% Spec./Drawings ASME Insp. Report

Sec V/ VIII-1 Sec V / Sec VIII-1

WEP, Dimensions, completeness Spec./Drawings Spec./Drawings Insp.

of assembly Sec V/ VIII-1 Sec V / Sec VIII-1 Report

Inspection of Completed welds Visual inspection for Drawings/ Spec / Drawings/ Spec / Insp. Report

reinforcement, Undercuts, 100% ASME Sec VIII-1 ASME Sec VIII-1

Weld bead, surface defects etc.

RADIOGRAPHY EXAMINATION OF WELDS Soundness of Full Weld As per Drg. Drawings/ Spec / Drawings/ Spec / NDT Report

(As per Approved Drgs.) ASME Sec VIII-1/ V ASME Sec VIII-1 / V Reviewe

of RT films

Visual and Dimensional Insp.shell/ch.shell Dimensions, completeness 100% Drawings/ Spec / Drawings/ Spec / Insp. Report

Assl.(Internals & externals) of assembly ASME Sec VIII-1/ V ASME Sec VIII-1/ V

positive Material Identification Alloying Element check in As per TOYO Spec./Drawings Spec./Drawings Insp. Report

(Applicable for SS Materials) Parent metal & weld spec. & Sec.II part 2a & Part C Sec.II part 2a & Part C

Ferrite check of SS welds Appd.Proc. Approved Procedure Approved Procedure

3.8 NDE After PWHT (If Applicable) Note-5 Soundness of weldsAs per Drg./

NDE MAPDrawing/Spec

Drawing/

ASME SEC-VIII-1Insp.Report W W(10%)

4

Visual & Dimensional 100% Drawings/Spec. Drawings/Spec. Insp. Report

inspection, Thickness & Profile check. ASME SEC.VII Div.1 ASME Sec.VIII-1

100% ASME Sec.VIII Div.1/ ASME Sec.V/

SEC.V/Spec. Spec.

Dished ends/ formed components PT Examination 100% ASME Sec.V ASME VIII Div.I

On Inside & Out side KR,SF & EDGE Spec./Drawings & Sec.V. Spec./DRG Insp. Report

HT chart review ASME Sec.VIII-1 ASME Sec.VIII-1 HT Chart

If applicable 100% /Spec./DRG/Appd.Drg. /Spec./DRG

Test Coupon (If applicable) 100% Spec./Drawings. ASME Sec.VIII Div.1 Insp. Report W R

5

Tube sheet Maching/ Drilling Hole Dia/PPCD/Ligament/Layout 100% Drawings/ Spec / Drawings/ Spec /

OTL/Steps/OD/Thk./Grooving/Hole Finish TEMA TEMA

Inspection of Tube To Tube Sheet joint % of expansion Drawings/ Spec / Drawings/ Spec /

Welding/expansion 100% PT for Root, First & Final layer 100% ASME Sec VIII-1 ASME Sec VIII-1 Insp.Report

TEMA TEMA

Inspection of Tube Bundle before visual & Dimensional inspection 100% Drawings/ Spec / Drawings/ Spec / Insp.Report

Instertion into the shell As per Approved DRG. TEMA TEMA

Main shell inside surface inspection Insde flush of nozzle conn & 100% Drawings/ Spec / Drawings/ Spec / insp. Report

before tube Bundle instertion in to shell cleaniness of shell

INSPECTION AND TEST PLAN FOR HEAT EXCHANGERS of 3

INSPECTION DURING FABRICATION

3.1

W

W R

3.2Assembly of Nozzles

100% W R

3.3 W W

3.4 W FILM REVIEW

3.5 W W

3.6 W W

3.7PWHT OF SHELL/CH. SHELL

(As per approved drawings)

Heating Time

Cooling Time

Soaking Time & Temp.

100%ASME SEC VIII Div.1

Drawing/Spec

Drawing/

ASME SEC-VIII-1

Insp.Report/

PWHT CHARTW R

INSPECTION OF FORMED COMPONENT

4.1

W W

RT of weld seam (If applicable) RT Report WFILM

REVIEW

W W

W R

INSPECTION OF TUBE BUNDLE

5.1 Insp.Report W W

5.2 W RW

5.3 W W

5.4 W W

TECHNIP TOYO

SCOPE OF INSPECTION


S.R. INSPECTION QUANTUM REFERENCE FORMAT OF HDO TPI


6

6.1Soap Suds test of RF PADS at Test

Pressure as per Appd.Drg. Leak checking 100%

Drawings/Spec.

ASME SEC VII Div.1

Drawings/Spec.

ASME SEC VII Div.1 Insp. ReportW W

Leak test of Tube To Tube sheet Leak checking from TTS jointjoint weld/Expansion 100% Insp. Report

Hydrostatic test as per Appd Drg. leak Check 100% Drawings/Spec./ Drawings/Spec./ Insp.

Shell Side ASME Sec.VIII-1 ASME Sec.VIII-1 Report

Tube Side Appd.Procedure Appd.Procedure

Drying of equipment Cleanliness of Shell side Drawings / Spec. Drawings / Spec. Insp.

Shell Side/Tube Side Tube side Report

Pickling & Passivation of SS parts Visual inspection afer 100% Drawings / Spec. Drawings / Spec. Insp.

Pickling & Passivation Appd.Procedure Appd.Procedure Report

Surface preparation/cleaning Visual insp for Drawings./Spec. Drawings./Spec.

workmanship 100% Appd.Procedure Appd.Procedure Insp. Report

Painting Visual insp & DFT Measurement 100% Drawings./Spec. Drawings./Spec. Insp. Report

Spare Item Varification Mandatory spare varifed as per 100% Drawings./Spec. Drawings./Spec. Insp. Report

Spares shall include in IRN DRG.

Final Stamping of equipment and Verifying stamping details Name plate Name Plate/

marking etc. & Rub off Drawings / Spec. Drawings / Spec. Rub-Off

Nitrogen Filling N2 pressure & non return Full Drawings/Spec. Drawings/Spec. Insp.

( If required as per Drg.) valve. exchenger Report

DOCUMENTATION Verification & Compilation

of inspection & test records 100% Spec. (VDR) Spec. Q.C. Dossier

and other documents with Index

NOTES : 1 ) For Above Mentioned items Hydrogen service is required. All requirement as per Clause no.3.8.10 of D-102 shall be followed.

2) In absence of old mock up procedure New mock up procedure shall be carried out under TPIA.

6) After PWHT, hardness of base metal, weld metal & HAZ shall be checked (225 BHN Max.) except exchanger under HIC/H2S services (For HIC/H2S service, Hardness shall be 200 BHN Max.)

8) NDE Shall be performed as per Approved NDE MAP.

9) All areas where temporary attachment was welded and removed shall be examined by MT or PT.

10) Chloride content of water used for Hydro test shall have <100ppm for CS/LAS material and <30 ppm for austenitic stainless material.

11) Inspection Requirements of Appendix-B of E-102 shall be followed as applicable. Main dimensions of HE shall be checked after PWHT

12) welding surface shall be inspected by PT after hydrostatic test for all SS HE's and CS HE's ( base metal thk>38 mm or 100% RT is specified)

HOLD -H : MANDATORY INSPECTION POINT WORK SHALL NOT PROCEED FURTHER WITHOUT THE PRESENCE OF THE REPRESENTATIVE OF THE TPI.

WITNESS-W :I NSPECTION POINT OF THE HDO-QC IN CASE THE REPRESENTATIVE OF THE TPI DOES NOT ATTEND WITHIN AGREED PERIOD.

REVIEW-R : THE ENTAILS REVIEW OF APPROPRIATE DOCUMENTATION.

LEGENDS : H - HOLD H.T. - HEAT TREATMENT R/W - REVIEW OR WITNESS

W - WITNESS R.T. - RADIOGRAPHIC TEST RW - RANDOM WITNESS

R - REVIEW U.T. - ULTRASONIC TEST TPIA - THIRD PARTY INSPECTION AGENCY

A - APPROVAL T.C. - TEST CERTIFICATES

INSPECTION AND TEST PLAN FOR HEAT EXCHANGERSPAGE 3 OF 3

CHARACTERISTICS ACCEPTANCE STD.

TESTINGS

6.2

Drawings/Spec.

ASME SEC VIII Div.1

Appd.Procedure

Drawings/Spec.

ASME SEC VII Div.1

Appd.Procedure

W W

6.3 W H

`7.0 W R

`8.0 W R

`9.0 W R

`10.0 W W

`11.0 W +

`14.0 W H

4) Inspection of major bought out items like Plates, Tube sheet, Girth flanges and Fittings shall be carried out at sub vendor's work under TPIA

`12.0 W H

`13.0 w R

PREPARED BY REVIEWED BY APPROVED BY

P.V.CHAUDHARI R.R.SHARMA

SR. ENGINEER (HDO, A'BAD) SR. MANAGER (Q.C.) HDO, A'BAD TECHNIP

TECHNIP TOYO

7) For Tag NO. E-01A/B. E-05A/B/C, E-06 & E-08, The Tests specimen, subjected to anticipated heat treatment cycle, are taken through the thickness and the said reduction shall not be less than35% of the initial cross section as pe ASTM A770

3) Where AXENS Spec. IN-042.0 Applicable and PWHT required in the job, Simulation Tensile shall be carried out after Actual PWHT cycle plus one additional cycle & Simulation Impact shall be carried out after Actual PWHT cycle

For major Bought out items such as plates,Pipes,Forgings, Tube sheet, Girth flanges and Fittings only as per Clause No.5.0(Inspection and Testing) of 00774 -91-SP-0610-02 Rev.0

5) UT after PWHT required where thickness of butt weld is 50 mm (for CS) and 38mm (for SS).


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