DBB BNCPP B M v29 0015 Revb Ifa

Title:
INSPECTION AND TEST PLAN (ITP)
Doc. No.:
DBB-BNCPP-B-M-V29-0015
Rev.:
B
Date:
02.09.2015
Revision Sheet
REVISION
DATE
DESCRIPTION OF CHANGE
23-JULY-2015
Issued for Review
02-SEPT-2015
Issued for Approval
Hold List
HOLD NO.
DESCRIPTION
5.1 (Page 4)
RT status waiting for pending TQ.
5.1 (Page 5)
RT status waiting for pending TQ.
File Name: CCM-QCP-623- ITP
STATUS
Page:
2 of 6
INSPECTION TEST PLAN - GTC/GTG EXHAUST STACK for BARONIA PROJECT
Page: 03 of 06
PROJECT :
BARDEGG-2 & BARONIA
COMPANY :
PETRONAS
PURCHASER: HYUNDAI HEAVY INDUSTRIES CO LTD
TAG No. :
A-2401 / A-2402 (WHRU EXHAUST STACK) - 2units & GT7510 / GT7520 / GT7530 / GT7540 (GTG EXHAUST DUCT) - 4units
INSPECTION: HYUNDAI / PETRONAS
ITEM : GENERAL
Activity No.
CHARACTERISTIC
ITP NO. : CCM05/HHI/2015-03

REV. NO.
B
DATE : 02/09/2015
P.O. NO. : QD546BCQ1A
TYPE OF CHECK
QUANTUM OF
CHECK
REF.DOC.
ACCEPTANCE STANDARD
RECORD
SUB VENDOR
CERS
HHI
PCSB
Contract & Purchase Order
Contract & P.O (PO No.:

QD546BCQ1A)
Contract & P.O (PO No.:

QD546BCQ1A)
1. CONTRACT/PO REVIEW
1.1
Contract & PO Review
2. DOCUMENT APPROVAL
2.1
GA Drawings
Approval of Drawing
100%
GA Drawings (DBB-BNCPP-B-MV29-0005)
Approved Drawings
2.2
WPS/PQR and Welder

Qualifications
Approval of Procedure
100%
WPS/PQR and Welder Certificate

(DBB-BNCPP-B-M-V29-0021) /
CSP-18
Approved WPS/PQR and Welder

Certificate
2.3
NDE Procedure and Operator

Qualification
Approval of Procedure
100%
NDE Procedure and Operator

Certificate (DBB-BNCPP-B-M-V290017)
Approved NDE Procedure and

Operator Certificate
2.4
ITP
Approval of ITP
100%
Inspection & Test Plan (DBBBNCPP-B-M-V29-0015)
Approved Inspection & Test Plan
PIM
Project Specification
GAD,WPS/PQR,Welder
Qualification & ITP
PIM MOM
AS PER DRAWING/ ASME

Material Test Report / Mill
AS PER DRAWING/ ASME SEC.IISEC.II-A (EN10204 Type 3.1) &
Certificate. (CiTECH-QA-03P-01A)
A & PTS 15.10.11
PTS 15.10.11
3. PRE INSPECTION MEETING

3.1
ITEM : GTC EXHAUST STACK - 2 units

1. MATERIAL INSPECTION
1.1
Stainless Steel Materials
Visual,Chemical, Tensile,
Hardness & Heat Treatment
verified with Mill Certificate
100%
1.2
Expansion Joint
100%
AS PER DRAWING
AS PER DRAWING

1.3
Fastners ( Stud & Bolts)
Each Heat No.
AS PER DRAWING & PTS

30.10.02.11

30.10.02.11

1.4
Positive Material Identification
Stainless Steel Material
100%
PMI Report
As Per Drawing / ASME Sec.II-A As Per Drawing / ASME Sec.II& PMI Procedure (DBB-BNCPP-B- A & PMI Procedure (DBBBNCPP-B-M-V29-0048)
M-V29-0048)
REMARKS

TYPE OF CHECK
QUANTUM OF
CHECK
REF.DOC.
ACCEPTANCE STANDARD
RECORD
SUB VENDOR
CERS
HHI
PCSB
Measure of Dimension
100%
APPROVED CITECH DRAWING
APPROVED CITECH
DRAWINGS & QCP-08.
Fit-up & Edge Preparation of

Exhaust Stack Parts
Dimensions, Edge
Preparations & Alignment
100%
Approved CITECH Drawing
Approved CITECH Drawing
Fit-Up Report ( CITECH-QA-03P03A)
SW/R
Weld Map
Doc. Review
100%
Weld Map
As Per ASME SEC-II C / PTS

Spec. (PTS 31.22.20.31)
Consumable Certificate
CHARACTERISTIC
Activity No.
2. MARKING & CUTTING

2.1
Page: 04 of 06
Marking & Cutting of GTC

Exhaust Stack
3. FIT-UP & EDGE PREPARATIONS

3.1
4. WELDING
4.1
4.2
Welding Consumable
Doc. Review
100%

31.22.20.31, CSP-17
4.3
Welding Works
Check on Welding Parameter

and Visual
100%
As Per ASME SEC-XI / PTS

31.22.20.31 / CSP-14/15/16

Spec. (PTS 31.22.20.31)
Welding Summary Sheet
5. NON-DESTRUCTIVE TESTING (NDT)

5.1
Long Seam & Circ. Seam Butt

Welds
Radiographic Testing
100%
As Per SEC-V ,VIII Div-1 / PTS

31.22.20.31
As Per ASME SEC VIII Div-1

UW 51/ PTS 31.22.20.31
RT Films & Reports (GI-RT-ASME01)
5.2
Other Joints
Dye Penetrant Testing
10%

31.22.20.31
As Per SEC ASME VIII Div-1/

PTS 31.22.20.31
DPT Reports (GI-PT-ASME-01
R/M
Measurement of Dimension &

Welding Visual
100%
Approved CITECH Drawings
Dimensional Report & Visual

Report (CiTECH-QA-03P-09A)
Salt Test and Pull-Off Test
Each Paint
Specification
Painting Procedure (DBB-BNCPP- Painting Procedure (DBBTest Panel Report (Salt Test and
B-M-V29-0019) / PTS 30.48.00.31 BNCPP-B-M-V29-0019) & PTS
Pull-Off Test)
30.48.00.31
/ CSP-10
Painting Procedure (DBB-BNCPP- Painting Procedure (DBBB-M-V29-0019) / PTS 30.48.00.31 BNCPP-B-M-V29-0019) & PTS
30.48.00.31
/ CSP-09
6. FINAL DIMENSION & VISUAL

6.1
Completed Exhaust Stack
7. BLASTING & PAINTING

7.1
Test Panel
7.2
Blasting and Painting
Surface Preparation & Blasting

Internal Coating
100%
External Coating
Painting Report
8. FINAL INSPECTION
8.1
Visual & Cleanliness Inspection
GTC Exhaust Stack
100%
As Per Approved Drawing
Review of Stage Inspection

Report/Test Report
100%
As Per PTS 31.22.10.35
As Per PTS 31.22.10.35
All Relevant Doc. & Report
W/R
Packing List
Release Note by HHI
9. FINAL DOCUMENT
9.1
Quality Record Review
10. PACKING & SHIPMENT

10.1
Presevation & Packing

Inspection
Review of Packed Item and

Packing List
100%
10.2
Inspection Release Note
Issuance of IRN
Unpacking & Preservation

Procedure (DBB-BNCPP-B-M-V29- Procedure (DBB-BNCPP-B-MV29-0039)
0039)
As Per Approved Drawing &
Packing List

Packing List
REMARKS

ITEM : GTG EXHAUST STACK - 4 units
Activity No.
CHARACTERISTIC
TYPE OF CHECK
QUANTUM OF
CHECK
REF.DOC.
ACCEPTANCE STANDARD
RECORD
Page: 05 of 06
SUB VENDOR
CERS
HHI
PCSB
AS PER DRAWING/ ASME

AS PER DRAWING/ ASME SEC.IISEC.II-A (EN10204 Type 3.1) &
A & PTS 15.10.11
PTS 15.10.11
1. MATERIAL INSPECTION
1.1
Stainless Steel Materials
100%
1.2
Expansion Joint
100%
AS PER DRAWING
AS PER DRAWING

1.3
Fastners ( Stud & Bolts)
Each Heat No.

30.10.02.11

30.10.02.11

1.4
Positive Material Identification
Stainless Steel Material
100%
PMI Report
Measure of Dimension
100%
APPROVED CITECH
DRAWINGS & QCP-08.
GTG Exhaust Duct Parts
Dimensions, Edge
Preparations & Alignment
100%
APPROVED CITECH
DRAWINGS & QCP-08.
Fit-Up Report (CITECH-QA-03P03A)
SW/R
4.1
Weld Map
Doc. Review
100%
Weld Map
4.2
Welding Consumable
Doc. Review
100%
As Per ASME SEC-II C / PTS Spec.

(PTS 31.22.20.31)

Spec. (PTS 31.22.20.31)
Consumable Certificate
4.3
Welding Works
Check on Welding Parameter

and Visual
100%
As Per ASME SEC-XI / PTS Spec.

(PTS 31.22.20.31)

Spec. (PTS 31.22.20.31)
Welding Summary Sheet
As Per Drawing / ASME Sec.II-A As Per Drawing / ASME Sec.II& PMI Procedure (DBB-BNCPP-B- A & PMI Procedure (DBBBNCPP-B-M-V29-0049)
M-V29-0049)
2. MARKING,CUTTING & FORMING

2.1
Marking & Cutting of GTG

Exhaust Duct Parts
3. FIT-UP & EDGE PREPARATIONS

3.1
4. WELDING
5. NON-DESTRUCTIVE TESTING ( NDT )

5.1
Long Seam & Circ. Seam Butt

Welds
Radiographic Testing
100%

31.22.20.31
As Per ASME SEC VIII Div-1

UW 51/ PTS 31.22.20.31
RT Films & Reports (GI-RT-ASME01)
5.2
Other Joints
Dye Penetrant Testing
10%

31.22.20.31
As Per SEC ASME VIII Div-1/

PTS 31.22.20.31
DPT Reports (GI-PT-ASME-01
R/M
REMARKS

TYPE OF CHECK
QUANTUM OF
CHECK
REF.DOC.
ACCEPTANCE STANDARD
RECORD
SUB VENDOR
CERS
HHI
PCSB
Measurement of Dimension &

Welding Visual
100%
Dimensional Report & Visual

Report (CiTECH-QA-03P-09A)
Salt Test and Pull-Off Test
Each Paint
Specification
Painting Procedure (DBB-BNCPP- Painting Procedure (DBBTest Panel Report (Salt Test and
B-M-V29-0019) / PTS 30.48.00.31 BNCPP-B-M-V29-0019) & PTS
Pull-Off Test)
30.48.00.31
/ CSP-10
Painting Procedure (DBB-BNCPP- Painting Procedure (DBBB-M-V29-0019) / PTS 30.48.00.31 BNCPP-B-M-V29-0019) & PTS
30.48.00.31
/ CSP-09
CHARACTERISTIC
Activity No.
Page: 06 of 06
6. FINAL DIMENSION & VISUAL

6.1
Completed GTG Exhaust Stack
7. BLASTING & PAINTING

7.1
Test Panel
7.2
Blasting and Painting
Surface Preparation & Blasting

Internal Coating
100%
Painting Report
External Coating
8. FINAL INSPECTION
8.1
Visual & Cleanliness Inspection
GTG Exhaust Stack
100%
Review of Stage Inspection

Report/Test Report
100%
As Per PTS Spec. (PTS

31.22.10.35)
As Per PTS Spec. (PTS

31.22.10.35)
All Relevant Doc. & Report
W/R
Packing List
Release Note by HHI
9. FINAL DOCUMENT
9.1
Quality Records Review
10. PACKING & SHIPMENT

10.1
Presevation & Packing

Inspection
Review of Packed Item and

Packing List
100%
10.2
Inspection Release Note
Issuance of IRN

Procedure (DBB-BNCPP-B-M-V29- Procedure (DBB-BNCPP-B-MV29-0039)
0039)
Packing List

Packing List
GENERAL
NOTES
1. ALL MEASURING INSTRUMENTS SHALL BE CALIBRATED

2. ALL COLUMN IN ITP SHALL BE SIGNED-OFF AFTER COMPLETION OF INSPECTION
3. ALL MATERIAL ORIGIN FROM CHINA, INDIA, AND EASTERN EUROPE SHALL NOT BE USED
4. INSPECTION NOTIFICATION SHELL BE SUBMITTED FOR "H", "W", "SW" POINT IN THE ITP 10 WORKING DAYS IN ADVANCE USING INSPECTION NOTIFICATION TO HHI INSPECTION CO-ORDINATOR.
5. ALL SHARP EDGES SHALL BE ROUNDED (MIN. RADIUS > 2mm)
6. IN CASE INSPECTION POINT SHOWS TWO (2) KIND OF INSPECTION POINTS WITH FORWARD SLASH ("/") THIS MEANS "AND", NOT "OR".
7. INSPECTION POINTS IN APPROVED ITP CAN BE CHANGED WHEN REQUIRED BY PROJECT
LEGENDS
CERS=CITECH ENERGY RECOVERY SYSTEM ; HHI= HYUNDAI HEAVY INDUSTRIES ; PCSB= PETRONAS CARIGALI SDN BHD; PTS= PETRONAS TECHNICAL SPECIFICATION.
H=HOLD ; SW=SPOT WITNESS ;R=REVIEW;M=MONITORING;W=WITNESS ; RW=RANDOM WITNESS; A=APPROVAL
SUDHANKUMAR
Prepared by CITECH
VEERABATHIRAN
Reviewed by CITECH
Approved by HYUNDAI
REMARKS

DBB BNCPP B M v29 0015 Revb Ifa

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Title:

INSPECTION AND TEST PLAN (ITP)

Issued for Review

Issued for Approval

RT status waiting for pending TQ.

RT status waiting for pending TQ.

File Name: CCM-QCP-623- ITP

INSPECTION TEST PLAN - GTC/GTG EXHAUST STACK for BARONIA PROJECT

ITP NO. : CCM05/HHI/2015-03

Contract & Purchase Order

Contract & P.O (PO No.:

Contract & P.O (PO No.:

Contract & PO Review

WPS/PQR and Welder

WPS/PQR and Welder Certificate

Approved WPS/PQR and Welder

NDE Procedure and Operator

NDE Procedure and Operator

Approved NDE Procedure and

Inspection & Test Plan (DBBBNCPP-B-M-V29-0015)

Approved Inspection & Test Plan

AS PER DRAWING/ ASME

3. PRE INSPECTION MEETING

ITEM : GTC EXHAUST STACK - 2 units

Stainless Steel Materials

Material Test Report / Mill

Fastners ( Stud & Bolts)

Each Heat No.

AS PER DRAWING & PTS

AS PER DRAWING & PTS

Material Test Report / Mill

Positive Material Identification

Stainless Steel Material

INSPECTION TEST PLAN - GTC/GTG EXHAUST STACK for BARONIA PROJECT

APPROVED CITECH DRAWING

Fit-up & Edge Preparation of

Approved CITECH Drawing

Approved CITECH Drawing

Fit-Up Report ( CITECH-QA-03P03A)

As Per ASME SEC-II C / PTS

2. MARKING & CUTTING

Marking & Cutting of GTC

3. FIT-UP & EDGE PREPARATIONS

As Per ASME SEC-II C / PTS

Check on Welding Parameter

As Per ASME SEC-XI / PTS

As Per ASME SEC-XI / PTS

Welding Summary Sheet

5. NON-DESTRUCTIVE TESTING (NDT)

Long Seam & Circ. Seam Butt

As Per SEC-V ,VIII Div-1 / PTS

As Per ASME SEC VIII Div-1

RT Films & Reports (GI-RT-ASME01)

Dye Penetrant Testing

As Per SEC-V ,VIII Div-1 / PTS

As Per SEC ASME VIII Div-1/

DPT Reports (GI-PT-ASME-01

Measurement of Dimension &

Approved CITECH Drawings

Approved CITECH Drawings

Dimensional Report & Visual

Salt Test and Pull-Off Test

6. FINAL DIMENSION & VISUAL