Inspection Procedure For Contract.docx

Contents 1.

TEST, INSPECTION AND COMPLETION.....................................................................................................2

2.

SHOP INSPECTION AND TESTS .................................................................................................................4

3.

SUB-ORDERS AND SUB-CONTRACTS.......................................................................................................7

4.

MATERIAL TESTS ........................................................................................................................................8

5.

INSPECTION AND TESTING OF WELDING ................................................................................................9

6.

EXAMINATION OF WELD ...........................................................................................................................12

7.

INSPECTION OF EQUIPMENT & COMPONENTS.....................................................................................13

8.

FABRICATION AND INSPECTION .............................................................................................................15

9.

INSPECTION AND TESTING OF PAINTING OF EQUIPMENT, PIPING AND DUCTING ..........................18

10.

INSPECTION AND TESTING OF INSTRUMENTS .....................................................................................21

11.

INSPECTION FOR ELECTRICAL PANELS ................................................................................................23

12.

TESTS AT MANUFACTURER'S WORKS ...................................................................................................24

1. a.

TEST, INSPECTION AND COMPLETION Tests and Inspection

1.1

Testing, pre-commissioning & commissioning shall involve, though not limited to these, various testing e.g. hydro-static pressure, pressure decay tests, leak test, trial run of equipments / machinery, flushing by air, water, oil or steam as applicable, checking / setting various clearances / parameters, ensuring operation of various equipments/machinery free of undue restrictions, chemical cleaning, trial operation and loading etc. All the activities for commissioning of the set, as informed by CONSULTANT/PURCHASER from time to time shall be completed.

1.2

All the tests either on the field or at outside laboratories concerning the execution of the work and supply of materials by the CONTRACTOR shall be carried out by CONTRACTOR at his cost.

1.3

The work is subject to inspection at all times by the ENGINEER-IN-CHARGE/ ENGINEER. The CONTRACTOR shall carry out all instructions given during inspection and shall ensure that the work is being carried out according to the technical specifications of this bidding document, the technical documents that will be furnished to him during performance of work and the relevant codes of practice.

1.4

Compressed air for carrying out works shall be arranged by the CONTRACTOR at his own cost.

1.5

For material supplied by CUSTOMER/PURCHASER, CONTRACTOR shall carry out the tests, if required by the ENGINEER-IN-CHARGE/ ENGINEER, and the cost of such tests shall be reimbursed by the CONTRACTEE at actual to the CONTRACTOR on production of documentary evidence.

1.6

All the tests shall be repeated till all the equipments/machinery satisfy the requirement /obligations of CONSULTANT/PURCHASER and also the relevant statutory authority.

1.7

During trials/ tests, pre-commissioning/ commissioning, replacing/ changing mechanical / other seals of equipments like pumps, removal and cleaning / replacing of filters etc. is within the CONTRACTOR’s scope of work. Replacement spares for this purpose shall be provided by CONSULTANT/PURCHASER.

1.8

All results of inspection and tests will be recorded in the inspection reports, proforma of which will be approved by the ENGINEER-IN-CHARGE/ ENGINEER. These reports shall form part of the completion documents. Any work not conforming to execution drawings, specifications or codes shall be rejected and the CONTRACTOR shall carry out the rectifications at his own cost.

b.

Visual Inspection

Inspection of all welds shall be carried out as per the latest editions of the applicable codes and specifications. All finished welds shall be visually inspected for parallel and axial alignment of the work, excessive reinforcement, concavity of welds, shrinkage cracks, inadequate penetration, unrepaired burnthrough, under cuts, dimensions of the weld, surface porosity and other surface defects. Undercutting adjacent to the completed weld shall not exceed the limits specified in the applicable standard/code. c.

Final Inspection After completion of all tests as per specification the whole work will be subject to a final inspection to ensure that job has been completed as per requirement. If any defect is noticed, the CONTRACTOR will be notified by the ENGINEER-IN-CHARGE/ ENGINEER and he shall make good the defects with utmost speed. If however, the CONTRACTOR fails to attend to these defects within a reasonable time (time period shall be fixed by the ENGINEER-IN-CHARGE/ ENGINEER) then ENGINEER-IN-CHARGE/ ENGINEER may have defects rectified at CONTRACTOR cost.

2.

SHOP INSPECTION AND TESTS

2.1

GENERAL

2.1.1

The plant and equipment covered by the PURCHASE ORDER/CONTRACT shall be subjected to inspection and testing. The VENDOR/CONTRACTOR shall provide all services to establish and maintain quality of workmanship in his works and that of his SUB-VENDOR’s/SUB-CONTRACTOR’s works to ensure the mechanical accuracy of components, compliance with approved drawings, identification and acceptability of all materials, parts and equipment.

2.1.2

For supply of systems, the VENDOR/CONTRACTOR shall, at the start of the PURCHASE ORDER/CONTRACT, furnish a total list of items in his scope of work. This list, giving a brief description of the item, quantity, names of probable SUB-VENDORS/SUB-CONTRACTORS, and a blank column for agency for final approval of drawings and documents, shall be submitted for approval by PURCHASER/CONSULTANT. The blank column shall be filled by PURCHASER/CONSULTANT. The list shall be submitted within two weeks from the date of Letter of Intent.

2.1.3

For systems and major items such as pressure and load bearing items, machineries etc., the VENDOR/CONTRACTOR shall furnish quality plan giving details of checks and tests to be conducted by them on material, process, subassembly and assembly. These shall include requirements as prescribed in the applicable specifications, codes and statutory requirements. The quality plan shall be reviewed by the PURCHASER/CONSULTANT and the stages to be witnessed and verified shall be indicated by the PURCHASER/CONSULTANT in the approved quality plan.

2.1.4

The VENDOR/CONTRACTOR shall give the PURCHASER/CONSULTANT written notice of any material being ready for testing. The clear notice period shall be seven (7) days for local inspection and fifteen (15) days for Outstation/International inspection. Such tests shall be to the Vendor’s/CONTRACTOR's account except for the expenses of the PURCHASER/CONSULTANT. The PURCHASER/CONSULTANT, unless the inspection of the tests is virtually waived, shall fix a date for inspection with the VENDOR/CONTRACTOR and attend such tests within fifteen (15) days of the date on which the equipment is notified as being ready for test and inspection failing which, the VENDOR/CONTRACTOR may proceed with the tests and shall forthwith forward to the PURCHASER/CONSULTANT duly certified copies of tests.

2.1.5

In all cases where inspection and tests are required whether at the premises or works of the VENDOR/CONTRACTOR or of any SUB-VENDOR/SUBCONTRACTOR or at laboratory, the VENDOR/CONTRACTOR, except where otherwise specified, shall provide free of charge all facilities such as labor, materials, electricity, fuel, water, stores, test bed, apparatus and instruments, laboratory tests etc. as may be required by the PURCHASER/CONSULTANT to carry out effectively such tests of the equipment in accordance with the PURCHASE ORDER/CONTRACT and shall give facilities to the PURCHASER/CONSULTANT to accomplish testing.

2.1.6

The PURCHASER/CONSULTANT shall at all working hours have access to all parts of the VENDOR’s/CONTRACTOR's and his SUB-VENDOR’s/ SUBCONTRACTOR’s factory where the items of the plant are being prepared, for carrying out inspection activities as deemed necessary. A set of the relevant latest approved drawings with approval marking of the PURCHASER/CONSULTANT and drawings

for proprietary items shall be made available by PURCHASER/CONSULTANT, for reference during inspection.

the

VENDOR/CONTRACTOR

to

the

2.1.7

In the case of stage inspection hold points, the VENDOR/CONTRACTOR shall proceed from one stage to another only after the component is inspected by the PURCHASER/CONSULTANT and written permission given to proceed further. The same procedure shall be adopted for any rectifications and repairs suggested by the PURCHASER/CONSULTANT.

2.1.8

The PURCHASER/CONSULTANT shall have the right to inspect any machinery, material, structures, equipment or workmanship furnished or used by the VENDOR/CONTRACTOR and may reject any which is defective or unsuitable for the use and purpose intended, or which is not in accordance with the intent of the PURCHASE ORDER/CONTRACT. The VENDOR/CONTRACTOR, upon demand by the PURCHASER/CONSULTANT, shall remedy or replace at the VENDOR’s/CONTRACTOR's expense such defective or unsuitable items of the plant, or the PURCHASER/CONSULTANT may, at the expense of the VENDOR/CONTRACTOR, remedy or replace such defective or unsuitable items of the Plant.

2.1.9

All principal mill test reports, the VENDOR/CONTRACTOR inspection and tests reports, test certificates and test curves shall be supplied for all inspection and tests carried out including other records such as stress relieving charts, radiographic charts and other non-destructive testing records in accordance with the provisions of the PURCHASE ORDER/CONTRACT, duly certified by the main VENDOR/CONTRACTOR. The PURCHASER/CONSULTANT shall reserve the right to call for certificates of origin and test certificates for all raw material and equipment at any stage of manufacture.

2.1.10 The PURCHASER/CONSULTANT shall within fifteen (15) days from the date of inspection as defined herein give notice in writing to the VENDOR/CONTRACTOR of any non-conformance pertaining to all or any equipment and workmanship which in his opinion is not in accordance with the PURCHASEORDER/CONTRACT. The VENDOR/CONTRACTOR shall give due consideration to such objections and shall either make the modifications that may be necessary to meet the said objections or shall confirm in writing to the PURCHASER/CONSULTANT giving reasons therein that no modifications are necessary to comply with the PURCHASE ORDER/CONTRACT. 2.1.11 When the factory tests and documentation have been satisfactorily completed at the VENDOR’s/CONTRACTOR's or SUB-VENDOR's/CONTRACTOR's works, the PURCHASER/CONSULTANT shall issue acceptance note or shipping release note or a certificate to this effect within fifteen (15) days after completion, but if the tests are not witnessed by the PURCHASER/CONSULTANT, the certificate or comments thereof shall be issued within fifteen(15) days of the receipt of the VENDOR’s/CONTRACTOR's test certificate by the PURCHASER/CONSULTANT. Failure of the PURCHASER/ CONSULTANT to take such an action shall not prevent the VENDOR/ CONTRACTOR from proceeding with the work. The completion of these tests or the issue of the certificates shall not bind the PURCHASER/ CONSULTANT to accept the equipment, should it, on further tests after erection, be found not to comply with the PURCHASE ORDER/CONTRACT. 2.1.12 None of the plant and the equipment to be furnished or used in connection with the PURCHASE ORDER/CONTRACT shall be dispatched until shop inspection; satisfactory to the

PURCHASER/CONSULTANT has been made. However, such shop inspection and/or certification shall not relieve the VENDOR/CONTRACTOR of his responsibility for furnishing the plant and the equipment conforming to the requirements of the PURCHASE ORDER/CONTRACT nor prejudice any claim, right or privilege which the PURCHASER/CONSULTANT may have because of the use of defective or unsatisfactory items. Should the PURCHASER/CONSULTANT waive the right to inspect anytime, such waiver shall not relieve the VENDOR/CONTRACTOR in any way from his obligation under the PURCHASE ORDER/CONTRACT. In the event of the PURCHASER’s/CONSULTANT's inspection revealing poor quality of goods, the PURCHASER/CONSULTANT shall be at liberty to specify additional inspection procedures, if required, to ascertain the VENDOR/Contractor’s compliance with the equipment specifications.

3.

SUB-ORDERS AND SUB-CONTRACTS

3.1

In order to facilitate the inspection of bought-out materials and plant, the VENDOR/CONTRACTOR shall submit for approval, three (3) copies of all suborders and sub-contracts placed by him as soon as these are issued. Copies of any drawings referred to in the sub-order or sub-contracts shall also be submitted, unless agreed otherwise by the PURCHASER/CONSULTANT.

3.2

The sub-orders, sub-contracts and drawings referred to above shall include all components which are subjected to electrical and mechanical pressure or stress when the plant is in operation, and also auxiliaries and spares which are to be directly dispatched to site from the SUB-VENDOR’s/SUB-Contractor’s works.

3.3

All sub-orders and sub-contracts of the main VENDOR/CONTRACTOR shall clearly be marked with the main VENDOR’s/CONTRACTOR's name and the Purchaser’s/CONSULTANT’s name and the PURCHASE ORDER/CONTRACT reference. These shall include the following statement: The plant or the equipment which is the subject of this PURCHASE ORDER/CONTRACT shall comply in every respect with the requirements of the PURCHASER’s/CONSULTANT's technical specifications and shall be subject to inspection and tests to the satisfaction of the PURCHASER/CONSULTANT.

3.4

For the purpose of this Para, it is obligatory on the VENDOR/CONTRACTOR that he advises his SUBVENDOR/SUB-CONTRACTOR of the pertinent clauses in this specification when ordering bought-out plant, equipment or materials. In particular, the VENDOR/CONTRACTOR shall advise every SUBVENDOR/SUBCONTRACTOR that he is required to supply design calculations, drawings, inspection reports and test certificates strictly in accordance with this specification and technical information. The SUBVENDORS/SUB-CONTRACTORS should also be reminded that they shall include with their offer all tools and appliances necessary for proper maintenance and all spare parts. Itemized prices of the recommended spare parts shall be submitted together with the appropriate part numbers and drawings.

4.

MATERIAL TESTS

4.1

In the event of the PURCHASER/CONSULTANT being supplied with the certified particulars of tests which have been carried out for the VENDOR/CONTRACTOR by the supplier of material, the PURCHASER/CONSULTANT may, at his own discretion, accept the same as proper evidence of compliance with the requirements of appropriate specifications for the materials.

4.2

The VENDOR/CONTRACTOR is to provide test pieces as required by the PURCHASER/CONSULTANT to enable him to determine the quality of material supplied under the PURCHASE ORDER/CONTRACT. If any test piece fails to comply with the requirements, the PURCHASER/CONSULTANT may reject the entire lot of material represented by the test piece.

4.3

Critical materials used in manufacture of the equipment and construction of the plant covered by the PURCHASE ORDER/CONTRACT may also be subjected to one or more of the Non-Destructive Tests (NDT) as called for in the enquiry document or as mutually agreed. Salvaging of material due to unacceptable defect is to be attempted by the VENDOR/CONTRACTOR only after getting specific concurrence from the PURCHASER/CONSULTANT and according to the approved procedures.

5.

INSPECTION AND TESTING OF WELDING

5.1

All welding shall be as per standard specifications. Flanged joints shall also be provided to match the connecting ends of equipment, valves or where specified. Where specific equipment-piping connection necessitates several joints, unions shall also be provided. Only qualified welders proficient in welding in the vertical and overhead positions shall be allowed to weld these pipelines. Preferably welders with proficiency certificate from Govt. Test House or equivalent recognized authority should be put on the job. It shall be CONTRACTOR's responsibility to arrange for and bear all costs towards testing of welders. a. The following steps shall be taken besides controlling quality in general, to make effective control in carrying out welding: i)

Welding procedure (PQR & WPS) shall be prepared in line with prescribed standard and tests shall be carried out to qualify the procedures. Number of procedures will depend on variables like positions of welding, thickness range, etc. Once a welding procedure is qualified, strict adherence to it shall be made during actual welding.

ii) Welders employed shall be qualified as per prescribed standard. CUSTOMER/PURCHASER will have the right to check/ witness the certificate(s) / test(s) before and / or during execution of work. iii) Where applicable, welders shall be tested as detailed in codes specified for pipe welding, vessel welding and structural welding and appropriate to the corresponding weld position using test pieces of appropriate parent metal to be used on the job. The PURCHASER/CONSULTANT shall have the right to have any welder re-tested at any time during the PURCHASE ORDER/CONTRACT. iv) Makes of welding consumables such as electrodes, filler wires, argon, etc. shall be approved by CUSTOMER/PURCHASER before using it. Such consumables are, however, subject to qualifying initial check tests as per ASME codes. These consumables are in the scope of supply of CONTRACTOR. v) The CONTRACTOR shall submit batch test certificates, from the electrode manufacturers, giving details of physical and chemical tests carried out by them, for each batch of electrodes to be used. vi) Guidelines for acceptance of weld defects detected by radiographic / ultrasonic tests, wherever applicable, shall be governed by prescribed standard. b. Radiography and Inspection of welds i)

Radiographic examination shall be carried out by approved agency (having min level 2 certification) arranged by the CONTRACTOR at his cost.

ii) Weld areas to be radiographed shall be designated by the ENGINEER-IN-CHARGE/ ENGINEER or his representative. Overall 10% of the joints shall be radiographed. Cost towards radiography of

the pipelines shall be included in the erection cost of pipeline. However, for firefighting hydrant / foam lines, radiography is not envisaged. iii) Radiographs of the welds shall be taken as soon as the welding of joint is completed. If repairs are required they shall be carried out before continuing the other welds. iv) Repeat radiography due to CONTRACTOR fault or additional radiography necessitated due to poor performance of CONTRACTOR/welders shall be done at CONTRACTOR cost. v) Welds found faulty as a result of radiographic, visual or other tests must be chipped off to the satisfaction of the ENGINEER-IN-CHARGE/ ENGINEER and welded as per specifications and instructions. The welded portion shall be re-tested as per the instructions of the ENGINEER-INCHARGE/ ENGINEER or his representative. No claims for compensation whatsoever shall be entertained on this account. vi) For each weld performed by a welder found unacceptable, two additional checks shall be carried out on welds performed by the same welder. This operation is iterative and that of the two additional welds for each weld deemed unsatisfactory shall be continued till such time that two consecutive welds of satisfactory quality are found for every defective weld. vii) The CONTRACTOR shall carry out these additional radiographic testing at his own expense. To avoid the possibility of too many defective welds by a single welder remaining undetected for a long period to time, the CONTRACTOR shall promptly arrange for radiographic examination so that there is no accumulation of defective joints. viii) Hydrotest procedure Hydrostatic (Hydro) Testing is a process where components such as piping systems, equipment, and pressure vessels are tested for strength and leaks. Hydro tests are often required before start up, after shutdowns and repairs in order to validate that equipment will operate under desired conditions once returned to service. ix) Recommendations of applicable codes shall be followed for non-destructive tests, wherever applicable. 5.2

Copies of all welding procedures, procedure qualification records, welders ‘performance qualification certificates, post-heating and stress relieving records, NDT records and other test results shall be made available upon request of the PURCHASER/CONSULTANT.

5.3

The PURCHASER shall have free access to inspect welding or any other related operations at any time and at any stage of fabrication.

5.4

The PURCHASER may require non-destructive testing of any weld for reasons other than those given in the specification. The responsibility for the cost of such testing shall be mutually decided between the PURCHASER and the CONTRACTOR.

5.5

The CONTRACTOR shall inform the PURCHASER when the weld preparation and setting up for welding of various members selected by the PURCHASER is in progress so that the PURCHASER can inspect the assembly before welding starts.

5.6

Any examination by non-destructive methods on low alloy steels shall be performed after post weld heat treatment.

5.7

For a welded branch connection, the examination of and any necessary repairs shall be completed before any reinforcing pad is added.

6.

EXAMINATION OF WELD

6.1

Examination refers to the quality control functions performed by the CONTRACTOR during fabrication, erection and testing.

6.2

As a minimum, the following shall be examined by visual examination :

6.2.1

Materials and components to ensure that these are as per the specification and are free from defects. If defects are noticed on “free issue” items, these shall be brought to the notice of the PURCHASER without delay.

6.2.2

Joint preparation and cleanliness

6.2.3

Preheating as applicable

6.2.4

Fit-up, joint clearance, and internal alignment prior to joining

6.2.5

Variables specified by the welding procedure, including filler material, position and electrode

6.2.6

Condition of the root pass after cleaning - external and where accessible, internal

6.2.7

Slag removal and weld condition between passes

6.2.8

Appearance of the finished joint

7.

INSPECTION OF EQUIPMENT & COMPONENTS

7.1

The CONTRACTOR shall undertake the inspection of all components to be erected sufficiently in advance, to check their soundness, conformity to the approved VENDOR’s drawings and their compatibility with the approved erection procedure.

7.2

All inspection and tests on bought out items shall be made as required by specifications forming part of this contract. Various stages of inspection and testing shall be identified after receipt of Quality Assurance Programme from the CONTRACTOR / manufacturer.

7.3

Inspection calls shall be given, as per mutually agreed programme in prescribed proforma, giving details of equipment and attaching relevant test certificates and internal inspection report of the CONTRACTOR. All drawings, general arrangement and other contract drawings, specifications, catalogues etc. pertaining to equipment offered for inspection shall get approved by CUSTOMER/PURCHASER and copies shall be made available to CUSTOMER/PURCHASER before hand for undertaking inspection.

7.4

All inspections and tests shall be made as required by the specifications forming part of this contract. CONTRACTOR shall advise CUSTOMER/PURCHASER in writing at least fifteen days in advance of the date of final inspection / tests. Manufacturer’s inspection or testing certificate for equipment and materials supplied may be considered for acceptance, at the discretion of ENGINEER-IN-CHARGE/ ENGINEER. All costs towards related testing at site etc. shall be borne by the CONTRACTOR within their quoted rates.

7.5

The CONTRACTOR shall ensure full and free access to the inspection engineer of CUSTOMER/PURCHASER at the CONTRACTOR or their sub-contractor’s premises at any time during contract period to facilitate him to carry out inspection and testing assignments.

7.6

The CONTRACTOR / SUB-CONTRACTOR shall provide all instruments, tools, necessary testing and other inspection facilities to inspection engineer of CUSTOMER/PURCHASER free of cost for carrying out inspection.

7.7

Where facilities for testing do not exist in the CONTRACTOR / SUB-CONTRACTOR’s laboratories, samples and test pieces shall be drawn by the CONTRACTOR / SUB-CONTRACTOR in presence of Inspection Engineer of CUSTOMER/PURCHASER and duly sealed by the later and sent for tests in Government approved test house or any other testing laboratories approved by the Inspection Engineer at the CONTRACTOR cost.

7.8

The CONTRACTOR shall comply with the instructions of the Inspection Engineer fully and with promptitude.

7.9

The CONTRACTOR shall check the Total Indicated Run outs (TIR) on the shafts, mounted couplings and other rotary elements to be within prescribed limits which may in any case, unless specified otherwise, not exceed 0.03 mm. The TIR of motor’s shaft concentricity of spigots and perpendicularity or parallelism of mounting face to shaft axis shall be as specified in contract. In case of motors of speed more than 1000 rpm ‘precision ‘class TIR limits shall be applicable. Any deviations in this regard shall be brought to the notice of the ENGINEER before the CONTRACTOR undertakes the erection.

7.10

Drive couplings should not be loose with driver and driving equipment. Notice the arrangement and same shall be attended for proper installation.

7.11

The base/sole plate of the machine shall be checked sufficiently in advance for correctness of mounting holes with respect to the machine centerlines and anchor bolts provided on foundation, coplanar accuracies of the mounting pads of the base/sole plate, number and location of jackscrews, vent holes for grouting purposes in all bulk head section etc. The CONTRACTOR shall check the adequacy and compatibility of erection procedures with respect to the base/sole plates. The CONTRACTOR shall also check for any distortion or damage to the mounting reference faces during transit and bring to the notice of the ENGINEER any defect in order that corrective action could be undertaken in time.

7.12

The CONTRACTOR shall remove any protective coatings and paints on base/sole plates where they are to be embedded in concrete by approved means. Likewise machine components that shall be cleaned by approved means before assembly may be received loose with protective coatings and other preservation measures. The CONTRACTOR shall be responsible for removal of coatings and preparation of such components for assembly providing all enabling aids as per the MANUFACTURER’s/ENGINEER’s directions.

7.13

The CONTRACTOR shall ensure that the equipment / assemblies / component of the plant and equipment required to be inspected are not assembled or dispatched before inspection. In case of, equipment assembled at site, all components shall be checked for mounting/mating accuracies and run outs before assembly. The ENGINEER will generally provide the mounting/mating tolerances of such components for the CONTRACTOR’s guidance where such data is made available by MANUFACTURER.

7.14

VENDOR’s match marks shall be followed precisely during assembly. Extra care shall be exercised while unpacking and dismantling of dynamically balanced components carefully identifying like coupling halves, coupling pins, rotor elements, fasteners, keys etc. in order they are used in the appropriate places, so as not to affect the dynamic balancing carried out by VENDOR. The ENGINEER shall be kept informed of any discrepancy noticed in this regard.

7.15

On satisfactory completion of final inspection and testing, all accepted plant and equipment shall be stamped suitably and inspection certificate shall be stamped suitably and inspection certificate shall be issued in requisite copies for all accepted items. For stage inspection and for rejected items, only inspection memo shall be issued indicating there in the details of observations and remarks.

7.16

Final Testing and Inspection will be witnessed by Local Authorized Agency / AIA. The arrangement like special tools, tackles and consumables required carrying out the final testing and inspection, is in the scope of CONTRACTOR. Any deviations/ defects observed in the free supply by CUSTOMER/PURCHASER will be rectified by the CONTRACTOR at extra cost. Any deviations/ defects observed during the final inspection shall be rectified by the CONTRACTOR at his own cost.

8.

FABRICATION AND INSPECTION Fabrication and inspection procedures for vessels, heat exchangers, pipes, tubes and valves etc. shall be in accordance with procurement specifications, quality plan, applicable codes or any other approved equal.

8.1

Inspection of Pressure vessel:

8.1.1

All plates need to be identified against mill test certificates at the Vendor’s works before commencement of fabrication.

8.1.2

Ensuring that welding procedure and welders are qualified and welding electrodes are approved before commencement of fabrication.

8.1.3

Hydrostatic Test or load test is Standard Pressure test on Completed Vessels.

8.1.4

Pneumatic test is performed if hydro is not possible due to design or process reasons, however not recommended due to safety reasons..

8.1.5

Check for creep failure. Creep failure are characterized by bulging or blisters in the tube, thick-edged fractures often with very little obvious ductility, longitudinal "stress cracks" in either or both ID and OD oxide scales, external or internal oxide-scale thicknesses that suggest higher-than- expected temperatures, intergranular voids and cracks in the microstructure

8.1.6

Checking internal lining of reactors and vessels (if applicable) to specifications.

8.1.7

Checking trays of each diameter and type, mock assembled in the shop. (for process towers)

8.1.8

Checking for interchangeability of parts, where applicable for process towers

8.1.9

Ensuring that any uncommon down comers are fully assembled and offered along with their respective trays. (for process towers)

8.1.10 Inspect cutting and edge preparation, head forming and dimensions , Rolling for shell, second rolling of shell, fit up and weld (head to shell, pipe to flange)etc. 8.1.11 Safety Relief valves: Visually inspect for accumulations of Corrosion deposits. The probe should be inspected for corrosion and scale accumulations which will insulate the valve and probe from the tanks internals, and also for any illegal alterations, repairs or tampering. 

Check nameplate information and compare with stamping on pressure retaining item



Check for evidence that the valve or device is leaking or not sealing properly.



Check that seals are intact and show no evidence of tampering



Check that connecting bolting is tight and all bolts intact



Check for damaged or misapplied parts



Ensure that visible drain holes are not clogged with debris or deposits

8.1.12 Inspection of safety device installation:



Inspect inlet piping and its size and ensure that it meets the requirements of original code of construction



Inspect discharge piping and its size and ensure that it meets the requirements of original code of construction



Check that valve drain pipe is open



Check that discharge pipe is not binding on the valve body



Check the adequacy and condition of pipe supports



Check the possible hazards to personnel from the valve discharge or discharge pipe.

8.1.13 Inspection of Rupture Disk: 

Check rupture disk nameplate information including stamped burst pressure and coincident temperature to ensure it is compatible with the vessel and/or safety relief valve.



Carefully check markings indicating direction of flow to ensure they are correct.



Check that the space between rupture disk and safety relief valve is supplied with a pressure gauge, try cock, or tell tale indicator to indicate signs of leakage through the rupture disk.



If rupture disk is used on a valve outlet, the valve design must be of a type not influenced by back pressure from leakage through the valve.



For rupture disk installed on the valve inlet, review the installation to ensure that the combination rules of the code of construction have been applied.

8.1.14 Check for parameters which lead to Pressure vessel fatigue such as sharp corners, small radii, and small fillets, Surface quality, Weld quality, Material type, stresses resulting from the manufacturing processes such as forming, welding, etc., Size and distribution of internal defects, Grain size of steel, Environment, Temperature etc. 8.1.15 Tensile testing, bend testing, impact testing, drop weight testing to be carried out. 8.1.16 Inspection to be done during forming and shaping of component as per procedure. 8.1.17 Inspection to be done during assembling of parts. Ensure proper assembling procedure should be followed. 8.1.18 After production welding is completed, the welds are to be subjected to non-destructive examination such as radiography or ultrasonic examination for volumetric evaluation and dye penetrate or magnetic particle testing for surface examination. 8.1.19 Non destructive examination to be done before and after post weld heat treatment application (PWHT) 8.1.20 Leak testing of welds can be done using Pneumatic leak test, Halogen diode detector method, Helium leak detection methods 8.1.21 External Inspection: Insulation or other coverings, Evidence of leakage, Structural attachments, vessel connections, welded joints, surface inspection to be done.

8.1.22 A thorough inspection of vessel and its associated connections and components should be performed while under pressure. 8.1.23 The thickness survey of the pressure vessels wall and dished heads should be performed and documented by certified inspector using ultrasonic testing equipment. The ultrasonic testing equipment should be properly calibrated. 8.2

INSPECTIONOF PIPING

8.2.1

Piping should be inspected to ensure there is:

8.2.2



Provision of expansion



Provision for adequate support



No evidence of leakage



Proper alignment of connections



Proper rating for the service condition



No evidence of corrosion, erosion or cracking or detrimental conditions

A leak should be thoroughly investigated. A pressure test may be required to obtain additional information regarding the extent of a defect or detrimental condition.

8.2.3

Mill test reports(incl. heat treatment records etc.) to be checked

8.2.4

Non-destructive testing (RT, UT, MT or PT) (Review of all radiographs films) to be carried out, if applicable

8.2.5

Heat treatment execution, if specified

8.2.6

Metallographic examination, if applicable

8.2.7

Visual and dimensional control to be carried out

8.2.8

Hydrostatic test to be carried out, if applicable

8.2.9

Painting, coating, marking and color coding check to be done

8.2.10 Final visual inspection including packaging and quantity control 8.2.11 Documentation review prior to release(Final activity of Technical Inspection) 8.2.12 Pre-shipment Inspection to be done

9.

INSPECTION AND TESTING OF PAINTING OF EQUIPMENT, PIPING AND DUCTING

9.1

All paint materials including primers and thinners shall be procured directly from approved manufacturers by CONTRACTOR and shall be accompanied by manufacturer’s test certificates. Paint formulations without certificate shall not be accepted.

9.2

The CONTRACTOR shall provide for the purpose of inspection, thickness measuring instrument (Elcometer or other approved device), access ladder, lighting, personnel and any other necessary item at no extra cost to the PURCHASER.

9.3

The PURCHASER may call for batch-wise physical and chemical tests for paint materials. CONTRACTOR shall arrange to have such tests performed including batch-wise test of wet paints for physical & chemical analysis as per relevant standard test method. All costs there shall be borne by the CONTRACTOR. The CONTRACTOR shall produce test reports from manufacturer regarding the quality of the particular batch of paint supplied. The ENGINEER-IN-CHARGE shall have the right to test wet samples of paint at random for quality of same. Batch test reports of the manufacturers for each batch of paints supplied shall be made available by the CONTRACTOR.

9.4

The work involved shall be subject to inspection by the PURCHASER at all times. In particular the following stage inspections shall be carried out and the CONTRACTOR shall offer the work for inspection and obtain approval at every stage before proceeding with the next stage. The record of inspection shall be maintained in the registers. Stages of inspection are as follows:   

Surface preparation Each coat of primer application Each coat of finish paint application

Any defects noticed during various stages of inspection shall be rectified by the CONTRACTOR to the satisfaction of the PURCHASER before proceeding further. Irrespective of the inspection, repair and approval of intermediate stages of work, the CONTRACTOR shall be responsible for making good the defects found during final inspection and during the guarantee period.. Dry film thickness (D F T)) shall be checked and recorded after application of each coat and extra coat of paint should be applied to make-up the DFT specified without any extra cost to CUSTOMER/PURCHASER, the extra coat should have prior approval of ENGINEER-IN-CHARGE. 9.5

In addition to above, record should include type of shop primer already applied on equipment e.g. Red oxide zinc chromate or zinc chromate or Red lead primer etc.

9.6

Primer Application After surface preparation, the primer should be applied to cover the crevices, corners, sharp edges etc. in the presence of inspector nominated by ENGINEER-IN-CHARGE.

9.7

The shades of successive coats should be slightly different in color in order to ensure application of individual coats, the thickness of each coat and complete coverage should be checked as per provision of this specification. This should be approved by ENGINEER-IN-CHARGE before application of successive coats.

9.8

The CONTRACTOR shall provide standard thickness measurement instrument with appropriate range(s) for measuring.

9.9

Dry film thickness of each coat, surface profile gauge for checking of surface profile in case of sand blasting. Holiday detectors and pinhole detector and protector whenever required for checking in case of immersion conditions.

9.10

Prior to application of paints on surfaces of chimneys, the thickness of the individual coat shall be checked by application of each coat of same paint on M. S. test panel. The thickness of paint on test panels shall be determined by using gauge such as 'Elkometer'. The thickness of each coat shall be checked as per provision of this specification. This shall be approved by ENGINEER-IN-CHARGE before application of paints on surface of chimney.

9.11

At the discretion of ENGINEER-IN-CHARGE, the paint manufacturer must provide the expert technical service at site as and when required. This service should be free of cost and without any obligation to the CUSTOMER/PURCHASER, as it would be in the interest of the manufacturer to ensure that both surface preparation and application are carried out as per their recommendations. The CONTRACTOR is responsible to arrange the same.

9.12

Final inspection shall include measurement of paint dry film thickness, Adhesion, Holiday detection check of finish and workmanship. The thickness should be measured at as many points/ locations as decided by ENGINEER-IN-CHARGE and shall be within + 10% of the dry film thickness, specified in the specifications.

9.13

The CONTRACTOR shall arrange for spot checking of paint materials for Sp.gr., glow time (ford cup) and spreading rate.

9.14

All results of inspection and tests shall be recorded in the inspection and acceptance reports. These reports shall be submitted along with completion documents.

9.15

The CONTRACTOR shall arrange expert technical service at site from the paint manufacturer, free of cost, in case of any problem as and when required by the PURCHASER.

9.16

After completion of work the CONTRACTOR shall check and demonstrate to the PURCHASER that the DFT measured at least at 20 points on each item painted is not less than the specified thickness. Inadequate DFT shall necessitate the application of a further coat or coats of paint at no extra cost to the PURCHASER. The DFT shall be checked by using an Elcometer or other approved device.

10.

INSPECTION AND TESTING OF INSTRUMENTS

10.1

Verify that tests required to verify conformance of an item to specified requirements, and to demonstrate satisfactory performance for service, are planned and executed. Verify that the characteristics to be tested and test methods to be employed are specified. Verify that test results are documented and their conformance with acceptance criteria is evaluated.

10.2

Verify that the applicant has established controls for tools, instruments, gauges and other M&TE used for quality-affecting activities. Verify that M&TE is controlled, calibrated (at specified periods), and adjusted to maintain accuracy within necessary limits.

10.3

Verify that the applicant has established the requirements to identify the status of inspection and test activities. Verify that the status is indicated either on the items or in documents traceable to the items, where it is necessary to assure that required inspections and tests are performed, and to assure that items that have not passed the required inspections and tests are not inadvertently installed, used, or operated.

10.4 Visual Inspection 10.4.1 Field visual inspection shall ensure that each instrument:  has the correct tag number, range, etc.;  is in the proper place;  is correctly and rigidly installed;  is properly earthed where necessary;  is suitably protected against adverse environmental conditions. 10.4.2 Attention shall also be paid to the final accessibility of the instrument and the free space necessary for removal or partial disassembly. 10.5 Testing of Impulse Lines 10.5.1 With the process and instrument isolating valve closed, all instrument impulse lines shall be pressure-tested to a pressure of 1.5 times the intended upper operating pressure. Note: Local regulations may specify a higher pressure, e.g., two times the intended operating pressure. 10.5.2 Pressure testing shall be done with dematerialized water. After pressure testing, the impulse lines shall be disconnected from the process connections and then the instrument impulse lines shall be carefully drained and blown out. For safety reasons stainless steel tubes shall be used for testing purposes and not copper. Gas cylinders may be used for high pressure testing. 10.6 Testing of Sampling Systems of Analyzers 10.6.1 Sampling systems for on-line process analyzers and impulse lines shall be blown out, pressure-tested and leak tested using dry air or Nitrogen, after which the sampling systems shall be disconnected from the process connections. 10.6.2 Where necessary the sampling systems shall be cleaned, e.g., by solvent washing and dry gas (e.g. Nitrogen) purging. 10.6.3 All sample take-off/return connections shall be kept closed until the analyzer is commissioned.

10.7 10.7.1

Testing of Pneumatic Tubing Leak testing of pneumatic tubes shall be carried out using the bubble method and soap test; after the test the pneumatic signal loops shall be subjected to a full operational test. Special attention shall be paid to the correct line-up between 3-way or 4-way solenoid valves and the relevant final control element.

10.8 Testing of Instruments 10.8.1 All individual instruments shall be tested and (re)calibrated before installation, and a detailed testing of the instrument is not necessary at this stage, unless the function testing reveals an abnormal behavior. 10.8.2 Control valves and shut off valves equipped with actuators (complete with associated tubing, solenoid valves quick exhausts, boosters and positioners) shall be tested for full-stroke time. 10.8.3 Actuators for variable-pitch fans on air-cooled heat exchangers shall be tested for smooth-stroking in site before plant commissioning. Final adjustment shall be done when the plant is operating at its design duty and the heat exchanger is at operating temperature, such that:  Minimum pitch (usually negative to compensate for air flow due to heat conduction) shall cause zero air flow;  Maximum pitch shall not cause the maximum allowable motor current to be exceeded. 10.9 Testing of Instrument Loops 10.9.1 All instrument loops shall be fully tested for correct functioning; where necessary by simulating the signals. 10.9.2 All controllers shall have their settings for proportional, integral and derivative actions adjusted to a calculated value. Company approved loop check forms, shall be applied for recording the results. Note: The following equipment shall also receive attention at this stage:  Special high-signal or low-signal selectors calculating relays, etc. shall be adjusted;  The mechanical min/max stop on control valves shall also be adjusted;  The position of limit switches shall be checked and adjusted;  Selector switches shall be checked.

11.

INSPECTION FOR ELECTRICAL PANELS

11.1

Gaps or a missing grounding system: The grounding system provides an easy path for electricity to flow to the earth, should a problem like a short circuit occur. Allowing current to flow in this way helps a circuit breaker trip, preventing fire and shock. Without a ground path, a person is at risk of becoming the ground, resulting in electrocution.

11.2

Rust or corrosion: Watch for any rust around the panel, as well as circuit breakers that may not trip in response to an over current, due to internal corrosion. If breakers have these characteristics, replace them. If an electrical panel is badly corroded, the entire panel needs to be replaced.

11.3

Evidence of overheating: Watch for signs of melting or burning inside the electrical panel.

11.4

Signs of improper bonding: Look for improper wiring or damaged equipment in general.

11.5

Following test to be carried out:: 11.5.1 General Arrangement Check 11.5.2 Insulation Resistance Test 11.5.3 Withstand Voltage Test (Dielectric Test) 11.5.4 Control Panel Sequence Test 11.5.5 Mechanical Operation Test 

Locking



Interlocking systems



Drawing mechanisms



Opening and shutting mechanisms



Interchangeability.

11.5.6 Painting and Coating Inspection 11.5.7 Packing, Marking and Shipping: 

Verify that the packing materials conform to specifications and accepted practice for the mode of transport.



Verify protection against humidity, abrasion, distortion and other damage.



Verify shipping marks to marking instructions and record.



Verify handling marks.

12.

TESTS AT MANUFACTURER'S WORKS

12.1

GENERAL The tests at works shall include electrical, mechanical and hydraulic tests in accordance with the appropriate clauses of Statutory Regulation, relevant codes and standards and approved drawings and specifications and in addition any test called for by the PURCHASER/CONSULTANT to ensure that the plant being supplied fulfils the requirements of the specifications. The VENDOR/CONTRACTOR shall carry out all the shop tests and inspections as specified in addition to those normally required as per codes and standards. For items not covered by any code or specifically mentioned in the specifications, the tests are to be agreed with by the PURCHASER/CONSULTANT. If considered necessary by the PURCHASER/CONSULTANT, multi-part assemblies shall be fully erected and tested in the works prior to packing and dispatch to the site.

12.2

TEST CERTIFICATES Test certificates including test records, performance curves and balancing certificates shall be supplied according to the Distribution Schedule. All the tests shall be carried out in accordance with the provisions of the PURCHASEORDER/CONTRACT. All test certificates must be endorsed with sufficient information to identify the material or the equipment to which the certificates refer, and must carry at the top right hand corner the identification of the PURCHASER/CONSULTANT and the PURCHASE ORDER/CONTRACT.

12.3

CALIBRATION All instruments used for critical measurement such as pressure gauges for leak tests, instruments for measuring performance parameters; instruments for precision dimension measurements shall have valid calibration certificates traceable to national standards. This means that the calibrating agency engaged by the VENDOR/CONTRACTOR shall use instruments which are intern calibrated by Government approved agencies and such information shall be recorded in the calibration certificate issued by the calibrating agency by giving the certificate number, date and date of validity of the certificate given by the Government approved agency.