8吨油炉外协ITP.docx
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8吨油炉外协ITP.docx
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8吨油炉外协ITP
InspectionandTestPlanCodes
CodeDescription
HHOLD.NOTTOPROCEEDUNTILRELEASED
IINPROCESSINSPECTION
RDOCUMENTATIONTOBEREVIEWED
WINSPECTIONPOINT
Comments
1.AllInspectionPointsmustbepartofthesupplierqualityprocess(HoldPoint)
2.Alldocumentsshallbeclearlyidentifiedwiththefollowinginformation:
Plant;SpecificationNumber;PurchaseOrderNumberandEquipmentNumber.
3.TubeModulefabricationmustcomplywithASMEI.
4.AllweldingmustcomplywithASME9forpressurecontainingcomponents.
5.AllstructuralweldingmustcomplywithAWSDl.1.
6.DPECshallnoticeCustomeratleastsixteen(16)daysinwritingofthedateandtheplaceatwhichtheequipmentwillbereadyfortesting
ApplicableDeltakSpecifications
SpecificationNameDrawingNo:
1.Stainlesssteelcontaminationcontrol08001315
2.Headerinspectionspecifications08001143
3.Hydrostatictestingprocedure08001304
4.Threadedhydroplugweldpreparation08000932
5.Tubehandling08000810
6.Tubeinspection08001025
7.Casingfabrication08001082
8.Insulationblanket,international08001006
9.PostweldHeatTreatmentusinglocalstressreliefForcarbonandalloysteels08001023
10.Tubetoheaderweld-fullpenetration08001310
11.PWHTprocedureforcarbonandalloysteels08001275
12.Steamdrumfabrication08001086
13.Headerfabricationinspection08001143
14.Internalattachmentinspection08001142
VENDORREQUIRED
VendorRequiredDeliverableRecords
SUBMITTALDOCUMENTS
x
WeldProcedures&PQR's
ASMEManufacturer'sDataReports(MDRs)
x
WeldMap
x
WeldersQualifications
x
WeldingSpecification
1
CopyManufacturer'sDataReportsshippedwithcomponent
x
ElectrodeStorageProcedure
1
CopyManufacturer'sDataReportsineachVendorRecordsPkg
x
HeatTreatmentProcedure
x
NonconformityReportProcedure
1
Paper
x
InspectorQualifications
x
RadiographicExamProcedure
X
3.2a.Mfr'sDataReportsX
3.2dHydrotestReports
x
UltrasonicExamProcedure
X
3.2b.MaterialTestReports*X
3.2e.CodeStampRubbings
x
LiquidPenetrantExamProcedure
X
3.2c.P.W.H.T.Charts
3.2f.NameplatePhotocopies
x
MagneticParticleExamProcedure
*MTRsarerequiredforpressurecontainingfittings
x
QAProgram
x
EquipmentCalibrationCertificates
X
NDEExamReports
X
RTExamReaderSheets
x
PaintProcedure
X
FinalNCR's
X
PaintInspectionReport
x
QualityAssuranceManual
X
CertificateofCompliance
X
ShippingRelease
x
In-ProcessNCR's
X
Traveler
x
EquipmentphotoPhotographs
X
Dimensional/AsBuiltDrawings
X
FinalInspectionReport
1.HPsteamdrum-FORGINGS
Itm
InspectionPoint
Ref.Doc.
Vendor
DPEC
CTCI
PTTUT
Remarks
1
Furnacecalibrationprocedure
PO/SPEC
R
2
Furnacelayoutdrawing
PO/SPEC
R
3
Thermocouplelocationdiagram
PO/SPEC
R
4
NDEprocedureapproval
PO/SPEC
R
5
Supplieroperatingprocedureapproval,Heattreatmentprocedure,materialtraceability
PO/SPEC
R
6
Suppliercheckofflistapproval
PO/SPEC
R
7
Reviewmaterialreceipt
DWG
R
8
Checkheatcodestamping/identification
DWG
I
I
9
Verifyfurnacecalibrationrecords
PROCEDURE
I
10
Verifyfurnaceloadings
PROCEDURE
I
11
Verifyheattreatment
PROCEDURE
I
R
12
Checkthermocoupletemperaturerecords
PROCEDURE
I
13
Verifythermocoupleinsulated
PROCEDURE
H
14
Verifygrainstructuremetallograph/oneforeachfurnaceheat
DWG
H
15
Verifymechanicaltestingpercode
ASTM
H
R
16
Reviewqualitydocumentation
QAPLAN
R
R
2.HPsteamdrum
Itm
InspectionPoint
Ref.Doc.
Vendor
DPEC
CTCI
PTTUT
AI
1
PrefabricationMeeting
PO/SPEC
H
2
QAapproval
PO/SPEC
R
3
WPS/PQRapproval
PO/SPEC
R
R
4
Weldmapapproval
PO/SPEC
R
R
5
Welderqualificationandtrackwelderqualifications
PO/SPEC
H
R
6
NDEprocedureapproval
PO/SPEC
R
7
Supplieroperatingprocedureapproval(Forexample:
painting,PWHT,etc.)
PO/SPEC
R
8
Suppliercheckofflistapproval
PO/SPEC
R
R
9
Verifyshell/headUTperASTM578forplatesgreaterthan1.5"thickness.
SPEC
R
R
10
Layoutofadrumheadpriortoflamecutting/drillingnozzleholes
DWG
I
11
Verifyfit-upofmanwayring.Verifybasemetalcleanliness
DWG
I
12
Checkringflatnessandfinish
DWG
I
13
BackgougeofmanwayringandMT
DWG
I
R
14
Fit-up/subarcweldingoflongseams
DWG
I
15
Fit-upofshellcourses/checkoutofroundness
DWG
I
16
Fit-upofdrumheadtoshell
DWG
I
I
17
ReviewRTfilmoflong/roundseams
ASMEI
H
R
18
Hardnesstestonlong/roundseams
ITP
I
19
Checklayoutofnozzlespriortoflamecuttingholes
DWG
I
20
Checkfit-upofreinforcingnozzles
DWG
I
21
Checkback-gougingofreinforcingnozzles/MTrootforfullpenetrationweldsonly.
WPS
I
22
UTBasemetalaroundallsit-onnozzlesequalto4"offlamecutholeandlarger
SPEC
I
R
23
PT/MTholeplateedgeforsitonnozzleonly.
SPEC
I
R
24
MTtestallnozzlewelds
SPEC
I
R
25
MTtemporaryattachmentspriortoPWHT
SPEC
I
R
26
Verifywelderidentificationofallwelds
QAManual
I
27
Finalinspectallwelding
DWG
H
H
H
H
28
VerifyPWHT/procedureapproval
SPEC
I
R
R
29
CheckPWHTcharts
ASMEI
I
R
R
30
Hardnesstest
R
R
31
Hydrotestonehourminimumholdtime1.5MAWP
ASMEI
H
H
H
H
32
VerifyASMEcodestampings
DWG
H
H
33
Finalinspectinternalsand/orsurfaceblast
procedure
I
34
Finalinspectsurfaceprepareandpaint
procedure
I
35
Finalinspectpacking
I
36
Finalinspectshippingpreparation/identification
DWG
H
H
H
I
Reviewqualitydocumentation
ITP/P.O.
R
R
R
R
3.ModuleFabrication
3.1welderqualificationfortubetoheaderwelding
Itm
InspectionPoint
Ref.Doc.
Vendor
DPEC
CTCI
PTTUT
Remarks
Priortoproductionweldingeachweldermustdemonstratetheabilitytosuccessfullyweld
REF.DOC
1.
Aproductionmockupofthesameconfigurationasthepanelwelds(numberoftuberowswith3tubetoheaderwelds)
SPEC
I
2.
Theweldsmustbecross-sectionedtocheckforweldPenetrationanddefects
ASMECode
I
3.
Allweldsmustbeacceptablebeforeinitiatingproductionwelding
SPEC
H
R
R
3.2FINTUBESRECEIPTINSPECTION
Itm
InspectionPoint
Ref.Doc.
Vendor
DPEC
CTCI
PTTUT
AI
1.
Checkmaterialpackinglistitems.
DWG
R
2.
Checkheatcodemarkingsoneachtube,headerandtheromocouples
PO
R
3.
Review/approvetubematerialtestreportsperASMESectionII
SPEC.
R
R
4.
Checkfinlength,segmentsandthickness.
DWG
I
5.
Verifyfinmaterialspecifications.
DWG
R
R
R
R
6.
Checkfintubelengthswithtemplates(onetubeperbundle).(NoteanyvariationsexceedingdrawingstolerancesonanNCR)
DWG
I
7
PMItestonalloytube
ITP
I
3.3HEADERSFABRICATION
Itm
InspectionPoint
Ref.Doc.
Vendor
DPEC
CTCI
PTTUT
AI
1.
Reviewmaterialidentificationandstamping
DWG
I
R
2.
Checktubeholelayout/holediameter
DWG
I
3.
Checkheadercleanliness
DWG
I
4.
Visuallyinspectallaccessiblefullpenetrationwelds
DWG
I
5.
Verifybaffleplateinstallation
DWG
H
6.
MTorPTonheadergradeandendplateedgeafterwelding
ITP
I
7
Checkendplatefitup/weld
DWG
8.
Checkweldfittingfitup/weld
DWG
I
9.
PMItestonalloyheaderandwelding
ITP
I
10.
Checkfinaldimensions
DWG
I
11.
UTheaderendplatesweldingpercode
ASME1
H
12.
Radiographbuttweldspercode
ASME1
I
R
13
UTfullpenetrationheaderlugwelds(10%random)
ITP
I
R
14
MTfullpenetrationheaderlugandnozzlewelds(100%)
ITP
I
R
3.4CASINGFABRICATION
Itm
InspectionPoint
Ref.Doc.
Vendor
DPEC
CTCI
PTTUT
Remarks
1
ReceiptinspectionofallDeltaksuppliedmaterials
PO/SPEC
R
2
Checkmaterialdocumentationperdrawingspecifications
DWG/MTR
R
3
ConfirmthatproperWPSisutilized&welderqualification
DWG/WELDMAP/AWSD1.1
R
4
CheckIBeam/Fitups/Weldpenetration/Finalwelds.PT10%ofcompositewelds.
DWG
I
5
Checkfitupoffullpenetrationwelds
DWG
I
6
Confirmthatweldingisperformedinaccordancewithrequirements,includingproperbackgouging.
DWG/WELDMAP/AWSD1.1
H
7
UTTest100%ofallfullpenetrationwelding
STRUCTURALWELDSTD.
H
8
Checkallweldsaftersandblastandbeforepainting,verifysandblastprofile
DWGWELDMAPAWSD1.1
H
9
Checkpaintthickness,verifyweldableprimeapplication
DWGPROCEDURESPEC
I
10
Verifystudweldingtests,checkstudandweldsizepercode,insulationpinwelds
DWGAWSD1.1
H
11
Checkstudweldinglocationssizeandmaterial
DWGSPECAWSDl.l
H
12
Verifyinsulationthicknessanddensity(verify5%byweighttesting)andMTR
DWG06100159
W
13
Confirmproperinsulationinstallationandweatherprotectionplasticinstallation
DWG06100159
H
14
ChecklinerFabrication,dimensions,materials,verifyflamecutholeroundness,tolerance
DWG06100159
H
15
Confirmproperlinerinstallation,
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