Flawless Startup

Test and Inspection of Steel Piping

Applicable Codes : ASME SEC V, SEC IX, ASME B16.25, B 31.3, B 31.1

Material Traceability Control : Receipt Inspection

Inspection of Welding :

Welder Details

Welder Identification Welder Qualification for the Welding Procedure

Fixing Construction Screen / Shelters for protection against inclement weather Welding Blankets to cover weld area floor. Piping Line Class, Material and schedule Internal cleanliness of pipe spool and Cleanliness of groove. Check Joint Configuration (Groove size, Bevel Angle, Root Face, Root Gap) Piping Alignment. Temporary welds / Tack welds condition.

Visual Examination of Branch Connections Fit-up Branch connection Weld Penetration Note : Pipe Size < DN 150 VI may be replaced by RT

Welding Method Checking Procedure is as per approved WPS. Root welding of all Pipes – GTAW Consumables checking (Type and Dryness) Preheat and Inter pass temperature Welding equipment and machines. Shielding Gas Current , Voltage, HI w.r.t applicable WPS. NOTE: For Low alloy pipe welds – Insulation material availability to cover welds

immediately after welding.Visual Inspection after Welding

Cleaning of Weld seam Reinforcement checking. Contour grinding (outside) to facilitate RT.

Root Penetration (wherever accessible) Surface defects Cleanliness of Pipe spools. Flange face protection

NDT ( RT, DPE, MPE, UT) – ALL NDT after PWHT RT – Notes:

o 5% of Branch to run pipe welds of Branch connections with size < DN 150 to verify geometry and branch fit-up

o First 5 Production weld of each welder shall be RT 100%.o If random examination reveals a defect requiring repair, 2 additional

examinations shall be made on other welds made by same welderPWHT

Notes : Girth weld hardness of weld metal and HAZ shall be measured in Brinnel Hardness (HB)

o Min of 1 reading for pipe welds < DN 100o Min 2 readings for pipe welds DN 150 to DN 300o Min of 1 reading every 400 mm for pipe welds over DN 300

Ferrite No. For Austenitic SS 3 to 8 FN.PMI

Inspection of Completed Spool Pieces Shop Fabricated Spools:

o Dimensional inspectiono Orientation (Angle and Direction) of Bent portionso Field Welding allowance.o Visual inspection of inside of piping (Cleanliness, Removal of Backing gas

dams, Dryness)o Protection of Open ends and flange facings.

Inspection of Installed Piping Visual inspection

o Conformance of piping system to relative Spool DWG.o Alignment of piping (No twist and Vertical and Horizontal Alignment)o Checking of Pipe Shoeso Removal of Tack welds.o Pipe supports dimensions and locations.o Cold expansion provisiono Locking of Spring Supports

Instrument Branch Piping and Orifice Plateso Direction and Location of Branch.o Internal weld penetration smoothness at flange weld.o Orifice plate Tag nos and installation w.r.t the flow direction.

Installed Conditions of Flange Jointso Proper Bolt Lengths and Uniform Bolt Tightening as per Project

Specification.o Fastener Material identification ( Type, Grade and Colour Code)o Cleanliness of Flange Gasket Seat Surfaceso Compliance of Gasket Paste (if Used) with Manufacturer’s Specification.o Gasket Type, Thickness and Colour Code.o Stud Bolt Sealing and Flange Labelling.

Installed Conditions of Valves o Valve Tag plate Verification and Valve identification (to ensure specified

type is used).o Correctness of Installation of Valves w.r.t fluid flow directiono Replacement of Control Valves by temp FB Spool pieces.o Internals of Check Valves fixed in open position (to allow Hydro-testing and

flushing).o Re-instatement action and re-instatement punch list for internals and

Valves.Pressure test :

Generalo Check Test Flow Sheet for the following as min

Test Pressure and Test Fluid Locations of Blinds Open / Close position of Valves as specified. Vents and Drains location. Installed Instruments ( whether to be left installed or demounted)

o Ensure no hot or cold insulation of weld joints until the completion of Pressure test.

o Quality of Water used for Pressure test. ( Chloride Check, Cleanliness)o Min temp of test water for CS and ferrous materials to be >10⁰C

Inspection Stages Piping Erection and Testing.

Receipt inspection of Shop Fabricated Piping and Piping Components for Field welding (where ever applicable) at Construction site.Visual Inspection of SpoolFlushing of Spool prior to installation.Field Weld Joint Fit-up.Field Weld Root Run Completion.Field Weld Capping Completion.Installation of Pipe Supports.Weld PWHT (If applicable)– Temp/time records.Flange Alignment.Weld NDT (RT, DPE, MPE, UT, Hardness, FN, PMI etc).Pickling and Passivation (for SS welds).Final Touch-up painting.Installation of Flange Gaskets and Torqueing.Locking of Spring Supports.Ensure Validity of Calibration of Testing and Measuring equipment / instruments. ( Verify Calibration register).Pre-Hydro test Punching. Hydro-testing ( after system fill with water).Draining piping system after Hydro – test.Water Flushing.Drying.Re-instatement of Line-componentsRe-instatement punching.Painting acceptance.