Upload
mohsen
View
221
Download
0
Embed Size (px)
Citation preview
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 1/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
1 /56DOC N°:
H201 FQ 001
8, COURSLOUIS LUMIERE
94306 VINCENNES CEDEX
FRANCE
SPECIFICATIONOF
QUALITY CONTROL & INSPECTION PLAN
FOR
TUBULAR REFORMER
JSC “ACRON” – AMMONIA PLANT 4DDP Ancor Jobsite - VELIKY NOVGOROD
RUSSIA
Item:
H-201
02 Jun. 13 Adding convection section, air ducts
and flue gas ductsKB GGU MP
01 Oct. 13 Adding Piping and DeNOx unit KB GGU MP Customer : ACRON
Process Licensor : HALDOR TOPSOE 00 Sept. 13 First Issue KB GGU MP
REV. DATE DESCRIPTION
BY/PAR VISA BY/PAR VISA BY/PAR VISA
HPC Ref: UF 13006 ISSUED ETABLI
CHECKED VERIFIE
APPROVED APPROUVE
This document contains proprietary information belonging to HEURTEY PETROCHEM, its parent and/or affiliated companies and shall be used only for the purpose for which it was supplied. It shall not becopied, reproduced or otherwise used, nor shall such information be furnished in whole or in part to others, except in accordance with the terms of any agreement under which it was supplied or with theprior written consent of HEURTEY PETROCHEM and shall be returned upon request.Ce document contenant des informations confidentielles est la propriété de HEURTEY PETROCHEM, ses filiales et compagnies associées. Il ne peut être copié, reproduit, divulgué ou utilisé de quelque façonque ce soit, aussi bien dans sa totalité que partiellement, excepté en accord avec l es termes d’un engagement préétabli ou d’ autorisation formelle de HEURTEY PETROCHEM (retour à première demande).
CONTENTS LIST UF 13006
H201 FQ 001
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 2/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
2 /56DOC N°:
H201 FQ 001
CHAPTER DESIGNATION Note
I n s p e c t i o n
l e v e l
Revision
0 1 2 3 4
GENERAL NOTE “SCOPE OF INSPECTION” X
1 Inlet distributors 4 X
2 Combustion air preheater – E205 4 X
3 Steam fired combustion air preheater – E220 4 X
4 Burners 4 X
5 Air Blowers – K 201 & K 202 4 X
6 Hairpin tube in gas inlet and braces 4 X
7 Hairpin tube in gas outlet 4 X
8 Loose parts for catalyst tubes 4 X
9 Cold outlet collector 4 X
10 Hot Collectors 4 X
11 Radiant casing with grating, ladders and platforms 4 X
12 Convection casing with grating, ladders and platforms 4 X
13 Prefabrication of piping 4 X X
14 DeNOx D251 4 X X
15 Convection section 4 X
16 Flue gas ducts casing and air ducts casing 4 X
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 3/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
3 /56DOC N°:
H201 FQ 001
SCOPE of INSPECTIONFor
Tubular Reformer
GENERAL
1. PurposeThe Purpose of this Specification is to describe the Scope of inspection activities of HEURTEY PETROCHEM'sand of this customer ACRON for the AMMONIA PLANT 4, in DDP Ancor Jobsite VELIKY NOVGOROD, RUSSIANFederation.
2. VENDOR’s Responsibility
2.1 Vendor will remain fully responsible for the compliance of the fabrication processes, quality control processes,etc., with the applicable Laws, Regulations, Codes and all Project Specifications.
HEURTEY PETROCHEM and/or “ ACRON” inspection activities will never release the Vendor from the above
responsibilities.
2.2 As required in the Purchase Order and HPC Requisition "Documentation to be furnished by Vendor" which isindicated to the Specification, the Vendor (HPC Supplier) shall supply an Inspection and Test Plan (ITP)with detailed description of every Q-C/Inspection step required by the Laws, Regulations Codes,Project specifications, requisition, etc....
The Vendor's ITP will be reviewed and approved by HEURTEY PETROCHEM. HEURTEY PETROCHEMwill confirm its own scope of inspection and/or Client scope upon first submittal of the ITP by Vendor.
The ITP will be always submitted to HEURTEY PETROCHEM at least four (4) weeks prior to holding thePre-Production Meeting and/or Pre-Inspection Meeting.
3. Applicable PROCEDURES, SPECIFICATION…
3.1 Client Specifications:
3.1.1 Main documents for Tubular ReformerREF51001-Rev.0-H 201-List of documents for reformer radiant & convection sectionREF51002-Rev.0-H 201-Primary reformer_radiant section General arrangementREF51004-Rev.1-H 201-List of main componentsREF51005-Rev.0-H 201-Primary reformer_radiant section General arrangement of gas inletREF51006-Rev.0-H 201-Primary reformer_radiant section General arrangement of gas outletREF51007-Rev.1-H 201-Primary reformer_radiant section Inlet distributorREF51009-Rev.0-H 201-Primary reformer specification for low alloy inlet distributorREF51011-Rev.1-H 201-Primary reformer_radiant section Hairpin tube in gas inlet
REF51013-Rev.0-H 201-Primary reformer specification for hairpin tubes in gas inletREF51015-Rev.1-H 201-Primary reformer_radiant section Catalyst tube support_ flange_ two-part ring and gridREF51018-Rev.1-H 201-Primary reformer_radiant section Hairpin tube in gas outletREF51019-Rev.0-H 201-Primary reformer specification for hairpin tubes in gas outletREF51020-Rev.1-H 201-Primary reformer_radiant section Hot collectorREF51021-Rev.0-H 201-Primary reformer specification for hot collectorREF51024-Rev.0-H 201-Primary reformer_radiant section Cold outlet collectorREF51026-Rev.0-H 201-Primary reformer specification for refractory lining in cold collectorREF51027-Rev.0-H 201-Tubular reformer_radiant section Instrument connection for cold collectorREF51030-Rev.0-H 201-Primary reformer specification for field welding of inlet hairpin tubesREF51032-Rev.0-H 201-Primary reformer specification for field welding of outlet hairpin tubesREF51041-Rev.0-H 201-Primary reformer_radiant section General arrangement of steel structure. part IREF51042-Rev.0-H 201-Primary reformer_radiant section General arrangement of steel structure_ part II
REF51043-Rev.0-H 201-Primary reformer_radiant section Typical details of steel structure and casing
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 4/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
4 /56DOC N°:
H201 FQ 001
REF51044-Rev.0-H 201-Primary reformer specification for radiant and convection section steel structure and casingREF51045-Rev.0-H 201-Primary reformer_radiant section Reformer roofREF51048-Rev.0-H 201-Primary reformer_radiant section arrangement of platforms_ ladders and stairwaysREF51050-Rev.0-H 201-Tubular reformer_radiant section Braces for hairpin tubes in gas inletREF51051-Rev.0-H 201-Primary reformer_radiant section Guide ring for catalyst tubeREF51052-Rev.0-H 201-Tubular reformer_radiant section Access doorREF51053-Rev.0-H 201-Tubular reformer_radiant section Spring support for hairpin tube in gas inletREF51054-Rev.0-H 201-Primary reformer_radiant section Spring support for hairpin tube in gas outletREF51055-Rev.0-H 201-Primary reformer_radiant section Counterweight for hot collectorREF51056-Rev.0-H 201-Tubular reformer_radiant section Burner plate and refractory block
REF51059-Rev.0-H 201-Tubular reformer_radiant section General arrangement of refractory liningREF51060-Rev.0-H 201-Tubular reformer Typical refractory lining detailsREF51061-Rev.0-H-201-Tubular reformer radiant and convection section specification for refractory liningREF51065-Rev.0-H 201-Primary reformer_radiant section Insulation for hot partsREF51066-Rev.0-H 201-Tubular reformer_radiant section Arrangement of combustion air ductingREF51068-Rev.0-H 201-Primary reformer radiant and convection section specification for erectionREF51071-Rev.0-H 201-General arrangement Sketch of convection sectionREF51072-Rev.0-H 201-Tubular reformer specification for convection sectionREF51074-Rev. 0-H 201-Tubular reformer_radiant section Plinth layout (preliminary)
3.1.2 Other Specifications for Tubular Reformer:J61024-Rev.0-Typical Hook-up Drawings for Instrumentation in Petrochemical PlantsJ61025-Rev.0-General specification for instrument erection materials (piping & tubing)
J63203-1-Rev.0-Detailed specification for thermocouples in flue gas ductsJ63203-2-Rev.0-Detailed specification for thermocouples in primary reformer hot collectorJ63203-3-Rev.0-Detailed specification for thermocouples in primary reformer cold collectorP41001-Rev.0-MSD1-Reforming w_FD L2-Desulphurization and Reforming[1]P41401-Rev.1-C4 PFD1-Reforming-Desulphurization and ReformingP42103-Rev.0-P03-Natural gas preheatP42104-Rev.0-P04-Process air preheatP42105-Rev.0-P05-Hp steam superheatP42106-Rev.0-P06-Feed_steam mixingP42107-Rev.0-P07-Reformer convection sectionP42108-A-Rev.0-P08A-Flue gas blowerP42108-B-Rev.0-P08B-Combustion air blowerP42109-Rev.0-P09-Primary reformer fuel control
P42110-Rev.0-P10-Primary reformerP51201-H-002-Rev.0-Primary reformer gas burnersP51201-H-005-Rev.0-WHS-Convection Section CoilsP51201-H-Rev.0-H 201-Primary ReformerP51205-E-Rev.1-E 205 _ E 220-Combustion air preheatersP54251-V-Rev.0-V 251-Ammonia water storage tankP56201-K-Rev.0-K 201-Flue gas blowerP56202-K-Rev.0-K 202-Combustion air blowerP56251-K-Rev.0-K 251-Ammonia mixing blowerP59201-X-Rev.0-X 201-Flue gas stackP59251-J-Rev.0-Specification for J 251 DeNOx inlet sample ejectorP59252-J-Rev.0-Specification for J 252 DeNOx outlet sample ejector
3.2 HPC Documents :
3.2.1 Data Sheets (FJ)
3.2.2 Technical Specification (FS)
3.2.3 Drawings (FD)
3.2.4 Calculation Notes (FC)
3.2.5 General Specification (SG)
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 5/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
5 /56DOC N°:
H201 FQ 001
4. Specific and/or Important Requirements
4.1 Inspection Levels for Materials and Equipments
The inspection Levels for materials and/or equipments are as follow:
Level 0: No Inspection required; No Inspection Certificate required
Level 1: Documentation review only; Inspection Release Note (IRN) required
Level 2: Only final inspection required prior to Shipment; Inspection Release Note (IRN) required
Level 3: Inspection of all Witness and Hold points required by approved Supplier ITP and Scope ofinspection; Inspection Release Note (IRN) required
Level 4: Include Pre-Inspection Meeting (PIM), Inspection of all Witness and Hold points required by approvedSupplier ITP and Scope of inspection; Inspection Release Note (IRN) required
Level 5: Level 4 + Monitoring/expediting visits on regular basis (Weekly, Bi-weekly, Monthly…). Thefrequency visits shall be decided by HPC Project manager
Level 6: Level 4 + a full time resident inspector continuously, monitoring the fabrication (progress and quality); thecommencement of the resident status shall be decided by HPC Project manager.
4.2 Material test Certificates
For pressure retaining parts and all elements welded to the pressure retaining parts:
Vendor shall provide Mill certificates ASME (SA) / ASTM / EN-10204, 3.1 or 3.2 types which will give atleast the following data for each heat and/or heat treatment batch:
Material specification references
Heat number
Material description (plate thickness, tube diameter, thickness, etc...)
Material specification minimum requirements,
Actual chemical analysis, mechanical tests results,
Heat treatment conditions of the material (if required), with records/charts
Heat treatment conditions of the mechanical test samples,
Non-destructive tests (if required) fully documented results
MDMT: Minimum Design Metal Temperature
For Non-pressure parts:HEURTEY PETROCHEM recommends the Vendor to provide Material Certificates as above describedbut is ready to accept certificates of compliance for these parts unless required otherwise by the Laws,Regulations on Codes
Note: HEURTEY PETROCHEM reserves the right to reject all material Test Certificates altered by reproduction(photocopy) and/or illegible and/or not signed and dated by the Mill QC Responsible or not in compliance withthe latest edition of Material Specification in accordance with its requirements.
IMPACT Test: Vendor will refer to MDMT (Minimum Design Metal Temperature) stated in the applicable datasheet to HEURTEY PETROCHEM equipment data, to get the execution temperature of impact test.
4.3 Welding Consumables
For pressure retaining parts:For welding consumables used for execution of pressure retaining welds, the Vendor shall provide Millcertificate as described in applicable code, standard, according to ASME or EN-10204 (Certificate 3.1 or3.2 type).
A welding consumables used shall have a chemical composition which shall be within the range of thatspecified for the vessel shell and mechanical properties that are within range of that specified in theheat-treated condition.
When required by the contract, the conformity to the MDMT (as required hereafter in thisspecification) shall be indicated on the certificates
For Non-pressure parts:HEURTEY PETROCHEM recommends the Vendor to provide Material Certificates as above described
but is ready to accept certificates of compliance for these parts unless required otherwise by the Laws,Regulations on Codes
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 6/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
6 /56DOC N°:
H201 FQ 001
4.4 Refractory Bricks and Shapes
Use/Classification, Design, Supply, Installation and Maintenance of all REFRACTORY Materials shallcomply and in according with ISO 13705 (API560) section 11, as well as the following ISO Norms and/or ASTM Specification:
Fireclay brick: ISO 1109, ISO/DIS 10081, ASTM C27
Insulating Firebrick: ISO 2245, ASTM C155
Castable Refractory: ISO 1927, ASTM C401 (class N, O, P, Q or R)
Insulating Block (Mineral Slag wool, Neutral pH): ASTM C612 Cl5
4.5 Steel Structures
The steel Structure shall be in accordance with ISO 13705 (API560) Section 12The design and Engineering of building shall comply with all codes, norms and others regulations applicableThe effects of fatigue shall be verified in compliance with ANSI/AWS D1.1.
5. Manufacturer’s Record Book “MRB”
The details of the content and format of the manufacturer's file shall be discussed during Pre-Fabrication and/orPre-inspection Meeting (PIM), if any.This PIM wil l be held b efore commencement o f fabr icat ion and af ter f i rs t review, comments, approval of
manufacturer’s documents and drawings The Vendor will compile the Manufacturer's File progressively during the fabrication and will keep it up to date andwill make it available to HEURTEY PETROCHEM inspector during each visit.
6. Reminder
We remind the Vendor that the documents listed here below must be sent by fax and/or mailed to the followingaddresses:
Please contact Mrs. Elmira ZAKIROVA Tel: +7 (812) 448 76 80Email: [email protected]
Adresse: HEURTEY PETROCHEM SAService Gestion Documentation Technique 8, Cours Louis Lumière94306 VINCENNES Cedex - FRANCE
Detailed Inspection Test Plan (ITP) defining Main elements to be testedList of control & test operations carried out by the Vendor under his responsibility. Sub-contractorinspection & test plan, more detailed shall be issued.
Welding Book including Weld map, WPS and PQR NDE Procedures (RT, PT, MT, US “if required”…) PWHT Procedure (When applicable) Hardness test Procedure
PMI Procedure (if any) Notification for Inspection Form Non-Conformance reports Form Preservation, Packing Procedure Name plate (When required) Etc…
7. Main REQUIREMENTS
The Purchaser, Client reserves the right to witness or audit the Supplier's Quality Control at the Vendor'sfacilities when deemed necessary.
When code requirements are more stringent they shall prevail over the requisition, specification and
standards; should any doubt arise regarding the rules, the SELLER shall submit to the BUYER, all request ofdeviations and/or clarifications and obtain a written approval before proceeding.
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 7/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
7 /56DOC N°:
H201 FQ 001
Inspection authorities or people attending the controls & test
Controls and/or tests carried out by the VENDOR i.e. Subcontractor / Manufacturer are indicated by a cross(X) in the relevant column.
7.1 Pre-Award Meeting/Kick-off Meeting (KOM) and Pre-Inspection Meeting (PIM)
For certain Purchase Order, a Pre-Award meeting/Kick-off meeting could be scheduled. This meeting could becarried out in the HPC offices or in the supplier workshop.
Before commencement of Fabrication and minimum after first review/approval of manufacturer’s quality
documents, drawings and others documents, a PIM shall be obligatory performed on all main Purchase Order.This point will be indicated in the Scope of Inspection.
During the PIM, the following minimum requirement above, concerning the fabrication, the inspection and thetests shall be discussed to be in accordance to PO requirement:
- Review of technical requirements, covering codes, governing codes and/or standards- Final review of vendor’s detailed ITP - Review of fabrication & control/tests procedures submitted or to be submitted- Review of schedule of document’s submission - Review of sub. P.O. & their requirements- Review of fabrication schedule- Review finalization of Sub-Supplier inspection and test plan. (if any)- Welding and Heat treatment
- Material test report, Traceability… - Non-conformances- Supplier personnel qualification & training- Supplier documentation schedule timing for submission- Proposed Sub-suppliers review of suborders requirements- Records, reports and documentation data book- Workshop tour
7.2 Detail of INSPECTION POINTS
The interventions carried out by HEURTEY PETROCHEM (HPC), his CLIENT and/or the OFFICIAL INSPECTION AUTHORITY is indicated in the relevant column according to the type of intervention:
DOCUMENT APPROVAL: AThe vendor submits the documents for approval at least 10 calendar days before the relevant actiontakes place. The action shall not start before the approved (A) or for information (E) status has beengranted to the document.
DOCUMENT REVIEW: R (Only Documents)The Vendor performs the contractual controls & tests & sends to HPC, within 48 h, copy of the relevantcertificates & reports.
WITNESS POINT: W (hold 100%) SW (hold 10%)The Vendor notifies HPC 10 calendar days in advance by Email, or fax. If HPC does not attend, the Vendorcarries out the contractual controls & tests, sends the relevant certificates & report to HPC, and continuousthe manufacturing insofar as the results of the controls & test are acceptable.
HOLD POINT: HThe Vendor notifies HPC 10 calendar days in advance by Email or Fax. He is not allowed to carry out
controls & test without the presence of HPC, unless HPC has given its written agreement. If any case,HPC reserves the right to request the Vendor, who accept to defer tests & controls by a maximum of 5days working days from the initial purposed date. If HPC cannot be present within the 5 working daysfollowing the initial date, the Vendor carries out the control & tests according to the instructions given in §“Witness point”.
MONITORING/SURVEILLANCE: MNotifications to witness are advised informally – Activities proceed as planned
NOTA: Same requirement have to be applied by the Vendor to his sub-suppliers. All documents relevant tocontrol & tests operations or to non-conformity are regrouped by the vendor in the Quality Dossier whichis at the disposal of HPC’s Client’s inspectors at any time
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 8/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
8 /56DOC N°:
H201 FQ 001
Same requirements have to be applied by the MANUFACTURER/SUPPLIER to his Sub-Suppliers.
All documents relevant to control and tests operations or to non-conformity are regrouped by the
MANUFACTURER/SUPPLIER in quality Dossier which is at the disposal of CONTRACTOR or Client's
Inspector at any time.
7.3 Abbreviation:
Ceq : Carbon Equivalent SCR : Stress Relaxation Cracking
PQR : Procedure Qualification Record HT : Heat Treatment
WPS : Welding Procedure Specification PWHT : Post Welding Heat Treatment
WPQR : Welder's Performance Qualification Record IPWHT :Intermediate Post Welding Heat Treatment
NDE : Non-Destructive Examination DHT : Dehydrogenation Heat Treatment
RT : Radiographic Test PMI : Positive Metal Identification
UT : Ultrasonic Test SS : Stainless Steel
MT : Magnetic Particle Test CS : Carbon Steel
PT : Liquid Penetrate Test Thk : Thickness
TPIA : Third Party Inspection Authority’s HAZ : Heat Affected Zone
NoBo : Notify Nobody HPC : HEURTEY PETROCHEM
MDR : Manufacturer Data Record (Data Book) P/O : Purchase OrderIOMM : Installation Operation Maintenance Manual
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 9/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
9 /56DOC N°:
H201 FQ 001
1. Category: INLET DISTRIBUTORSSCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i f i c a t e R e p o r t
RemarksAcceptance Criteria
S U P
P L I E R
H
P C
H
T A S
A C
R O N
O T
H E R S
1.1. DATA / ENGINEERING
1.1.1 Design Temperature (°C): -27°C/560°C
Design Pressure (kg/cm²g): 41
X
1.1.2 Code : ISO 13705 (API560)
: API530: ASME B31.3
: RUSSIAN STANDARDS
X
1.1.3 HTAS Process Specifications
REF51009 : Specification for Low Alloyinlet distributor
REF51030 : Specification for fieldwelding of inlet hairpin tubes
X See point 3
1.1.4 HTAS Drawings
REF51005 : General arrangement of
gas inlet
REF51007 : Inlet distributor
X See point 3
1.1.5 HPC Documents
H201-FS-403 : Material requisition for
inlet distributors
X See point 3
1.2. Pre-award meeting or Kick-off meeting X W Report See point 7.1
1.3. PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
1.4. DOCUMENTS TO SUBMIT PRIOR PIM
1.4.1 Schedule Fabrication X A Shall be revised (when required) and
confirmed each end of month.
1.4.2 Detailed Inspection Test Plan X A To be approved by HTAS before start ofmanufacture.
1.4.3 Arrangement Drawing X A
1.4.4 Details Drawing X A
1.4.5 WELDING Book including: X A To be approved by HTAS before start ofmanufacture.
Root passes to be made by TIG Process
1.4.5.1 Welding Map X A
1.4.5.2 WPS X A
1.4.5.3 PQR X A ASME IX
1.4.5.4 Filler metal certificate X A EN 10204 type 3.1
1.4.5.5 Welders Qualifications X A ASME IX or equivalent
1.4.6 NDT Procedures including: X A
1.4.6.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 10/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
10 /56DOC N°:
H201 FQ 001
1. Category: INLET DISTRIBUTORSSCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i f i c a t e R e p o r t
RemarksAcceptance Criteria
S U P
P L I E R
H
P C
H
T A S
A C
R O N
O T
H E R S
1.4.6.2 Dye Penetrant procedure X A
ASME V + ASME VIII Div.1 App 8
REF51009
- Ends bevelled for welding: 100% - No
indication is allowed in bevel and within
10 mm of it
- 100% root and final capping passes – No
indication is allowed
1.4.6.3 Radiographic procedure (on butt welds): X A
ASME V + ASME VIII Div. 1 §UW-51
REF51009 100%
1.4.6.4 Analysis for weld metal deposited (P.M.I.)procedure X A ISO 13705 §17.5.4.310% of welds and materials
1.4.6.5 Hardness test procedure X AHardness to be checked by Brinell testingin HAZ.
1.4.6.6 Hydrostatic test procedure X A
REF51009
Complete assembly at 218 kg/cm2g
during 30 minutes mini.Water< 20 ppm Cl-
1.4.6.7 Leak test procedure X AREF51009
Test at 5 barg with oil free air.
1.5 MATERIAL IDENTIFICATION
1.5.1 Main pipe : ASTM A335 P22 X R Report EN10204 – 3.1
1.5.2 Cap : ASTM A234 WP22 Cl.3 X R Report EN10204 – 3.1
1.5.3 Weldolet : ASTM A182 F321H X R Report
Grain size to be in the range ASTM E112N°7 to N°4
EN10204 – 3.1
1.5.4 Support saddle : ASTM A387 Gr.22 X R Report EN10204 – 3.1
1.5.5 Guide plate : ASTM A36 or equivalent X R Report EN10204 – 3.1
1.6 WELDING EXAMINATION
1.6.1 Beveled ends examination X SW Report
100% PT on bevels
No indication allowed on the bevel or
within 10 mm of it.
1.6.2 Welding of main pipes
1.6.2.1 Visual examination of welds X SW Report 100%
1.6.2.2 Dye penetrant examination X SW Report100% of root pass and complete welds –
No indication is allowed
1.6.2.3 Radiographic examination X SW Report 100% RT on butt welds
1.6.3Welding of support saddles on main
pipe
1.6.3.1 Visual examination of welds X SW
Report 100%
1.6.3.2 Dye penetrant examination X SW Report100% of root pass and complete welds – No indication is allowed
1.6.4 Welding of weldolets on main pipe
1.6.4.1 Visual examination of welds X SW Report 100%
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 11/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
11 /56DOC N°:
H201 FQ 001
1. Category: INLET DISTRIBUTORSSCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i f i c a t e R e p o r t
RemarksAcceptance Criteria
S U P
P L I E R
H
P C
H
T A S
A C
R O N
O T
H E R S
1.6.4.2 Dye penetrant examination X SW Report100% of root pass and complete welds – No indication is allowed
1.7 FINAL EXAMINATION
1.7.1 Visual and Dimensional examination X H Report Drawing
1.7.2 PMI examination X W Report 10% of welds and materials
1.7.3 Hydrostatic test examination X H Report218 bars during 30 minutes minimum
No leak or deformation allowed
1.7.4Leak test
X WReport Test at 5 bargNo leak or deformation allowed
1.7.5 Cleaning X W
REF51009 §9
All scale, resulting from welding shall beremoved from internal surface
All traces of welding slag, grease, dye
shall be removed
1.7.6 Drying X W
REF51009 §9.4
Drying with clean, dry air to remove dust,swarf…
1.7.7 Marking X W
REF51009 §10
Use of indelible ink not harmful to the
alloy
1.7.8 Packing X W REF51009 §12
1.7.9Manufacturer Data Book including RTN
passport X H Approved HPC summary
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 12/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
12 /56DOC N°:
H201 FQ 001
2. Category: COMBUSTION AIR PREHEATER
– E205 SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i f i c a t e R e p o r t
RemarksAcceptance Criteria
S U P
P L I E R
H
P C
H
T A S
A C
R O N
O T
H E R S
2.1 DATA / ENGINEERING
2.1.1 MDMT: -27°C X
2.1.2
Code : ISO 13705 (API560)
: API530: AWS D1.1
: RUSSIAN STANDARDS
X
2.1.3 HTAS Specifications
P51205-E: Process specification for
E205/E220 Combustion Air preheaters
X See point 3
2.1.4
HPC Documents
H201-FS-741 : Material requisition
for air preheater
H201-FJ-741 : HPC Datasheet
X See point 3
2.2 Pre-award meeting or Kick-offmeeting
X WReport See point 7.1
2.3 PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
2.4 DOCUMENTS TO SUBMIT PRIOR PIM
2.4.1 Schedule Fabrication X A Shall be revised (when required) and
confirmed each end of month.
2.4.2 Detailed Inspection Test Plan X A To be approved by HTAS before start ofmanufacture.
2.4.3 Arrangement Drawing X A
2.4.4 Details Drawing X A
2.4.5 WELDING Book including:
2.4.5.1 Welding Map X A
2.4.5.2 WPS X A ASME IX
2.4.5.4 PQR X A ASME IX
2.4.5.5 Filler metal certificate X A EN 10204-3.1 ASME II Part C
2.4.5.6 Welders Qualifications X A ASME IX or equivalent
2.4.6 Painting procedure X A
2.4.7 NDT Procedures including: X A
2.4.7.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
2.4.7.2 Dye Penetrant procedure X A
ASME V Art. 6 + AWS D1.1
10% examination of main structural welds
2.4.7.3 Leak test procedure X A Supplier's procedure
2.5 MATERIAL IDENTIFICATION
2.5.1 Plates X R EN10204-3.1 By supplier
Suitable for -27°C
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 13/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
13 /56DOC N°:
H201 FQ 001
2. Category: COMBUSTION AIR PREHEATER
– E205 SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i f i c a t e R e p o r t
RemarksAcceptance Criteria
S U P
P L I E R
H
P C
H
T A S
A C
R O N
O T
H E R S
2.5.2 Profiles X R
EN10204-3.1By supplier
Suitable for -27°C
2.5.3 Consumables X R EN10204-3.1 ASME II Part C
2.6 WELDING EXAMINATION
2.6.1 Beveled ends examination X SW Report Approved procedure
2.6.2 Dye penetrant examination X SW ReportAWS D1.1 Section 6 Part C §6.10
10% of main structural welds
2.7 LEAK TEST X H ReportApproved procedure
No leak and distortion
2.8 FINAL EXAMINATION
2.8.1 Visual and Dimensional examination X H ReportDrawings
100%
2.8.2 Painting X H Report Approved procedure
2.8.3 Marking X W
Approved procedureUse of indelible ink not harmful to the
alloy
2.8.4 Packing X W Approved procedure
2.8.5Manufacturer Data Book including RTN
passport
X H Approved HPC summary
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 14/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
14 /56DOC N°:
H201 FQ 001
3.Category: STEAM FIRED COMBUSTION AIRPREHEATER – E220
SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p l i e
r ’ s R e c o r d
C e r t i f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H P
C
H T A
S
A C R O N
O T H E R S
3.1 DATA / ENGINEERING
3.1.1 MDMT: -45°C X
3.1.2 Code : ISO 13705 (API560)
: ASME VIII Div. 1: RUSSIAN STANDARDS
X
3.1.3
HTAS Specifications
P40001-BED R1: Design Basis
P51205-E: Process specification for
E205/E220 Combustion Air preheaters
X
See point 3
3.1.4
HPC Documents
H201-FS-742 : Material requisition for
Steam air preheater
H201-FJ-742 : HPC Datasheet
X
See point 3
3.2 Pre-award meeting or Kick-off
meeting
X W Report See point 7.1
3.3 PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
3.4 DOCUMENTS TO SUBMIT PRIOR PIM
3.4.1 Detailed Inspection Test Plan X ATo be approved by HTAS before start ofmanufacture.
3.4.2 Arrangement Drawing X A
3.4.3 Details Drawing X A
3.4.4 Schedule Fabrication X AShall be revised (when required) andconfirmed each end of month.
3.4.5 WELDING Book including:
3.4.5.1 Welding Map X A
3.4.5.2 WPS X A ASME IX
3.4.5.3 PQR X A ASME IX
3.4.5.4 Filler metal certificate X A EN 10204-3.1 ASME II Part C
3.4.5.5 Welders Qualifications X A ASME IX or equivalent
3.4.6 Painting procedure X A
3.4.7 NDT Procedures including: X A
3.4.7.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
3.4.7.2 Dye Penetrant procedure X A ASME V ART. 6 + ASME VIII Div.1 APP. 8
3.4.7.3 Radiographic procedure X A ASME V ART. 2 + AWS VIII Div.1 §UW-51
3.4.7.4 Hydrostatic test procedure X A Supplier's procedure
3.5 MATERIAL IDENTIFICATION
3.5.1 LP steam side
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 15/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
15 /56DOC N°:
H201 FQ 001
3.Category: STEAM FIRED COMBUSTION AIRPREHEATER – E220
SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
3.5.1.1 Tube / Manifold / Bends X R EN10204-3.1By supplier
Suitable for -45°C
3.5.1.2 Flanges X R EN10204-3.1By supplier
Suitable for -45°C
3.5.2 Air side
3.5.2.1 Structural steel X R EN10204-3.1By supplier
Suitable for -45°C
3.5.2.2 Casing X R EN10204-3.1By supplier
Suitable for -45°C
3.5.2.3 Consumables X R EN10204-3.1By supplier - ASME II Part C
Suitable for -45°C
3.6 WELDING EXAMINATION
3.6.1 Beveled ends examination X SW Report Approved procedure
3.6.2 Dye penetrant examination X SW ReportASME VIII Div. 1 App.8
10% when RT is not possible
3.6.3 Radiographic test X SW ReportASME VIII Div. 1 §UW-51
10% on buttwelds
3.7 HYDROSTATIC TEST X H Report
Approved procedure
No leak
3.8 FINAL EXAMINATION
3.8.1 Visual and Dimensional examination X H ReportDrawings
100%
3.8.2 Painting X H Report Approved procedure
3.8.3 Marking X W
Approved procedure
Use of indelible ink not harmful to the
alloy
3.8.4 Packing X W Approved procedure
3.8.5Manufacturer Data Book including RTNpassport
X H Approved HPC summary
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 16/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
16 /56DOC N°:
H201 FQ 001
4.Category: BURNERS SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
4.1 DATA / ENGINEERING
4.1.1
Type of burner: Forced draught
radiant wall type
Quantity: 432
- 360 size 1
- 72 size 2
X
4.1.2 Code : ISO 13705 (API560): RUSSIAN STANDARDS
X
4.1.3
HTAS SpecificationsP51201 R0: Primary reformer gasburners
REF51056: Tubular reformer_ radiantsection Burner plate and refractory
block
X
See point 3
4.1.4
HPC Documents
H201-FS-201: Material requisition forburners
X
See point 3
4.2 Pre-award meeting or Kick-off
meeting
X W Report See point 7.1
4.3 PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
4.4 DOCUMENTS TO SUBMIT PRIOR PIM
4.4.1 Detailed Inspection Test Plan X ATo be approved by HTAS before start of
manufacture.
4.4.2 Arrangement Drawing X A
4.4.3 Details Drawing X A
4.4.4 Schedule Fabrication X AShall be revised (when required) and
confirmed each end of month.
4.4.5 WELDING Book including:
4.4.5.1 Welding Map X A
4.4.5.2 WPS X A ASME IX
4.4.5.3 PQR X A ASME IX
4.4.5.4 Filler metal certificate X A EN 10204-3.1 ASME II Part C
4.4.5.5 Welders Qualifications X A ASME IX or equivalent
4.4.6 NDT Procedures including:
4.4.6.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
4.4.6.2 Dye Penetrant procedure X AASME V Art. 6 + ASME B31.3 Table
341.3.2 (Normal Fluid Service)
4.4.6.3 P.M.I. procedure X A Supplier’s procedure
4.4.7 Performance test procedure X A P51201 R0 §11
4.4.8 Preservation and packing procedure X A Supplier’s procedure
4.5 MATERIAL EXAMINATION
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 17/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
17 /56DOC N°:
H201 FQ 001
4.Category: BURNERS SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
4.5.1 Plate / tube / flange & bolting X R EN 10204-3.1 Carbon Steel suitable for low temperature(-45°C)
4.5.2 Gas riser X R EN 10204-3.1 Stainless Steel
4.5.3 Gas tip X R EN 10204-3.1 Cast 25 Cr 20 Ni
4.5.4 Burner block X R EN 10204-2.2 High density refractory
4.5.5 Consumables X R EN 10204-3.1 ASME II Part C
4.6 PERFORMANCE TEST
4.6.1 Flame stability testing X W Report P51201 R0 §11One test for each size of burner
4.6.2 Ignition test X W ReportP51201 R0 §11.4
One test for each size of burner
4.7 MECHANICAL EXAMINATION
4.7.1 Welding X SW Report Approved welding book
4.7.2 Penetrant test examination X SW Report100% on fuel gas welds and 10% on
casing welds
4.7.3 PMI examination X SW Report 100% on gas tips, nozzles and risers
4.7.4 Chemical cleaning of welds X SW Report 100% of welds
4.8 FINAL EXAMINATION
4.8.1 Visual and Dimensional examination X H Report
4.8.2 Air flow test X W ReportP51201 R0 §11.85% of burners of both sizes & mini. 3 of
each size
18.8.2 Marking X H
Approved procedure
Use of indelible ink not harmful to the
alloy
4.8.3 Packing X H Approved procedure
4.8.4Manufacturer Data Book including RTNpassport
X H Approved HPC summary E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 18/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
18 /56DOC N°:
H201 FQ 001
5.Category: AIR BLOWERS–K 201 & K 202 SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
5.1 DATA / ENGINEERING
5.1.1
MDMT
K-201: -27°C
K-202: -45°C
5.1.2
Code : ISO 13705 (API560)
: API 673
: RUSSIAN STANDARDS
X
5.1.3
HTAS Specifications
P56202 R0: Process specification for K202 Combustion Air Blower
P56201 R0: Process specification for K201 Flue Gas Fan
P55202-TK: Process specification forTK-202
P55201-TK: Process specification forTK-201
P40001: Design basis
REF5107: GA Convection section
J61021 R2: General specification for
instrumentation
4-1246 E R7: Painting
X
See point 3
5.1.4
HPC Documents
H201-FS-721 : Material requisition forforced draft fan (Air fan)
H201-FS-899A : Fan damper actuatorspecification
H201-FS-850 : ID-FD fan motordatasheet
H201-FJ-721 : Data sheet Heavy dutycentrifugal Fan (Air fan)
H201-FJ-722 : Data sheet Heavy dutycentrifugal Fan (Flue gas fan)
X
See point 3
5.2 Pre-award meeting or Kick-off
meeting
X W Report See point 7.1
5.3 PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
5.4 DOCUMENTS TO SUBMIT PRIOR PIM
5.4.1 Detailed Inspection Test Plan X ATo be approved by HTAS before start ofmanufacture.
5.4.2 Arrangement Drawing X A
5.4.3 Details Drawing X A
5.4.4 Schedule Fabrication X AShall be revised (when required) and
confirmed each end of month.
5.4.5 WELDING Book including:
5.4.5.1 Welding Map X A
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 19/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
19 /56DOC N°:
H201 FQ 001
5.Category: AIR BLOWERS–K 201 & K 202 SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
5.4.5.2 WPS X A ASME IX
5.4.5.3 PQR X A ASME IX
5.4.5.4 Filler metal certificate X A EN 10204-3.1 ASME II Part C
5.4.5.5 Welders Qualifications X A ASME IX or equivalent
5.4.6 NDT Procedures including:
5.4.6.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
5.4.6.2 Dye Penetrant procedure X A ASME V Art. 6 + AWS D1.1 Section 6 Part
C §6.10
5.4.6.3 Ultrasonic test procedure X AASME V Art. 2 + AWS D1.1 Section 6 PartC §6.13
5.4.7 Balancing test procedure X A API 673
5.4.8 Performance test procedure X A API 673
5.4.9 Running test procedure X A API 673
5.4.10 Preservation and packing procedure X A Supplier's procedure
5.4.11 Painting procedure X A 4-1246 E R7
5.5 MATERIAL EXAMINATION
5.5.1 Plate / steel profile X R EN 10204-3.1 Carbon Steel suitable for low temperature(-27°C for K201 and -45°C for K202)
5.5.2 Shaft X R EN 10204-3.1 Carbon Steel suitable for low temperature(-27°C for K201 and -45°C for K202)
5.5.3 Impeller X R EN 10204-3.1 Carbon Steel suitable for low temperature
(-27°C for K201 and -45°C for K202)
5.5.4 Blade material X R EN 10204-3.1 Carbon Steel suitable for low temperature
(-27°C for K201 and -45°C for K202)
5.5.5 Bolting X R EN 10204-2.2 Supplier's drawing
Standard
5.6 FANS INSPECTION
5.6.1 Balancing test X SW Report Compliance with approved procedure
5.6.2 Performance test X H Report Compliance with approved procedure
5.6.3 Running test X H Report Compliance with approved procedure
5.7 MOTORS
5.7.1 Low voltage directive X R
Certificate 73/23/EC
Compliance with directive
5.7.2 Machine directive X R
Certificate98/37/EC
Compliance with directive
5.7.3 Electromagnetic compatibility directive X R
Certificate2004/108/EC
Compliance with directive
5.7.4 Atex directive X R
Certificate94/9/EC
Compliance with directive
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 20/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
20 /56DOC N°:
H201 FQ 001
5.Category: AIR BLOWERS–K 201 & K 202 SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
5.8 MECHANICAL EXAMINATION
5.8.1 Welding X SW Approved welding book
5.8.2 Penetrant test examination X SW ReportISO 13705 §E.4.2.2
100% on impeller welds after running test
5.8.3 Ultrasonic examination of shaft X SW ReportApproved procedure
100% of the shaft
5.8.4 Painting
5.8.4.1 Surface preparation X SW Report Approved procedure
5.8.4.2 Thickness examination X SW Report Approved procedure
5.9 FINAL EXAMINATION
5.9.1 Visual and Dimensional examination X H ReportDrawings
100%
5.9.2 Marking X H Report
Approved procedure
Use of indelible ink not harmful to thealloy
5.9.3 Packing X H Approved procedure
5.9.4Manufacturer Data Book including RTNpassport
X H Approved HPC summary
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 21/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
21 /56DOC N°:
H201 FQ 001
6. Category: HAIRPIN TUBE IN GAS INLETAND BRACES
SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 1
No Inspection Item / Step
By
S u p p l i e r ’ s R e c o r d
C e r t i f i c a
t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L
I E R
H P C
H T A
S
A C R O N
O T H E
R S
6.1 DATA / ENGINEERING
6.1.1Design Temperature (°C): -27°C/560°C
Design Pressure (kg/cm²g): 41
X
6.1.2
Code : ISO 13705 (API560)
: API530: ASME B31.3
: RUSSIAN STANDARDS
X
6.1.3 HTAS Process Specifications
REF51013 : Primary reformer
Specification for hairpin tubes in gas inlet
X See point 3
6.1.4
HTAS drawings
REF51005 : General arrangement of gas
inlet
REF51011 : Hairpin tubes in gas inlet
REF51050 : Braces for hairpin tubes in
gas inlet
REF51053 : Spring support for hairpin
tube in gas inlet
REF51065 : Radiant section insulation
for hot parts
X See point 3
6.1.5HPC Documents
H201-FS-401 : Material requisition for
inlet hairpins
X See point 3
6.2 Pre-award meeting or Kick-off meeting X W Report See point 7.1
6.3 PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
6.4 DOCUMENTS TO SUBMIT PRIOR PIM
6.4.1 Schedule Fabrication X A Shall be revised (when required) and
confirmed each end of month.
6.4.2 Detailed Inspection Test Plan X A To be approved by HTAS before start of
manufacture.
6.4.3 Arrangement Drawing X A
6.4.4 Details Drawing X A
6.4.5 Bending procedure X A REF51013 §6Cold forming
6.4.6 WELDING Book including:6.4.6.
1 Welding Map X A
6.4.6.
2 WPS X A ASME IX
6.4.6.
3 PQR X A ASME IX
6.4.6.4 Filler metal certificate X A EN 10204-3.1 ASME II Part C
6.4.6.
5 Welders Qualifications X A ASME IX or equivalent
6.4.7 NDT Procedures including: X A
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 22/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
22 /56DOC N°:
H201 FQ 001
6. Category: HAIRPIN TUBE IN GAS INLETAND BRACES
SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 1
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i f i c a t e R e p o r t
RemarksAcceptance Criteria
S U P
P L I E R
H
P C
H
T A S
A C
R O N
O T
H E R S
6.4.7.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
6.4.7.2 Dye Penetrant procedure X A
ASME V Art. 6 + ASME VIII Div.1 App. 8
REF51013 §6.4
Bend arc surfaces and 150 mm surfacesadjacent to bends shall be free of
indications – 100% examination
REF51013 §7.7
Root passes and capping passes shall be100% dye penetrant tested
6.4.7.4 Radiography procedure X A REF51013 §7.8
100% of welds
6.4.7.3 UT Wall thickness measurement procedure X A REF51013 §6.5 and 8.2
Extent: 10% of pigtails
6.4.7.4Analysis for weld metal deposited (P.M.I.)
procedure X A 10% of tubes/flanges/weldolets
6.5 MATERIAL IDENTIFICATION
6.5.1 Tube: ASTM A312 TP321H X R Report
Cold drawn, solution annealed and pickled
Grain size to be in the range ASTM E112
N°7 to N°4
EN10204 – 3.1
1
6.6 MATERIAL EXAMINATION
6.6.1 PMI examination X SW Report 10% of tubes/flanges/weldolets
6.6.2 Grain size determination X R Report
REF51013 §5.4
Grain size in the range ASTM E112 N°7 to
N°4
6.6.3 Visual examination X W Report
REF51013 §8.1
Bend arc surfaces free of cracks and
buckles
6.6.4 Dye penetrant examination X W Report
REF51013 §6.4
Bend arc surfaces and 150 mm surfacesadjacent to bends shall be free of
indications – 100% examination
REF51013 §7.7Root passes and capping passes shall be
100% dye penetrant tested
6.6.4 Radiographic examination X W ReportREF51013 §7.8Welds shall be 100% radiographed
6.6.5 Dimensional examination X H Report
REF51013 §6.5 and 8.2
Bending tolerances: to be within ±3mm
Flattening of bend: Less than 8% -
Extent: 10% of the hairpins tubes
UT Wall thickness measurement: Wall
thinning < 10% -
Extent: 10% of pigtails
Ovality: to be checked on 10% of the
hairpins or minimum 20 pieces.
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 23/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
23 /56DOC N°:
H201 FQ 001
6. Category: HAIRPIN TUBE IN GAS INLETAND BRACES
SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 1
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i f i c a t e R e p o r t
RemarksAcceptance Criteria
S U P
P L I E R
H
P C
H
T A S
A C
R O N
O T
H E R S
6.7 FINAL EXAMINATION
6.7.1
Visual and Dimensional examination
including flattening of bend and wallthickness measurement
X H Drawings
6.7.2 Cleaning X W
REF51013 §9
All scale, resulting from welding shall beremoved from internal surface
All traces of welding slag, grease, dye
shall be removed
6.7.3 Marking X W
REF51013 §11
Use of indelible ink not harmful to the
alloy
6.7.4 Packing X W REF51013 §11
6.7.5Manufacturer Data Book including RTN
passport X H Approved HPC summary
7. Category: HAIRPIN TUBE IN GAS OUTLET SCOPE of INSPECTION R e
v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p l i e r ’ s R e c o r d
C e r t i f i c a t e R e p o r t
RemarksAcceptance Criteria
S U P P L I E R
H P C
H T A S
A C R O N
O T H E R S
7.1 DATA / ENGINEERING
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 24/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
24 /56DOC N°:
H201 FQ 001
7. Category: HAIRPIN TUBE IN GAS OUTLETSCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i f i c a t e R e p o r t
RemarksAcceptance Criteria
S U P
P L I E R
H
P C
H
T A S
A C
R O N
O T
H E R S
7.1.1Design Temperature (°C): -27°C/829°C
Design Pressure (kg/cm²g): 39
X
7.1.2
Code : ISO 13705 (API560)
: API530
: ASME B31.3: RUSSIAN STANDARDS
X
7.1.3
HTAS Process Specifications
REF51019 : Primary reformer
Specification for hairpin tubes in gas
outlet
X See point 3
7.1.4
HTAS drawings
REF51006 : General arrangement of gasoutlet
REF51018 : Hairpin tubes in gas outlet
REF51065 : Radiant section insulation
for hot parts
X See point 3
7.1.5
HPC Documents
H201-FS-402 : Material requisition forgas outlet hairpins
X See point 3
7.2 Pre-award meeting or Kick-off meeting X W Report See point 7.1
7.3 PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
7.4 DOCUMENTS TO SUBMIT PRIOR PIM
7.4.1 Schedule Fabrication X A Shall be revised (when required) and
confirmed each end of month.
7.4.2 Detailed Inspection Test Plan X A To be approved by HTAS before start of
manufacture.
7.4.3 Arrangement Drawing X A
7.4.4 Details Drawing X A
7.4.5 Bending procedure X A REF51019 §6
Cold forming
7.4.6 NDT Procedures including: X A
7.4.6.1NDT Operator certifications X A
EN 473 (Level II) or SNT TC 1A (ASNT)
7.4.7.2 Dye Penetrant procedure X A
ASME V Art. 6 + ASME VIII Div.1 App. 8
REF51019 §6.7
Bend arc surfaces and 150 mm surfacesadjacent to bends shall be free of
indications – 100% examination
7.4.7.3 UT Wall thickness measurement procedure X A REF51019 §6.5 and 7.2
Extent: 10% of pigtails
7.4.7.4Analysis for weld metal deposited (P.M.I.)procedure
X A 10% of tubes
7.5 MATERIAL IDENTIFICATION
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 25/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
25 /56DOC N°:
H201 FQ 001
7. Category: HAIRPIN TUBE IN GAS OUTLETSCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i f i c a t e R e p o r t
RemarksAcceptance Criteria
S U P
P L I E R
H
P C
H
T A S
A C
R O N
O T
H E R S
7.5.1 Tube: ASTM B407 X R Report
Cold drawn, solution annealed and pickled
Grain size to be in the range ASTM E112
N°5 to N°3
EN10204 – 3.1
7.6 MATERIAL EXAMINATION
7.6.1 PMI examination X SW Report 10% of tubes
7.6.2 Grain size determination X R Report
REF51019 §5.3
Grain size to be in the range ASTM E112
N°5 to N°3
7.6.3 Visual examination X W Report
REF51019 §7.1
Bend arc surfaces free of cracks andbuckles
7.6.4 Dye penetrant examination X W Report
REF51019 §6.7Bend arc surfaces and 150 mm surfaces
adjacent to bends shall be free ofindications – 100% examination
7.6.5 Dimensional examination X H Report
REF51019 §6.4 and 7.2
Bending tolerances: to be within ±3mm
Flattening of bend: Less than 8% -
Extent: 10% of the hairpins tubes
UT Wall thickness measurement: Wall
thinning < 10% -Extent: 10% of pigtails
Ovality: to be checked on 10% of thehairpins or minimum 20 pieces.
7.7 FINAL EXAMINATION
7.7.1
Visual and Dimensional examination
including flattening of bend and wallthickness measurement
X H Drawings
7.7.2 Cleaning X W
REF51019 §8
All scale, resulting from welding shall be
removed from internal surface
All traces of welding slag, grease, dye
shall be removed
7.7.3 Marking X W
REF51019 §10
Use of indelible ink not harmful to the
alloy
7.7.4 Packing X W REF51019 §12
7.7.5Manufacturer Data Book including RTN
passport X H Approved HPC summary
8. Category: LOOSE PARTS FOR CATALYST
TUBES SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 0
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 26/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
26 /56DOC N°:
H201 FQ 001
No Inspection Item / Step
By
S u p p l i e r ’ s R e c o r d
C e r t i f i c a t e
R e p o r t
RemarksAcceptance Criteria
S U P P L I E R
H P C
H T A S
A C R O N
O T H E R S
8.1 DATA / ENGINEERING
8.1.1 Design Temperature : Inlet 560°C
Main tube 901°C
Outlet 829°C 901°C
Design Pressure : Inlet 41 kg/cm²g
Main tube 41 kg/cm²g
Outlet 41 kg/cm²g
X
8.1.2 Code : ISO 13705 (API560)
: API530: ASME B31.3
: RUSSIAN STANDARDS
X
8.1.3 HTAS Drawings
REF51011 : Radiant section Hairpin
tube in gas inlet REF51015 : Radiant section Catalysttube support, flange, two-part ring and
grid
X See point 3
8.1.4 HPC Documents
H201-FS-101 : Material requisition for
catalyst tubes element
X See point 3
8.2. Pre-award meeting or Kick-offmeeting
X WReport See point 7.1
8.3. PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
8.4. DOCUMENTS TO SUBMIT PRIOR PIM
8.4.1 Schedule Fabrication X A
Shall be revised (when required) andconfirmed each end of month.
8.4.2 Detailed Inspection Test Plan X A
To be approved by HTAS before start ofmanufacture.
8.4.3 Arrangement Drawing X A
8.4.4 Details Drawing X A
8.4.5 NDT Procedures including: X A
8.4.5.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
8.4.5.2 Dye Penetrant procedure X A
ASME V Art. 6 + ASME VIII Div.1 App. 8
Tube support, Cast grid to be 100% dye
penetrant tested
Weld of weldolet/inlet flange to be 100%dye penetrant tested
Welding between inlet flange and
weldolet to be 100% dye penetranttested
8.4.5.3 Radiographic test procedure X A
ASME VIII Div. 1 §UW-51 & ASME V Art.
2
Welding between inlet flange and
weldolet to be 100% radiographed.
8.4.5.4Analysis for weld metal deposited(P.M.I.) procedure X A
10% of inlet flanges and weldolet, welding
between inlet flange and weldolet, looseinlet flange, two-part rings
8.5. MATERIALIDENTIFICATION/INSPECTION
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 27/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
27 /56DOC N°:
H201 FQ 001
8. Category: LOOSE PARTS FOR CATALYSTTUBES SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p l i e r ’ s R e c o r d
C e r t i f i c a t e R e p o r t
RemarksAcceptance Criteria
S U P P
L I E R
H P
C
H T
A S
A C R
O N
O T H
E R S
8.5.1Catalyst tube grid
Static cast ASTM A351 Gr.HK40 X R
REF51015
EN 10204 – 3.1
8.5.1.1 Visual examination X R Report REF51015
8.5.1.2 Dimensional examination X R ReportREF51015
100%
8.5.1.3 Dye penetrant examination X R ReportASME V Art. 6 + ASME VIII Div.1 App. 8
100% examination
8.5.2 Inlet flanges and weldolets
ASTM A312 TP321H X R
REF51011
EN 10204 – 3.1
8.5.2.1 P.M.I. X R ReportREF51011
10% of each heat n°
8.5.2.2 Grain size determination X R Report
REF51011
Grain size to be in the range ASTM E112N°7 or coarser.
8.5.3 Loose flanges
ASTM A312 TP321H X R
REF51015
EN 10204 – 3.1
8.5.3.1 P.M.I. X R ReportISO 13705 §17.5.4.3
10% of each heat n°
8.5.3.2 Grain size determination X R ReportREF51011Grain size to be in the range ASTM E112
N°7 or coarser.
8.5.4 Two-part ring
AISI 304 X R
REF51015
EN 10204 – 3.1
8.5.4.1 P.M.I. X R ReportISO 13705 §17.5.4.3
10% of each heat n°
8.5.5 Spiral wound metal gasket
AISI 304 X R
REF51015
EN 10204 – 3.1
8.5.6 Stud bolts and nuts
ASTM A193 Gr.B16 et ASTM A194 Gr.4
X RREF51015
EN 10204 – 3.1
8.5.7Catalyst tube bottom support
ASTM A297 HH X R
REF51015
EN 10204 – 3.1
8.5.7.1 Dye penetrant examination X R ReportASME V Art. 6 + ASME VIII Div.1 App. 8
100% tested
8.5.8 Welding flat weldolet / Flange X R
8.5.8.1 Approved welding book X R
8.5.8.2 P.M.I. X R ReportISO 13705 §17.5.4.3
10% of each heat n°
8.5.8.3 Dye penetrant examination X R ReportASME V Art. 6 + ASME VIII Div.1 App. 8
100% – No indication is allowed
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 28/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
28 /56DOC N°:
H201 FQ 001
8. Category: LOOSE PARTS FOR CATALYSTTUBES SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p l i e r ’ s R e c o r d
C e r t i f i c a t e R e p o r t
RemarksAcceptance Criteria
S U P P
L I E R
H P
C
H T
A S
A C R
O N
O T H
E R S
8.5.8.4 Radiographic examination X W Report
ASME V Art. 2 + ASME VIII Div.1 §UW-51
100%
8.6. FINAL EXAMINATION OF COMPLETEASSEMBLY
8.6.1 Visual & Dimensional examinationincluding PMI and flange assembly
X H
Drawings
10% mini. to be checked during final
inspection
8.6.2 Marking X H
H201-FS-101 Part.6
Use of indelible ink not harmful to the
alloy
8.6.3 Packing X H H201-FS-101 Part.7
8.6.4 Manufacturer Data Book including RTNpassport
X H Approved HPC summary
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 29/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
29 /56DOC N°:
H201 FQ 001
9. Category:COLD OUTLET COLLECTOR SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
9.1. DATA / ENGINEERING
9.1.1 Design Temperature (shell): -27/400°C Design Pressure: 39 kg/cm²g
Operating Temperature : 804°COperating Pressure : 32 kg/cm²g
X
9.1.2 Code : ISO 13705 (API560)
: API530: ASME B31.3
: RUSSIAN STANDARDS
X
9.1.3 HTAS Process Specifications
REF51024 : Radiant section cold outletin Cold Outlet Collector
REF51026 : Refractory lining in cold
Collector
S-02949 B30004: HTAS vendor list for
refractory lining vendors
4-1246 E R7 : Painting
X See point 3
9.1.4 HTAS Drawings
REF51027 : Instrument connection ofcold Collector
REF51020 : For information details ofhot collector
REF51002 : Radiant section GAD forinformation details of radiant layout
X See point 3
9.1.5 ACRON documentation
YK-A-1441_pril : Connection to
secondary reformer
33753-OT-1 : Site condition, general
requirements for complete plants
X See point 3
9.1.6 HPC Documents
H310-FS-406 : Requisition package forCold Collector
SG1505 : Refractory and insulationconcrete application
X See point 3
9.2. Pre-award meeting or Kick-off meeting X W Report See point 7.1
9.3. PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
9.4. DOCUMENTS TO SUBMIT PRIOR PIM
9.4.1 Schedule Fabrication X AShall be revised (when required) and
confirmed each end of month.
9.4.2 Detailed Inspection Test Plan X ATo be approved by HTAS prior the start of
manufacture
9.4.3 Arrangement/detail Drawings (If any) X A
9.4.4 WELDING Book including:
9.4.4.1 Welding Map X A
9.4.4.2 WPS X A ASME IX
9.4.4.3 PQR X A
ASME IX
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 30/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
30 /56DOC N°:
H201 FQ 001
9. Category:COLD OUTLET COLLECTOR SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
9.4.4.4 Filler metal certificate X AASME II Part C
EN 10204 type 3.1
9.4.4.5 Welders Qualifications X A ASME IX or equivalent
9.4.5 NDT Procedures including:
9.4.5.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
9.4.5.2
Radiographic procedure (on butt welds) X A
ASME VIII Div. 1 §UW-51
& ASME V Art.2
100%
9.4.5.3
Ultrasonic test procedure (on nozzles) X A
ASME VIII Div. 1 §UW-53 & App.12
& ASME V art.4
100%
9.4.5.4
Magnetic particle inspection procedure X A
ASME VIII Div. 1 App.6
& ASME V art.7
100%
9.4.5.5
Penetrant test examination procedure X A
ASME VIII Div. 1 App.8
& ASME V art.6
100%
9.4.6 PMI procedure X A 10% of welds and material
9.4.7 Heat treatment procedure X APreheating: min. 150°C
PWHT: 2h at 705-730°C
9.4.8 Hardness test procedure X AHardness to be checked by Brinell testing
in weld, HAZ & base metal
9.4.9 Hydrostatic test procedure X AH201-FS-406
66 bars during min. 30 minutes
9.4.10 Refractory lining procedure X A REF51026
9.4.11 Painting procedure X A 4-1246/E R7
9.4.12 Preservation and packing procedure X A Supplier's procedure
9.5. MATERIAL
IDENTIFICATION/INSPECTION
9.5.1 Shell & head : ASTM A387 Gr. 11 Cl.2 X R Report EN10204 – 3.1
9.5.2 Pipe : ASTM A335 P11 X R Report EN10204 – 3.1
9.5.3 Flange : ASTM A182 F11 X R Report EN10204 – 3.1
9.5.4 Stud bolts / nuts : A193 Gr. B7 / A194 Gr. 3 X R Report EN10204 – 3.1
9.5.5Support saddle & foundation plates : ASTMA283 Gr. A or equivalent
X R Report EN10204 – 3.1
9.5.6 Spiral Wound Gaskets : SS 18/8 graphite X R Report EN10204 – 3.1
9.5.7Insulating Castable Refractory : JM 2300 VL1or equal
X R Report EN10204 – 3.1
9.5.8Castable refractory 94% Al2O3 : JM Firecrete95 or equal
X R Report EN10204 – 3.1
9.5.9Ceramic fibre blanket compressed : 1260°C /
128 kg/m3 X R Report EN10204 – 2.2
9.6. WELDING EXAMINATION
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 31/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
31 /56DOC N°:
H201 FQ 001
9. Category:COLD OUTLET COLLECTOR SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
9.6.1 Beveled ends examination X SW Report 100% PT or MT on bevels
9.6.2 Welding of shell / head
9.6.2.1 Visual examination of welds X SW Report 100%
9.6.2.2Dye penetrant examination or Magnetic
particle inspection on root passes X SW Report 100%
9.6.2.2Dye penetrant examination or Magnetic
particle inspection after PWHT X SW Report 100%
9.6.2.3 Radiographic examination after PWHT X R Report 100%
9.6.3 Welding of nozzles / shell
9.6.3.1 Visual examination of welds X SW Report 100%
9.6.2.2Dye penetrant examination or Magnetic
particle inspection on root passes X SW Report 100%
9.6.3.2Dye penetrant examination or Magnetic
particle inspection after PWHT X SW Report 100%
9.6.3.3 Ultrasonic examination after PWHT X SW Report 100%
9.6.4 Welding of internal plates
9.6.4.1 Visual examination of welds X SW Report 100%
9.6.2.2
Dye penetrant examination or Magnetic
particle inspection on root passes X SW Report 100%
9.6.4.2Dye penetrant examination or Magnetic
particle inspection after PWHT X SW Report 100%
9.7. POST WELD HEAT TREATMENT X SW Chart
9.8. HARDNESS EXAMINATION X SW Report 225 HB max
9.9. PMI EXAMINATION X SW Report 10% of welds and material
9.10. HYDROSTATIC TEST X W Report 66 bars during min. 30 minutes
9.11. FINAL INSPECTION BEFORE LINING X H Report Approved procedure
9.12. REFRACTORY APPLICATION REF51026 §9
9.12.1 Preparation of surface X SW Report
9.12.2 Welding of SS anchors X SW Report Soundness of the weld to be hammertested
9.12.3 Mixing of refractory X SW Report Water analysis
9.12.4 Installation of refractory X SW Report REF51026 §9
9.12.5
Refractory material testing :
- Compressive strength,
- Permanent linear change,
- Density,
- Chemical composition,
- Tensile strength for ceramic fiber blankets
X SW Report
R REF51026 §7 & §9
One test piece shall be taken daily with
material type and date marking.
First and last cube to be tested for each
material
9.12.6 Curing X SW Approved procedure
9.12.7 Dry-out X W Chart Approved procedure
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 32/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
32 /56DOC N°:
H201 FQ 001
9. Category:COLD OUTLET COLLECTOR SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
9.13. BUTTWELDING OF FINAL SECTIONS
9.13.1 Sections alignment & welding X SW Approved welding book
9.13.2 Local PWHT X SW Chart Approved procedure
9.13.3 Hardness examination X SW ReportApproved procedure
225HB max
9.13.4 Ultrasonic examination of closing welds X SW Report 100%
9.13.5 Dye penetrant examination or Magneticparticle inspection of closing welds
X SW Report 100%
9.14. FINAL EXAMINATION BEFORE
PAINTING X W Report Approved procedure
9.15. PAINTING
9.15.1 Surface preparation X SW Report Approved procedure
9.15.2 Thickness examination X SW Report Approved procedure
9.16. TRIAL ASSEMBLY WITH TRANSFERPIECE
X H Report
9.17. FINAL EXAMINATION
9.17.1 Visual and dimensional examination X H Report Drawing
9.17.1 Marking X H
REF51026 §13
Use of indelible ink not harmful to thealloy
9.17.1 Packing X H Approved procedure
9.17.1 Manufacturer Data Book including RTN
passport X H Approved HPC summary
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 33/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
33 /56DOC N°:
H201 FQ 001
10. Category:HOT COLLECTORS SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 1
No Inspection Item / Step
By
S u p p l i e r ’ s R e
c o r d
C e r t i f i c a t e R e
p o r t
RemarksAcceptance Criteria
S U P P L I E R
H P C
H T A S
A C R O N
O T H E R S
10.1. DATA / ENGINEERING
10.1.1 Design Temperature (shell): -27/829°C
Design Pressure: 39 kg/cm²g Operating Temperature : 804°C
Operating Pressure : 32 kg/cm²g
X
10.1.2 Code : ISO 13705 (API560): API530
: ASME B31.3: RUSSIAN STANDARDS
X
10.1.3 HTAS Process Specifications
REF51021 : Specification for hot
Collector
REF51024 : Radiant section cold outlet
in Cold Outlet Collector
X See point 3
10.1.4 HTAS Drawings
REF51020 : Hot collector drawing
REF51002 : Radiant section GAD for
information details of radiant layout
REF51006 : General arrangement of gas
outlet for information about connections
X See point 3
10.1.5 ACRON documentation
33753-OT-1 : Site condition, general
requirements for complete plants
X See point 3
10.1.6 HPC Documents
H310-FS-405 : Requisition package for
Hot Collector
X See point 3
10.2. Pre-award meeting or Kick-off meeting X W Report See point 7.1
10.3. PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
10.4. DOCUMENTS TO SUBMIT PRIOR PIM
10.4.1 Schedule Fabrication X AShall be revised (when required) and
confirmed each end of month.
10.4.2 Detailed Inspection Test Plan X ATo be approved by HTAS prior the start of
manufacture
10.4.3 Arrangement/detail Drawings (If any) X A
10.4.4 WELDING Book including:
10.4.4.1 Welding Map X A
10.4.4.2 WPS X A ASME IX
10.4.4.3 PQR X A ASME IX
10.4.4.4 Filler metal certificate X AASME II Part C
EN 10204 type 3.1
10.4.4.5 Welders Qualifications X A ASME IX or equivalent
10.4.5 NDT Procedures including:
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 34/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
34 /56DOC N°:
H201 FQ 001
10. Category:HOT COLLECTORS SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 1
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
10.4.5.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
10.4.5.2
Radiographic procedure (on butt welds) X A
ASME VIII Div. 1 §UW-51
& ASME V Art.2
100% of static and centrifugally cast
100% of butt welds
10.4.5.3
Penetrant test examination procedure X A
ASME VIII Div. 1 App.8
& ASME V art.6
100% of machined surfaces
100% of beveled ends within 25mmThe first three root passes made by each
welder
10.4.6Boroscope X A
Root pass of main tube shall be checkedfor full penetration
10.4.7 PMI procedure X A 10% of welds and material
10.4.8 Leak test procedure X AREF51021
5 bars during min. 10 min
10.4.9 Hydrostatic test procedure X A
REF51021
77 bars during min. 30 minutes
20ppm Cl.
10.4.10 Eddy current test procedure X AREF51021
100% of bored tubes10.4.11 Preservation and packing procedure X A Supplier's procedure
10.5. MATERIAL
IDENTIFICATION/INSPECTION
10.5.1 Main tube : 20Cr 32Ni Nb X R Report EN10204 – 3.1
10.5.2 Cone : 20Cr 32Ni Nb X R Report EN10204 – 3.1
10.5.3 End cap : 20Cr 32Ni Nb X R Report EN10204 – 3.1
10.5.4Nozzle for Hairpin tubes: ASTM B564 ALLOYUNS NO8811
X R Report EN10204 – 3.1 Grain size ASTM n°5 to 3.
10.5.5 Sleeve : ASTM B409 ALLOY UNS NO8811 X R Report EN10204 – 3.1 Grain size ASTM n°5 to 3.
10.5.6½” nozzle for thermowell: ASTM B564 ALLOYUNS NO8811
X R Report EN10204 – 3.1 Grain size ASTM n°5 to 3.
10.5.7 ½” Pipe nom. SCH160: ASTM B407 ALLOYUNS NO8811
X R Report EN10204 – 3.1 Grain size ASTM n°5 to 3.
10.5.8Flange 18” Nom class 600 ANSI B16.25 : ASTM
A182 F11 X R Report EN10204 – 3.1
10.5.9 Tee : 20Cr 32Ni Nb X R Report EN10204 – 3.1
10.5.10 End cap : ASTM B564 ALLOY UNS NO8811 X R Report EN10204 – 3.1 Grain size ASTM n°5 to 3.
10.6. WELDING EXAMINATION
10.6.1 Beveled ends examination X SW Report 100% PT or MT on bevels
10.6.2 Welding of main tube / tube ends
10.6.2.1 Visual examination of welds X SW Report 100%
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 35/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
35 /56DOC N°:
H201 FQ 001
10. Category:HOT COLLECTORS SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 1
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
10.6.2.2
Dye penetrant examination or Magneticparticle inspection on 3 first root passes
made by each welder X SW Report
10.6.2.3Boroscope check on root passes for fullpenetration
X SW Report 100%
10.6.2.4Dye penetrant examination or Magnetic
particle inspection on final root passes X SW Report 100%
10.6.2.5 Radiographic examination X R Report 100%
10.6.3 Welding of nozzles / main tube
10.6.3.1 Visual examination of welds X SW Report 100%
10.6.2.2
Dye penetrant examination or Magnetic
particle inspection on 3 first root passes
made by each welder
X SW Report
10.6.3.3Dye penetrant examination or Magneticparticle inspection on final root passes
X SW Report 100%
10.6.4 Welding of end cap / ½” nozzle
10.6.4.1 Visual examination of welds X SW Report 100%
10.6.4.2Dye penetrant examination or Magnetic
particle inspection on root passes X SW Report 100%
10.6.4.3 Dye penetrant examination or Magneticparticle inspection on final passes
X SW Report 100%
10.6.4.4 Radiographic examination X R Report 100%
10.7. PMI EXAMINATION X SW Report 10% of welds and material
10.8. LEAK TEST X W Report 5 bars during min. 10 min
10.9. HYDROSTATIC TEST X W Report 77 bars during min. 1 hour - 20ppm Cl. 1
10.10. FINAL EXAMINATION
10.10.1 Visual and dimensional examination X H Report Drawing
10.10.2 Marking X H
REF51026 §13
Use of indelible ink not harmful to the
alloy10.10.3 Packing X H Approved procedure
10.10.4 Manufacturer Data Book including RTN
passport X H Approved HPC summary
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 36/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
36 /56DOC N°:
H201 FQ 001
11.Category: RADIANT CASING WITHGRATING, LADDERS AND PLATFORMS
SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
11.1 DATA / ENGINEERING
11.1.1
Design casing temperature: +55°C
Ambient temperature for design: -38°C
MDMT : -45°C
X
11.1.2 Code : ISO 13705 (API560)
: AWS D1.1
: RUSSIAN STANDARDS
X
11.1.3
HTAS Specifications
4-1246 E R7: Painting
P40001 : Project design basis
REF51041 : Specification for steel
structure, part 1
REF51042 : Specification for steel
structure, part 2
REF 51002: General arrangement of
Radiant section
REF 51044: Primary reformer
specification for radiant and convection
section steel structure and casing
REF 51043: Typical details of steel
structure and casing
REF 51048: Arrangement of Platforms,Ladders and Stairways
REF 51047: Peep door
REF 51045: Reformer roof
REF 51050: Brace for hairpin tubes ingas inlet
REF 51051: Guide ring for catalysttube
REF 51055: Counterweight for hotcollector
REF 51052: Access door
REF 51053: Spring support for hairpin
tube in gas inlet
REF 51054: Spring support for hairpintube in gas outlet
REF 51056: Burner plate and
refractory block
REF 51059: General arrangement of
refractory
REF 51066: Arrangement ofcombustion air ducting
REF 51074: Radiant section plinthlayout
REF 51060: Typical lining details.
REF 51005: General arrangement of
gas inlet
REF 51006: General arrangement of
See point 3
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 37/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
37 /56DOC N°:
H201 FQ 001
11.Category: RADIANT CASING WITHGRATING, LADDERS AND PLATFORMS
SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
gas outlet
REF 51066: Arrangement of
combustion air ducting
11.1.4
HPC Documents
H201-FS-301 : Material requisition for
radiant panels and penthouse
DG031 rev 1 Base plate details
H211 FE 501 Rev 05 Lining anchor
details (for information only from
example project)
DG 3303 Rectangular platform details
DG 3304 Handrail details
DG 3307 Stairway
DG 3308 Ladder
DG 3309 Ladder with cage protection
H201-FD-001 Foundation layout
H201-FD-002 Foundation base plate –
details
H201-FD-010 Radiant section generalassembly – general data
H201-FD-020 Radiant section generalassembly – Elevation
H201-FD-030 Radiant section generalassembly – Plan view I
H201-FD-031 Radiant section general
assembly – Plan view
X
See point 3
11.2 Pre-award meeting or Kick-offmeeting
X W Report See point 7.1
11.3 PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
11.4 DOCUMENTS TO SUBMIT PRIOR PIM
11.4.1 Detailed Inspection Test Plan X ATo be approved by HTAS before start ofmanufacture.
11.4.2 Arrangement Drawing X A
11.4.3 Details Drawing X A
11.4.4 Schedule Fabrication X AShall be revised (when required) and
confirmed each end of month.
11.4.5 WELDING Book including:
11.4.5.1 Welding Map X A
11.4.5.2 WPS X A AWS D1.1
11.4.5.3 PQR X A AWS D1.1
11.4.5.4 Filler metal certificate X A EN 10204-2.2 ASME II Part C
11.4.5.5 Welders Qualifications X A AWS D1.1 or equivalent
11.4.6 NDT Procedures including: X A
11.4.6.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 38/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
38 /56DOC N°:
H201 FQ 001
11.Category: RADIANT CASING WITHGRATING, LADDERS AND PLATFORMS
SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
11.4.6.2 Dye Penetrant procedure X AASME V Art. 6 + AWS D1.1 Section 6 PartC §6.10
11.4.6.3 Radiographic procedure (if applicable) X AASME V Art. 2 + AWS D1.1 Section 6 Part
C §6.12
11.4.6.4 Ultrasonic test procedure X AASME V Art. 5 + AWS D1.1 Section 6 PartC §6.13
11.4.7 Lining procedure X A REF51061 R0
11.4.8 Painting procedure X A 4-1246 E R7 Table 9.2 Item 11
11.5 MATERIAL IDENTIFICATION
11.5.1 Material for structural steel X R EN 10204-3.1 Carbon Steel suitable for low ambienttemperature (-45°C)
11.5.2 Grating X R EN 10204–2.2 Hot dip galvanized acc. to ASTM A123
11.5.3 Structural bolts X R EN 10204-3.1 Suitable for low ambient temperature
(-45°C)
11.5.4 Ladders and handrails X R EN 10204–2.2Carbon Steel suitable for low ambient
temperature (-45°C)
11.5.5 Lining materials X R
11.5.5.1 Bricks for side walls and floors X R EN 10204–2.2
REF51061 R0 §5.1
Al2O3 + TiO2: 35-45%
SiO2: 40-55%
Fe2O3: max. 1%
11.5.5.2 Bricks for furnace hot face X R EN 10204–2.2
REF51061 R0 §5.2
Al2O3 + TiO2: 55-65%
SiO2: 35-40%
Fe2O3: max. 0.8%
11.5.5.3 Firebricks for radiant floor top layer X R EN 10204–2.2
REF51061 R0 §5.3
Al2O3 + TiO2: 38-42%
ASTM C27 High Duty
11.5.5.4 Ceramic fibre lining for furnace side and endwalls, arch and flue gas duct
X R EN 10204–2.2
REF51061 R0 §5.4
For 1260°C grade modules: Al2O3 + ZrO2:
min. 45%
For 1425°C grade modules: 35% Al2O3 +
15% ZrO2
11.5.5.5 Peephole blocks (precast refractory castable) X R EN 10204–2.2
REF51061 R0 §5.5
Al2O3 + TiO2: min. 38%
SiO2: max. 38%
11.5.5.6 Block insulation X R EN 10204–2.2 REF51061 R0 §5.6
11.5.5.7 Air setting mortar for bricks X R EN 10204–2.2
REF51061 R0 §5.7
Cold curing time acc. to ASTM C 199Medium Duty
11.5.5.8 Loose fibre filling for catalyst tube bottoms X R
EN 10204–2.2
REF51061 R0 §5.8
45% Al2O3
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 39/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
39 /56DOC N°:
H201 FQ 001
11.Category: RADIANT CASING WITHGRATING, LADDERS AND PLATFORMS
SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
11.5.5.9Ceramic fibre blanket for covering of loosefibre
X R EN 10204–2.2
REF51061 R0 §5.9
For 1260°C grade modules: Al2O3 + ZrO2:
min. 45%
For 1425°C grade modules: 35% Al2O3 +
15% ZrO2
11.5.6 Consumables X R EN 10204–2.2ASME II Part C
NAKS certificates for onsite welds
11.6 WELDING EXAMINATION X SW REF51044 R.A §7 & AWS D1.1
11.7 NDT EXAMINATION REF51044 R.A §7 & AWS D1.1
11.7.1 Dye penetrant examination X SW Report
AWS D1.1 Section 6 Part C §6.10
100% on lifting lugs welds. Free of cracks,
undercutting, linear indications over 2 mmand rounded indications over 4 mm
11.7.2 Radiographic examination X SW Report
AWS D1.1 Section 6 Part C §6.12
100% on full penetration BW for
reconstituted beams
11.7.3 Ultrasonic test X SW Report
AWS D1.1 Section 6 Part C §6.13
100% on area where lifting lugs arewelded
11.8 TRIAL ASSEMBLY X W Report Approved drawings
11.9 LINING APPLICATION
11.9.1 Preparation of surface X SW
11.9.2 Welding of anchors X SW
11.9.3 Mixing of refractory X SW Report Water Analysis
11.9.4 Application of refractory X SW ReportPre-qualification of refractory material &
installers
11.9.5 Visual and dimensional examination X SW ReportApproved drawings & procedure
After drying of castable
11.9.6 Production samples X SW Report
Approved procedure :
Compressive strength
Permanent linear changeDensity
Chemical compositionTensile strength (ceramic fiber blankets)
11.9.7 Anchors bending & hammer testing X SW Report Approved procedure
11.10 PAINTING EXAMINATION X W
4-1246 E R7
Surface preparation, climatic conditions,Wet film thickness and DFT
11.11 FINAL EXAMINATION
11.11.1 Visual and Dimensional examination X H ReportDrawings
100%
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 40/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
40 /56DOC N°:
H201 FQ 001
11.Category: RADIANT CASING WITHGRATING, LADDERS AND PLATFORMS
SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
11.11.2 Marking X W
Approved procedure
Use of indelible ink not harmful to the
alloy
11.11.3 Packing X W Approved procedure
11.11.4Manufacturer Data Book including RTNpassport
X H Approved HPC summary
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 41/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
41 /56DOC N°:
H201 FQ 001
12.Category: CONVECTION CASING WITHGRATING, LADDERS AND PLATFORMS
SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
12.1 DATA / ENGINEERING
12.1.1
Design casing temperature: +55°C
Ambient temperature for design: -38°C
MDMT : -45°C
X
12.1.2 Code : ISO 13705 (API560)
: AWS D1.1
: RUSSIAN STANDARDS
X
12.1.3
HTAS Specifications
4-1246 E R7: Painting
P40001 : Project design basis
REF 51071: General arrangement,
sketch of Convection section
REF 51044: Primary reformer
specification for radiant and convectionsection steel structure and casing
REF 51043: Typical details of steel
structure and casing
REF 51048: Arrangement of Platforms,
Ladders and Stairways
REF 51074: Radiant section plinth
layout
See point 3
12.1.4
HPC Documents
H201-FS-303 : Material requisition forconvection fabrication
H201-FD-402 Convection coil E-201
H201-FD-403 Convection coil E-202A
H201-FD-404 Convection coil E-203A
H201-FD-405 Convection coil E-203B
H201-FD-406 Convection coil E-206
H201-FD-407 Convection coil E-204A
H201-FD-408 Convection coil E-202B
H201-FD-409 Convection coil E-204B
H201-FD-081 Convection section
general assembly – Plan views II
H201-FD-080 Convection section
general assembly – Plan views I
H201-FD-070 Convection section
general assembly – Elevation
H201-FD-060 Convection section
general assembly – General data
H201-FD-002 Foundation base plate –
details
X
See point 3
12.2 Pre-award meeting or Kick-offmeeting
X W Report See point 7.1
12.3 PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
12.4 DOCUMENTS TO SUBMIT PRIOR PIM
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 42/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
42 /56DOC N°:
H201 FQ 001
12.Category: CONVECTION CASING WITHGRATING, LADDERS AND PLATFORMS
SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
12.4.1 Detailed Inspection Test Plan X ATo be approved by HTAS before start ofmanufacture.
12.4.2 Arrangement Drawing X A
12.4.3 Details Drawing X A
12.4.4 Schedule Fabrication X AShall be revised (when required) andconfirmed each end of month.
12.4.5 WELDING Book including:
12.4.5.1 Welding Map X A
12.4.5.2 WPS X A AWS D1.1
12.4.5.3 PQR X A AWS D1.1
12.4.5.4 Filler metal certificate X A EN 10204-2.2 ASME II Part C
12.4.5.5 Welders Qualifications X A AWS D1.1 or equivalent
12.4.6 NDT Procedures including: X A
12.4.6.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
12.4.6.2 Dye Penetrant procedure X AASME V Art. 6 + AWS D1.1 Section 6 Part
C §6.10
12.4.6.3 Radiographic procedure (if applicable) X AASME V Art. 2 + AWS D1.1 Section 6 Part
C §6.12
12.4.6.4 Ultrasonic test procedure X AASME V Art. 5 + AWS D1.1 Section 6 PartC §6.13
12.4.7 Lining procedure X A REF51061 R0
12.4.8 Painting procedure X A 4-1246 E R7 Table 9.2 Item 11
12.5 MATERIAL IDENTIFICATION
12.5.1 Material for structural steel X R EN 10204-3.1 Carbon Steel suitable for low ambient
temperature (-45°C)
12.5.2 Grating X R EN 10204–2.2 Hot dip galvanized acc. to ASTM A123
12.5.3 Structural bolts X R EN 10204-3.1 Suitable for low ambient temperature
(-45°C)
12.5.4 Ladders and handrails X R EN 10204–2.2Carbon Steel suitable for low ambienttemperature (-45°C)
12.5.5 Lining materials X R
12.5.5.1Castable for upper part of convection section
and furnace floor X R EN 10204–2.2
REF51061 R0 §5.1
Al2O3 + TiO2: min 38%
SiO2: max 38%
12.5.5.2 Castable for lower part of convection section X R EN 10204–2.2
REF51061 R0 §5.2
Al2O3 + TiO2: min 31%
SiO2: max 36%
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 43/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
43 /56DOC N°:
H201 FQ 001
12.Category: CONVECTION CASING WITHGRATING, LADDERS AND PLATFORMS
SCOPE of INSPECTION R e v
Supplier: Inspection Level: 4 0
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
12.5.6 Consumables X R EN 10204–2.2ASME II Part C
NAKS certificates for onsite welds
12.6 WELDING EXAMINATION X SW REF51044 R.A §7 & AWS D1.1
12.7 NDT EXAMINATION REF51044 R.A §7 & AWS D1.1
12.7.1 Dye penetrant examination X SW Report
AWS D1.1 Section 6 Part C §6.10
100% on lifting lugs welds. Free of cracks,undercutting, linear indications over 2 mm
and rounded indications over 4 mm
12.7.2 Radiographic examination X SW ReportAWS D1.1 Section 6 Part C §6.12
100% on full penetration BW forreconstituted beams
12.7.3 Ultrasonic test X SW Report
AWS D1.1 Section 6 Part C §6.13
100% on area where lifting lugs are
welded
12.8 TRIAL ASSEMBLY X W Report Approved drawings
12.9 LINING APPLICATION
12.9.1 Preparation of surface X SW
12.9.2 Welding of anchors X SW
12.9.3 Mixing of refractory X SW Report Water Analysis
12.9.4 Application of refractory X SW ReportPre-qualification of refractory material &
installers
12.9.5 Visual and dimensional examination X SW ReportApproved drawings & procedure
After drying of castable
12.9.6 Production samples X SW Report
Approved procedure :
Compressive strengthPermanent linear change
DensityChemical composition
Tensile strength (ceramic fiber blankets)
12.9.7 Anchors bending & hammer testing X SW Report Approved procedure
12.10 PAINTING EXAMINATION X W
4-1246 E R7
Surface preparation, climatic conditions,
Wet film thickness and DFT
12.11 FINAL EXAMINATION
12.11.1 Visual and Dimensional examination X H ReportDrawings
100%
12.11.2 Marking X W
Approved procedure
Use of indelible ink not harmful to the
alloy
12.11.3 Packing X W Approved procedure
12.11.4Manufacturer Data Book including RTN
passport
X H Approved HPC summary
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 44/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
44 /56DOC N°:
H201 FQ 001
13.Category: PREFABRICATION OF PIPING SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 1
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
13.1 DATA / ENGINEERING
13.1.1Code : ASME B31.1
: ASME B31.3 X
13.1.2 HTAS Specifications
4-1246 E R7: Painting X
See point 3
13.2 Pre-award meeting or Kick-off
meeting
X W Report See point 7.1
13.3 PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
13.4 DOCUMENTS TO SUBMIT PRIOR PIM
13.4.1 Detailed Inspection Test Plan X ATo be approved by HTAS before start of
manufacture.
13.4.2 Arrangement Drawing X A
13.4.3 Details Drawing X A
13.4.4 Schedule Fabrication X AShall be revised (when required) andconfirmed each end of month.
13.4.5 WELDING Book including:
13.4.5.1 Welding Map X A
13.4.5.2 WPS X A ASME IX
13.4.5.3 PQR X A ASME IX
13.4.5.4 Filler metal certificate X A EN 10204-3.1 ASME II Part C
13.4.5.5 Welders Qualifications X A ASME IX or equivalent
13.4.6 NDT Procedures including:
13.4.6.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
13.4.6.2 Radiographic procedure X A
ASME V Art. 2 + ASME B31.1 §136.4.5
ASME B31.3 Table 341.3.2 Normal Fluid
Service
13.4.6.3 Dye Penetrant procedure X A
ASME V Art. 6 + ASME B31.1 §136.4.4
ASME B31.3 Table 341.3.2 Normal Fluid
Service
13.4.7 Heat treatment procedure X A Supplier's procedure
13.4.8 Hardness test procedure X A Supplier's procedure
13.4.9 Hydrostatic test procedure X A
ASME B31.1 §137
ASME B31.3
13.4.10 Painting procedure X A 4-1246 E R7 Table 9.2 Item 11
13.5 MATERIAL IDENTIFICATION
13.5.1 Pipe X R EN 10204-3.1 As per iso
13.5.2 Elbow X R EN 10204-3.1 As per iso
13.5.3 Flange X R EN 10204-3.1 As per iso
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 45/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
45 /56DOC N°:
H201 FQ 001
13.Category: PREFABRICATION OF PIPING SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 1
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
H
T A S
A C
R O N
O T H E R S
13.6 WELDING EXAMINATION
13.6.1 Beveled ends examination X SW Report 100% PT on bevels
13.6.2 Welding X SW Report
100% visual
10% PT on socket and branch welds
10% RT on buttwelds
13.7POST WELDING HEAT TREATMENT(IF APPLICABLE)
X SWChart Approved procedure
13.7.1 Hardness test examination X SW Report Approved procedure
13.8 HYDROSTATIC TEST X SW Chart Approved procedure
13.9 PAINTING EXAMINATION
4-1246 E R7
Surface preparation, climatic conditions,
Wet film thickness and DFT
13.9.1 Surface preparation X SW Report Approved procedure
13.9.2 Thickness examination X SW Report Approved procedure
13.10 FINAL EXAMINATION
13.10.1 Visual and Dimensional examination X H ReportDrawings
100%
13.10.2 Marking X W
Approved procedure
Use of indelible ink not harmful to the
alloy
13.10.3 Packing X W Approved procedure
13.10.4Manufacturer Data Book including RTNpassport
X H Approved HPC summary
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 46/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
46 /56DOC N°:
H201 FQ 001
14.Category: DeNOx – D251 SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 1
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
R O S N E F T
H
T A S
O T H E R S
14.1 DATA / ENGINEERING
14.1.1
Design Temperature :
R251: -27°C / 380°C
X251: -27°C / 380°C
X252: -27°C / 380°C
V251: -45°C / 70°C
P252 A/B: -45°C / 50°C
MP252 A/B: -45°C / 50°C
K251: -45°C / 380°C
MK251: -45°C / 380°C
J251: -27°C / 510°C
J252: -27°C / 380°C
J253: -27°C / 510°C
J254: -27°C / 510°C
J255: -27°C / 380°C
X
14.1.2
Code : ISO 13705 (API560): ASME VIII Div. 1
: ASME IX: AWS D1.1: ASME B16.25
: ASME 16.20: ASME B31.3
: API 675
: OSHA (Noise level)
: ASME V: EN 10204
: RUSSIAN STANDARDS
X
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 47/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
47 /56DOC N°:
H201 FQ 001
14.Category: DeNOx – D251 SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 1
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
R O S N E F T
H
T A S
O T H E R S
14.1.3
HTAS Specifications
P52251-R R1: Process specification for
R251 DeNOx reactor
P54251-V R1: Process specification for
V251 Ammonia water storage tank
P56251-K R0: Process specification for
K251 motor driven centrifugal blower
P56252-P R0: Process specification forP252 A/B Ammonia water dosing pump
P59251-J R0: Specification for J251DeNOx inlet sample ejector
P59252-J R0: Specification for J252DeNOx outlet sample ejector
P59251-X R0: Specification for X251Ammonia water injector
P59252-X R0: Specification for X252
Ammonia/flue gas mixer
P59253-J R0: Specification for J253
Ammonia/flue injection grid
P59254-J R0: Specification for J254
inlet sample grid
P59255-J R0: Specification for J255
outlet sample grid
4-1246 E R7: Painting
P40001-BED R1: Design Basis
M80001 R1: General piping
specification
REF51071-R0: General arrangement
of convection section
J61021-Rev. 2: General specification
for instrument
J61025-Rev. 0: General specification
for instrument erection materials(piping & tubing)
J61024-Rev. 0: Typical hook-updrawings for instrumentation in
petrochemical plantsJ61021-1-Rev. 1: Selection list for
instrumentation and control peripherals
X
See point 3
14.1.4
HPC Documents
H201-FS-723 R0 : Material
requisition for DeNOx system package
H201-FD-806 R0 : PID for DeNOx unit
H201-FD-801 R0 : PID for Reformerconvection section
X
See point 3
14.2 Pre-award meeting or Kick-off
meeting
X W Report See point 7.1
14.3 PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
14.4 DOCUMENTS TO SUBMIT PRIOR PIM
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 48/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
48 /56DOC N°:
H201 FQ 001
14.Category: DeNOx – D251 SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 1
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
R O S N E F T
H
T A S
O T H E R S
14.4.1 Detailed Inspection Test Plan X ATo be approved by HTAS before start ofmanufacture.
14.4.2 Arrangement Drawing X A
14.4.3 Details Drawing X A
14.4.4 Schedule Fabrication X AShall be revised (when required) andconfirmed each end of month.
14.4.5 WELDING Book including:
14.4.5.1 Welding Map X A
14.4.5.2 WPS X A ASME IX
14.4.5.3 PQR X A ASME IX
14.4.5.4 Filler metal certificate X A EN 10204-3.1 ASME II Part C
14.4.5.5 Welders Qualifications X A ASME IX or equivalent
14.4.6 NDT Procedures including:
14.4.6.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
14.4.6.2 Dye Penetrant procedure X AASME V Art. 6 + ASME VIII Div.1 App 8
14.4.6.3 Radiographic procedure X AASME V Art. 2 + ASME VIII Div.1 §UW-51& UW-52
14.4.6.4 Ultrasonic test procedure X A
ASME V Art. 5 + AWS D1.1 Section 6 Part
C §6.13
14.4.7 Hydrostatic test procedure X A 1 hour mini.
14.4.8 Running test procedure X A
14.4.9 Balancing test procedure
14.4.10 Functional and performance procedure X A Noise level must not exceed 80dBA at 1m
14.4.11 PMI procedure X A 100% of welds and material
14.4.12 Painting procedure X A 4-1246 E R7
14.4.13 Preservation and packing procedure X A Supplier's procedure
14.5 MATERIAL IDENTIFICATION
14.5.1 Shell & head X R EN10204-3.1 Material as per drawing / requisition
14.5.2 Flange X R EN10204-3.1 Material as per drawing / requisition
14.5.3 Piping X R EN10204-3.1 Material as per drawing / requisition
14.5.4 Gaskets X R EN10204-3.1 Material as per drawing / requisition
14.5.5 Bolts/nuts X R EN10204-3.1 Material as per drawing / requisition
14.5.6 Motors X R EN10204-3.1 Material as per drawing / requisition
14.5.7 Pumps X R EN10204-3.1 Material as per drawing / requisition
14.6 MATERIAL/WELDING EXAMINATION
14.6.1 Beveled ends examination X SW Report 100% PT
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 49/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
49 /56DOC N°:
H201 FQ 001
14.Category: DeNOx – D251 SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 1
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
R O S N E F T
H
T A S
O T H E R S
14.6.2 Tank V251 X SWReport
Chart
100% visual
100% PT
100% RT after PWHT
Hardness 197 HB max. for CS after PWHTon weld, HAZ and material.
Pressure test during min. 1 hour20ppm Cl.
14.6.3 Ammonia mixing blower and motor K251 X SW Report
Running test for motors
Balancing test
Functional and performance test
Running test
100% PT on impeller welds after runningtest
14.6.4 Ammonia water dosing pump P252A/B X SW Report
Running test for motors
Functional and performance test
Running test
Hydrostatic test
14.6.5 DeNOx inlet sample ejector J251 X R Report Functional and performance test
14.6.6 DeNOx outlet sample ejector J252 X R Report Functional and performance test
14.6.7 Ammonia water injector X251 X R
Certificate of
conformance As per supplier standard
14.6.8 Ammonia/Flue gas mixer X252 X R Report 100% PT
14.6.9 Ammonia/Flue gas injection grid J253 X R Report 100% PT
100% of welds and material
14.6.10 Inlet sample grid J254 X SW Report 100% PT
100% PMI of welds and material
14.6.11 Outlet sample grid J255 X R Report 100% PT
14.6.12 Piping X SW Report100% PT on welds
100% RT on welds
14.6.13 Steel structure for DeNOx unit X R Report
100% PT on lifting lugs welds
10% PT on welds100% UT on lifting lugs welds
14.7 HYDROSTATIC TEST X H ReportApproved procedure
1 hour mini., No leak
14.8 PAINTING As per H201-FS-723 part.12
14.8.1 Surface preparation X SW Report Approved procedure
14.8.2 Thickness examination X SW Report Approved procedure
14.9 FINAL EXAMINATION
14.9.1 Visual and Dimensional examination X H ReportDrawings
100%
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 50/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
50 /56DOC N°:
H201 FQ 001
14.Category: DeNOx – D251 SCOPE of INSPECTION
R e v
Supplier: Inspection Level: 4 1
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
R O S N E F T
H
T A S
O T H E R S
14.9.2 Marking X H
Approved procedure
Use of indelible ink not harmful to the
alloy
14.9.3 Packing X H Approved procedure
14.9.4Manufacturer Data Book including RTNpassport
X H Approved HPC summary
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 51/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
51 /56DOC N°:
H201 FQ 001
15.Category: Cross flow heat exchanger – Convection Section Coils
SCOPE of INSPECTION R e v
Supplier: HPM Inspection Level: 4 2
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
R O S N E F T
H
T A S
O T H E R S
15.1 DATA / ENGINEERING
15.1.1 Minimum Design Temperature : -27°C X
15.1.2
Code : API530
: ASME B31.3 (process gas coils
: ASME I (steam coils)
: RUSSIAN STANDARDS
X
15.1.3
HTAS Specifications
REF51072 R0: Specification for
convection sectionP51201-H-005 R0: Process
specification for Waste Heat Section
convection section coils
REF51061 R0: Radiant and convection
section specification for refractory lining
REF51071 R0: General arrangement
sketch of convection section
X
See point 3
15.1.4
HPC Documents
SG 1431 Rev5: Fin Welding on
Furnaces & Boilers Tubes
H201-FS-303: Material requisition for
Convection fabrication
H201-FD-402: Convection coil E-201
H201-FD-403: Convection coil E-202A
H201-FD-404: Convection coil E-203A
H201-FD-405: Convection coil E-203B
H201-FD-406: Convection coil E-206
H201-FD-407: Convection coil E-204A
H201-FD-408: Convection coil E-202B
H201-FD-409: Convection coil E-204B
H201-FD-901: Lifting diagrams &
lifting lugs
X
See point 3
15.2 Pre-award meeting or Kick-off
meeting
X W Report See point 7.1
15.3 PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
15.4 DOCUMENTS TO SUBMIT PRIOR PIM
15.4.1 Detailed Inspection Test Plan X ATo be approved by HTAS before start of
manufacture.
15.4.2 Arrangement Drawing X A
15.4.3 Details Drawing X A
15.4.4 Schedule Fabrication X AShall be revised (when required) andconfirmed each end of month.
15.4.5 WELDING Book including:
15.4.5.1 Welding Map X A
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 52/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
52 /56DOC N°:
H201 FQ 001
15.Category: Cross flow heat exchanger – Convection Section Coils
SCOPE of INSPECTION R e v
Supplier: HPM Inspection Level: 4 2
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
R O S N E F T
H
T A S
O T H E R S
15.4.5.2WPS
X AASME IX
Root pass by TIG process
15.4.5.3 PQR X A ASME IX
15.4.5.4 Filler metal certificate X A EN 10204-3.1 ASME II Part C
15.4.5.5 Welders Qualifications X A ASME IX or equivalent
15.4.6 NDT Procedures including:
15.4.6.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
15.4.6.2 Dye Penetrant procedure X A ASME V Art. 6 + ASME I §A-270
15.4.6.3 Radiographic procedure X AASME V Art. 2 + ASME I PW-51
15.4.6.4 Hydrostatic test procedure X AASME I PW-541 hour mini
15.4.7 Preservation and packing procedure X A Supplier's procedure
15.5 MATERIAL IDENTIFICATION
15.5.1 Tube X R EN10204-3.1
ASTM A312 Gr.TP304H
ASTM A312 Gr.TP304H + Helical fins
SS304HASTM A106 Gr. B + Helical fins CS
ASTM A335 Gr.P11 + Helical fins 11Cr
15.5.2 Inlet Manifold X R EN10204-3.1
ASTM A335 Gr.P11
ASTM A335 Gr.P22
ASTM A106 GR. B
15.5.3 Outlet Manifold X R EN10204-3.1
ASTM A335 Gr.P22
ASTM A312 Gr.TP321H
ASTM A106 GR. B
ASTM A335 Gr.P11
15.6 WELDING EXAMINATION
15.6.1
Beveled ends examination X SW ReportApproved procedure
100% PT on bevels
15.6.2 Welding of tube to inlet/outlet manifold X SW Report
Approved welding book
100% visual
Approved procedure
100% RT on buttwelds
Approved procedure
100% PT when RT is not possible
15.7 HYDROSTATIC TEST X H Report
Approved procedure
One hour minimum
No leak
15.8 FINAL EXAMINATION
15.8.1 Visual and Dimensional examination X H ReportDrawings
100%
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 53/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
53 /56DOC N°:
H201 FQ 001
15.Category: Cross flow heat exchanger – Convection Section Coils
SCOPE of INSPECTION R e v
Supplier: HPM Inspection Level: 4 2
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
R O S N E F T
H
T A S
O T H E R S
15.8.2 Marking X H
Approved procedure
Use of indelible ink not harmful to the
alloy
15.8.3 Packing X H Approved procedure
15.8.4 Manufacturer Data Book X H Approved HPC summary
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 54/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
54 /56DOC N°:
H201 FQ 001
16.Category: FLUE GAS DUCTS CASING ANDAIR DUCT CASING
SCOPE of INSPECTION R e v
Supplier: HPM Inspection Level: 4 2
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
R O S N E F T
H
T A S
O T H E R S
16.1 DATA / ENGINEERING
16.1.1
Design furnace temperature: 1150°C
Design casing temperature: 55°C
above ambient
Ambient temperature for design: 27°C
MDMT for structural parts : -27°C
X
16.1.2 Code : ISO 13705 (API560)
: AWS D1.1
: RUSSIAN STANDARDS
X
16.1.3
HTAS Specifications
4-1246 E R7: Painting
REF51061 R0 : Specification for
refractory lining
REF51040 R0 : Specification for steel
structure and casing
X
See point 3
16.1.4
HPC Documents
H201-FS-302: Material requisition forPenthouse fabrication
H201-FS-304: Material requisition forFlue gas fabrication
X
See point 3
16.2 Pre-award meeting or Kick-offmeeting
X W Report See point 7.1
16.3 PRE-INSPECTION MEETING (PIM) X H Report See point 7.1
16.4 DOCUMENTS TO SUBMIT PRIOR PIM
16.4.1 Detailed Inspection Test Plan X ATo be approved by HTAS before start of
manufacture.
16.4.2 Arrangement Drawing X A
16.4.3 Details Drawing X A
16.4.4 Schedule Fabrication X AShall be revised (when required) andconfirmed each end of month.
16.4.5WELDING Book including:
16.4.5.1 Welding Map X A
16.4.5.2 WPS X A AWS D1.1
16.4.5.3 PQR X A AWS D1.1
16.4.5.4 Filler metal certificate X A EN 10204-2.2 ASME II Part C
16.4.5.5 Welders Qualifications X A AWS D1.1 or equivalent
16.4.6 NDT Procedures including: X A
16.4.6.1 NDT Operator certifications X A EN 473 (Level II) or SNT TC 1A (ASNT)
16.4.6.2 Dye Penetrant procedure X AASME V Art. 6 + AWS D1.1 Section 6 Part
C §6.10
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 55/56
UF13006_ACRON_H201 rev02
HPC Ref:
UF 13006 Page
55 /56DOC N°:
H201 FQ 001
16.Category: FLUE GAS DUCTS CASING ANDAIR DUCT CASING
SCOPE of INSPECTION R e v
Supplier: HPM Inspection Level: 4 2
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
R O S N E F T
H
T A S
O T H E R S
16.4.6.3 Radiographic procedure (if applicable) X AASME V Art. 2 + AWS D1.1 Section 6 PartC §6.12
16.4.6.4 Ultrasonic test procedure X AASME V Art. 5 + AWS D1.1 Section 6 Part
C §6.13
16.4.7 Lining procedure X A REF51061 R0
16.4.8 Painting procedure X A 4-1246 E R7 Table 9.2 Item 11
16.5 MATERIAL IDENTIFICATION
16.5.1 Material for structural steel X R EN 10204-3.1
Carbon Steel suitable for low ambient
temperature (-43°C)
16.5.2 Structural bolts X R EN 10204-3.1 Suitable for low ambient temperature(-43°C)
16.5.3 Lining materials
16.5.3.1 Ceramic fibre lining for flue gas duct X R EN 10204–2.2
REF51061 R0 §5.4
For 1260°C grade modules: Al2O3 + ZrO2:min. 45%
For 1425°C grade modules: 35% Al2O3 +
15% ZrO2
16.5.4 Consumables X R EN 10204–2.2 ASME II Part C
16.6 WELDING EXAMINATION X SW REF51040 R0 §7 & AWS D1.1
16.7 NDT EXAMINATION REF51040 R0 §7 & AWS D1.1
16.7.1 Dye penetrant examination X SW Report
AWS D1.1 Section 6 Part C §6.10
100% on lifting lugs welds. Free of cracks,
undercutting, linear indications over 2 mm
and rounded indications over 4 mm
16.7.2 Radiographic examination X SW Report
AWS D1.1 Section 6 Part C §6.12
100% on full penetration BW forreconstituted beams
16.7.3 Ultrasonic test X SW ReportAWS D1.1 Section 6 Part C §6.13
100% on area where lifting lugs are
welded
16.8 TRIAL ASSEMBLY X W Report Approved drawings
16.9 LINING APPLICATION FOR FLUE GASDUCT
16.9.1 Preparation of surface X SW
16.9.2 Welding of anchors X SW
16.9.3 Mixing of refractory X SW Report Water Analysis
16.9.4 Application of refractory X SW ReportPre-qualification of refractory material &
installers
16.9.5 Visual and dimensional examination X SW ReportApproved drawings & procedure
After drying of castable
E x a m
p l e
7/26/2019 Sec 1.I_Typical Quality Assurance & Inspection Plan
http://slidepdf.com/reader/full/sec-1itypical-quality-assurance-inspection-plan 56/56
16.Category: FLUE GAS DUCTS CASING ANDAIR DUCT CASING
SCOPE of INSPECTION R e v
Supplier: HPM Inspection Level: 4 2
No Inspection Item / Step
By
S u p p
l i e r ’ s R e c o r d
C e r t i
f i c a t e
R e p o r t
Remarks
Acceptance Criteria
S U P P L I E R
H
P C
R O S N E F T
H
T A S
O T H E R S
16.9.6 Production samples X SW Report
Approved procedure :
Compressive strength
Permanent linear changeDensity
Chemical compositionTensile strength (ceramic fiber blankets)
16.9.7 Anchors bending & hammer testing X SW Report Approved procedure
16.10 PAINTING EXAMINATION X W Report
4-1246 E R7
Surface preparation, climatic conditions,
Wet film thickness and DFT examination
16.11 FINAL EXAMINATION X H Report
16.11.1 Visual and Dimensional examination X H ReportDrawings
100%
16.11.2 Marking X W
Approved procedure
Use of indelible ink not harmful to thealloy
16.11.3 Packing X W Approved procedure
16.11.4 Manufacturer Data Book X H Approved HPC summary
E x a m
p l e