Project: GTG-IV Tankage Works at Euro-IV,

CPCL-Manali, Chennai NRP PROJECTS PRIVATE LIMITED

Doc No.: NRP/FQP/001 Rev 00
Date : 26.06.2010
INSPECTION AND TEST PLAN
Quantum Acceptance Standard / Inspection by
S.No Characteristics Type of Check Record Format Remarks
% Reference Standard NRP TCE CLIENT
A Engineering
1 Drawings & Documents Drawings and Design 100% Applicable Standards & Drawings and Design
Calculations Drawings Calculations
2 Tank Fabrication and Erection As per Job requirement Random Applicable Standards & Procedure
Methodology Drawings
3 Welding Documentation WPS / PQR & Weld Map Random Applicable Standards & WPS / PQR
Drawings
4 Welding Repair Procedure WPS / PQR 100% Applicable Standards & WPS / PQR
Drawings
5 Radiographic Testing Procedure ASME Sec V. ASME Spot as per API 650 Test Procedures
Sec VIII Div 1 Latest Edition
6 Magnetic Particle Testing Procedure ASME Sec V. ASME Spot as per API 650 Applicable Standards & Test Procedures
Sec VIII Div 1 Latest Edition Drawings
7 Penetrant Testing Procedure ASME Sec V. ASME Spot as per API 650 Applicable Standards & Test Procedures
Sec VIII Div 1 Latest Edition Drawings
8 Vacuum Box Test Procedure As per Job requirement Spot as per API 650 Applicable Standards & Test Procedures
Latest Edition Drawings
9 Hydro / Pneumatic Test Procedure As per Job requirement Spot as per API 650 Applicable Standards & Test Procedures
Latest Edition Drawings
10 Calibration Procedure As per Job requirement As per IS 2007 & 2008 Applicable Standards & Calibration Procedures
Drawings

B Fabrication
1 Inspection of Welding
1.1 Welding Procedure Specification Review of WPS 100% ASME Sec IX WPS
(WPS)
1.2 Welding Procedure Qualification Witness Welding & 100% ASME Sec IX / API 650 PQR
(PQR) Test APP R
1.3 Welder Qualification Test / Certificate Witness welding and Random ASME Sec IX WPQ
(WPQ) Test
1.4 NDT Operator qualification records NDT Training Random SNT-TC-1A Training Records
Certificates
1.5 Receiving inspection of welding VI, MCR Random ASME Sec II C / API 650 As per Internal Control
consumables APP R Procedures
1.6 Storage of welding consumables VI Random Manufacturer Register
recommendation
1.7 Baking and drying or welding VI and check Random Manufacturer Welding Electrode
consumables temperature recommendation Register
1.8 Production weld test coupon Witness welding and Random API 650 Appendix-R Lab Report
Test

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Project: GTG-IV Tankage Works at Euro-IV,
CPCL-Manali, Chennai NRP PROJECTS PRIVATE LIMITED
Doc No.: NRP/FQP/001 Rev 00
Date : 26.06.2010
INSPECTION AND TEST PLAN
Quantum Acceptance Standard / Inspection by
S.No Characteristics Type of Check Record Format Remarks
% Reference Standard NRP TCE CLIENT
1.9 Welder Evaluation Review of radiography Random JSS Performance Report
& other NDT reports of
seams welded by each
welder

2 Material Inspection
2.1 Receiving inspection VI, All materials Random Applicable Standards & MRIR / Delivery
Drawings Challan

3 Fabrication of Bottom, Shell,

Deck and Roof Plates
3.1 Annular & Bottom plate MI, MCR Random Applicable Standards & SIR
Drawings
DI, VI Random Applicable Standards & SIR
Drawings
3.2 Shell, Deck & Roof Plates MI, MCR Random Applicable Standards & SIR
Drawings
DI, VI Random Applicable Standards & SIR
Drawings
3.3 Miscellaneous parts, stiffeners, MI, MCR Random Applicable Standards & SIR
attachments, etc., Drawings
DI, VI Random Applicable Standards & SIR
Drawings
VI, DI Random Applicable Standards & SIR
Drawings

4 Fabrication of Roof Parts

4.1 Roof plate (cutting of plates) MI, MCR Random Applicable Standards & SIR
Drawings
DI, VI Random Applicable Standards & S/R
Drawings
Fitup, welding Random Applicable Standards & SIR
Drawings
4.2 Roof Strl. Cutting and assembly MI, MCR Random Applicable Standards & SIR
Drawings
Fitup, welding Random Applicable Standards & S/R
Drawings
DI, VI Random Applicable Standards & S/R
Drawings

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Project: GTG-IV Tankage Works at Euro-IV,
CPCL-Manali, Chennai NRP PROJECTS PRIVATE LIMITED
Doc No.: NRP/FQP/001 Rev 00
Date : 26.06.2010
INSPECTION AND TEST PLAN
Quantum Acceptance Standard / Inspection by
S.No Characteristics Type of Check Record Format Remarks
% Reference Standard NRP TCE CLIENT
5 Fabrication of Manhole and Nozzle
5.1 Plate, pipe, flanges and fittings for MI, MCR Random Applicable Standards & SIR
Manhole, Nozzle, etc., (cutting, Drawings
fabrication of pipes and assembly) DI, VI Random Applicable Standards & S/R
Drawings
Fitup, welding Random Applicable Standards & S/R
Drawings
VI, Material Map Random Applicable Standards & S/R
Drawings
(Roof & Final)
100% RT of 10% of all Random Applicable Standards & S/R
piping joints Drawings

6 Fabrication of Deck Plates

6.1 Deck plate and deck stiffeners MI, MCR Random Applicable Standards & SIR
Drawings
DI, VI Random Applicable Standards & SIR
Drawings
6.2 Deck Rings (Outer and Inner) MI, MCR Random Applicable Standards & SIR
Drawings
DI, VI Random Applicable Standards & SIR
Drawings
6.3 Covering sleeve (for nozzle neck) MI, MCR Random Applicable Standards & SIR
Drawings
DI, VI Random Applicable Standards & SIR
Drawings
DI, VI Random Applicable Standards & S/R
Drawings

7 Fabrication of Staircase
7.1 Staircase MI, MCR Random Applicable Standards & TC
Drawings
DI, VI Random Applicable Standards & S/R
Drawings
Fitup, welding Random Applicable Standards & S/R
Drawings

8 Erection of Annular / Bottom plates

8.1 DI, VI Random Applicable Standards & SIR
Drawings

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Project: GTG-IV Tankage Works at Euro-IV,
CPCL-Manali, Chennai NRP PROJECTS PRIVATE LIMITED
Doc No.: NRP/FQP/001 Rev 00
Date : 26.06.2010
INSPECTION AND TEST PLAN
Quantum Acceptance Standard / Inspection by
S.No Characteristics Type of Check Record Format Remarks
% Reference Standard NRP TCE CLIENT
8.2 DI, VI Random Applicable Standards & SIR
Drawings
8.3 Fitup, welding Random Applicable Standards & SIR
Drawings
VI, Material Map Random Applicable Standards & SIR
Drawings
VT 100% Applicable Standards & SIR
Drawings
RT (Annular Plate Butt 50% Applicable Standards & SIR
Joints) Drawings
8.4 Erection of Shell to Shell Assembly Fitup, welding Random Applicable Standards & SIR
(including jigs for jacking) Drawings
VI, Material Map Random Applicable Standards & SIR
Drawings
RT (Weld steam) As per API 650 Applicable Standards & SIR
Latest Edition Drawings
Radius Each Shell Course Random Applicable Standards & SIR
Drawings
Plane Each Shell Course Random Applicable Standards & SIR
Drawings
Peaking and Banding (local Each Shell Course Random Applicable Standards & SIR
deviations from theoretical shape) Drawings
Tank Height and Plumbness Each Shell Course and Random Applicable Standards & SIR
deviations from theoretical shape) after erection of final Drawings
shell course
8.5 Shell to Bottom annular plate Fitup, welding Random Applicable Standards & SIR
assembly Drawings
VI Random Applicable Standards & SIR
Drawings
Oil Chalk Test 100% Applicable Standards & SIR
Drawings
8.6 Permanent attachments (Anchor Fitup, welding Random Applicable Standards & SIR
plates, etc.,) Drawings
VI Random Applicable Standards & SIR
Drawings

9 Erection of Roof
9.1 Frame to frame assembly Fitup, welding Random Applicable Standards & SIR
Drawings
VI Random Applicable Standards & SIR

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Project: GTG-IV Tankage Works at Euro-IV,
CPCL-Manali, Chennai NRP PROJECTS PRIVATE LIMITED
Doc No.: NRP/FQP/001 Rev 00
Date : 26.06.2010
INSPECTION AND TEST PLAN
Quantum Acceptance Standard / Inspection by
S.No Characteristics Type of Check Record Format Remarks
% Reference Standard NRP TCE CLIENT
Drawings
9.2 Roof plate to roof plate assembly Fitup, welding Random Applicable Standards & SIR
Drawings
VI Random Applicable Standards & SIR
Drawings
VT Random Applicable Standards & SIR
Drawings
9.3 Roof plate to RF pad of Nozzles Fitup, welding Random Applicable Standards & SIR
Drawings
VI Random Applicable Standards & SIR
Drawings
RF Pad pneumatic leak 100% Applicable Standards & SIR
check Drawings
9.4 Manhole / Nozzle sleeve to Fitup, welding Random Applicable Standards & SIR
reinforcing plate Drawings
VI Random Applicable Standards & SIR
Drawings
9.5 Compression Ring to Roof Plate Fitup, welding Random Applicable Standards & SIR
Drawings
VI Random Applicable Standards & SIR
Drawings

10 Erection of Nozzle & Piping

10.1 Pipe to pipe, Pipe to Shell and Fitup, welding Random Applicable Standards & SIR
attachments Drawings
VI, Material Map for Random Applicable Standards & SIR
piping Drawings

11 Erection of Roof Structure

11.1 Roof Structure Fitup, welding Random Applicable Standards & SIR
Drawings
VI Random Applicable Standards & SIR
Drawings

12 Check before Hydro Test VI, Record Book 100% Applicable Standards & SIR
Drawings

13 Hydro Test of Tanks VI, Check for leak 100% Approved Drg. & API - SIR
650

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Project: GTG-IV Tankage Works at Euro-IV,
CPCL-Manali, Chennai NRP PROJECTS PRIVATE LIMITED
Doc No.: NRP/FQP/001 Rev 00
Date : 26.06.2010
INSPECTION AND TEST PLAN
Quantum Acceptance Standard / Inspection by
S.No Characteristics Type of Check Record Format Remarks
% Reference Standard NRP TCE CLIENT
14 Tank Settlement Reading Measurement 100% Applicable Standards & Applicable Standards
Drawings & Drawings

15 Pneumatic Test of Tank Roof VI, Check for leak 100% Approved Drg. & API - SIR
650

16 Cleaning VI 100% Project Specification SIR

17 Tank Calibration Random Approved Drg. & API - SIR & Report
650

18 Painting Surface preparation, VI, Random Approved Drg. & Project SIR
DFT Specification

19 Closure of Tank Nozzles VI Random Approved Drg. & Project SIR

Specification

20 Mechanical Completion Any punch list points 100% Mechanical

issued by TCE / CPCL Completion Note
LEGEND:
SIR - Stage Inspection Report VI - Visual Inspection
IPR - Implementation and Preparation of Record DI - Dimensional Inspection
A - Approval MI - Material Identification
H - Hold Point (Proceed with further work only after inspection W - Witness (Vendor to give inspection cell:
of that particular stage Witnessing of inspection, if present)
R - Review (Submission of Documents for Review) MCR - Material Certification Review
S - Spot Witness PT - Liquid Penetrant Examination
V - Vendor VT - Vacuum Box Test
HT - Hydrostatic Test PNT - Pneumatic Test

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Project: GTG-IV Tankage Works at Euro-
IV, CPCL-Manali, Chennai NRP PROJECTS PRIVATE LIMITED
Doc No.: NRP/FQP/001 Rev 00
Date : 26.06.2010
QUALITY ASSURANCE PLAN
Method of Exten of Reference Accept Record Agency
S.No Characteristics Type of Check CAT Remarks
Check Check Documents Norms Format P W V
1 Raw Materials
1.1 Plate for shell, bottom, annular Physical, Chemical M Physical & As per Spec. Approved Approved Mill TC 2 1 1, 2
plates, deck of roof, wind girders properties Chemical test drawing / drawing
and nozzle > 12" and flanges Heat Treatment data sheet

Dimensions and visuals M Measurement As per Spec. Approved Material

visual drawing / Inspection
data sheet Report

1.2 Structurals Dimensions and visuals M Measurement 1 Approved Material 3 1 1, 2

visual drawing specification

1.3 Pipes for nozzles < 12" Dimensions and visuals M Measurement As per TCE TCE apprd. Material Material 3 1 1, 2
visual specification drawing / specs as per Inspection
data sheet data sheet Report

1.4 Flanges for Nozzles Physical, Chemical M Physical & Random Approved Material Mill TC or 3 1 1, 2
properties Chemical test drawing / specs as per lab report /
Heat Treatment data sheet data sheet mfrs TC

Dimensions and visuals M Measurement As per Spec.

visual

1.5 Pipe fittings Physical, Chemical M Physical & As per Spec. Approved Approved Mill TC or 3 1 1, 2
properties Chemical test drawing / drawing & lab report /
Heat Treatment data sheet material mfrs TC
TEC material specification
specs

Dimensions and surface M Measurement As per TCE Approved Approved Material

check visual Spec. drawing / drawing Inspection
data sheet Report

1.6 Bolts, nuts for nozzle flanges and Physical, Chemical M Physical & Material Approved Material Mill TC or 3 1 1, 2
structurals properties Chemical test check drawing / specs as per lab report
Heat Treatment data sheet data sheet

Dimensions M Measurement 1 Approved Approved IR 3 1 1

visual drawing / drawing

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Project: GTG-IV Tankage Works at Euro-
IV, CPCL-Manali, Chennai NRP PROJECTS PRIVATE LIMITED
Doc No.: NRP/FQP/001 Rev 00
Date : 26.06.2010
QUALITY ASSURANCE PLAN
Method of Exten of Reference Accept Record Agency
S.No Characteristics Type of Check CAT Remarks
Check Check Documents Norms Format P W V
data sheet

2 In Process
2.1 Welding Procedure Specification Correctness M Scrutiny 1 WPS ASME WPS ASME WPS 1 1,2
Sec.IX Sec.IX
API 650 API 650

2.1.1 Welding Procedure Qualification Weld soundness M Physical / 1 WPS ASME PQR 2 1,2 1,2
record Mechanical / Sec.IX &
NDT test WPS

2.1.2 Welder evaluation Weld soundness M Physical test 1 WPS ASME ASME PQR 2 1,2 1,2
Sec.IX Sec.IX &
API 650 WPS
API 650

2.1.3 Welding consumables & storage Witness M Chemical 1 WPS ASME WPS ASME Manufacturer 2 1,2 1,2
baking electrodes analysis Sec.II Part C Sec.II Part C TC's

2.1.4 Welding procedure qualification Weld soundness M Radiography 1 WPS ASME WPQ 2 1,2 2
record Sec.IX &
WPS

2.2 Plate cutting for bottom, shell & Dimensional & checking M Measurement 1 Cutting Approved IR 2 2 1
roof diagonal visual layout drawing

2.2.1 Rolling of plates Dimensions M Measurements 1 Approved Approved IR 2 2 1

drawing drawing

2.2.2 Weld fitups Alignment dimensions M Measurements 1 Approved Approved IR 2 1, 2 1

drawing drawing

2.2.3 Butt welds (vertical) Visual M Visual Approved Approved Dimension 2 1, 2 1

drawing drawing report

Radiographic test M RT API 650 API 650 Radiography 3 1, 2 1

report

Plumbness M By plumb At every 30" API 650 API 650 2 1, 2 1

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Project: GTG-IV Tankage Works at Euro-
IV, CPCL-Manali, Chennai NRP PROJECTS PRIVATE LIMITED
Doc No.: NRP/FQP/001 Rev 00
Date : 26.06.2010
QUALITY ASSURANCE PLAN
Method of Exten of Reference Accept Record Agency
S.No Characteristics Type of Check CAT Remarks
Check Check Documents Norms Format P W V

2.3 Bottom plate, Lap joint, Backing Visual M Visual 1 Approved API 650 IR 2 1, 2 1
Strip joint & Roof plate Lap joint drawing

Welding M Visual / Vaccum 1 API 650 API 650 IR 2 1, 2 1

test, press test

2.4 Nozzle to flange & Nozzle to shell Dimensions & M Visual, Meas 1 Approved API 650 IR 2 1, 2 1
Orientation of Nozzle drawing

2.4.1 Butt Joint between shell courses Visual M Visual 1 Approved Approved IR 2 2 1
(Horizontal, Welds) drawings drawings

Radiographic M RT 1 API 650 API 650 IR 3 2 1

2.4.2 Shell to Bottom plate Weld soundness M Visual / Vaccum 1 Approved No leakage IR 2 1, 2 1
chalk test drawings

2.5 Appurtenances and attachments Alignment M Visual 0.1 Approved Approved IR 2 2 1

drawings drawings

Dimensions M Visual 0.1 Data sheet Data sheet IR 2 2 1

3 Inspection prior to release for Completeness, M Verification of 1 Approved Approved IR 2 1 1

hydro test cleanliness, overall all records drawings / drawings /
dimensions, Data sheet Data sheet
orientations, etc.,

4 Final Inspection
4.1 Final Assembly Leak tightness CR Hydro test 1 Approved Approved TR 2 1, 2
drawings drawings

Vertically settlement M Plumb At every 30" Approved Approved IR 2 1, 2 1

drawings drawings

Tank calibration M Measurements Random Approved Approved IR 2 1, 2 1

drawings drawings

Page 9 of 10
Project: GTG-IV Tankage Works at Euro-
IV, CPCL-Manali, Chennai NRP PROJECTS PRIVATE LIMITED
Doc No.: NRP/FQP/001 Rev 00
Date : 26.06.2010
QUALITY ASSURANCE PLAN
Method of Exten of Reference Accept Record Agency
S.No Characteristics Type of Check CAT Remarks
Check Check Documents Norms Format P W V
Testing of Valves M Visual 1 Approved Approved IR 2 1, 2 1
drawings drawings

4.2 Cleaning Cleaning EXT & INT M Visual 1 Technical Technical IR 2 1, 2 1

after hydro test specification specification

4.3 Painting / Stamping Surface preparation, M Visual, Coating 1 Approved Approved IR 2 2, 1 1

surface finish, coating thickness gauge procedure procedure
thickness

4.4 QA / QC Documentation Review of all TC, IR M 1 TCE TCE IR 2 2, 1 1

for previous stages specification specification
API 650 API 650

5 Standard Boughtout items

LEGEND:
P - Performed by CR - Critical
W - Witnessed by M - Major
V - Verified by IR - Inspection Record

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