INSPECTION AND TEST PLAN (ITP)

for Plate & Frame Heat Exchanger

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TABLE OF CONTENT

1. INTRODUCTION…………………………………………….….3

1.1.PROJCT DESCRIPTION……………………………………3

1.2.DEFINITION OF TERMS…………………………………..3

2. SCOPE…………………………………………………………....4

3. APPLICABLE CODES AND STANDARDS…………………..4

4. REFERENCES DOCUMENTS……….………………………..6

5. CONFLICTING REQUIREMENT……………………………7

6. INSPECTION REQUIREMENTS…………………………....8

7. SUPPLIER’S QUALITY CONTROL PLAN(SQCP)………..8

8. INSPECTION AND TEST PLAN……………………………..9

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1. INTRODUCTION
1.1 Project Description
………Company name …………… has planned to construct a ………… Plant name
…………… unit. Nominal capacity of the plant is ………… cubic meter per annual to
produce…….. Products name ………… products.

A typical ITP (Inspection and Test Plan) for Plate & Frame Heat Exchanger in the oil and
gas industries usually includes a detailed plan for the inspection and testing of the Plate &
Frame Heat Exchangers at various stages of fabrication and installation. The ITP typically
covers the materials used, welding procedures, non-destructive testing, surface preparation,
paint/coating application, and final inspection. The purpose of the ITP is to ensure that the
Plate & Frame Heat Exchanger meet the required specifications and standards and are safe
for use in the oil and gas industries.

1.2 Definition of Terms

The following terms provides definitions for certain words used within this specification:

Client: ………………………

Company: ………………………

Contractor/Purchaser: ………………………

Engineering: ………………………

Subcontractor: ………………………

Project name: ………………………

Location: …………………………
Supplier: Any vendor, manufacturer who supply any Service, Material or Equipment for the
project.
Shall/Must: Refer to a mandatory requirement
Should: Refer to a recommendation
May: Refer to one acceptable course of action

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2. SCOPE

2.1) This document outlines the minimum requirements for inspecting, testing, and preparing
Plate & Frame Heat Exchanger for shipment in the project.

2.2) The supplier is responsible for ensuring the equipment passes inspection and testing in
compliance with applicable codes and standards, process conditions, and other specified
conditions in this ITP.

2.3) The CONTRACTOR/PURCHASER’s Inspection and Test Plan for Plate & Frame Heat
Exchanger is an engineering document, which defines:

➢ The involvement of CONTRACTOR/PURCHASER representatives in each phase of

fabrication, control, and testing requiring inspection should be specified.
➢ The obligations outlined in the manufacturer's contract align with the general purchase
conditions.

2.4) It is important to note that the inspection procedure manual of the CONTRACTOR
/PURCHASER cannot be used as a replacement for the supplier's quality control plan. The
supplier must carry out all the necessary tests in compliance with the contractual documents,
specifications, codes, and standards, and maintain the corresponding documentation.

2.5) During the pre-inspection meeting, these ITPs shall be used as a basis for defining the
material inspection plan.

2.6) This ITP summarizes the work to be done by SUPPLIER and CONTRACTOR
/PURCHASER.

2.7) Compliance with this document and accompanying data does not absolve the SUPPLIER
of their own responsibilities, guarantees, or contractual obligations.

3. APPLICABLE CODES AND STANDARDS

The applicable codes and standards listed on the equipment data sheet below are the main
references. Other codes and standards specified in the relevant COMPANY engineering
documents and technical specifications are also applicable. The table below refers to the
following standards for inspecting and testing the relevant equipment.

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 The supplier is responsible for complying with all mandatory regulations related to the design,
fabrication, testing, and inspection of ITP for Plate & Frame Heat Exchanger.
Note: The manufacturer and contractor must consider the latest codes and standards.

Standard Title
ASME Section VIII- Div. 1 Boiler and Pressure vessel code
ASME Section II ASME Boiler & Pressure Vessel Code, Material
ASME Section V ASME Boiler & Pressure Vessel Code, Non-Destructive Testing
ASME Boiler & Pressure Vessel Code, Welding and Brazing
ASME Section IX
Qualifications
API STANDARD 662 Plate Heat Exchanger for General Refinery Services
NACE MR0175/ISO 15156 H2S‐Containing Environments in Oil and Gas Production
ASTM E562 Standard Test Method for Determining Volume Fraction by Systematic
Manual Point Count
IPS- C-TP-102(1) Construction Standard for Painting
IPS –C –TP-742(1) Construction Standard for Corrosion Consideration During Fabrication
and Installation
IPS‐G‐ME‐150(1) Engineering and Material Standard for Towers, Reactors, Pressure
Vessels and Internals
IPS-G-GN-210(0) General Standard for Packing & Package
IPS‐G‐ME‐220(2) General Standard for Shell and Tube Heat Exchangers

IPS- C-TP-101(1) Construction Standard for Surface Preparation

IPS-E-TP-100(1) Engineering Standard for Paints (Edition 2010)
IPS-E-TP-350(1) Engineering Standard for Linings (Edition 2010)
IPS-E-TP-700(1) Engineering Standard for Thermal Insulation (Edition 2010)
ASCE-7-05 Minimum Design Loads for Buildings and Other Structures
BS EN 10204 Metallic products- type of material inspection
ASME B 16.5 Pipe Flanges and Flanged Fittings
ASME B 16.47 Large Diameter Steel Flanges, NPS 26 through NPS 60 (Series “B”)
WRC 107 Welding Research Council
ASME B 16.20 Ring joint gaskets and grooves for steel pipe flanges.
AME B 16.21 Non-metallic gaskets for pipe flanges.
ASME B 16.9 Factory made weight steel butt welding fittings

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4. REFERENCES DOCUMENTS

According to latest revision of MR's reference table.

Abbreviations:

IPS: Iran Petroleum Standard (or any other COMPANY Standard)

ITP: Inspection and Test Plan

MR: Material Requisition

PO: Purchase Order

KOM: Kick of Meeting

PIM: Pre-Inspection Meeting

TPA: Third Party Agency

IRN: Inspection Release Note

SRN: Shipping Release Note

MCC: Manufacturer compliance Certificate

MOM: Minutes of Meeting

Hold (H): A hold point is a designated point during or following specific activities that are
defined in ITP. Inspection or examination shall not proceed unless the designated parties
have witnessed the inspection, examination, or test.

TPA must clearly specify if activities are Accepted or Rejected, and sign and stamp all related
reports as HOLD POINT.

Vendor/Contractor must be notified 7 working days prior to action.

Witness (W): A witness point is a specific point during or after a significant task that requires
inspection or examination in accordance with related procedures. If the inspector is not

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 present for the previously established activity, work may continue through the designated
witness point.

All reports related to the TPA will be signed and stamped with the phrase "Witnessed by
TPA". The results of all activities will be clearly specified as either Accepted or Rejected.
The Vendor/Contractor must be informed at least three working days prior to any relevant
action.

Review(R): The process involves reviewing the results of any inspections or tests to ensure
that they were carried out in accordance with the approved procedures, specifications, or
acceptance criteria. Although it is not mandatory for the involved party to be present during
the inspection, the inspection results should still be reviewed, and all documents should be
signed and stamped as reviewed. The results of all activities should be clearly specified as
accepted or rejected. The TPA document should be reviewed within 7 days.

Review and Approved (RA): RA requires signed and stamped documents for reviewed and
approved parties. Work cannot proceed without necessary party approval.

Monitor (M) or Spot witness (SW): The charge person has a wide range of responsibilities
that involve inspecting, checking, and controlling activities and their proper sequence
through observation, information gathering, and verbal communication. They also ensure
that the routing and supporting documents are correct in order to expedite the process. If any
non-conformity is found during the inspection, it must be promptly reported to the supplier,
contractor/purchaser, and company.

5. CONFLICTING REQUIREMENT

If there is a disagreement, the order of importance will be as follows:

• Purchase order
• Clarification
• Material Requisition
• Data sheet/Drawing
• Project Specification
• IPS standard
• International codes and standard

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 In case of any conflict, it is required to consult "COMPANY" in writing.

6. INSPECTION REQUIREMENTS

6.1) All items and materials shall be thoroughly inspected in accordance with the
requirements of the CONTRACTOR/PURCHASER. However, it is important to note that
acceptance of any work or release of material /equipment by the CONTRACTOR
/PURCHASER does not absolve the supplier of any responsibility to comply with all
relevant codes, standards, and specifications.

6.2) Inspectors or representatives shall have unrestricted access to all supplier and sub-
supplier shops.

6.3) Refer to the table provided in this Inspection and Test Plan for the minimum inspection
points required.

6.4) Certification, Records and any other Inspection Document shall be in accordance with
the requirements of EN 10204:2004; “Metallic Products - Types of Inspection Documents”.

7. SUPPLIER’S QUALITY CONTROL PLAN (SQCP)

The supplier must provide a quality control plan for equipment/material type.
CONTRACTOR /PURCHASE must approve prior to Pre-Inspection meeting.

The supplier's quality control plan is a document that outlines the sequence of operations,
controls, and tests according to the supplier's expertise and the CONTRACTOR
/PURCHASER requisition.
It is required that every operation clearly specifies the following information:
• Reference documents (drawings, procedures, etc.…)
• Acceptance criteria (code, etc.…)
• Frequency of test
• Recording documents for control and tests.
• Involvement of the Quality Control department of the Supplier and/or his sub supplier.

The minimum inspection activities defined in the CONTRACTOR/PURCHASER Inspection

Procedure Manual must be included in the SQCP.

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 Other Activities:
In case any activity is deemed necessary during the project execution, and it is not listed in
the ITP table, any party involved must prepare a proposal that describes the activity in ITP
format. The proposal must be submitted to COMPANY for approval before the activity is
commenced.

NOTE 1: In case the TPA inspector finds any deviation from the COMPANY project
specifications during any stage, they must prepare and submit an NCR report to COMPANY
for finished or partially finished works.

NOTE 2: In case of any conflict with reference standards, codes, datasheets, or specifications,
written approval from COMPANY is required before starting work.

8. INSPECTION AND TEST PLAN

The manufacturer will prepare ITP for each item and submit it via Contractor for
COMPANY'S review and comment only when the manufacturer is defined, and the PO is
placed. Additionally, each ITP related to each item will be finalized before PIM and after all
the engineering documents are completed and finalized.

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 Action
Reference Acceptance Frequency of Verifying
Row Activities COMPA Remark
Documents Criteria test Document Manufacturer Contractor TPI
NY
Kick off Meeting
A Contract/PO -- -- MOM H H -- H --
(KOM)
Pre-Inspection Project
B --- -- MOM H H H H --
Meeting (PIM) Specification
1-Document Review
Engineering
Documents
Project detailed Project Project Engineering
1.1 100% H RA R R --
documents (including Specification Specification Document
DWG, calculation,
etc.)
TPA shall verify
WPS, WPQT Note1 developed WPSs
1.2 ASME IX ASME IX -- WPS and WPQT H RA R R
and 2 and PQRs cover
all weld lines
Welder Qualification
1.3 ASME IX ASME IX -- Welder Certificate H RA RA R --
(WQT)
Qualification and
Certification of NDT
Project Certification of
1.4 Personnel & and ASNT -- H RA RA R --
Specification NDT Personnel
Calibration Certificate
of all NDT Equipment
Non-Destructive
Project
1.5 Testing Procedure ASME V -- NDT Procedures H RA RA R --
Specification
(NDT)
Visual and
Project Approved
1.6 Dimensional -- VT/DT Procedure H RA RA R --
Specification Drawings
Inspection Procedure

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 Action
Reference Acceptance Frequency of Verifying
Row Activities COMPA Remark
Documents Criteria test Document Manufacturer Contractor TPI
NY

Hardness Test Project Hardness Test

1.7 ASTM -- H RA RA R --
Procedure Specification Procedure

Project Positive Material

Positive Material
1.8 ASME II Specification/ -- Inspection H RA RA R --
Inspection Procedure
ASME II Procedure
Post Weld Heat Project
1.9 ASME VIII -- PWHT Procedure H RA RA R --
Treatment Procedure Specification
Hydrostatic and Hydrostatic and
Project
1.10 Pneumatic Test ASME VIII -- Pneumatic Test H RA RA R --
Specification
Procedure Procedure
Surface Preparation IPS‐E‐TP‐100 Painting
Project
1.11 and Painting Project -- Inspection H RA RA R --
Specification
Inspection Procedure Specification Procedure
Packing and
Packing and Marking Project Project
1.12 -- Marking H RA RA R --
Procedure Specification Specification
Procedure
2- Activities based on manufacturer work sequence
ASME II-A/B
ANSI B16.5
Raw Material Receive ANSI B16.47
Project Material
2.1 and Storage ASME B 100% H RA H/RA R
Specification Certificates --
Note3,4,5,6 16.20
AME B 16.21
ASME B 16.9
Preparation of plate, Raw material
Approved Approved MT Test shall be
2.2 and cones (Cutting , 10% Dimensional H SW SW R
Drawings Drawings done on Bevels
Beveling and Rolling) Report

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 Action
Reference Acceptance Frequency of Verifying
Row Activities COMPA Remark
Documents Criteria test Document Manufacturer Contractor TPI
NY
Marking and Opening Approved Approved
2.3 10% Inspection Report H W H R --
of Nozzles Drawings Drawings
Fit up and assembly
Approved Approved
2.4 Internal and External 10% Inspection Report H W H R --
Drawings Drawings
Parts
WPS and WPS and
2.5 Welding 10% Inspection Report H SW SW R --
WPQT WPQT
Visual and
Approved Approved DT/VT inspection
2.6 Dimensional 100% H W H R --
Drawings Drawings Report
inspection
NDT Review all
radiographs Review UT Based on
Approved Based on NDT activities
Test Reports. approved
2.7 Welding and related design NDT reports H RA RA R shall be
1. Review MT test reports Welding and
2. Review PT test NDT Map code witnessed by TPI
NDT Map
reports
PMI and ferrite check
ASME II/
for cladded and Approved One point on
2.8 Project PMI report H W H W --
Stainless-Steel parts Procedure each weld line
Specification
Note 7
Approved Approved
Execution of Major
2.9 Repair Repair 100% Repair Report H H H W --
Repairs (If any)
Procedure Procedure
Approved Approved
Post Weld Heat PWHT curve and
2.10 PWHT PWHT 100% H W H W --
Treatment report
Procedure Procedure
Production Test Plate ASME VIII- ASME VIII-Div. Destructive Test
2.11 100% H W H W
(If any) Note 8 Div. 1-UCS 67 1-UG84i Reports

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 Action
Reference Acceptance Frequency of Verifying
Row Activities COMPA Remark
Documents Criteria test Document Manufacturer Contractor TPI
NY
Approved Approved
2.12 NDT after PWHT Welding and Welding and 100% NDT report H W H W --
NDT map NDT map
Approved NACE
Hardness Test after 3 points on Hardness Test
2.13 Hardness MR0175/ H W W W --
PWHT each wed line Report
Procedure ISO15156
DT/VT inspection
Final Visual and
Approved Approved Report/Release
2.14 Dimension inspection 100% H W H W --
Drawings Drawings for Hydrostatic
Note 9
test
Hydrostatic Test Note Approved API 662 Project Hydrostatic Test
2.15 100% H H H H --
10 Procedure Specification report and graph
Hydrostatic
Drainage and and API 662
2.16 cleanness after Pneumatic Project 100% Inspection Report H W W R
Hydrostatic test Test Specification
Procedure
Approved Project Painting
2.17 Surface Treatment 100% H W H W --
Procedure Specification inspection Report
Approved
Packing and Marking Packing and Project
2-18 100% Packing List H H H R --
Check marking Specification
procedure
Spare Part Project
2.19 Spare Part Check 100% Packing List H W W R
Philosophy Specification
Mill test
Final Documentation EN10204:200 certificate and all
2.20 -- 100% RA RA RA R
Control Note 12 4 inspection
Reports
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 Action
Reference Acceptance Frequency of Verifying
Row Activities COMPA Remark
Documents Criteria test Document Manufacturer Contractor TPI
NY
Final inspection of
Project IRN/SRN/ MCC/
2.21 consignment prior to -- 100% H H H H
Specification Packing list
shipment
All document
Shipping Document
2.22 P.O -- 100% related to RA RA RA R
Control
shipment
2.23 TQ (Just in case) Contract/P.O -- -- Approved TQ form H H H H --
Project Finalized and
2.24 NCR (Just in case) -- -- H H H H
Specification closed record NCR

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Notes:
1) If welding is used to join pressure parts, the vendor shall prepare a new WPQT, and TPI
shall fully witness all WPQT sequences (welding of samples and lab testing).
2) WPQT hardness testing must be conducted in compliance with clause 7.3.3.2 of NACE
MR0175-2/ISO 15156-
3) The original hard copy of the raw material is the only acceptable form, and TPI will
review it. If the hard copy is not available, all necessary tests will be conducted, and TPI
will oversee the sampling and testing process.
4) Clause 9.2.2 of IPS-G-ME-150(1) specifies that when hydrogen or wet H2S service is
specified, all plate materials used for pressure retaining portion must undergo ultrasonic
examination. The method and acceptance criteria for the ultrasonic examination of the
plate's material for the Plate & Frame Heat Exchanger shall be in accordance with ASTM
Standard Specification A-578, acceptance "level 1".
5) Clad plates must undergo ultrasonic inspection to ensure bond integrity before being
shipped, in accordance with the procedures and methods specified in A578/A578M.
Additionally, the surface of cladded plates must be subjected to PT testing.
6) HIC and SSC requirements will be taken into account according to project specifications
as needed.
7) Technical specifications for the pressure vessel project and metallurgical requirements
for carbon steel and corrosion-resistant alloys in sour service projects shall be considered
for material certification review.
8) Where impact testing is mandatory as per ASME Sec VIII-Div. 1-UCS 67 requirements,
production testing must be carried out in accordance with UG-84i requirements. A third-
party inspector must observe all tests.
9) Prior to the Hydrostatic test, all previously required tests must be double-checked for any
overlooked tests.
10) Water analysis and gauge calibration must be checked according to project specifications
and related codes.
11) All rolling, assembly, and welding must meet the technical specifications for the Pressure
Vessel Project requirements.
12) All manufacturing-verified documents must be included in the final book.
General Notes:
1) ITP will be prepared by manufacturer & submitted via Contractor for Company's review/
comment only when the manufacturer is defined/PO is placed. Also, each ITP related to
each item will be finalized prior to PIM and when all the engineering documents are
completed/ finalized.
2) Company keeps the right to make changes in ITP steps, SEQUENCE; involved parties
roles required documentation acceptance criteria based on project specification
/manufacturer quality level.

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