Residue Hydrocracker Unit of Panipat

Refinery Expansion Project (P25)

Panipat, Haryana, India

Title: INSPECTION AND TEST PLAN FOR HAGO MP STEAM GENERATOR. Rev. No : 01
402-E-09. Page : 1 of 14
Doc. No.: B269-RHCU-LT-402-MES-QD-TEMA(2)-04-001

OWNER : INDIAN OIL CORPORATION LIMITED (IOCL)

PMC : ENGINEERS INDIA LIMITED (EIL)
PROJECT : PANIPAT REFINERY EXPANSION PROJECT (P25)
UNIT : RESIDUE HYDROCRACKER UNIT
EPC CONTRACTOR : LARSEN & TOUBRO (L&T)
PMC JOB NO : B269
L&T JOB NO : RHQPJ/2022-23/EPCM1FOA/05
EQUIPMENT TAG : 402-E-09
EQUIPMENT DESCRIPTION : HAGO MP STEAM GENERATOR
VENDOR NAME : TEMA INDIA LIMITED
VENDOR P.O. NO. : Refinery/75001-27976/HAL , Dt.: 06.03.2023
VENDOR DOCUMENT NO. : ITP / 23-062 / 001
DOCUMENT SUBMISSION STATUS – REVIEW STATUS
VENDOR L&T EIL
DOC. CATEGORY:  CODE 1 – NO COMMENTS. PROCEED WITH  CODE 1 – NO COMMENTS. PROCEED WITH
(USE TICK MARK) MANUFACTURE / FABRICATION / MANUFACTURE / FABRICATION /
R  I CONSTRUCTION AS PER THE DOCUMENT. CONSTRUCTION AS PER THE DOCUMENT.
 CODE 2 – PROCEED WITH MANUFACTURE /  CODE 2 – PROCEED WITH MANUFACTURE /
ISSUED FOR FABRICATION / CONSTRUCTION AS PER FABRICATION / CONSTRUCTION AS PER
COMMENTED DOCUMENT. REVISED COMMENTED DOCUMENT. REVISED
DOCUMENT REQUIRED. DOCUMENT REQUIRED.
 CODE 3 – DOCUMENT DOES NOT CONFORM TO  CODE 3 – DOCUMENT DOES NOT CONFORM TO
 INFORMATION BASIC REQUIREMENTS AS MARKED. RESUBMIT BASIC REQUIREMENTS AS MARKED. RESUBMIT
FOR REVIEW FOR REVIEW
 REVIEW
 CODE R – DOCUMENT IS RETAINED FOR  CODE R – DOCUMENT IS RETAINED FOR
 CONSTRUCTION RECORDS. PROCEED WITH MANUFACTURE / RECORDS. PROCEED WITH MANUFACTURE /
FABRICATION FABRICATION
 AS BUILT
 CODE V – VOID  CODE V – VOID
Lalit Ladumor 23.08.2023
NAME DISCIPLINE SIGN. DATE NAME DISCIPLINE SIGN. DATE

Revised as per comments & submitted Santosh B.C.

01 Anil Sinha 06.07.2023
for Review Zingade Dharmameher
B.C.
00 Issued for Review Vinod Yadav Anil Sinha 13-04-2023
Dharmameher
Rev. No. Description Prepared by Reviewed by Approved by Approved Date

ALL RIGHTS RESERVED

THIS DOCUMENT IS DEVELOPED BY L&T AND INFORMATION CONTAINED IS PROPERTY OF IOCL, PANIPAT REFINERY. IT SHALL NOT BE
USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS SUPPLIED. CONFIDENTIAL – NOT TO DISCLOSE WITHOUT AUTHORIZATION
 Residue Hydrocracker Unit of Panipat
Refinery Expansion Project (P25)
Panipat, Haryana, India

Title: INSPECTION AND TEST PLAN FOR HAGO MP STEAM GENERATOR. Rev. No : 01
402-E-09. Page : 2 of 14
Doc. No.: B269-RHCU-LT-402-MES-QD-TEMA(2)-04-001

REVISION HISTORY SHEET

REV. REV. DATE REVISED PAGE REVISION DESCRIPTION

NO.
00 13-04-2023 - First Issue

01 06.07.2023 ALL Second Issue

ALL RIGHTS RESERVED

THIS DOCUMENT IS DEVELOPED BY L&T AND INFORMATION CONTAINED IS PROPERTY OF IOCL, PANIPAT REFINERY. IT SHALL NOT BE
USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS SUPPLIED. CONFIDENTIAL – NOT TO DISCLOSE WITHOUT AUTHORIZATION
 I
QUALITY CONTROL PLAN
TEMA Page : 3of14
IND I A LTD.
(Inspection & Test Plan)
For Shell & T u be Heat Exchanger

Vendor No. : ITP / 23-062 / 00 1.

Clien t : Larsen & Toubro Limited.

O WNER : Indian Oi l Corporation Limited , Panipat Refinery.

PMC : Engineers India Limited.

Proj ect : Residue Hydrocracker Unit (RHCU) Panipat Refinery Expansion Project.

Inspection : TPI

Code of Construction : ASME SEC. Vlll DIV. I, 202 1 Ed.+ TEMA CLASS-R 10th Ed.2019+ API 660 Ed.20 15 +!BR (Shell Side).

INT/EXT. Design Press u re

MDMT°C
(Kg/C m2g)
Eq uip men t No. Title/ Service Ty pe
S hell - Tube
S hell s id e T ube side
sid e s ide

402-E-09 HAGO MP STEAM GENERA TOR 22.6 I FY 29.3 /FY -0.7 -0.7 H-AKT

Drawing No.: - SOBIE I 2328 14-1

MANUFACTURER'S SERIAL NO. : TIE I 23 I 042

() I\
' \
K... ~~ 1?
pp•.
I.A'"

I 06.07.2023 00 Revised as per co mm ents a nd Ma rked as & Santos h

Z in gade
B.C.
Dharmamcher
A nil Sinh a

B.C.
00 13.04.2023 00 Iss ued for App r ova l Vin od Ya d av A nil Sinha
D harmamc hcr
QA Ma nager
Head QA & C
QCP Drg E ngin eer QC
Rev. Date Rev. DESCRIPTION Prepared I
No. No. C h ecked
Reviewed Approved By
By
Bv
 Page 4 of 14

QUALITY CONTROL PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Documents No. : ITP / 23-062 / 001. Rev. 1

CLIENT : Larsen & Toubro Limited. EQUIPMENT NO. : 402-E-09. INSPECTION CATEGORY : A
B
PROJECT : RHCU, Panipat Refinery Expansion Project. TYPE : H- AKT
P.O. NO. : Refinery/75001-27976/HAL , Dt.: 06.03.2023. INSPECTION BY : TPI / EIL

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL L&T/ L&T/ EIL
TIL EIL Remark
SIGN TPI TPI Sign Sign

1 Inspection and Test Plan. Stages of inspection & testing ASME Sec. VIII Div. 1. ASME Sec. VIII Div. 1. Signed and Approved
PR , EIL SPEC : 6-81-0009. PR , EIL SPEC : 6-81-0009. ITP. H* A/R

2 Drawing & Design Approval of Drawing & Design Calculation ASME Sec. VIII Div. 1, ASME Sec. VIII Div. 1, Approved Drawing &
TEMA CL-R , API660. TEMA CL-R , API660. Design Calculation.
PR , DATA SHEET NO.: B269- PR , DATA SHEET NO.: B269- H* A/R
RHCU-LT-402-PC-DS-0408. RHCU-LT-402-PC-DS-0408.

3 Pre inspection meeting PIM agenda PO , PR , PIM agenda. PO , PR , PIM agenda. PIM MOM
H* H

4 Approval of documents
4.1 NDE procedures RT , UT , PT , MT. ASME Sec. VIII Div. 1. ASME Sec. VIII Div. 1. Approved procedure
ASME Sec. V, PR. ASME Sec. V, PR.
H* A

4.2 Inspection & testing Procedures Hydro testing, Pneumatic test of TTJ, ASME Sec. VIII Div. 1. ASME Sec. VIII Div. 1. Approved procedure
PMI, Hardness, Surface preparation & ASME Sec. V, PR. ASME Sec. V, PR.
H* A
painting etc.

4.3 Manufacturing Procedures. Dish Ends forming procedure, Weld Repair ASME Sec. VIII Div. 1. ASME Sec. VIII Div. 1. Approved procedure
Procedure, PWHT Procedure. ASME Sec. V, MR:I-RM-3010.2H- ASME Sec. V, MR:I-RM-
1231-451-XSA-507, Specification : 3010.2H-1231-451-XSA-507,
I-ET-3010.2H-1231-451-XSA-507. Specification : H* A
I-ET-3010.2H-1231-451-XSA-
507.
4.4 Welding & Testing Plan Welding & Testing Plan ASME Sec. VIII Div. 1. ASME Sec. VIII Div. 1. Approved Welding &
ASME Sec.IX, PR. ASME Sec.IX, PR. Testing Plan H* R

4.5 WPS / PQR WPS / PQR Qualification. ASME Sec. VIII Div. 1. ASME Sec. VIII Div. 1. Approved WPS/PQR
ASME Sec.IX, PR. ASME Sec.IX, PR. # Witness
H* A# for new
Qualification

4.6 Welders/ Welding Operators, Welder Qualification Record. ASME Sec. IX, PR. ASME Sec. IX, PR. Welder List
H* R

4.8 Qualification of Tube to Tube Review Existing WPS/PQR or Else prepare ASME Sec. VIII Div. 1. ASME Sec. VIII Div. 1. Approved WPS/PQR
sheet Joint Mock up new. ASME Sec.IX, PR. ASME Sec.IX, PR. Test Record
# Witness
H* A# for new
Qualification
 Page 5 of 14

QUALITY CONTROL PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Documents No. : ITP / 23-062 / 001. Rev. 1

CLIENT : Larsen & Toubro Limited. EQUIPMENT NO. : 402-E-09. INSPECTION CATEGORY : A
B
PROJECT : RHCU, Panipat Refinery Expansion Project. TYPE : H- AKT
P.O. NO. : Refinery/75001-27976/HAL , Dt.: 06.03.2023. INSPECTION BY : TPI / EIL

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL L&T/ L&T/ EIL
TIL EIL Remark
SIGN TPI TPI Sign Sign

5 MATERIAL IDENTIFICATION
5.1 Material Identification of Review of MTC / MTR / Check test report ASME Sec. II A & B, ASME Sec. II A & B, Material identification
Pressure parts & Non-Pressure (Material shall be check tested if not meeting ASME Sec. VIII Div. 1, ASME Sec. VIII Div. 1, Report / Material Heat
parts welded to pressure parts. ( the additionl requirement of TDC.) Approved Drawing, Approved Approved Drawing, Approved Chart R R
Plates , Forgings , Tubes etc. ) Material Specification (TDC) Material Specification (TDC) PMI Report
Certification 3.2
Approved PMI procedure, PR Approved PMI procedure, PR
for all Pressure
Dimensions H* W parts & Non
pressure parts
Visual & Verification of Identification welded to pressure
marking / Traceability. H* W
parts.
Gasket face finish of flanges ( as per drawing) In absence of 3.2
H* R
Certificate ,
Certificate of compliance as per code & TDC Material shall be
on MTC H* R check tested under
any Reputed TPI.
PMI check for LAS materials.
$ (RW During final inspection of H* R$
assemblies.)
5.2 Fasteners. Review of MTC / MTR ASME Sec. VIII Div. 1. ASME ASME Sec. VIII Div. 1. ASME Material identification R R
Sec.II A, Drawing, PR. Sec.II A, Drawing, PR Report / Material Heat
Certificate of compliance as per code
Chart R R
PMI Report
PMI check for LAS , SS materials.
( $ RW During final inspection of H* R$
assemblies.
Visual, dimensional and marking
inspection, correlation with MTC / H* RW
MTR minimum 5%
5.3 Gaskets Review of MTC / MTR TDC , ASME Sec. VIII Div. 1. TDC , ASME Sec. VIII Div. 1. Material R R
Certificate of compliance as per code ASME Sec.II A, MR, PMI ASME Sec.II A, MR, PMI identification
Procedure, PR Procedure, PR Report / Material R R
Heat Chart
Visual, dimensional and marking
inspection, correlation with MTC/ MTR H* RW

5.4 Material Identification of Non- Review of MTC / MTR / Check test report. ASME Sec. II A, ASME Sec. VIII ASME Sec. II A, ASME Sec. Material Identification
Pressure parts. Div. 1, Approved Drawing , VIII Div. 1, Report / Material Heat H* R
( Baffles, Tie rods, Spacers, Approved PMI procedure Approved Drawing , Chart,
Visual & Dimensions. H* R
Structure etc. ) Approved PMI procedure Approved PMI
Verification of Identification marking. procedure H* R
PMI check for LAS materials. H* R
5.5 Welding Consumables Review of test certificates ASME Sec. II C, PR. ASME Sec. II C, PR , Test Certificates, R R
PMI for LAS Consumable. PMI Procedure. EN 10204-3.1
H* R
PMI Report.
 Page 6 of 14

QUALITY CONTROL PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Documents No. : ITP / 23-062 / 001. Rev. 1

CLIENT : Larsen & Toubro Limited. EQUIPMENT NO. : 402-E-09. INSPECTION CATEGORY : A
B
PROJECT : RHCU, Panipat Refinery Expansion Project. TYPE : H- AKT
P.O. NO. : Refinery/75001-27976/HAL , Dt.: 06.03.2023. INSPECTION BY : TPI / EIL

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL L&T/ L&T/ EIL
TIL EIL Remark
SIGN TPI TPI Sign Sign

6 MANUFACTURING OF MAIN SHELL ASSEMBLY.

6.1 SHELL DISH END.
6.1.1 Inspection of Dish End for Main Review of Manufacturing Report ASME Sec. VIII Div. 1, Approved ASME Sec. VIII Div. 1, Report
shell after forming. Drawing, NDE Procedure , Dish end Approved Drawing, NDE R -- --

PFHT ( Normalizing )- Review of PFHT forming procedure. Procedure , Dish end forming PFHT Chart,
Chart. procedure. Calibration Cert. Of
Thermocouple & R R
Recorder.

PT of inside & outside after Forming & NDE Report

H* RW# # At selected Spot
PFHT.
Marking, Dimensions, Profile with template, Report
Visual, Mnimum thickness. H* W

Mechanical testing of test coupon after Report

PFHT.( If material not tested after simulation H* R
HT).

6.2 LONG SEAM JOINT FOR MAIN SHELL , CONE AND PORT SHELL.
6.2.1 Set Up Verification of Identification marking, weld Approved WPS / PQR , Approved WPS / PQR , Set up Report.
geometry, offset, circumference , Ovality, Approved Drawing. Approved Drawing.
Attachment of PTC as applicable. H* W# # First of a kind

6.2.2 NDE NDE of WEP as per WTP. Approved WTP. Approved NDE Procedure NDE reports
H* R

6.2.3 Tack Welding Check WPS / Welder Qualification , Welding Approved WPS / PQR , Approved WPS / PQR , Report
Parameters. Approved WTP, Approved WTP,
Approved Drawing. Approved Drawing. H* R

6.2.4 Visual Inspection Visual Inspection of Tack weld / Fit up ASME SEC.VIII, DIV.1, ASME SEC.VIII, DIV.1, Report
Approved Drawing. Approved Drawing.
H* R

6.2.5 In Process Welding NDE after Back Chipping as per WTP. Approved WTP, Approved NDE Procedure NDE Report
Approved NDE Plan
H* R

Dimension of girth flanges after Verification of Dimensions , bolt hole , Approved drawing Approved drawing Dimension report
6.2.6 final machining Gasket finish. H* R
 Page 7 of 14

QUALITY CONTROL PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Documents No. : ITP / 23-062 / 001. Rev. 1

CLIENT : Larsen & Toubro Limited. EQUIPMENT NO. : 402-E-09. INSPECTION CATEGORY : AB
PROJECT : RHCU, Panipat Refinery Expansion Project. TYPE : H- AKT
P.O. NO. : Refinery/75001-27976/HAL , Dt.: 06.03.2023. INSPECTION BY : TPI / EIL

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL L&T/ L&T/ EIL
TIL EIL Remark
SIGN TPI TPI Sign Sign

6.3 CIRCULAR SEAM JOINT : MAIN SHELL TO MAIN SHELL, CONE, DISH END JOINTS, CONE TO PORT SHELL , PORT SHELL TO GIRTH FLANGE JOINTS.
6.3.1 Set Up Verification of Identification marking, weld Approved WPS / PQR , Approved WPS / PQR , Set up Report.
geometry, offset, Alignment & Orientation of Approved Drawing. Approved Drawing.
LS Joint, Dimensions, PTC as applicable. H* W# # First of a kind

6.3.2 NDE NDE of WEP as per WTP. Approved WTP. Approved NDE Procedure NDE reports
H* R
6.3.3 Tack Welding Check WPS / Welder Qualification , Welding Approved WPS / PQR , Approved WPS / PQR , Report
Parameters. Approved WTP, Drawing. Approved WTP, Drawing. H* R

6.3.4 Visual Inspection Visual Inspection of Tack weld / Fit up ASME SEC.VIII, DIV.1, ASME SEC.VIII, DIV.1, Report
Approved Drawing. Approved Drawing. H* R

6.3.5 In Process Welding NDE after Back Chipping as per WTP. Approved WTP, Approved NDE Procedure NDE Report
Approved NDE Plan H* R

6.4 NOZZLE NECK TO NOZZLE FLANGE JOINT

6.4.1 Set Up Verification of Identification marking, weld Approved WPS / PQR , Approved WPS / PQR , Set up Report.
geometry, offset, Dimensions Approved Drawing. Approved Drawing. H* R

6.4.2 NDE NDE of WEP as per WTP. Approved WTP. Approved NDE Procedure NDE reports
H* R

6.4.3 Tack Welding Check WPS / Welder Qualification , Welding Approved WPS / PQR , Approved WPS / PQR , Report
Parameters. Approved WTP, Approved WTP, H* R
Approved Drawing. Approved Drawing.

6.4.4 Visual Inspection Visual Inspection of Tack weld / Fit up ASME SEC.VIII, DIV.1, ASME SEC.VIII, DIV.1, Report
Approved Drawing. Approved Drawing. H* R

6.4.5 In Process Welding NDE after Back Chipping / Root run as per Approved WTP, Approved NDE Procedure NDE Report
WTP. Approved NDE Plan H* R

6.5 NOZZLE TO NOZZLE , NOZZLE TO MAIN SHELL AND NOZZLE TO CONE JOINTS.
6.5.1 Set Up Verification of Identification marking, weld Approved WPS / PQR , Approved WPS / PQR , Set up Report.
geometry, offset, Orientation , Elevation, Approved Drawing. Approved Drawing.
H* W# # First of a kind
Projection , Bolt hole straddling.

6.5.2 NDE NDE of WEP as per WTP. Approved WTP. Approved NDE Procedure NDE reports H* R
6.5.3 Tack Welding Check WPS / Welder Qualification , Welding Approved WPS / PQR , Approved WPS / PQR , Report
Parameters. Approved WTP, Drawing. Approved WTP, Drawing. H* R

6.5.4 Visual Inspection Visual Inspection of Tack weld / Fit up ASME SEC.VIII, DIV.1, ASME SEC.VIII, DIV.1, Report
H* R
Approved Drawing. Approved Drawing.
6.5.5 In Process Welding NDE after Back Chipping as per WTP. Approved WTP, Approved NDE Procedure NDE Report
Approved NDE Plan H* R
 Page 8 of 14

QUALITY CONTROL PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Documents No. : ITP / 23-062 / 001. Rev. 1

CLIENT : Larsen & Toubro Limited. EQUIPMENT NO. : 402-E-09. INSPECTION CATEGORY : AB
PROJECT : RHCU, Panipat Refinery Expansion Project. TYPE : H- AKT
P.O. NO. : Refinery/75001-27976/HAL , Dt.: 06.03.2023. INSPECTION BY : TPI / EIL

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL L&T/ L&T/ EIL
TIL EIL Remark
SIGN TPI TPI Sign Sign

6.6 SADDLE SUPPORT AND OTHER ATTACHMENTS TO MAIN SHELL.

6.6.1 Identification Verification of Identification marking ASME Sec. VIII Div. 1, ASME Sec. VIII Div. 1, Set Up report / Job card.
H* R
Approved Drawing, Approved Drawing,
Visual, dimensions, weld edge preparation WTP, & NDE Procedures WTP, & NDE Procedures
H* R

6.6.2 Welding Check WPS / Welder Qualification ,

H* R

6.7 FINAL INSPECTION OF MAIN SHELL ASSEMBLY.

6.7.1 Visual Inspection of complete Visual Check for Surface Defects ASME Sec. VIII Div. 1 , ASME Sec. VIII Div. 1 , Report
assembly. TEMA-R, Approved Drawing. TEMA-R, Approved Drawing. H* W

6.7.2 Dimensional Inspection Dimensional Verification of assembly. Report

H* W

6.7.3 Gauge Passing before PWHT Gauge Passing Insertion into Shell Insertion into Shell Report
H* W

6.7.4 Pneumatic Test of Nozzles Pneumatic Test of Nozzles RF Pads from Approved Drawing. Approved Drawing. Report
RF Pads. inside & outside. @ 1.25 kg/cm² using
H* W
soap solution.

6.7.5 Production Test coupon. Verification of test results as per WTP. As per WTP As per WTP PTC result
As applicable. H* W

6.7.6 NDE As per WTP NDE Procedure NDE Procedure NDE Report H* RW

7 MANUFACTURING OF CHANNEL SHELL AND FLOATING HEAD ASSEMBLY .

7.1 FLOATING HEAD DISH.
7.1.1 Inspection of Floating Head Dish Review of Manufacturing Report ASME Sec. VIII Div. 1, Approved ASME Sec. VIII Div. 1, Report R -- --
after forming. Drawing, NDE Procedure , Dish end Approved Drawing, NDE
PFHT ( Normalizing & Tempered ) - Review forming procedure. Procedure , Dish end forming PFHT Chart,
of PFHT Chart & Calibration Cert. Of procedure. R R
Thermocouple & Recorder.

PT of inside & outside after Forming & NDE Report

PFHT. H* W
R

Marking, Dimensions, Profile with template, Report

Visual, Mnimum thickness. H* W

Mechanical testing of test coupon after Report

PFHT.( If material not tested after simulation H* R
HT).
 Page 9 of 14

QUALITY CONTROL PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Documents No. : ITP / 23-062 / 001. Rev. 1

CLIENT : Larsen & Toubro Limited. EQUIPMENT NO. : 402-E-09. INSPECTION CATEGORY : A
B
PROJECT : RHCU, Panipat Refinery Expansion Project. TYPE : H- AKT
P.O. NO. : Refinery/75001-27976/HAL , Dt.: 06.03.2023. INSPECTION BY : TPI / EIL

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL L&T/ L&T/ EIL
TIL EIL Remark
SIGN TPI TPI Sign Sign

7.2 LONG SEAM JOINT FOR CHANNEL SHELL.

7.2.1 Set Up Verification of Identification marking, weld Approved WPS / PQR , Approved WPS / PQR , Set up Report.
geometry, offset, circumference , Ovality, Approved Drawing. Approved Drawing. H* R
Attachment of PTC as applicable.
7.2.2 NDE NDE of WEP as per WTP. Approved WTP. Approved NDE Procedure NDE reports H* R
7.2.3 Tack Welding Check WPS / Welder Qualification , Welding Approved WPS / PQR , Approved WPS / PQR , Report
H* R
Parameters. Approved WTP, Drawing. Approved WTP, Drawing.
7.2.4 Visual Inspection Visual Inspection of Tack weld / Fit up ASME SEC.VIII, DIV.1, ASME SEC.VIII, DIV.1, Report
H* R
Approved Drawing. Approved Drawing.
7.2.5 In Process Welding NDE after Back Chipping as per WTP. Approved WTP, Approved NDE Procedure NDE Report
H* R
Approved NDE Plan
DHT. (During weld interuption or after As per WTP As per WTP, WPS / PQR. DHT Record
completion of weld ) H* R

7.2.6 Dimension of girth flanges and Verification of Dimensions , bolt hole , Approved drawing Approved drawing Dimension report
Channel cover after final Gasket finish. H* W
machining
7.3 CIRCULAR SEAM JOINT : CHANNEL TO GIRTH FLANGES AND FLOATING HEAD DISH TO GIRTH FLANGE JOINTS.
7.3.1 Set Up Verification of Identification marking, weld Approved WPS / PQR , Approved WPS / PQR , Set up Report.
geometry, offset, Alignment & Orientation of Approved Drawing. Approved Drawing.
H* W# # First of a kind
LS Joint, Dimensions, PTC as applicable.

7.3.2 NDE NDE of WEP as per WTP. Approved WTP. Approved NDE Procedure NDE reports H* R
7.3.3 Tack Welding Check WPS / Welder Qualification , Welding Approved WPS / PQR , Approved WPS / PQR , Report
H* R
Parameters. Approved WTP, Drawing. Approved WTP, Drawing.
7.3.4 Visual Inspection Visual Inspection of Tack weld / Fit up ASME SEC.VIII, DIV.1, ASME SEC.VIII, DIV.1, Report
H* R
Approved Drawing. Approved Drawing.
7.3.5 In Process Welding NDE after Back Chipping as per WTP. Approved WTP, Approved NDE Procedure NDE Report
H* R
Approved NDE Plan
DHT. (During weld interuption or after As per WTP As per WTP, WPS / PQR. DHT Record
completion of weld ) H* R

7.4 NOZZLE NECK TO NOZZLE FLANGE JOINT

7.4.1 Set Up Verification of Identification marking, weld Approved WPS / PQR , Approved WPS / PQR , Set up Report.
H* R
geometry, offset, Dimensions Approved Drawing. Approved Drawing.
7.4.2 NDE NDE of WEP as per WTP. Approved WTP. Approved NDE Procedure NDE reports H* R
7.4.3 Tack Welding Check WPS / Welder Qualification , Welding Approved WPS / PQR , Approved WPS / PQR , Report
Parameters. Approved WTP, Drawing. Approved WTP, Drawing. H* R

7.4.4 Visual Inspection Visual Inspection of Tack weld / Fit up ASME SEC.VIII, DIV.1, ASME SEC.VIII, DIV.1, Report
H* R
Approved Drawing. Approved Drawing.
7.4.5 In Process Welding NDE after Back Chipping / Root run as per Approved WTP, Approved NDE Procedure NDE Report
WTP. Approved NDE Plan H* R

DHT. (During weld interuption or after As per WTP As per WTP, WPS / PQR. DHT Record
completion of weld ) H* R
 Page 10 of 14

QUALITY CONTROL PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Documents No. : ITP / 23-062 / 001. Rev. 1

CLIENT : Larsen & Toubro Limited. EQUIPMENT NO. : 402-E-09. INSPECTION CATEGORY : A
B
PROJECT : RHCU, Panipat Refinery Expansion Project. TYPE : H- AKT
P.O. NO. : Refinery/75001-27976/HAL , Dt.: 06.03.2023. INSPECTION BY : TPI / EIL

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL L&T/ L&T/ EIL
TIL EIL Remark
SIGN TPI TPI Sign Sign

7.5 NOZZLE TO NOZZLE , NOZZLE TO CHANNEL SHELL JOINTS.

7.5.1 Set Up Verification of Identification marking, weld Approved WPS / PQR , Approved WPS / PQR , Set up Report.
geometry, offset, Orientation , Elevation, Approved Drawing. Approved Drawing.
H* R
Projection , Bolt hole straddling.

7.5.2 NDE NDE of WEP as per WTP. Approved WTP. Approved NDE Procedure NDE reports H* R
7.5.3 Tack Welding Check WPS / Welder Qualification , Welding Approved WPS / PQR , Approved WPS / PQR , Report
H* R
Parameters. Approved WTP, Drawing. Approved WTP, Drawing.
7.5.4 Visual Inspection Visual Inspection of Tack weld / Fit up ASME SEC.VIII, DIV.1, ASME SEC.VIII, DIV.1, Report
H* R
Approved Drawing. Approved Drawing.
7.5.5 In Process Welding NDE after Back Chipping as per WTP. Approved WTP, NDE Plan Approved NDE Procedure NDE Report H* R
DHT. (During weld interuption or after As per WTP As per WTP, WPS / PQR. DHT Record
completion of weld ) H* R

7.6 OTHER ATTACHMENTS TO CHANNEL AND FLOATING HEAD ASSEMBLY.

7.6.1 Identification Verification of Identification marking ASME Sec. VIII Div. 1, ASME Sec. VIII Div. 1, Set Up report / Job card. H* R
Visual, dimensions, weld edge preparation Approved Drawing, Approved Drawing, H* R
WTP, & NDE Procedures WTP, & NDE Procedures
7.6.2 Welding Check WPS / Welder Qualification , H* R
DHT. (During weld interuption or after As per WTP As per WTP, WPS / PQR. DHT Record
completion of weld ) H* R

8 FINAL INSPECTION OF CHANNEL ASSEMBLY.

8.1 Visual Inspection before PWHT Visual Check for Surface Defects ASME Sec. VIII Div. 1 , ASME Sec. VIII Div. 1 , TEMA- Report
H* W
TEMA-R, Drg. R, Drg.
8.2 Dimensional Inspection Dimensional Verification Approved Drawing Approved Drawing Report H* W
8.3 Pneumatic Test of Nozzles Pneumatic Test of Nozzles RF Pads from Approved Drawing. Approved Drawing. Report
H* R
RF Pads. inside & outside. @ 1.25 kg/cm².
8.4 Production Test coupon. Verification of test results as per WTP. As per WTP As per WTP PTC result
H* W
RW
As applicable.
8.5 NDE before PWHT. As per WTP NDE Procedure NDE Procedure NDE Report and
H* R
Summary.
8.6 PMI PMI Check for Material & Weld. Approved PMI Procedure. Approved PMI Procedure. PMI Report. H* W
8.7 Released for PWHT Previous stages clearance, Closing of NCR if Drawing Drawing Inspection report.
H* H
any.
8.8 Heat Treatment of Complete Thermocouples Location , Loading, Drawing and approved Heat Drawing and approved Heat Charge Card, HT Chart
Assembly Calibration of Thermocouples/ Recorder, Treatment Procedure Treatment Procedure H* R--
Chart Review.
8.9 Visual Inspection after PWHT Visual Check for Surface Defects ASME Sec. VIII Div. 1, ASME Sec. VIII Div. 1, Report
H* RW
TEMA-R, Approved Drg. TEMA-R, Approved Drg.
8.10 Dimensional Inspection Dimensional Verification Approved Drawing Approved Drawing Report H* R
RW
8.11 Pneumatic Test of Nozzles Pneumatic Test of Nozzles RF Pads from Approved Drawing. Approved Drawing. Report
H* W
RF Pads. inside & outside. @ 1.25 kg/cm².
8.12 NDE After PWHT As per WTP WTP , NDE Procedures WTP , NDE Procedures NDE Report H* RW
Hardness Approved Drawing , Hardness Approved Drawing , Hardness
8.13 Hardness checked for weld & HAZ. Hardness Report. H* w
RW
Procedure. Procedure.
 Page 11 of 14

QUALITY CONTROL PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Documents No. : ITP / 23-062 / 001. Rev. 1

CLIENT : Larsen & Toubro Limited. EQUIPMENT NO. : 402-E-09. INSPECTION CATEGORY : A
B
PROJECT : RHCU, Panipat Refinery Expansion Project. TYPE : H- AKT
P.O. NO. : Refinery/75001-27976/HAL , Dt.: 06.03.2023. INSPECTION BY : TPI / EIL

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL L&T/ L&T/ EIL
TIL EIL Remark
SIGN TPI TPI Sign Sign

9 FINAL INSPECTION OF FLOATING HEAD ASSEMBLY.

9.1 Visual Inspection before PWHT Visual Check for Surface Defects ASME Sec. VIII Div. 1 , ASME Sec. VIII Div. 1 , TEMA- Report
H* W
TEMA-R, Drg. R, Drg.
9.2 Dimensional Inspection Dimensional Verification Approved Drawing Approved Drawing Report H* W
9.3 Production Test coupon. Verification of test results as per WTP. As per WTP As per WTP PTC result
H* R
As applicable.
9.4 NDE before PWHT. As per WTP NDE Procedure NDE Procedure NDE Report and
H* RW# RT Film review
Summary.
9.5 PMI PMI Check for Material & Weld. Approved PMI Procedure. Approved PMI Procedure. PMI Report. H* W
9.6 Released for PWHT Previous stages clearance, Closing of NCR if Drawing Drawing Inspection report.
any. H* H

9.7 Heat Treatment of Complete Thermocouples Location , Loading. Drawing and approved Heat Drawing and approved Heat Charge Card H* --
Assembly Treatment Procedure Treatment Procedure
Calibration of Thermocouples/ Recorder, HT Chart
Chart Review. H* R

9.8 Visual Inspection after PWHT Visual Check for Surface Defects ASME Sec. VIII Div. 1, ASME Sec. VIII Div. 1, Report
TEMA-R, Approved Drg. TEMA-R, Approved Drg. H* RW

9.9 Dimensional Inspection after Dimensional Verification Approved Drawing Approved Drawing Report H* RW
PWHT
9.10 NDE After PWHT As per WTP WTP , NDE Procedures WTP , NDE Procedures NDE Report H* RW RT Film review
Hardness Approved Drawing , Hardness Approved Drawing , Hardness
9.11 Hardness checked for weld & HAZ. Hardness Report. H* RW
Procedure. Procedure.
10 MANUFACTURING OF TUBE BUNDLE
10.1 Tube sheet ( Stationary & Visual and dimensions TEMA-R, API660. TEMA-R, Form QC/08
Floating ) final inspection after Tube hole finish, Go-No Go check, Weld Approved Drawing Approved Drawing
H* W
drilling and machining grooves, hole layout, Ligament, tie rod holes,
Impingement rod holes etc.
Finish of gasket face & Flattness.
H* R
(As per drawing)
10.2 Inspection of baffles, Support Visual and dimensions. TEMA-R, TEMA-R, Form QC/11
plates after drilling and (Tube hole finish, hole layout & size, chamfer, Approved Drawing Approved Drawing
H* R
machining notch, tie rod holes, cut orientation)

10.3 Skeleton for tube bundle Visual & dimensions TEMA-R, TEMA-R, Form QC/10 & H* R
Cleaning of tube holes, tube loading & tube Approved Drawing Approved Drawing Job card
H* R
projection
Baffle orientation arrangement H* R
10.4 Tube to Tube sheet joint Tube to tube sheet joint setup TEMA-R, ASME SEC-IX TEMA-R, ASME SEC-IX Report / Job Card,
( Tube Projection ) Approved Drawing, Approved Drawing, Pneumatic test report. H* R

Expansion of Tube to tube sheet Joint. TTJ Mock up. NDE Procedure,
Pneumatic test Procedure. TTJ Mock up , H* RW
Pneumatic test Pneumatic Test Procedure
H* W
 Page 12 of 14

QUALITY CONTROL PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Documents No. : ITP / 23-062 / 001. Rev. 1

CLIENT : Larsen & Toubro Limited. EQUIPMENT NO. : 402-E-09. INSPECTION CATEGORY : A
B
PROJECT : RHCU, Panipat Refinery Expansion Project. TYPE : H- AKT
P.O. NO. : Refinery/75001-27976/HAL , Dt.: 06.03.2023. INSPECTION BY : TPI / EIL

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL L&T/ L&T/ EIL
TIL EIL Remark
SIGN TPI TPI Sign Sign

10.5 Tube Bundle final inspection Completeness of Bundle & visual inspection TEMA -R, TEMA -R, Form QC/19 , Form
Approved Drawing, & Approved Drawing, & QC/13 H* W
PMI Procedure PMI Procedure NDE Report
Dimensions H* W
Sharp corners rounding off H* W
NDE as per WTP H* R
Ring passing through bundle H* -- --
Positive material identification (PMI)
H* W
Cleanness of Complete Assembly. Inspection report.
H* W
11 Fasteners and all other Positive material identification Approved Drawing, Approved Drawing, FORM.QC/13
H* W
applicable components PMI Procedure PMI Procedure
12 Close out of Non Conformity. ( Verification of Close out of any Non NCR NCR Form QC / 32 ,
If Any ) Conformity H* R

13 Clearance for Verification of Material Completeness/ review Signed reports

Hydro Static Test of Material Heat Chart/NDE as per
WTP/PMI/Hardness test results/PWHT ---- ---- H* R
Charts.

14 TESTING
Approved Drawing, Approved Drawing, Report
14.1 Tightening of Fasteners. Record of Tightening / Tensioning. H* R

14.2 Hydrostatic Test. Tube side hydro test with tube bundle out side Approved Drawing , Approved Drawing , Hydro test report
of main shell with Floating head assemby to Approved Testing Procedure. Approved Testing Procedure. including calibration
H* W
check tube to tube sheet joint & Floating head certificates of pressure
bolting joints. gages , Water test
Tube side Final hydro test after bundle report.
inserted into main shell. H* W

Shell side Final hydro. H* W

14.3 NDE After Hydro Test. As per WTP NDE Procedure NDE Procedure NDE Report
( As applicable ) H* R

15 As built drawings -- ASME Sec.VIII Div.1. ASME Sec.VIII Div.1. As Built Drawings H* R
16 Draining & Drying Both Shell side & Tube side Approved Drawing , Approved Approved Drawing , Approved Report
procedure procedure H* W

17 Surface Preparation Blasted surface examination. Drawing, Surface preparation and Drawing, Surface preparation and Form QC/17 H* RW
& Painting painting Procedure painting Procedure
Final DFT & Visual after Painting H* W
18 Nitrogen filling Leakage at bolted joints & Pressure gauge Approved Drawing, Approved Drawing, Report
protection Approved procedure Approved procedure H* W
 Page 13 of 14

QUALITY CONTROL PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Documents No. : ITP / 23-062 / 001. Rev. 1

CLIENT : Larsen & Toubro Limited. EQUIPMENT NO. : 402-E-09. INSPECTION CATEGORY : AB
PROJECT : RHCU, Panipat Refinery Expansion Project. TYPE : H- AKT
P.O. NO. : Refinery/75001-27976/HAL , Dt.: 06.03.2023. INSPECTION BY : TPI / EIL

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL L&T/ L&T/ EIL
TIL EIL Remark
SIGN TPI TPI Sign Sign

19 Shipping preparation inspection Verification of Name plate. Approved Drawing Approved Drawing. Rub- offs or Photo of H* R
and Dispatch Clearance. PO , Applicable Project PO , Applicable Project name plate attachment,
Attachment of Name plate on Exchanger.
Specification. Specification. Spares List, MTC. H* W
Visual , dimension check , MTC review for
spares & Accessories. H* W
( Scope of Supply items )
Marking / Stenciling , CG Marking. Transportation Drawing. Transportation Drawing. Repot or Photo. H* R
20 IBR FORMS / DOCUMENTS. 1) Rub off, IBR IBR IBR signed Forms.
2) FORM II (I) - Certificate of Inspection
for shop assembled Boiler.
3) FORM III - Constructor's Certificate of H* --- ---
Manufacturer and Test.
4) FORM IV A.
21 Inspection Release Certificate Issuance of Inspection Release Certificate PO , MRApplicable Project PO , Applicable Project IRC
Specification. Specification. H* H

22 Documentation Document Folder including NR-13 Dossier. Approved VDB Index Approved VDB Index QC Dossier
H* R

23 LIST OF DOCUMENTS

S.N. DOCUMENT TITLE VENDOR DOCUMENT NO CLIENT DOCUMENT NO

1 Welding & Testing Plan including WPS / PQR. WTP-E-232814 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-003
2 Procedure For Radiographic Examination of Welded Joints NDE / 23-062 / D001 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-005
3 Procedure For Ultrasonic Examination of Full Penetration Welds NDE / 23-062 / D002 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-006
4 Procedure For Liquid Pentrant Examination NDE / 23-062 / D003 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-007
5 Procedure For Magnetic Particle Examination By Yoke Technique NDE / 23-062 / D004 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-008
6 Procedure For Post Weld Heat Treatment. PWHT / 23-062 / 001 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-009
7 Procedure For Hardness Check of Pressure Retaining Welds HD / 23-062 / 001 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-010
8 Procedure For Pneumatic Test of Tube to Tube Sheet Joint PT / 23-062 / 001 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-011
9 Procedure For Hydrostatic Test of equipment. PT / 23-062 / 003 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-012
Procedure For Draining, Drying and Nitrogen Purging for Preservation
10 DDN / 23-062 / 001 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-013
of Equipment.
11 Procedure For Packing and Transportation Instructions. PP / 23-062 / 001 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-014
12 Procedure for mock up test, expansion of Tube to tubesheet joint TTJ / 23-062 / 001 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-015
13 Procedure for Positive Material Identification (PMI) PMI / 23-062 / 001 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-016
14 Procedure for Weld repair WR / 23-062 / 001 B269-RHCU-LT-402-MES-QD-TEMA(2)-04-017

15 Surface Preparation and Painting Procedure SP / 23-062 / 001 B269-RHCU-LT-402-MES-OD-TEMA(2)-04-001

16 Vendor Manufacturing Data Book Index. VI / 23-062 / 001 B269-RHCU-LT-402-MES-DI-TEMA(2)-04-001

17 Vendor Manufacturing Data Book. (402-E-09) VDB / 23-062 / 001 B269-RHCU-LT-402-MES-OD-TEMA(2)-04-002
 Page 14 of 14

0
CLIENT
TEMA
IN 0 I A LT 0.

: Larsen & Toubro Limited.

: RHCU , Panipat Refinery Expansion Project.
QUALITY CONTROL PLAN (INSPECTION AND TEST PLAN)
SHELL & TUBE HEAT EXCHANGER
Documents No.: ITP / 23-062 / 001. Rev. I

EQU I PMENT NO.

TYPE
: 402-E-09. INSPECTION CATEGORY: AB
1

PROJECT :H-AKT
P.O. NO. : Refinerv/75001-27976/ HAL , Dt. : 06.03 .2023. I NSPECTION BY : TPI I EIL L:.::,

Description Reference Document Accepta nce Criteria Format of Report

A INSPECTION BY AND SIGNATURE

S.No. Ac tivity
I
T IL
TIL S IGN
L&T / L&T/
IEIL I Sign
EIL I Remar k
TPI
I TP I Sign
I
LEGENDS:

H* : Hold I Perfonn by TEMA

H: Hold (Not to proceed without the concerned parties signing off of the inspection activity unless a waiver has been received by the Vendor in writing.

W: Notification of the concerned parties is mandatory, lfTPIA does not wish to attend or does not attend the witness point, Vendor must proceed with internal inspection and work shall go ahead without delay provided that control and tests reports
are available to TPIA for review.

R: Concerned parties must review, approve and sign off the Vendor's manufacturing I testing documents and inspection I tests records and certificates.

N2 : Nitrogen TDC : Technical Delivery condition. ( Materials purchase specification ) TTJ: Tube to Tube Sheet Joint

PO: Purchase Order NDE : Non distructive examination PFHT : Post Fonning Heat Treatment

TP IA: Third party Inspection Agency RT : Radiographic test HAZ : Heat affected zone

TIL: Tema India Ltd. (Quality Control ) UT : Ultrasonic test HT : Heat treatment

QC: Quality Control. ( Tema India Ltd. ) PT : Penetrant test PMI : Positive material identification

PQR: Procedure Qualification Record MT : Magnetic particle test IRN : Inspection release note

WPQ: Welder Perfonnance Qualification WTP: Welding and testing plan PWHT : Post weld heat treatment

WPS : Welding Procedure Specification D FT : Dry film thickness

~
or:,(07().02-3
x~~~
~~
~ oG o1

Approve d By: He ad QA & C. Reviewed a nd Accepte d

Pre p a red by : Ch e c ked By:
S a ntosh Zi na ade B.C.Dh a rm a m eher Anil S inh a Bv