CONSTRUCTION

WUHUAN Talcher Fertilizers Project

ENGINEERING 17125-PC09-PP-003

CO., LTD
INSPECTION AND TEST PLAN 1 of 10 Rev.0

ITP FOR BUILDING’S WATER SUPPLY AND

DRAINAGE

For Bidding

0 For Bidding

Rev. Description Prepared by Checked by Approved by Date

 ITP for Building’s Water Supply and Drainage

Inspection Class Remarks

No. Items Name Standard or code executed inspection method Acceptance criteria Frequency Record OWNER/ WUHU Subcontra
PMC AN ctor

1 Preparative for the construction

1.1 PQR /WPS Preparation ASME Ⅸ QW Review PQR & WPS ASME Ⅸ QW 100% PQR / WPS H H P

1.2 Welder Qualification ASME Ⅸ QW Site examination ASME Ⅸ QW 100% WPQ H H P

Visual ,and Measurement

1.3 Receiving Material Check MTO Spec./DWG, standards 100% Conformation Material at Site W H P
,Review Certificate

Measurement device Check (pressure test Certificate for measurement meet the construction
1.4 Design requirement All construction facilities Confirmation of Construction facilities at site R R P
gage,holiday test machine,survey device,etc) device requirement.

Construction facilities Check, Certificate for measurement meet the construction

1.5 Design requirement All construction facilities A05 Confirmation of Construction facilities at site R R P
(Excavator,welding machine,ect) device requirement.

NDT Operator/Interpreter Certificate ASME B31.3, Spec All NDT Person

1.6 Review Certificate ASME B31.3, Spec A06 Confirmation of Human Resource at site R R P
Laboratory Operator ASME BPVC V Laboratory Operator

2 FW Construction

2.1 Shot or grit blasting Specification for Coating apparatus test Specification for Coating Every pipeline Shot or grit blasting report W H P

2.2 Painting & PE tape construction Specification for Coating Visual inspection Specification for Coating Every pipeline Holiday (Pin hole) test Record H H P

Inspection of internal cleaness prior of

2.3 Spec Visual Spec 100% _ S W P
installation

Cutting and Beveling of each parts & Check of

2.4 Spec Visual Spec 100% _ S W P
identification

2.5 Fit-up inspection ASME B 31.3 Visual, Review NDE Report ASME B 31.3 100% Welding Report And Daily Visual Inspection W H P

Visual check and Review NDE

2.6 Monitoring of Welding WPS/Spec ASME B 31.3 100% Welding Report And Daily Visual Inspection S W P
Report

NDT Request Report

According to drawing RT Test Report
2.7 NDT ASME B31.3, Spec ASME B31.3 W W P
required PT Test Report
UT Test Report

Visual, Review Piping Test

2.8 Pressure Test ASME B31.3, Spec ASME B31.3 100% Process Piping Test Package W W P
Package -4105 of 11
 ITP for Building’s Water Supply and Drainage

Inspection Class Remarks

No. Items Name Standard or code executed inspection method Acceptance criteria Frequency Record OWNER/ WUHU Subcontra
PMC AN ctor

Line Check (Punch List acc. to Isometric

2.9
DWG)
WPS/DWG WPS/DWG 100% Process Piping Test Package(include Punch List ) w W P

Process Piping Test Package(inclue NDT Test

2.10 Test Package Spec./DWG Spec./DWG 100%
Reports, Hydrostatic Test Report) w H P

3 PTW & SW Construction

3.1 Prefabrication Spec Visual Spec 100% _ S W P

Inspection of internal cleaness prior of

3.2 Spec Visual Spec 100% _ S W P
installation

Construction standard for

3.3 Bonding inspection Water Supply and Sewerage Visualt Spec./DWG 100% Bonding Report And Daily Visual Inspection S H P
Systems Original Edition

Work Procedure for

Building’s Water Supply Visual, Review Piping Test
3.4 Pressure Test Spec 100% Process Piping Test Package H H P
and Drainage,Design Package
document

Work Procedure for

Building’s Water Supply Visual, Review Piping Test BUILDING'S WSD PIPE INSPECTION
3.5 Gravity Test Spec 100% W W P
and Drainage,Design Package CHECKLIST
document

3.6 Line Check before Cover WPS/DWG _ WPS/DWG 100% Process Piping Test Package(include Punch List ) R W P

BUILDING'S WSD PIPE INSPECTION

3.7 Fixture installation Spec./DWG Visual Spec./DWG 100% S W P
CHECKLIST

4 Final check & Handover

BUILDING'S WSD PIPE INSPECTION

4.1 Commissioning Spec./DWG Visual Spec./DWG 100% W W P
CHECKLIST

H—Hold Point: Mandatory, do not proceed without presence of authorized inspection personnel or signed waiver
-4104 of 11
 ITP for Building’s Water Supply and Drainage

Inspection Class Remarks

No. Items Name Standard or code executed inspection method Acceptance criteria Frequency Record OWNER/ WUHU Subcontra
PMC AN ctor

W—Witness Point:Notification of authorized inspection personnel required, but no need hold if inspector is not available
remark

S—Spot: Witness or random check :No need to issue the requisition of inspection

R—Review Point: Review report or document only

P—Performer

-4103 of 11
 Job No. XXXX
Talcher Fertilizers Limited
XXXX-00000-WPQ-001

Welder Performance Qualification (WPQ) Page: 1 of N

Certified Welders Registration Table

Item Welder's Name Welder's Code Certified Project No. Remarks

1 XXX W-CT1-001 SMAW+GTAW

2
3
4
5

SUB-CONTRACTOR WUHUAN OWNER/PMC

Name

Signature
Date
 WELDER PERFORMANCE QUALIFICATION (WPQ)
=============================================================================================
Welder’s name Identification No.
Test Description
Identification of WPS followed □ Test coupon □ Production weld
Specification and type/grade or UNS Number of base metal(s) Thickness
Testing Variables and Qualification Limits
Welding Variables (QW-350) Actual Values Range Qualified
Welding process(es)
Type (i.e.; manual, semi-automatic) used
Backing (with/without)
□Plate □Pipe(enter diameter if pipe or tube)
Base metal P-Number to P-Number
Filler metal or electrode specification(s) (SFA) (info. only)
Filler metal or electrode classification(s) (info. only)
Filler metal F-Number(s)
Consumable insert (GTAW or PAW)
Filler Metal Product Form (solid/metal or flux cored/powder)
(GTAW or PAW)
Deposit thickness for each process
Process 1 3 layers minimum □Yes □No
Process 2 3 layers minimum □Yes □No
Position qualified (2G, 6G, 3F, etc.)
Vertical progression (uphill or downhill)
Type of fuel gas (OFW)
Inert gas backing (GTAW, PAW, GMAW)
Transfer mode (spray/globular or pulse to short circuit-GMAW)
GTAW current type/polarity (AC, DCEP, DCEN)
----------------------------------------------------------------------------------------------------------------------------------------------------------------
RESULTS
Visual examination of completed weld (QW-302.4)
□ Transverse face and root bends [QW-462.3(a)] □ Longitudinal bends [QW-462.3(b) □ Side bends (QW-462.2)
□ Pipe bend specimen, corrosion-resistant weld metal overlay [QW-462.5(c)]
□ Plate bend specimen, corrosion-resistant weld metal overlay [QW-462.5(d)]
□ Pipe specimen, macro test for fusion [QW-462.5(b)] □ Plate specimen, macro test for fusion [QW-462.5(e)]
Type Result Type Result Type Result

Alternative Volumetric Examination Results (QW-191): RT □ or UT □ (check one)

Fillet weld — fracture test (QW-181.2) Length and percent of defects
□ Fillet welds in plate [QW-462.4(b)] □ Fillet welds in pipe [QW-462.4(c)]
Macro examination (QW-184) Fillet size (in.) x Concavity/convexity (in.)
Other tests
Film or specimens evaluated by Company
Mechanical tests conducted by Laboratory test no.
Welding supervised by
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance
with the requirements of Section IX of the ASME BOILER AND PRESSURE VESSEL CODE.
Organization
Date Certified by
 Doc. No.
OWNER LOGO Talcher Fertilizers Limited

CONSTRUCTION
WUHUAN Talcher Fertilizers Project Project No.-17125
ENGINEERIN
G CO., LTD
Process Piping Test Package 1 of 19 Rev.0A

Process Piping Test Package

For Construction

SUBCONTRACTOR WUHUAN OWNER/ PMC OTHER

Seal N/A

Sign

Date
FORM NO. P-006
 WUHUAN
Talcher Fertilizers Project

24 Hours pressure test notice

Test Pack Number:

System:

Test
Notice Issue Date:
Type:
Test
Medium:
Test
Subcontractor:
Pressure:

Advance Notice is Hereby Issued to:

WUHUAN CONSTRUCTION
●
TEAM:

● WUHUAN SUPERVISOR:

● PMC/Owner:

Schedule:

Date: Time:

Location:

FORM NO. P-006-1

 WUHUAN
Talcher Fertilizers Project
TEST PACK

☆ SYSTEM NUMBER:

☆ TEST PACK NUMBER:

☆ SUBCONTRACTOR/WUHUAN CONSTRUCTION TEAM:

☆ SUBCONTRACTOR /WUHUAN CONSTRUCTION TEAM:

DATE:

☆ WUHUAN SUPERVISOR:

DATE:

FORM NO. P-006-2

 WUHUAN
Talcher Fertilizers Project

Pressure Test Pack Table of Contents

System No.:

Test Package No.:

Description YES N/A

Pressure Test Pack Table of Contents [FORM NO. P-006-3]
★
Test Pack Assembly Check Sheet [FORM NO. P-006-4]
★
Pressure Test Pack Routing Form [FORM NO. P-006-5]
★
Pressure Test Legend [FORM NO. P-006-6]
★
Pressure Test Diagrams (P&IDs)[ FORM NO. P-006-7]
★
Pressure Test Isometric List [FORM NO. P-006-8]
★
Isometrics (Current Revision) with weld maps [FORM NO. P-006-9]
★
Welding Report [FORM NO. P-006-10]
★
Pressure Test Check Punch List [FORM NO. P-006-11]
★
Piping Pressure Test Preparation Checklist [FORM NO. P-006-12]
★
Minimum Thickness of Blank For Pressure Testing [FORM NO.
★
P-006-13]

★ Pressure Test Gages Calibration Certificates [FORM NO. P-006-14]

Pressure Test Relief Valve Certificates (Pneumatic test)[ FORM NO.

★
P-006-15]

★ Water Analysis Report (SS and CS)[ FORM NO. P-006-16]

★ Pressure Testing Report [FORM NO. P-006-17]

★ Reinstatement Check List [FORM NO. P-006-18]

FORM NO. P-006-3

 WUHUAN
Talcher Fertilizers Project
Test Pack Assembly Check Sheet

System
Test Pack No.
No.

Cursory Check (inserted and header info correct)

Table of Contents Form

ISO metric List

ISO are latest revision

ISO list matches ISO s in the testpack

Testpack Routing Form

Pressure Test Report

Pressure Test Reinstatement

Engineering Check

Check for applicable waivers

Pressure Test Diagrams (Test P&ID's)

Test limits shown

Test gages shown

Check valves status indicated

Vent location(s) shown

Test inlet location shown

Test pressure shown

In-line items replaced by temp. spool indicated

Location and arrangement of test manifold

Location of pressure relief valves

Relief valve size(s) and set pressure(s)

Blind Thickness checked

Pressure Test Certificate

Test type correct (hydro, pneumatic, service, )

Test pressure matches Line List Checked By

Hold time correct Date

FORM NO. P-006-4

 WUHUAN
Talcher Fertilizers Project

Pressure Test Pack Routing Form

System No.

Test Pack No.

No. Act by Activity Conform Date

Subcontractor/Constructio
1 Prepare Test Pack
n Team

2 WUHUAN Supervisor Review Test Pack

Review Test Pack & Proceed (Return within one

3 Owner/PMC
week)
Subcontractor/Constructio
4 Create Field Copy
n Team
Confirm that test pack contains latest rev. ISO and
5 WUHUAN Supervisor
P&ID
Issue Test Pack Copy to Field for verification line is
6 WUHUAN Supervisor
complete
Review and Approval test package, and Submit Cat
7 Owner/PMC
A Punch
Subcontractor/Constructio
8 Rectify Cat.A Punch
n Team

9 WUHUAN Supervisor Verify Cat.A Punch

10 WUHUAN Supervisor Welding Database Check

11 Owner/PMC Witness Testing and Sign-Off Test Pack

12 WUHUAN Supervisor Test Pack Complete and Close Test Package.

FORM NO. P-006-5

 WUHUAN
Talcher Fertilizers Project
Pressure Test Legend
TB TESTING BLIND OR PLUG
TO TEST OPEN (VALVES)
TC TEST CLOSE (VALVES)
FP FILLING POINT
TS TEMPORARY TEST SPOOL
PG PRESSURE TEST GAGE
RV RELIEF VALVE
RI REMOVE INTERNALS
DR DRAIN POINT
TL TEST LIMIT
VP VENT POINT

LOCATION OF TEMP SUPPORT (IF NECESSARY)

CEL Survey report for Center Elevation of UG Pipe

FORM NO. P-006-6

 WUHUAN
Talcher Fertilizers Project

This page is left for marked-up P&ID

FORM NO. P-006-7

 WUHUAN
Talcher Fertilizers Project
PRESSURE TEST PIPING ISO LIST

System No: Test Type：

Test Pack No. Test Medium：

Test Pressure

No. Isometric No. Line No. Rev. No Remarks

FORM NO. P-006-8

 WUHUAN
Talcher Fertilizers Project

This page is left for Isometrics with weld maps

FORM NO. P-006-9

 WUHUAN
Talcher Fertilizers Project
Welding Report

Test Pack No.:

Welder No. Filler Material NDT Result RT/UT

Joint Welding NDT NDT
No. Line No. Drawing No. Type Report
No Date Rate Date
Welder 1 Welder 2 Prime Fill/Cover ACC REJ No

1 1 BW W-07hj-005 ER308L E308L-16 5% REJ ***

2 1R BW W-07hj-005 Acc 5% ACC
3
4
5
6
7
8
9
10
11
12
13
14
15
17
19
20
21
FORM NO. P-006-10
 WUHUAN
Talcher Fertilizers Project
Pressure Test Check Punch List
Category 'A' items to be completed before Pressure Test Test Pack No

Category 'B' items can be completed after Pressure Test

CAT Raised by Completed Accepted

No. Line No. Description of Punch
Name and Name and Name and
A or B
Sign / Date Sign / Date Sign / Date

FORM NO. P-006-11

 WUHUAN
Talcher Fertilizers Project
PIPING PRESSURE TEST PREPARATION CHECKLIST

TEST PACK NO. SYSTEM NO:

Subcontractor : Date:
Item Yes By

1 Pre-Test Punch Lists clear and complete.

2 Blinds installed as shown on test diagram

3 Pressure gages and relief valves correctly installed.

4 Confirm instruments removed / isolated for test.

Orifice plates, relief valves, control valves, flow nozzles
5
and strainers removed.
6 Vents/Drains correctly installed.

7 Confirm no interference to rotation of spectacle blinds.

8 Check that gags on spring supports are in position.

Confirm temporary pipe supports are installed if
9
required.
10 Check Valve removed if required.
Check all pressure connections correct as per
11
specification.
Check all orifice taps have been plugged and/or seal
12
welded.
Temporary gasket is not allowed on high pressure
13
system.

14 Inlet location and test manifold as specified.

15 System is ready to be tested.

Contractor Engineer

Signature:

Name:
Date:
From No.P-006-12
 WUHUAN
Talcher Fertilizers Project

Minimum Thickness of Blank of Pressure Testing(Reference)

Test Size(inch)尺寸（英寸）
Pressure 1 2
2 3 4 5 6 8 10 12 14 16 18 20 24
Mpa 1/2 1/2
0.7 1.6 2.0 2.3 3.0 4.0 4.5 5.5 7.0 9.0 10.5 11.5 13.0 14.5 16.5 19.5

1.4 2.3 2.7 3.5 4.0 5.5 6.5 7.5 10.0 12.5 15.5 16.0 18.5 21.0 23.0 28

2.1 2.7 3.4 4.0 5.0 6.5 8.0 9.5 12.0 15.0 18.5 20.0 22.5 25.5 28.5 34

2.8 3.2 4.4 5.5 6.0 7.5 9.0 11.0 14.0 17.5 21.0 23.0 26.0 29.5 32.5 39

3.5 3.5 4.5 6.0 6.5 8.5 10.0 12.0 16.0 19.5 23.5 25.5 29.0 33.0 36.5 43.5

4.2 4.0 4.5 6.0 7.0 9.0 11.0 13.5 17.5 21.5 25.5 8.0 32.0 36.0 40.0 48

4.9 4.0 5.0 7.0 7.5 10.0 12.0 14.5 18.5 23.0 27.5 30.0 34.5 39.0 43.0 51.5

5.6 4.5 5.5 7.0 8.0 10.5 13.0 15.5 20.0 25.5 29.5 32.5 37.0 41.5 46.0 55.5

6.3 5.0 6.0 7.5 8.5 11.0 14.0 16.0 21.0 26.5 31.0 34.0 39.0 44.0 49.0 58.6

7.0 5.0 6.0 8.0 9.0 12.0 14.5 17.0 22.5 27.5 33.0 36.0 41.0 46.5 51.5 62

7.7 5.5 6.5 8.0 9.5 12.0 15.0 18.0 23.5 29.0 34.5 38.0 43.0 48.5 54.0 65

8.4 5.5 7.0 8.5 10.0 13.0 16.0 18.5 24.5 30.5 36.0 39.5 45.0 51.0 56.5 68

9.1 5.5 7.0 9.0 10.5 13.5 16.5 19.5 25.5 31.5 39.5 41.0 47.0 53.0 58.5 70.5

9.8 6.0 7.5 9.0 10.5 14.0 17.0 20.0 26.5 33.5 39.0 42.5 49.0 55.0 61.0 73

10.5 6.0 7.5 9.5 11.0 14.5 17.5 21.0 27.0 34.0 40.0 44.0 50.5 57.0 63.0 75.5

11.2 6.5 8.0 10.0 11.5 14.5 18.0 21.5 28.0 34.0 41.5 45.5 52.0 58.5 65.0 78

11.9 6.5 8.0 10.0 12.0 15.0 18.5 22.0 29.0 36.0 43.0 47.0 54.0 60.5 69.0 80.5

12.6 6.5 8.5 10.5 12.0 15.5 20.0 23.0 30.0 37.0 44.0 48.5 55.5 62.0 69.0 83

13.3 7.0 8.5 10.5 12.5 16.0 20.0 23.5 30.5 38.0 45.5 49.5 57.0 64.0 71.0 85

14.0 7.0 9.0 10.5 13.0 16.5 20.5 24.0 31.5 39.0 46.5 51.0 58.5 65.5 73.0 87.5

17.5 8.0 10.0 12.0 14.5 18.5 23.0 27.0 35.0 44.0 52.0 57.0 65.0 73.5 81.5 97

21.0 8.5 11.0 13.0 15.5 20.0 25.0 30.0 38.5 48.0 57.0 62.5 71.0 80.5 89.0 107

In case where piping diameter is 26" or above, following formula shall be applied to determine the thickness of
blind plate
THKmm=dg×3P/16SE(See ASME B31.3 par304.5.3)

dg=inside diameter of gasket(mm); P=Test Pressure(kg/cm2); S=allowable stress(kg/cm2); E=quality factor

From No.P-006-13
 WUHUAN
Talcher Fertilizers Project

This page is left for pressure test gage calibration certification

From No.P-006-14
 WUHUAN
Talcher Fertilizers Project

This page is left for pressure test relieve valve certificate(Pneumatic test)

From No.P-006-15
 WUHUAN
Talcher Fertilizers Project

This page is left for Water analysis report(SS and CS)

From No.P-006-16
 WUHUAN
Talcher Fertilizers Project

Pressure Testing Report

System No. Sub-Contractor：

Test Method

Test Media

Temperature

Test Pressure（MPa)

Holding Time

Pres.(Mpa)

Time(min.)

Test Results and Comments:

WUHUAN
Owner/PMC Subcontractor
Supervisor Construction Team
Signature: Signature: Signature: Signature:

Date: Date: Date: Date:

From No.P-006-17
 WUHUAN
Talcher Fertilizers Project
REINSTATEMENT CHECK LIST
TEST PACK NO. SYSTEM NO.

Subcontractor Date:

No. Description Yes No N/A

Test system reinstated in accordance with the latest revision of the
1
P&ID's.
2 Correct bolts and gaskets are installed at all mechanical joints.

3 Compound on screwed connections in accordance with specifications.

4 All vents and drains are installed, including vents and drains for testing.
All process blinds, spectacle have been correctly installed as indicated
5
on the P&ID's.
Control valves reinstated in accordance with specification and in correct
6
flow direction.
7 All locking devices / interlocks installed on specified valves.

8 All valves function properly and all spindles have been lubricated.

9 All chainwheels and extended spindles installed.

10 All inline instruments reinstated and undamaged.

11 All relief valves installed or connections blanked.

12 Restriction orifice plates correctly installed.

13 All pump suction strainers correctly installed.

14 Flow direction correct for all strainers, traps, check and globe valves.

15 System released for chemical cleaning, （if applicable.）

Contractor:
Remarks:
Signature :
Name:
1. Where signature not required, state NA.
Date :
From No.P-006-18
 Reprort No.

Id No.
HOLIDAY (PIN HOLE) TEST RECORD
P-007
Tag Description: Tag No.:
P.O.No.: Inspection Classification Area/Unit:
Sub-Contractor: WUHUAN □ OWNER /PMC □ Turnover System:
Work Package: Sub-Contractor □ Other □ Sub-System:

Pin Hole
Surface Visual Test/Measure
ISO-Sheet Spool Sub-Contractor WEC
Preparation Inspection thickness
Number Number
Acc Rej Acc Rej Acc Rej Signature Date Signature Date

NOTES :

SUBCONTRACTOR WUHUAN OWNER/PMC OTHER

Name: Name: Name: Name:

Signature: Signature: Signature: Signature:

Date： Date： Date： Date：

Form No.:P-007
 Talcher Fertilizers Project
Bonding Report And Daily Visual Inspection
Report No.: 17125-Unit-PE-VIS-001 Unit: Date:
Joint Visual
Item Line No. Dwg No Remarks
No. DIN thick Check
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Total(DIN) 60

SUBCONTRACTOR WUHUAN OWNER/PMC OTHER

Date: Date: Date: Date:

 WUHUAN

Reprort No.

Id No.
BUILDING'S WSD PIPE INSPECTION CHECKLIST P-010

Tag Description: Tag No.:

P.O.No.: Inspection Classification Area/Unit:
Sub-Contractor: WUHUAN □ OWNER/PMC □ Turnover System:
Work Package: Sub-Contractor □ Other □ Sub-System:
Drawing Number Sheet Drawing Number Sheet

Sub-Contractor WUHUAN
Item Description of Check
Signature Date Signature Date
1 Pipe fabrication and installation inspection completed
2 Cleaning of pipe completed
3 Support installation completed
4 Pressure test satisfactory
5 Gravity test satisfactory
6 Coating and wrapping checked
7 Holiday test satisfactory
8 Fixture installation
9 System commissioning completed
10
11
12
13
NOTES :
1. THE INDOOR WSD PIPING LAYOUT SHOULD BE ADJUSTED IN SITE

SUBCONTRACTOR WUHUAN OWNER/PMC OTHER

Name: Name: Name: Name:

Signature: Signature: Signature: Signature:
Date： Date： Date： Date：

Form No.:P-009
 Talcher Fertilizers Limited WUHUAN Job. No.
WUHUAN
ENGINEERING
Reprort No.
CO.,LTD. Coal Gasification Plant, Talcher XXXX-xxxxxx-PP-AI03-001

Id No.
Shot/Grit Blasting Report AI-03
Item Description: Area/Unit:

Surface preparation method: □ Blasting □ Power tool □ Hand cleanBlasting Details: □ Abressive □ Grit tool □
Shot
Inspection instrument details:
Surface Visual Sub-Contractor
Description Size Remarks
Preparation Inspection confirmed

NOTES :

SUBCONTRACTOR WUHUAN Owner/PMC

Name: Name: Name:

Signature: Signature: Signature:

Date: Date: Date: