INSPECTION & TEST PLAN FOR HAIRPIN EXCHANGER 1 Page 6 PROJECT : TPPI REVAMPING PROJECT OWNER : PT. TRANS PACIFIC PETROCHEMICAL INDOTAMA LOCATION : TUBAN SERVICE : HAIRPIN EXCHANGER TAG. NO. : 204-E-001A, 204-E-002A/B, 203-E-001 DOCUMENT NO. : D2209 ITP-01 COMPANY DOC. NO. : V-8000026543-130 DOCUMENT TITLE : INSPECTION & TEST PLAN FOR HAIRPIN EXCHANGER PREPARE REV DATE PURPOSE CHECK APPROVE APPROVE PT. DIHI PT. TPPI NAME NAME NAME A 15-Dec-22 Issued for Review AYS ADR IRF B 8-Feb-23 Re-Issued for Review DMS AYS IRF C 29-Mar-23 Re-Issued for Review DMS AYS IRF D 2-Jun-23 Issued for Approval DMS AYS IRF E 4-Jul-23 Issued for Approval DMS AYS IRF 0 20-Jul-23 Issued for Construction AYS ADR IRF NAME DATE Owner : PT.Trans-Pacific Petrochemical Indotama Project : TPPI REVAMPING PROJECT Item No. : 204-E-001A, 204-E-002A/B, 203-E-001 Quantity : 4 EA Doc. No. : D2209 ITP-01 INSPECTION AND TEST PLAN ( HAIRPIN EXCHANGER PACKAGE ) Rev. No. : 0 Issue Date : 20 Juli 2023 Page : 2 of 6 INSPECTION PARTY NO. MANUFACTURING ACTIVITY Procedure Qualification 1-1. Procedure Qualification Record (PQR) DESCRIPTION REFERENCE Acceptance Criteria Report/ Certificate DIHI AI TPE TPPI PI MIGAS M A A A - - O M A A A - - O I. Review of the PQR - ASME Section IX - Client Datasheet - ASME Sec. VII Div. 1 - ASME Sec. IX - TEMA Class "R" - ASME Sec. V - TEMA - TPPI Spec U86 1-2. Welding Procedure Specification (D2209 WPS-01) (V-8000026543-123) Review of the welding procedure - ASME Section IX 1-3. Welders and welding operation qualification test Review of the welders and welding operator qualification test records - ASME Sect. VIII Div. 1 M A A A - - O 1-4. Fabrication Procedure (D2209 FAB-01) (V-8000026543-124) Review of all fabrication procedures - ASME Sect. VIII Div. 1 M A A A - - O 1-5. Inspection and Test Procedure Review of inspection procedure such as Visual Test Procedure and Dimensional Test Procedure - ASME Sect. VIII Div. 1 - ASME Sect. V M A A A - - O 1-6. PWHT Procedure (D2209 HTP-01) (V-8000026543-141) Review of Holding Time, Temperature, Heating Rate - ASME Sect. VIII Div. 1 and Cooling Rate, Etc - TEMA Class ''R'' - Approved Document M A A A - - O 1-7. NDE Procedure (D2209 NDE-01) (V-8000026543-132) - Review RT Procedure - Review MT Procedure - Review PT Procedure - ASME Sect. VIII Div. 1 - ASME Sect. V Article 10 M M A A A A A A - - O O 1-8. Strength Calculation - - ASME Sect. VIII Div. 1 - TEMA Class ''R'' M A A A - - O 1-9. Drawing - - ASME Sect. VIII Div. 1 - TEMA Class ''R'' - M A A A - - O M R R W - - - Pre Inspection Meeting Note : M : Preparation and Inspection R : Review SW : Spot Witness H : Hold Point - W : Witness O : Report Required A : Approval R : Review - Specification, Eng. Doc, Quality TPE : PT Tripatra Engineering DIHI : PT. Daekyung Indah Heavy Industry TPPI : PT. Trans-Pacific Petrochemical Indotama AI : Authorized Inspector PI : Perusahaan Inspeksi MIGAS : Direktorat Jendral Minyak Dan Gas Bumi Owner : PT.Trans-Pacific Petrochemical Indotama Project : TPPI REVAMPING PROJECT Item No. : 204-E-001A, 204-E-002A/B, 203-E-001 Quantity : 4 EA Doc. No. : D2209 ITP-01 INSPECTION AND TEST PLAN ( HAIRPIN EXCHANGER PACKAGE ) Rev. No. : 0 Issue Date : 20 Juli 2023 Page : 3 of 6 INSPECTION PARTY NO. II. MANUFACTURING ACTIVITY PURCHASING (Raw Material and Component) 2-1. Requisition for Purchasing 2-2. Receiving inspection material DESCRIPTION Review of the material requisition sheet REFERENCE - Acceptance Criteria Report/ Certificate DIHI AI TPE TPPI PI MIGAS - ASME Sec. II A & ASME Sec. II C - U85 : Material of Construction - ASME Sec VIII Div.1 - Fabrication drawing - Certification EN 10204 Type 3.1 - Specification M - - - - - - M W R W - - O Material inspection as per requirement of the customer specification and/or material specification a. Visual examination of the surface material b. Dimensional check and minimum thickness control c. Material identification and transfer of identification mark d. Review of the certification material test report - Fabrication drawing - Purchase requisition - Purchase order - Mill Certificate - ASME Sec II Part A - ASME Sec II Part C - ASME Sec VIII Div.1 a. Visual check b. Dimensional check c. Transfer of identification mark - Cutting Layout - Fabrication Drawing - Fabrication Tolerance - Fabrication Drawing M R R R - - O 3.A.1-2. Marking of nozzle opening a. Dimensional check after marking before cutting - Fabrication Drawing - TEMA Class ''R'' - Fabrication Drawing M R R R - - O 3.A.1-3. Fit-up & welding pipe to pipe / neck a. Visual and dimensional check before welding b. Offset, clean, edge preparation - Fabrication Drawing - Fabrication Tolerance - Welding Procedure Spec. - Fabrication Drawing - ASME Sec. VIII Div. 1 M R R R - - O* 3.A.1-4. NDE examination of main seam a. Visual check of weld to make sure that no defect after welding b. Dimensional check after weld including reinforced weld c. RT ( 100% for Butt Welds ) - NDE Procedure - ASME Sec. V - TPPI Spec U86 M R R SW - - O III Inspection during fabrication III.A.1 At Shop Fabrication : 3.A.1-1. Pipe Marking - RT Full for item no. 204-E-001R & 203-E-001R - RT Spot for item no. 204-E-002R d. PT/MT - On 1st pass (root) and finish weld Note : M : Preparation and Inspection R : Review SW : Spot Witness H : Hold Point W : Witness O : Report Required A : Approval R : Review TPE : PT Tripatra Engineering DIHI : PT. Daekyung Indah Heavy Industry TPPI : PT. Trans-Pacific Petrochemical Indotama AI : Authorized Inspector PI : Perusahaan Inspeksi MIGAS : Direktorat Jendral Minyak Dan Gas Bumi *: Report Requiered : Fit Up, Visual, Dimensional, Welding Traceability report Owner : PT.Trans-Pacific Petrochemical Indotama Project : TPPI REVAMPING PROJECT Item No. : 204-E-001A, 204-E-002A/B, 203-E-001 Quantity : 4 EA NO. MANUFACTURING ACTIVITY III.A.2 Tube Bundle Inspection 3.A.2-1. Tubesheet inspection Doc. No. : D2209 ITP-01 Rev. No. : 0 Issue Date : 20 Juli 2023 Page : 4 of 6 INSPECTION AND TEST PLAN ( HAIRPIN EXCHANGER PACKAGE ) DESCRIPTION REFERENCE Acceptance Criteria INSPECTION PARTY DIHI AI TPE TPPI PI MIGAS Report/ Certificate a. Dimensional check Diameter holes and thickness - Fabrication drawing - TEMA Class ''R'' - Fabrication drawing M W R W - - O a. Dimensional check b. Baffle direction c. Mock up tube to tube sheet - Fabrication drawing - TEMA Class ''R'' - Fabrication drawing M W R W - - O M W R W - - O 3.A.2-3. Fit-up tube to tubesheet a. Visual and dimensional check before insert tube b. Offset, clean, edge preparation - Fabrication drawing - Inspection & Test Procedure (V-8000026543-131) - Fabrication drawing - Inspection & Test Procedure (V-8000026543-131) M W R W - - O 3.A.2-4. Expanding tube to tubesheet joint a. Check dimensional b. Check expanding ratio c. Visual inspection after expanding - Fabrication drawing - Inspection & Test Procedure (V-8000026543-131) - Fabrication drawing - Inspection & Test Procedure (V-8000026543-131) M W R W - - O 3.A.2-5. Strength Weld a. Check welding parameter b. PT inspection on first pass and finish weld - WPS & PQR - Inspection & Test Procedure (V-8000026543-131) - WPS & PQR - Inspection & Test Procedure (V-8000026543-131) M W R W - - O 3.A.2-6. Helium leak testing, and soap test a. Check tube to tubesheet joint - ASME Sect.V, Article 10 - ASME Sect.V, Article 10 M W R W - - O 3.A.2-7. Post Weld Heat Treatment ( All item for U-Tubes ) ( for item no. 203-E-001 on Both Side ) a. Cooling Rate b. Heating Rate c. Holding Time d. Holding Temperature - PWHT Procedure - Data Sheet - ASME Sect. VIII Div. 1 - PWHT Procedure - Data Sheet - ASME Sect. VIII Div. 1 M W R W - - O III.A.3 Final Inspection 3.A.3-1. - Over all dimensional check & visual check - Setting/joint flange to flange conection a. Visual check after weld b. Dimensional check - Fabrication drawing - TEMA Class ''R'' M W R W W - O 3.A.3-2. Hydrostatic test a. Check of calibration status of pressure - Pressure Test Procedure (V-8000026543-125) - Inspection and Test Procedure - Project Specification - ASME Sec. VIII Div. 1 - TEMA - No Leakage M H H H H H O** gauge and recorder b. Check number/range of pressure gauge c. Check position of pressure gauge d. Check of pressure e. Check of temperature f. Check of leakage and deformation - Fabrication drawing W : Witness O : Report Required A : Approval R : Review TPE : PT Tripatra Engineering DIHI : PT. Daekyung Indah Heavy Industry TPPI : PT. Trans-Pacific Petrochemical Indotama AI : Authorized Inspector PI : Perusahaan Inspeksi 3.A.2-2. Tube bundle arrangement Note : M : Preparation and Inspection R : Review SW : Spot Witness H : Hold Point - ASME Sec. VIII Div. 1 (UG-99) - Fabrication Drawing - Pressure Test Procedure - 120 Minutes Holding Time - Chloride Content < 250 ppm MIGAS : Direktorat Jendral Minyak Dan Gas Bumi ** : Valid calibration and certificate include water analysis certificate indicate chloride cente Owner : PT.Trans-Pacific Petrochemical Indotama Project : TPPI REVAMPING PROJECT Item No. : 204-E-001A, 204-E-002A/B, 203-E-001 Quantity : 4 EA Doc. No. : D2209 ITP-01 INSPECTION AND TEST PLAN ( HAIRPIN EXCHANGER PACKAGE ) Rev. No. : 0 Issue Date : 20 Juli 2023 Page : 5 of 6 INSPECTION PARTY NO. IV. MANUFACTURING ACTIVITY DESCRIPTION Painting a. Check of area/surface condition after blasting - External Coating a) Surface preparation b) Pinting inspection b. Check of painting material & colors c. Check of dry film thickness d. Visual check of surface condition after painted V. Packing & Shipping Preparation VI. REFERENCE Acceptance Criteria DIHI AI TPE TPPI PI MIGAS Report/ Certificate - Painting Procedure (V-8000026543-127) - TPPI Spec N50 - Approved painting Procedure (V-8000026543-127) - Thickness - RH < 85% M R R W - - O a. Dryness check b. Preservation check : Nitrogen (N2) c. Spare part check d. Center Of Gravity (COG) e. Orientation marking f. etc - Packing List - Correct Marking - Name Plate detail drawing - Correct Marking - Pre-shipping check list for vessel / HE - Preservation Procedure (V-8000026543-126) M R R W - - O Name Plate Check a. Drawing - Drawing - Drawing M R R W - - - VII. Inspection Release Certificates ( IRC ) a. Satisfactory completion as per P.O - Satisfactory completion as per P.O M - - A - - O VIII. Manufacturer Data Report ( MDR ) a. All relevant information as per code requirement in data report - ASME Sect. VIII Div. 1 - ASME Sec. VIII Div. 1 - MDR Index M R R A - - O*** W : Witness O : Report Required A : Approval R : Review TPE : PT Tripatra Engineering DIHI : PT. Daekyung Indah Heavy Industry TPPI : PT. Trans-Pacific Petrochemical Indotama AI : Authorized Inspector PI : Perusahaan Inspeksi MIGAS : Direktorat Jendral Minyak Dan Gas Bumi Note : M : Preparation and Inspection R : Review SW : Spot Witness H : Hold Point *** : MDR Index Page 6 of 6 Parties Approval PT. Daekyung Indah Heavy Industry ( Ahmad Yusa ) Sign & Name PT. Trans Pacific Petrochemical Indotama PT. PJ TEK Mandiri ( PI ) Ditjen MIGAS Sign & Name Sign & Name ( Nizar Z. ) Sign & Name
