Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4

GENERAL NOTE, (this NOTE TO BE REMOVED - entire row to be deleted):

The below typical ITP contains the requirements as per Tecnimont practice, then, it shall be customized according to project requirements and it shall be filled in and submitted as requested in the correspondent Supply Specification.
Vendor is fully responsible for proper fill the ITP taking into consideration the follow:
1. STEP OF ACTIVITIES: to be customized as per project requirements. Activities which are not applicable shall be identified as "NA" (Not Applicable) with first document submission and deleted from the ITP in the next revision after TCM
acceptance only.
2. REFERENCE DOCUMENTS: to be filled in by Vendor taking into account the applicable:
a. Vendor documents procedure (referencing TCM documents codes according to the VDL)
b. CODES, Regulations and/or any other recognized reference which can be use as operational procedure
3. ACCEPTANCE CRITERIA: paragraphs or sections of CODES, Regulations, Standards, Project Specifications and/or specific values useful for evaluate the tests results
4. REPORT REQUESTED: any modifications shall be preliminary agreed with Tecnimont project team.
5. INVOLVEMENTS: the columns foresee the type of involvement of Sub-Supplier (if any), Supplier, Tecnimont and Company/Owner. According to Quality Category or Critical Rating (usually is shown on Material requisition cover page)
finalized by project Vendor shall use the correspondent column (1, 2, 3, or 4).
(*) In case Sub supplier is involved, all inspection activities performed in its workshop must be considered as "H" HOLD POINT for Sub supplier.
(**) Supplier involvements in sub supplier inspection activities must be as a minimum the same as per TCM involvements.
The column shall be suitable for showing scheduled dates of inspections and signature of the personnel (of each part, Sub Supplier, Supplier, TCM, Company, NB) involved during the test.
The columns dedicated to “Company/Owner” shall be finalized with Tecnimont project team. Any modifications on the type of attendance/involvement shall be preliminary agreed with TCM project team. “NB” means Notified Body column
contents shall be agreed/shared with Tecnimont project Team.
At the end of each Inspection Activties all Witnessed or reviewed steps must be signed and dated by all parties involved.
 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4

1-BEFORE FABRICATION

H H H H H H

1.1 PRE-INSPECTION MEETING N MOM to be issued by Contractor

H H AR AR AR AR

DWG AND ENGINEERING DOCUMENTS REVIEW N

H H AR AR AR AR
MECHANICAL (AND OR THERMAL)
N
CALCULATION REVIEW

H H AR AR AR AR

WELDING BOOK (WPS/PQR) REVIEW N

H H R R R R
Review will be at Contractor's
WELDERS AND WELDING OPERATORS
N Inspector charge in Supplier's
QUALIFICATION workshop

MANUFACTURING PROCEDURES REVIEW H H AR AR R R

(ie: forming; bending; bolting; pickling;
N
expanding etc. as applicable to the scope of
supply)
H H AR AR R R

NDE PROCEDURES REVIEW N

H H R R R R

NDE OPERATORS REVIEW N

 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4

TESTING PROCEDURES REVIEW H H AR AR AR R

(ie: hydrotest; pneumatic; helyum; ferrite;
N
hardness, etc. as applicable to the scope of
supply)
INCOMING MATERIAL CHECK & CHECK OF H H H H H H
MARKING
(this steps shall include Visual and Dimensional, Y
MTC review, NDE etc. as applicable to the
scope of supply)
H H W W R R
Tube-to-Tubesheet weld mock-up
N
(Execution)

H H W W R R
Tube-to-Tubesheet weld mock-up
Y
(Laboratory testing)

2-DISHED HEADS FABRICATION

H H M M M M

2.1 Cutting and bevelling of plates N

H H M M M M

PT or MT on bevels Y

H H M M M M

Forming of dished heads N

H H W W SW M

Visual and dimensional check of formed head Y

 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4
H H W W SW M
PT on knuckle area of dished heads (internal
Y
and external)

H H R R R R
Plate test coupon for head (if hot formed).
Y
Mechanical test

3-SHELL FABRICATION

H H M M M M

3.1 Cutting and bevelling of plates for shell N

H H M M M M

PT or MT on bevels Y

H H M M M M
Fit-up check for longitudinal and
circumferential welds (including shell to Dished N
heads circumferential welds)

H H M M M M
Welding monitoring (including welding of
Production Weld Test Coupon, where N
applicable)

H H M M M M

100% PT on back-gouging Y

H H R R R R
RT on longitudinal and circumferential welds RT films review to be notified
Y
(% to be specified) to TCM
 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4
H H M M M R
100% PT or MT on final welds (external and
Y
internal side)

4-CHANNEL FABRICATION

H H M M M M

4.1 Cutting and bevelling of plates for channel N

H H M M M M

PT or MT on bevels Y

H H M M M R
Fit-up check for longitudinal and
circumferential welds (including channel to N
Dished heads circumferential welds)

H H M M M M
Welding monitoring (including welding of
Production Weld Test Coupon, where N
applicable)

H H M M M M

100% PT on back-gouging Y

H H R R R R
RT on longitudinal and circumferential welds RT films review to be notified
Y
(% to be specified) to TCM

H H M M M R

100% PT or MT on final welds Y

 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4

5-NOZZLE FABRICATION

H H M M M M

5.1 Cutting of pipe (if not forged nozzle) N

H H M M M M

100% PT or MT on bevels Y

H H M M M M

Fit-up check of nozzle pipe to flange N

H H M M M M

Welding monitoring N

H H M M M M

100% PT on back gouging and after root pass Y

H H M M M M

100% PT or MT on final welds Y

H H R R R R

RT on circumferential welds (% to be specified) Y

H H M M M M

VT and dimensional check of nozzles Y

 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4

6-ASSEMBLY OF NOZZLES (to shell/channel/heads)

H H M M M M

6.1 Marking of nozzle opening and cutting Y

H H M M M M

6.2 100% PT or MT on bevels Y

H H M M M M

6.3 Fit-up check N

H H M M M M

6.4 Welding monitoring N

H H M M M M

6.5 100% PT on back gouging Y

H H M M M M

6.6 PT or MT on final welds Y

H H M M M M
UT on nozzle to shell / head welds, before
6.7 application of reinforcing pads (% to be Y
specified)

7-TUBE BUNDLE FABRICATION

 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4
H H M M M M

7.1 Tubesheet and baffles cutting and drilling Y

H H W W R R
Tubesheet and baffles VT and dimensional
N
check

H H R R R R

Bending of tubes (if any) Y

H H R R R R
Stress relieving of bended tubes plus 300mm
Y
on straight parts

H H W W W W

Boroscopic Inspection Y

H H M M M M

Complete bundle cage: tubes insertion N

H H M M M M

Tube to tubesheet joint fit-up N

H H M M M M

Tube to tubesheet welding monitoring N

H H W W M R

100% PT on tube to tubesheet welds Y

 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4
H H W W M M

Tube to tubesheet joints Air leak test Y

H H M M M M

Tube to tubesheet joint expansion Y

H H W W M R
100% PT on tube to tubesheet welds, after
Y
expansion

H H W W M R

Visual and Dimensional check of Tube bundle Y

8-INSPECTION BEFORE PWHT

H H W W M R
100% PT or MT on temporary attachments
8.1 Y
removal and arc strikes

H H W W M R

Internal Visual inspection of shell and channel Y

H H W W M R

Visual and dimensional check, before PWHT Y

H H W W M M

Bundle template insertion check N

 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4
H H W W R R
Air leak test with soap solution on reinforcing
Y
PAD

9-PWHT

H H M M R R
Application of thermocouple on exchanger and
9.1 N
calibration certificates review

H H W W R R
PWHT, including all Production Weld Test
N
Coupons (PTC)

H H R R R R

PWHT Chart review N

H H W W R R
Hardness test on all treated welds including
Y
external attachments

H H R R R R

Mechanical tests on PTC's Y

10-INSPECTIONS AFTER PWHT

H H W W R R

10.1 100% PT or MT on thermocouple removal areas Y

 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4
H H W W R R
VOLUMETRIC NDE on full penetration welds
Y
(% to be specified)

H H W W R R
Recordable UT on non-radiographable
Y
welds (% to be specified)

H H W W R R
PT or MT on 100% welds
Y
(internal, external, saddle and stiffeners)

H H H H H H
Internal Visual inspection of shell and channel,
Y
after PWHT

H H H H H H
Visual and dimensional check, after PWHT,
Y
including UT thickness check

H H W W M M

Tube bundle insertion check Y

H H W W R R

Final marking check verification Y

11-FINAL TESTS / INSPECTIONS

H H W W R R
Air leak test with soap solution on reinforcing
11.1 Y
PAD
 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4
H H R R R R
Test water quality check, test water
temperature check and equipment wall Y
temperature check

Release to proceed with Hydrotest: H H H H H H

1- Certification Dossier (CED) with all
Y
Reports/Certificates reviewed and signed;
2- Closing of NCR's (if any)
H H H H H H
Hydrotest
(Indicate the correct sequence of hydrotest of Y
shell side and tube side)

H H W W R R

Equipment draining and dry out Y

 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4

12-PAINTING

H H R R R R
Preparation grades of welds, cut edges and
12.1 Y
other areas with surface imperfections

H H R R R R

Removal of grease and contaminants Y

measurement and recording of environmental H H R R R R

conditions before and during surface
Y
preparation (metal temperature, dew point
and relative humidity)
H H H H H H
Visual examination of steel, surface
preparation and measurements of roughness Y
after abrasive blasting

H H W SW R R

Dust and salts removal Y

Measurements and recording of ambient H H W R R R

conditions before, during and after paint
Y
application (air temperature, metal
temperature, dew point and relative humidity)
H H W R R R

Primer application Y

H H W R R R

Measure of the wet film thickness for primer Y

 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4
H H W R R R

Measure of the dry film thickness for primer Y

H H W SW R R

MEK test (only for inorganic zinc rich primer) Y

H H W SW R R

intermediate application Y

H H W R R R
Measure of the wet film thickness for
Y
intermediate

H H W R R R
Measure of the dry film thickness for
Y
intermediate

H H W R R R

Finish application Y

H H W SW R R

Measure of the wet film thickness for finishing Y

H H H H H H
Measure of the dry film thickness for finishing
Y
and visual examination

H H W SW R R

Holiday test (wet sponge) Y

 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4
H H W SW R R

Adhesion test (pull-off) Y

H H W SW R R

Adhesion test (cross cut) Y

H H W W W W
Repairing (if any) excluding touch ups due to
Y
mechanical damage
 Contractor Identification Code

INSPECTION & TESTING PLAN (ITP)

STD-ZE-ITP-000001-IS00_C.S. SHELL & TUBE HEAT EXCHANGER Sheet__of__ Rev__

Owner Identification Code

Item Tag Number: Design code: PWHT: Service:

Joint efficiency: Material: MDMT: Impact test (Yes/No)
Quality Category (QC): (See Note) Vendor: Vendor Job:
Involvements
Report TCM
Acceptance criteria/ verifying
Pos. Quality related activity Reference documents requested Sub [Q. Category] Company / Note
documents Supplier AI / NB
(Y/N) Supplier Owner
1 2 3 4

13-PACKING AND FINAL DOCUMENTATION REVIEW

H H W W R R

13.1 Verification of flanges surface (no damages) N

H H W W R R

Nameplate and warning plate check N

H H W W R R
Packing check and Packing List check
Packing certificate to be filled
(including commissioning and start up spare Y
and signed
parts)

H H H H W R
Dew point to be measured to
Preservation check (N2 filling, Silica Gel bags or
Y ensure complete drying out of
other agreed methods)
the equipment

H H W W R R
Sealing of threated holes of reinforcing pads Different sealing to be agreed
Y
(by plastic plugs or other suitable method) with Contractor

H H H H H H

NCR's closing out verification Y

H H

Review of Certification Dossier (CED) Y H H H H

H H

Release and Authorization to shipment Y H H H H