INSPECTION GUIDELINES FOR

MECHANICAL
MARAFIQ IWPP (1)

J.P. QUEMION October 31,2008

HOW QUALITY ASSURANCE MANAGERS

DRAFT AN I.T.P.

It follow the fabrication/construction sequence

At each step of fabrication, he give guidance
to inspectors
At each step, he specify the applicable
document for reference (i.e. drawing,
specification, codes, standard)

HOW QUALITY ASSURANCE MANAGERS

DRAFT AN I.T.P.

At each step, he specify how should things be

done
At each step, he specify which forms are to be
used by inspectors

I.T.P.
INSPECTION AND TEST PLAN
Why do you have to follow ITP?
To obtain quality as per contract;
no more, no less
How to follow ITP? Inspection Points:

* - Report or Certificate to be provided

R - Review of documents or Random
Check
W - Witness Point
H - Hold Point

REPORT OR CERTIFICATE TO BE PROVIDED

Document required for the concerned party.

This indicates that the document should be
submitted as applicable
(this includes but not limited to mill
certificates, data sheets, manufacturers
certificates, test reports, etc.

R
REVIEW OF DOCUMENTS OR RANDOM CHECK

Refers to the review of the documents as

submitted by the subcontractor (*) or
documents relative to the specific item in the
ITP. R may also means an actual check
conducted at random by the concerned party.

W
WITNESS

Concerned party should be notified in writing

at least 24 hours in advance.
This is a stage of the work where the
presence of the concerned party is expected
to witness a specified item in the ITP.
In this case, work will proceed even if the
concerned party failed to arrive at the
specified time.

H
HOLD POINT

Concerned party should be notified in writing

at least 24 hours in advance.
This is a stage of the work where the
concerned party is expected to arrive. Work
shall not continue or progress if he is or his
designated representative is not present.
Hold point often require a final inspection
prior acceptance or typical production.

WHAT SUPERVISORS SUPPOSED

TO DO FOR A PARTICULAR JOB
Know the Specifications involved
Know every points/items in the ITP
Know which drawings are for a particular work
The most important thing,
KNOW WHAT YOU
ARE DOING
Enjoy your work

FOR EXAMPLE

CARBON STEEL PIPE ERECTION (LP STEAM LINE)

Review the following (as applicable):
Specifications
Codes for acceptance criteria
Standards for acceptance
criteria
Drawings

STANDARDS AND SPECIFICATION

APPLICABLE FOR CARBON STEEL PIPING
0000H426 Specification for Pipe works
Fabrication and welding
0000H403 Specifications for the Construction
and Inspection of Carbon Steel Weldments
0000H415 Selection of Filler Metal
6600H441 Specification for Pipe Work Erection
ASME B31.3 Process Piping
ASME Section IX, Qualification Standards for
Welding & Brazing Procedures
AWWA

STANDARDS AND SPECIFICATION

APPLICABLE FOR CARBON STEEL PIPING
0000H424 Rev. E - Specification for
Construction of Welded Stainless Steel or
Dissimilar Metals (CS-SS) Assemblies
ASTM A106/API 5L
ANSI B16.9
ANSI B16.11
WPS/PQR
Welders qualification

ASME/ANSI B31.3 - 2006

Process Piping
Rules for the Process Piping Code Section B31.3 have
been developed considering piping typically found in
petroleum refineries; chemical, pharmaceutical, textile,
paper, semiconductors, and cryogenic plants; and related
processing plants and terminals.

Section IX of the ASME Boiler and Pressure

Vessel Code
Overview
There are three steps in qualifying welders and welding procedure
specifications to Section IX of the ASME Boiler and Pressure Vessel
Code (BPVC).

prepare a welding procedure specification (WPS). The WPS must

contain the minimum requirements that are specified by the code. The
WPS provides guidance for welding by specifying ranges for each
variable
a procedure qualification record (PQR) is used to verify the WPS. The
WPS is qualified by welding procedure qualification test coupons. The
variables and tests used are recorded on a PQR

Section IX of the ASME Boiler and Pressure

Vessel Code
Overview
There are three steps in qualifying welders and welding procedure
specifications to Section IX of the ASME Boiler and Pressure Vessel
Code (BPVC).

the performance of the welders is verified by welding performance

qualification test coupons. The variables and tests used with the
particular variable ranges qualified are recorded on a welders
performance qualification (WPQ) record

Outline of Articles in ASME Section IX

Article I - Welding General Requirements QW-100

Article II - Welding Procedure Qualifications
QW-200
Article III - Welding Performance Qualifications
QW-300
Article IV - Welding Data QW-400
Article V - Standard Welding Procedure
Specifications (SWPS) QW-500

ASTM A106

This specification covers seamless carbon steel pipe for

high-temperature service in NPS 1/S to NPS 48 inclusive,
with nominal (average) wall thickness as given in ANSI B
36.10. It shall be permissible to furnish pipe having other
dimensions provided such pipe complies with all other
requirements of this specification. Pipe ordered under this
specification shall be suitable for bending, flanging, and
similar forming operations, and for welding. When the
steel is to be welded, it is presupposed that a welding
procedure suitable to the grade of steel and intended use
or service will be utilized.

API 5L

This specification covers seamless and welded steel

line pipe. It includes plain-end, thread-end, and belledend pipe, as well as through-the-flowline (TFL) pipe
and pipe with ends prepared for use with special
couplings.
Although the plain-end line pipe meeting this
specification is primarily intended for field makeup by
circumferential welding, the manufacturer will not
assume responsibility for field welding.

ASME/ANSI B16.9 - 2001

Factory-Made Wrought Steel Butt welding Fittings

This Standard covers overall dimensions,

tolerances, ratings, testing, and markings for
wrought factory-made butt welding fittings in
sizes NPS 1/2 through 48 (DN 15 through
1200).

ASME/ANSI B16.11 - 2001

Forged Steel Fittings, Socket-Welding and Threaded

This Standard covers ratings, dimensions,

tolerances, marking and material requirements
for forged fittings, both socket-welding and
threaded.

ITP step no. 1

Identification of prefabricated sections
The applicable document is SIDEM
drawing and is R for both SIDEM &
Client column. This maybe a spool (pipe
to pipe, pipe to fitting, etc) that should be
checked if it conforms with the applicable
drawing.

ITP step no. 2

WPS and PQR
The applicable document is
0000H441/0000H403. These specifications
requires that WPS / PQR must be submitted
to SIDEM prior welding works start.
Qualification of welding shall be done in
accordance with ASME Section IX. These
documents however are done before, all you
need to do is to review its completeness and
applicability and if it is implemented at site

Common Welding Processes

Shielded Metal Arc Welding (SMAW)

Gas Tungsten Arc Welding (GTAW)
Gas Metal Arc Welding (GMAW)
Flux Core Arc Welding (FCAW)
Submerged Arc Welding (SAW)
Stud Arc Welding (SW)

ITP step no. 3

Welders Performance Qualifications
The applicable document is 0000H403. This
specification requires that Welders must be
qualified before any welding work commence.
Qualification of Welders is done in accordance
with the requirements of ASME Section IX and
the qualified WPS.

ITP step no. 4

Welders Identification
The applicable document is 0000H441
This specification requires
that Welders must be
qualified before any welding
work commence
Qualified welders should be given
an ID. You have to check

whether his ID correspond to

the welding process he is
working on.

ITP step no. 5

Filler Metal Certificate

Review of the filler metal certificates

Tests conducted in accordance with the
requirements of AWS (ASME Section II
part C)

Electrode Identification
SMAW

Electrode Identification
GMAW/GTAW

ITP step no. 6

Fit Up Inspection
Two Main things to be considered:
Pipe Fit Up/Alignment
Angularity, Elevation,
Level, Coordinates,
etc
Joint Fit Up
Welding

What to consider during Fit Up

Identify possible welding problems

(i.e. inadequate root spacing or a bevel that
will not allow full penetration)
Potential for weld distortion
Safety Precautions

Pipe Fit Up

Linear dimensions (intermediate or overall),

apply to the face to face, face to end, and
end to end measurements of fabricated
straight pipe and headers; centre to end or
centre to face of nozzles or other
attachments; or centre to face of bends

Linear Dimensions

Fit Up Alignment

Tolerances

Linear tolerances: 1/8" (3.0 mm) for sizes

10" and under, 3/16" (5.0 mm) for sizes 12"
through 24" and 1/4 (6.0 mm) for sizes
over 24" through 36".
Linear tolerances for sizes over 36 are
subject to tolerances of 1/4" (6.0 mm),
increasing by 1/16" (2.0 mm) for each 12"
in diameter over 36".

Joint Fit-up (Weld)

ITP step no. 7

Inspection In course of Welding
Base metal & Filler metal requirements addressed
(WPS)
Protection for welding such as wind and rain barriers
Welding consumable handling addressed (rod ovens
etc.)
Make sure all involved know that the welder is
responsible for the quality of the welds he makes
Determine if the welder understands the welding
procedure
Make sure the welder meets the qualification
requirements

ITP step no. 8

Weld Visual Inspection
General Appearance of the weld
Size
Profile
Distortion
Shrinkage, etc
Visible Surface Discontinuities
Cracks
Porosity
Slags
Cold lap
Undercuts
Underfill, etc

DISTORTION/SHRINKAGE

UNDERFILL/UNDERCUT

POROSITY

UNDERFILL/UNDERCUT/GAS CUT

SPLATTER/COLD LAP

Acceptance Criteria

ITP step no. 9

100% Magnetic Particle Inspection on Internal
surface of Weld Seam
Nondestructive Testing (NDT)
Visual Examination (VT)
Radiographic Testing (RT)
Magnetic Particle Testing (MPT)
Liquid Penetrant Testing (LPT)
Ultrasonic Testing (UT)

ITP step no. 10

5% RT (Except on non pressure pipe, drain,
vents..)
Random radiography
It is required that 5% of the total circumferential
welds shall be 100% examined
This shall cover all welders within the line
under consideration
The radiographic film (test report) shall be
evaluated by an ASNT certified level II (at least)

ITP step no. 11

Check of Flange fit up
Material (Size & rating)
Level
Horizontal Angularity
Vertical Angularity
Bolt hole straddle

Flange Fit Up

TOLERANCE

Flange Fit Up

ANGULARITY

ITP step no. 12

Inspection of Supports & Hangers Installation

As per SIDEM drawing

Specs 0750S402

ITP step no. 13

Check of piping component installation
Valves, fitting, orifice plate, check valves
Expansion bellows, Instrumentations
Material check (Marking,
size & rating)
Flow direction
If additional support is
necessary

ITP step no. 14

Check of Instrument Installation (provision only)
Weldolet, Sockolet, Threadolet
Proper locations
In coordination with
Instrument supervisors

ITP step no. 15

Final Inspection
Line Check
Punch list
Release for test/painting/insulation

QUALITY AND PROGRESS SHOULD NOT

PULL EACH OTHER

QUALITY DOES NOT HOLD BACK

PROGRESS

NO PROGRESS WITHOUT QUALITY

QUALITY AND PROGRESS TOGETHER WILL

RESULT TO SUCCESS