Coal Fire Steam Power Plant ( 3 x 7 MW ) Project

INSPECTION & TEST PLAN ( ITP )

CONTRACT No. : PLG-SA-200-MR-MC-0005 PROJECT NAME : CFSPP 2X100 MW PROJECT

JOB No. : G – 2001 DESCRIPTION : INSTALLATION OF BOILER

LEGEND CLASSIFICATION :
Notification
H – Hold Point : As Notification point, however work may not proceed beyond this point without acceptance or formal waiver from Inspection
Authority ( Client / Owner ).
A1 – 100% Inspection or Test : Execution or Inspection by GKE
A2 – Random Inspection : Inspection by GKE at random sample ( 20 % )
W – Witness : Witness or Inspection by Client/Owner and Sub-Contractor may proceed if Client/Owner not appearance at the pointed time
Witness point shall be given by notification
SW – Spot Witness : Witness of Inspection by Client / Owner and to be done at spot or random ( Random sample )
R – Review : Review of Certificate / Document to ensure compliance with specification
A – Approval : Approval documentation ( Procedure, Work Instruction, Inspection report, etc )

ABBREVIATIONS :
AWS = American Welding Society PWHT = Post Weld Heat Treatment ASME = American Society Mechanical Engineers
CSA = Canadian Standard Association TP = Inspection Test Plan ASNT = American Society Non Destructive Testing
WPS = Welding Procedure Specification Tech.Spec. = Technical Specification STM = American Society Testing of Material
PQR = Procedure Quality Report N/A = Not Applicable API = American Petroleum Institute
NDE = Non Destructive Examination WQTR = Welder Qualification Test Record

NOTES :
1. Ref. Inspection Activities & Approval Section of Document
a. Where there is a Subcontractor element, the Subcontractor involved will sign the approval of the activity ( NDE / PWHT )
b. Where there is no Subcontractor element, GKE will sign approval of activity and present to the Client.
c. This Inspection test Plan at INSPECTION ACTIVITY COOLUM should be understood to all concerns person will be in charge of tank work.

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2. Inspection Test Plan Status

It is to be understood that the Inspection forms an integral parts of the control/verification documentation is needed
However, where no other documents are required or exit “The Inspection Test Plan” only will be understood to be the control/verification document.

INSPECTION AND TEST PLAN

Contract No. : PLG-SA-200-MR-MC-005 Sheet No. :
Job No. : G-2001 Revision No. : A
Client : PT. PLN ( Persero ) Date : ………………….
Project : CFSPP 2x100 MW Prepared by : QA / QC
Location : Tanjung Selaki - Tarahan

Description :
INSTALLATION OF BOILER

LEVEL OF INSPECTION
REFERENCE VERIFYING ACCEPTANCE
No. ITEM ACTIVITIES
DOCUMENT DOCUMENT CRITERIA
GKE ADHI PLN

1.0 SPECIFICATION, PROCEDURE, CONTRACT DOCUMENT

REVIEW : QA Manual /
a. Technical Specification Approved Tech.
Applicable Codes R R R/A
a.1. Review Client’s approved technical Specification Spec
and Standards
a.2. Finalized deviation, amendments or Queries

b. Drawing Control QA Manual / Approved Drawing R R R/A

b.1. Review Client’s approved drawings Contract Doc. with Last revision

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 Coal Fire Steam Power Plant ( 3 x 7 MW ) Project

c. Material Control Approved Mat’l

Material Receiving, Handling and Storage Procedure QA Manual /
Receiving,
c.1. Check compliance with specification, generate new Contract Doc. R R R/A
Handling, Storage
procedure if required Vendor Manual
Proc

d. Welding Control
d.1. Welding Procedure
QA Manual /
d.1.1. Check compliance with specification, Approved WPS &
Contract Doc. R R R/A
generate new WPS and qualify PQR if required PQR
ASME IX

REFERENCE VERIFYING ACCEPTANCE LEVEL OF INSPECTION

No. ITEM ACTIVITIES
DOCUMENT DOCUMENT CRITERIA
GKE ADHI PLN

d.2. Welder Qualification

Approved Welder R R R/A
d.2.1. Check compliance with specification,
Qualification &
validity if QA Manual / Certification
Required qualify welder Contract Doc.
ASME IX Test Certificate of
d.3. Welding Consumables R R R/A
Consumable
d.4. Check compliance with specification, mill certificate

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 Coal Fire Steam Power Plant ( 3 x 7 MW ) Project

e. NDE Control
e.1. NDE Procedure Approved NDE
e.1.1. Check compliance with specification of QA Manual / Procedure R R R/A
the codes Contract Doc.
NDE Operator R R R/A
e.2. NDE Operators Qualification
e.2.1. Check compliance with specification and certificate
ASME I / ASME V /
validity Calibration R R R/A
e.3. Equipment Calibration Certificates ASNT-TC-1A Certificates
e.3.1. Check compliance with specification and
validity

f. Pre-Heat and Post Weld Heat Treatment Control

f.1. Pre-Heat and PWHT Procedure Approved PWHT R R R/A
f.1.1. Check compliance with specification of QA Manual /
the codes Contract Doc. Proc. Calibration R R R/A
f.2. Equipment Calibration Certificates ASME I / ASME V / Certificates
f.2.1. Check compliance with specification and ASNT-TC-1A
validity

g. Testing Control
Hydrostatic / Pneumatic / Service Test Procedure QA Manual / Approved Testing R R R/A
g.1. Check compliance with specification, generate new Contract Doc. Proc.
Procedure if required ASME I

REFERENCE VERIFYING ACCEPTANCE LEVEL OF INSPECTION

No. ITEM ACTIVITIES
DOCUMENT DOCUMENT CRITERIA
GKE ADHI PLN

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 Coal Fire Steam Power Plant ( 3 x 7 MW ) Project

2.0 RECEIVING MATERIAL

Material Receiving,
a. Check material received are in line with delivery note, PO, Inspection Report A1 A1 W
Handling
Packing List (Material spec/size/quantity), Visually inspect ( MRR or Release
And Storage Proc.
for Irregularities of surface. Notes )

Material Receiving,
b. Check mill certificate against material received
Handling Mill Certificate A1 A1 SW
And Storage Proc.

c. Material without mill certificate or without any correlation Material Receiving, Material Receiving
between mill certificate and material shall be considered Handling Non Conformance A1 A2 SW
irrelevant material than report to Client And Storage Proc. report

3.0 INITIAL PREPARATION

Contract Doc / Qualification Test
a. WPS/PQR Qualification Test ASME Sect. IX report A1 A1 W
a.1. Generate new WPS (if required) Technical Spec ( WPS/PQR
Approved )
b. Welder Performance Qualification Test Contract Doc / Testing Report
b.1. Visual Check ASME Sect. IX ( WPQTR A1 A1 W
b.2. NDE, Radiography test Technical Spec Approved )

4.0 INSTALLATION
a. Doing Marking on several location
a.1. Center line of furnace on upper side of the primary Inspection Report A1 A1 SW
support beams and on the bottom floor Tech. Spec /
a.2. Furnace elevation to every four main columns at Drawing None A1 A2 SW
every stages
a.3. Drum Center Line on upper side on the primary None A1 A1 W
Support beam

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REFERENCE VERIFYING ACCEPTANCE LEVEL OF INSPECTION

No. ITEM ACTIVITIES
DOCUMENT DOCUMENT CRITERIA
GKE ADHI PLN

b. Lifting of Economizer
Check the distance between components and distance from Tech. Spec /
Inspection Report A1 A1 SW
the center of furnace Drawing

c. Lifting of the Drum

c.1. Leveling of the drum in the right elevation and
position in relation to the center lines of rear wall, Tech. Spec /
Inspection Report A1 A1 W
furnace and boiler. Drawing
Locking of drum to the right position

d. Big Down comer’s,

Tech. Spec /
Inspection Report A1 A1 W
Assembly, welding, PWHT and inspection Drawing

e. Suspension Rod
e.1. Preassemble on the ground, check the right position Tech. Spec /
of the rod. None A1 A2 SW
Drawing
Ensure the safety and lock the nuts well.

e.2. Lifting of tertiary beams together with the rod to the Tech. Spec /
right position None A1 A2 SW
Drawing

e.3. Locate beams and rods to right position according to Tech. Spec / None A1 A2 SW
center lines of furnace and boiler Drawing

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e.4. Tertiary beam shall be tack welded temporary to right Tech. Spec /
position None A1 A2 SW
Drawing

LEVEL OF INSPECTION
REFERENCE VERIFYING ACCEPTANCE
No. ITEM ACTIVITIES
DOCUMENT DOCUMENT CRITERIA
GKE ADHI PLN

f. Assembly of disk spring to the Super heater Suspension

rods on the ground.
f.1. Lifting of the Super heater headers, after Tech. Spec /
None A1 A2 SW
preassembling in the ground floor, as the material Drawing
coming for the header is not a single
(ex:1 prim s/h header consist of two joints from end to end)

g. Lifting of long buck stay to the platform before the tertiary Tech. Spec /
None A1 A2 SW
beam of the frame will be assembly Drawing

h. Before first lifting of Super heater elements secondary,

check on the ground :
A1 A2 SW
h.1. Removing of shield plugs from the end of element None
Tech. Spec /
tubes
Drawing
h.2. Cleanliness of the inside of tubes by pressure air Inspection Report A1 A1 SW
h.3. Cleaning and protection of weld preparation Inspection Report A1 A2 SW

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 Coal Fire Steam Power Plant ( 3 x 7 MW ) Project

i. Other Super heater elements, will follow the same phase

of assembly for primary Super heater elements, and Tech. Spec /
sequence of erection work for Super heater will be begun Inspection Report A1 A2 SW
Drawing
with primary and tertiary Super heater

j. Lifting of Super heater primary & tertiary after lifting of Tech. Spec / None
economizer 1 & 2 element will be erected from top by crane Drawing A1 A2 SW

LEVEL OF INSPECTION
REFERENCE VERIFYING ACCEPTANCE
No. ITEM ACTIVITIES
DOCUMENT DOCUMENT CRITERIA
GKE ADHI PLN

k. Before first lifting of furnace wall, check on the ground :

A1 A2 SW
k.1. Removing of shield plugs from the end of mall tubes Tech. Spec / None
A1 A2 SW
k.2. Cleanliness of the inside of tubes by pressure air Drawing Inspection Report
A1 A2 SW
k.3. Cleaning and protection of weld preparation None

l. Lifting upper parts of furnace wall and roof :

Center line of upper header of front wall shall be chosen as Tech. Spec /
basis of measurement (0-point). None A1 A2 SW
Drawing
This cover also the measurement of lower part of furnace

m. Distance check between upper header of front wall and Tech. Spec / Inspection Report A1 A1 SW
drum : Drawing
m.1. Elevation check of header
m.2. Cross-measure between upper header of front wall
and drum.
m.3. Check the position of upper headers and cross
measure of upper part of furnace

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n. Lock the upper headers of walls Tech. Spec /

None A1 A2 SW
Drawing

o. Seal welding of wall at super heater area :

o.1. Note the following during welding of header butt weld Tech. Spec / Welding Inspection A1 A2 SW
and wall seal welding Drawing Record
o.1.1. Align the wall panels in proper location
( WIR )
o.1.2. Tack welding of wall panels to each other
o.1.3. Tack weld the header but joint
o.1.4. Recheck the alignment of wall panel and
diagonal check
o.1.5. Full weld the butt joint

REFERENCE VERIFYING ACCEPTANCE LEVEL OF INSPECTION

No. ITEM ACTIVITIES
DOCUMENT DOCUMENT CRITERIA
GKE ADHI PLN

o.2. Penetrate test of seal welds before lifting super Tech. Spec / Inspection Report A1 A1 SW
heater Drawing

p. Lifting of Side walls of second pass

p.1. Elevation check of upper headers and vertical Tech. Spec /
Inspection Report A1 A1 SW
Location of parts Drawing

q. Check on the ground : ( first element )

Tech. Spec / Inspection Report A1 A1 SW
q.1. Cleanliness of the inside of Super heater Packages
Drawing None
( Cleaning by pressurized air )
A1 A2 SW
q.2. Cleaning and protection of weld preparation
Tech. Spec /
Drawing

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 Coal Fire Steam Power Plant ( 3 x 7 MW ) Project

r. Location and vertical location check Super heater elements. Tech. Spec /
None A1 A2 SW
Drawing

s. Super heater element is welded to each tube header, and

welding only can start the fit up and alignment of the super
Tech. Spec /
heater tube element to the header is good, and make sure None A1 A2 SW
Drawing
that the gap for all tube header is not much different ( still in
tolerance )

t. Welding Super heater Elements to the casing roof and Tech. Spec /
None A1 A2 SW
Check for tightness Drawing

u. Upper Circulation Tubes and Saturated Steam Pipes :

WPQT, NDE
assembly, welding and inspection. Tech. Spec /
Report, Electrode A1 A1 SW
Assembly shall be started from the shortest Circulation Drawing
Cert, WIR
Tubes ( Tubes from to Wall Header )

LEVEL OF INSPECTION
REFERENCE VERIFYING ACCEPTANCE
No. ITEM ACTIVITIES
DOCUMENT DOCUMENT CRITERIA
GKE ADHI PLN

v. Connection Pipe of Super heater : assembly, welding and Tech. Spec / WPQT, NDE
PWHT. The tube shall be earlier ready lifted to the platforms Report, PWHT A1 A1 SW
Drawing
Chart
w. Lifting of air ducts to the platform to be in context with Tech. Spec /
boilers steel construction assembly phases and ITP None A1 A2 SW
Drawing

x. Welding of upper parts of furnace and check for welder WPQT, NDE
qualification and production weld, radiographic examination Tech. Spec /
Report, Electrode A1 A1 SW
and welding arrangement. Drawing
Cert, WIR

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 Coal Fire Steam Power Plant ( 3 x 7 MW ) Project

y. Welding and radiographic examination off but welds arch

Tech. Spec /
during the welding of side tubes of arch, the side wall should WIR, NDE Report A1 A1 SW
Drawing
not be locked

z. Check the tightness of seal well between arch and side

walls as well as the location and support of arch
z.1. Assure the expanding allowance of supporting beams Inspection Report A1 A1 SW
of arch for example with adapting piece
z.2. Assure the measure between the assembly welds of Tech. Spec / Inspection Report A1 A1 SW
rear wall and side wall Drawing

z.3. Assure the wall and side wall butt weld lines are in None A1 A2 SW
horizontal position

aa. Lifting and assembly Cyclone into several part on position

Tech. Spec /
Cross over duct to be fitted to cyclone after cyclone already None A1 A2 SW
Drawing
welded

LEVEL OF INSPECTION
REFERENCE VERIFYING ACCEPTANCE
No. ITEM ACTIVITIES
DOCUMENT DOCUMENT CRITERIA
GKE ADHI PLN

bb. The connecting pipes of economizer, assembly, welding and Tech. Spec /
WIR, NDE Report A1 A1 SW
inspection Drawing

cc. Lifting of lower part of furnace walls Tech. Spec / None A1 A2 SW

Drawing

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 Coal Fire Steam Power Plant ( 3 x 7 MW ) Project

dd. Welding lower parts of furnace

( wall tube butt welds of Headers and seal welds )
dd.1. Check alignment of wall panels
Tech. Spec / A1 A1 SW
dd.2. Check of welding arrangements WPQT, NDE
Drawing A1 A1 SW
dd.3. Check of welding of root layer of header butt welds Report
A1 A1 SW
dd.4. The butt welds of wall tubes None
A1 A1 SW
ee. Measurement of the horizontal position and straightness of Tech. Spec /
None A1 A2 SW
lower upper part of walls Drawing

ff. Pre-Hydrostatic activities

ff.1. Assure that all actions listed boiler proper Tech. Spec /
Pre - hydro test checklist B01-003-0 has been Inspection Report A1 A1 SW
Drawing
completed and accepted ( see the list )

gg. Pre – Hydrostatic Inspection

A1 A1 SW
gg.1. Check the hanger rods in all areas are loaded as per
Inspection Report
the design loads, adjust as required with jack
A1 A1 SW
gg.2. Check creep allowance when all temporary support
Tech. Spec / Inspection Report
are removed
Drawing A1 A1 SW
gg.3. The lock pieces of the spring hanger shall be released
gg.4. Assure that all welding to pressure containing parts
A1 A1 R/A
has been completed, inspected, NDT completed, heat
treated and all documentation are prepared.

LEVEL OF INSPECTION
REFERENCE VERIFYING ACCEPTANCE
No. ITEM ACTIVITIES
DOCUMENT DOCUMENT CRITERIA
GKE ADHI PLN

hh. Checking of Construction and Pressure Vessel Tech. Spec / Approved WIR, A1 A1 R/A
Documentation Drawing PWHT Chart, NDE
hh.1. All welding, heat treatment, test and examination has Report

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 Coal Fire Steam Power Plant ( 3 x 7 MW ) Project

been done and accepted

ii. Leak test with pressure air

ii.1. All high pressure part ( Boiler Pressure with 3 to 5 bar ) Inspection Report A1 A1 W
Tech. Spec /
Drawing
ii.2. Low pressure piping to be in context with piping Inspection Report A1 A1 W
assembly and ITP

jj. Final Inspection before Hydro test Tech. Spec /

Inspection Report A1 A1 W
Drawing

kk. Leak test with pressure air Tech. Spec /

Inspection Report A1 A1 W
Drawing

ll. Hydro test according to the procedure approved Tech. Spec /

Inspection Report A1 A1 W
Drawing

mm.Mechanical Implementation Inspection of :

- Feed Water Pump - Fans
- Pumps - Burners
- Conveyors Tech. Spec /
- Regulating Units ( Dampers, Valves, etc ) Inspection Report A1 A1 SW
Drawing
- Piping ( Support, Hydro test, Flushing )
- Gate Feed Hoppers
Assure that the locking of Oil Burner System is tested

LEVEL OF INSPECTION
REFERENCE VERIFYING ACCEPTANCE
No. ITEM ACTIVITIES
DOCUMENT DOCUMENT CRITERIA
GKE ADHI PLN

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 Coal Fire Steam Power Plant ( 3 x 7 MW ) Project

nn. Checking Mechanical Completion of other areas and other

Tech. Spec /
ITP’s ( Piping, Tank & Silos, Pressure vessels, equipment, Inspection Report A1 A2 SW
Drawing
….etc )

oo. Approval to conduct the acid cleaning and development of

Magnetite film
oo.1. Opening of Inspection Nozzle, Flushing
Tech. Spec / None
A1 A2 SW
oo.2. Visual Inspection Drawing
oo.3. Welding and examination of Inspection Nozzle

pp. Steam Blows, Checking the targeted plate Tech. Spec /

None A1 A2 SW
Drawing

qq. Testing of Interlock and Safety Equipment Tech. Spec /

None A1 A2 SW
Drawing

rr. Hand Over the all Documentation to Clients All Inspection

TQP A1 A1 R/A
report

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