GUJARAT NARMADA VALLEY FERTILIZERS COMPANY LIMITED

50000 MTPA PAC PROJECT

SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

PART A - INSPECTION INSTRUCTIONS TO VENDORS

1. GENERAL

1.1 This instruction covers the general requirements for shop inspection and testing of
equipment and materials (GOODS) to be supplied by the Contractor. Contractor
shall be responsible for inclusion of inspection requirements herein and
requirements of applicable individual specification as contractual requirements of
Sub vendors.

1.2 In addition to the general requirements contained in this specification, the

Contractor shall be responsible for all other inspection requirements as defined by
documents included in or referenced by the Purchase Order, Requisition,
Specification or Data sheets applicable to the Order.

1.3 GOODS for which no individual specification is issued can be inspected and tested
in accordance with this instruction and Contractor's standards approved by the
Purchaser

1.4 All deviations from this instruction and related inspection specifications shall be
previously proposed to the Purchaser in writing and shall be approved by the
Purchaser before placement of the order.

1.5 The word "specification(s)" used in this instruction and related inspection
specifications often collectively means all technical specifications, drawings, and
other technical documents supplied b^ the Purchaser and also specifications and
technical documents as may be agreed and/or made by the Contractor and the
Purchaser.

2. DEFINITIONS
Words used in this instruction and related inspection specifications shall have the
following meanings, unless the context requires otherwise :
Test Report: Means the individual record or certificate for respective test or
inspection.
QC Dossier: means the compiled document package consisting of prescribed
Purchaser's cover sheet for QC Dossier, Contractor's cover sheet,
table of contents, Test Reports, and other necessary documents.
Purchaser: means Gujarat Narmada Valley Fertilizer Company limited
Purchaser's Inspector: Means inspector(s) dispatched by the Purchaser or
inspector(s) of inspection agencies designated by
the Purchaser.
Owner’s Inspector: Means one or combination of inspector(s) dispatched
by the Owner and inspector(s) of the inspection
agency (agencies) designated by the Owner.
Contractor: Means a supplier or manufacturer of GOODS.
Sub vendor: Means an organization, company or individual under
contract to Contractor for the supply of material,
equipment sub-assemblies or services necessary to
the completion of Contractor’s scope of work.

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50000 MTPA PAC PROJECT
SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

3. CODES AND STANDARDS

All codes and standards for the inspection of GOODS shall be in accordance with
those specified in section 6.1 of the ITB.

4. CLARIFICATION OF CONFLICTS
If there is any conflict between the related specifications, codes and standards, the
Contractor shall immediately consult with the Purchaser in writing for clarification.
Failure of Contractor to seek, in writing, clarification of conflicting requirements prior
to acceptance of the Purchase Order shall constitute obligation of Contractor to
comply with all of the conflicting requirements at no additional cost, even to the
extent that rework and/or retesting may be required.

5. RESPONSIBILITY FOR QUALITY

5.1 Inspection or non-inspection by the Purchaser shall not relieve the Contractor of its
obligation for quality control activities and guarantees for the workmanship or
performance of the GOODS.

5.2 The Contractor shall be responsible for inspection and testing of the GOODS,
including parts and materials supplied by Sub vendors.

5.3 The Contractor shall carry out all inspections and testing specified in the purchase
documents.

5.4 All Contractor's fabrication documents, including, but not limited to, welding,
nondestructive examination, heat treatment, and major repair procedures, specified
in the requisition shall be reviewed and approved by the Purchaser prior to start of
fabrication.

6. PRE-INSPECTION MEETING

The Purchaser may require holding a pre-inspection meeting(s) at Contractor and/or

Sub vendors to resolve questions concerning the compliance with the purchase
documents, specifically inspection requirements and related specifications. Final
inspection items shall also be defined at the meeting. Contractor shall arrange to
provide the following documents for this meeting;

1) Copy (Copies) of Purchaser's requisitions, drawings, specifications of the latest

revision and other documents necessary for discussion at the meeting.
2) List of missing documents such as specifications referenced in the Purchaser's
requisition, but not received by the Contractor.
3) Questionnaire about Purchaser's documents.
4) Contractor's drawings, diagrams, and schedules.
5) Fabrication procedure
6) Inspection procedure including NDE procedure
7) Written welding documents
8) Major repair procedure
9) Sample of inspection record(s) for a similar jab previously done by the Contractor
10) Other documents considered necessary

Contractor shall also arrange for meeting attendance by all Contractor

representatives necessary to achieve resolution of technical questions, schedules,

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50000 MTPA PAC PROJECT
SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

and inspection requirements.

7. WITNESS INSPECTION NOTICE

7.1 The Contractor shall notify the Purchaser of readiness for witness inspection in
writing at least 4 calendar weeks prior to the date when the GOODS will be ready
for inspection.
The Contractor shall also inform the Purchaser of the definite witness inspection
date and time at least 10 working days in advance of the date of the witness
inspection.

7.2 Verbal inspection notice is not acceptable. Notice shall be sent to Purchaser by
Facsimile (telefax) OR e-MAIL. The inspection notice shall also include the map or
the necessary information to reach Contractor's shop, if such information was not
given in advance.

7.3 Work shall not proceed beyond "Inspection Hold Points" established by contract
correspondence, Specifications or Pre-Inspection Meeting without written
authorization of Purchaser.

8. WITNESS INSPECTION

Purchaser's and/or Owner's Inspector shall have free entry to those parts or areas
of manufacturing shops of the Contractor or its sub vendors where and when work,
testing or inspection on the GOODS is being performed.
Access shall not be limited to "normal office hours" and escort shall not be required
except when agreed for reasons of safety or proprietary work.
Where escort restriction is agreed, Contractor and/or Sub vendor shall make escort
available during all hours of shop fabrication, testing or inspection.

8.2 Purchaser's and Owner's Inspector reserve the right to monitor, audit, and visit
plants or other inspection locations with or without prior notice to the Contractor or
Sub vendor.

8.3 For inspection items designated for witness of Purchaser's and/or Owner's
inspector, but not designated as inspection hold points, Contractor may, at
Contractor's cost and risk, elect to proceed with fabrication after completion of
Contractor's in-house inspection, provided that the witness inspection is repeated
for witness of the Purchaser's and/or Owner's inspector at time of next inspection
visit.

8.4 The Contractor, when so requested, shall provide one additional copy of the latest
approved drawings for the use of Owner's Inspector prior to the start of inspection.

8.5 The Contractor shall furnish Purchaser's and/or Owner's Inspector with shop test
data, mill certificates, and other materials to verify that each GOODS meets the
requirements of the applicable specifications. Free copy, telex, facsimile (tele
- fax), and telephone service by the Contractor shall be made available to
Purchaser's and/or Owner's Inspector.

8.6 Safety equipment and inspection tools as necessary to safely and expeditiously
demonstrate compliance with applicable specifications, as well as assistance from

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50000 MTPA PAC PROJECT
SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

Contractor's or Sub vendor's inspection representative shall be made available to

Contractor's and/or Owner's Inspectors.

8.7 When requested by the Purchaser, the Contractor shall prepare the required
number of QC Dossier, its part, or other documents for Owner's Inspector by the
requested date.

8.8 Nothing herein shall preclude Contractor's inspection or contracts representative

from accompanying Contractor's and/or Owner's Inspector to Sub vendor locations
for inspection purpose.

9. RELEASE FOR SHIPMENT

9.1 Purchaser's Inspector will issue "Inspection Release Note" to the Contractor shortly
after the final inspection and review of QC Dossier prepared by the Contractor.

9.2 The Contractor shall not ship any GOODS without securing the Inspection Release
Note.

9.3 When the Contractor is permitted to ship on condition to perform the additional work
at the work site, the Contractor shall bear all costs and expenses incurred by such
work.
(1) Special provision for storage or proper care
(2) Repair and/or Inspection

10. DOCUMENTATION
Incomplete, inaccurate or illegible documentation shall be the cause for rejection of
GOODS until such time as satisfactory rectification has been effected.

10.1 Documents to be Submitted

All Contractor's inspection and test procedures, including, but not limited to, welding,
nondestructive examination, heat treatment, definition of major repairs, and major
repair procedures, required for submittal in the requisition shall be reviewed and
approved by the Purchaser prior to start of fabrication or prior to use, whichever is
the earlier.
(1) The Contractor shall submit to the Purchaser 5 white copies for documents such as
Contractor's shop inspection and test procedure and welding procedure
specification as required.
Unless otherwise specified, all these documents shall be prepared in English.
The Contractor will be requested to submit these documents prior to fabrication.
(2) The Purchaser will need a maximum of fifteen (15) working days, excluding mailing
time, from the receipt of the Contractor document to study and accept or give
alternative decisions.

10.2 Submittal of QC Dossier

(1) The Contractor shall prepare QC Dossier in English and submit 5 white copies to
the Purchaser within seven (7) working days after completion of the final inspection
of the GOODS.
(2) For details of QC Dossier preparation, refer to section 11 of this specification.

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50000 MTPA PAC PROJECT
SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

11. PREPARATION OF QC DOSSIER

11.1 Unit of Preparation

(1) The QC Dossier of individual pressure vessels, heat exchangers, tanks, and towers
shall be prepared for each equipment.
(2) The QC Dossier of unit or packaged items such as boiler units, compressor units,
etc. shall be prepared for each unit or package including subsidiary equipment and
accessories.
(3) The QC Dossier of materials, pumps, valves, fittings, instruments, and electrical
equipment, which are not included in (1) and (2) above, may be prepared for each
order.
In case of partial shipment, the QC Dossier may be divided for each shipment.

11 .2 Forms
To prepare the QC Dossier, the Contractor may use its standard forms.

11.3 Compilation
(1) As far as possible, A4 (210mm X 297mm) or 8-1/2 in. x 11 in. size paper shall be
used for the test report sheet. For larger sizes, A3 ( 297 mm X 420 mm) may be
used, folded to A4 size.
When thickness of the QC Dossier is too thick to compile in one package, it can be
divided into two or more packages.

(2) Construction of QC Dossier

As far as possible, Test Reports in the QC Dossier shall be in the following order :
(a) List of material certificates with part Nos. and part names
(b) Material certificates
(c) Nondestructive examination records
(d) Visual inspection certificates
(e) Dimensional inspection records
(f) PWHT chart and thermocouple location map
(g) Hydrostatic test records, Leak test records
(h) Running test records, Performance test records, Operation test records
(i) Nameplate rubbing
(j) Cross Sectional Drawings / GA Drawings / Fabrication Drawings, Tolerances for
precision parts, etc.
(j ) Operation & Maintenance Instructions for machinery.

11.4 Signature Requirements

(1) Each document in QC Dossier shall have the verification signature by the
Contractor.
(2) Signature by Purchaser's Inspector
When witness inspection or review of documents is done by Purchaser's Inspector,
each respective sheet of the QC Dossier shall bear either witness signature or
review signature of Purchaser's Inspector.
(3) Each test report sheet shall have the following data or information in addition to
signatures :
Test data and/or results
Date of test
Identification of components tested

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50000 MTPA PAC PROJECT
SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

11.5 SOFT COPIES

Apart from Hard Copies, Soft Copies as per following descriptions shall be
submitted by the Contractor:

No. Of Copies: 2 Sets.

Medium: CD – R of reputed make viz. SONY / SAMSUNG / MOSER BAER
Formats: All Drawings shall be in AUTO CAD 2004.
All reports shall be in Editable Format.

11.6 Measuring Units

(1) In principle, measuring units on QC Dossier documents shall be metric unit except
English unit may be applied for pipe, fitting, flange, flange bolts/nuts, and rating.
(2) Units for mill certificates of raw materials may be in accordance with specified
codes and standards applicable to such materials.

11.7 Retention of Test Report

Contractor shall retain original sheets of Test Report for at least 5 years after
shipment of GOODS.

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 GUJARAT NARMADA VALLEY FERTILIZERS COMPANY LIMITED
50000 MTPA PAC PROJECT
SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

PART B - INSPECTION PHILOSOPHY FOR PRESSURE VESSELS AND HEAT

EXCHANGERS

1. CODES AND STANDARDS

The requirements in the following codes and standards also form a part of the
requirements of this specification.
(1) ASME Code, Section II
(2) ASME Code, Section VIII, Division 1
(3) ASME Code, Section V
(4) ASME Code, Section IX
(5) TEMA
(6) Codes, standards & regulations listed at Section 6.1 of the ITB.
(7) Other codes, standards and regulations specified in each
individual specification

2. Main materials shall be verified to conform to the specified materials by mill test
reports. The mill test reports shall include chemical analysis of each lot or heat of
material and a statement that it has been tested in accordance with and meets the
physical and mechanical requirements of the applicable specification.

3. WITNESS INSPECTION

3.1 Pressure vessels for which ASME official code stamps (U) is required shall be
inspected by the ASME Authorized Inspector in accordance with the requirements
of ASME Code, Section VIII, Division 1.

3.2 In addition, all pressure vessels shall be subject to inspection, at the option of the
Purchaser or representatives of the Purchaser at all reasonable times and places
before, during and/or after fabrication.

3.3 Witness test and inspection agenda shall be in accordance with Table 3

3.4 The Owner has the right of access to the Contractor's or Sub vendor's shop for
inspection matters. If the Contractor received any instruction from the Owner's
Inspector, the Contractor should report to the Purchaser before making any
changes.

4. PRINCIPAL REQUIREMENTS
All inspection and tests shall conform to the requirements of ASME Code, Section
VIII, Division 1.

5. ADDITIONAL REQUIREMENTS TO ASME CODE

The following inspections shall be carried out in addition to, but not be limited to, the
requirements of ASME Codes.

5.1 Material

1) The following materials for the pressure parts shall be inspected by ultrasonic
examination method in accordance with SA-578 Level B of ASME Code, Section II.
Test results shall be described in mill test reports.
(a) Carbon steel plates of 50 mm (2 inches) thick and over

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50000 MTPA PAC PROJECT
SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

(b) Low-alloy steel plates of 25 mm (1 inch) thick and over

(c) Low temperature service carbon steel plates of 19 mm (3/4 inch) thick and over

Pressure Parts having thickness from 16 mm to 50 mm shall be ultrasonically tested

as per SA 435.

2) For heat treated materials, test specimens shall be prepared from actual vessel
material which has been subjected to an equivalent total thermal treatment as the
vessel material in the final fabricated condition.

3) Chemical analysis of weld filler metal shall be certified by the weld filler metal
supplier.

5.2 Radiographic Examination

1) In addition to radiographic examination required by the ASME Code or design

drawings, the Purchaser reserves the right to take additional exposures as desired
to check weld quality.

2) When spot radiography is specified, the radiographic examination shall be made as

follows:
- For cylindrical vessels, one spot radiograph shall be taken in each circumferential
joint and in each longitudinal joint between adjacent circumferential joints at
locations designated by the Purchaser's Inspector.
- All “T” joints shall be radiographed.
When 100 % or Full Radiography is specified, radiography shall be taken for 100 %
of the Butt Joints, including those of Nozzles of all sizes.

3) If any part of a shell or head seam will be covered by a nozzle reinforcing pad or
other structural overlay, that portion of the seam shall be spot radio graphed before
it is covered.

5.3 Magnetic Particle Examination

1) Magnetic particle examination shall be carried out for all welded joints of low-alloy
steel and lifting lugs in accordance with Appendix 6 of ASME Code, Section VIII,
Division 1.

2) For 100% radio graphed vessels, all welded joints between nozzles and vessel shell
and between nozzles and flanges shall be examined by the magnetic particle
method prior to the installation of any reinforcing pads. This examination shall
include:
- The back side of the root area after the root pass has been back gouged or ground
in preparation for the welding required to complete the joint.
- Both sides of the complete weld.

3) Final nozzle welds shall be examined by the magnetic particle method after post
weld heat treatment, unless these welds are inaccessible.

4) When magnetic particle examination is specified, the DC prod method shall be used
prior to final post weld heat treatment, and the AC yoke or coil method after final
post weld heat treatment.

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SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

5) Nonmagnetic materials shall be examined by the liquid penetrant method in

accordance with Appendix 8 of ASME Code, Section VIII, Division 1 for the same
weld joints as defined in above paragraphs, instead of magnetic particle
examination.

6) For materials having either:

a) a minimum specified tensile strength of 551 MPa (80,000 psi) or greater, or
b) a total nominal alloy content greater than 4 percent, or
c) a thickness of 38 mm (1-1/2 inches) or greater,
All attachment welds and all areas where fit up bars, etc. are temporarily attached
shall be examined by magnetic particle method, before final post weld heat
treatment (PWHT), and after hydrostatic testing.
Austenitic steels and nickel steels are exceptions.

5.4 All forgings except for flanges as per ANSI shall be UT tested as per ASTM A 388
for the thickness greater than 100 mm and shall be procured in
normalized/annealed condition. Acceptance standards shall be as per AM 203.2 of
ASME Section VIII Div. 2. In case any defect is found, no repair by welding shall be
allowed.

5.5 All forgings including nozzle flanges shall be examined for surface defects by
MP/PT testing after machining as per ASTM A 275.

5.6 Tube sheet and Girth flanges shall of forged quality & ultrasonic tested not have any
segmental weld joint.

5.7 All heat exchanger tubes shall be 100% eddy current tested in addition to hydro
testing

5.8 Hydrostatic Tests

1) Vessels fabricated in shop shall be subject to hydrostatic test in horizontal position

in the fabricator's shop.

Water temperature for hydrostatic test shall not be lower than 15°C during the test.
Where the ductile-to-brittle transition temperature of steel is known to be, or
suspected to be 4°C or higher, it is the fabricator's responsibility to raise the
temperature of the water to at least 15°C higher than the transition temperature.

Vessels fabricated from solid, clad or lined austenitic stainless steel shall be tested
with potable water containing minimum concentration of chloride and not more than
50 ppm chloride.

Test gaskets for nozzles connecting to piping or instruments may be of asbestos or

other materials. Test gaskets for other than the above shall be of same specification
as service gaskets. Such gaskets used for hydrostatic tests shall be shipped in
place. In addition, two sets of service gaskets (one for replacing at site and another
for construction spare) shall be shipped loose together with the equipment.

2) The test pressure shall be held for one hour or one hour per inch of vessel
thickness, whichever longer.

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SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

3) When austenitic stainless steel materials will be exposed to water during hydro
testing or water washing, the following shall apply:

a) Only treated water or freshwater with less than 50 ppm total chlorides and pH
greater than 7 shall be used.
b) The water shall be drained immediately after testing or washing and the vessel shall
be dried by blowing with dry air or dry nitrogen.

4) Heat Exchanger Testing

a) Hydrostatic test methods and sequence shall be established before fabrication and
submitted for the approval of the Purchaser.
b) Heat exchangers shall be alternately hydro tested on each side with no water in the
other side being exposed.
c) Girth flange joints taken apart after hydrostatic test shall be reassembled with
unused gaskets and retested for tightness by air at the design pressure.

5.9 Leak Tests

1) When specified, pressure vessels shall be leak tested at the air pressure specified
on the individual specification and/or drawing.

2) All reinforcing plates shall be tested at air pressure of 1 to 1.4 Kg/cm^ (15 to 20
psig) unless otherwise specified.

3) All tube to tubesheet weld joints of heat exchangers shall be leak tested at the air &
with pressure specified on the drawings.

5.10 Impact Tests

1) Materials of each pressure-containing component, welding procedure qualification
test plates and production impact test plates shall be impact tested on the basis of
individual material specification (class of steel), thickness, and design temperature
specified for each item in the individual specification in accordance with ASME
Code, Section VIII, Division 1.

2) Shells, heads, nozzles, man ways, reinforcing pads, flanges, skirts, tube sheets, flat
cover plates, support lugs, etc., shall be treated as separate components.

3) Results of impact tests shall be incorporated into the vessel records and submitted
to the Purchaser.
The data shall include specimen size, direction in which material being tested
(longitudinal or transverse), test temperature, breaking energy of each specimen,
and average values of breaking energy for a set of three specimens.

5.11 Hardness Tests

1) If post weld heat treatment is required, Brinell hardness tests of the base metal,
weld metal and heat affected zone (HAZ) shall be made for weld seams of pressure
vessels of P-l, P-3, P-4, P-5, P-6, P-7, p-1OA and P-10B materials listed in ASME
Code Section IX. The Brinell hardness shall not exceed the limits set in Table 5.7.

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50000 MTPA PAC PROJECT
SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

Table 5.7
Material P-Number Maximum Brinell Hardness

P-l 200
P-3, P-4 225
P-5, P-6 235
P-7 225
P-10a, P-10B 225

2) When hardness test is required by Paragraph 1) above, the detailed requirements

for the hardness test shall be in accordance with the following procedure.
a) The hardness testing shall be conducted following the completion of all post weld
heat treatments.
b) The surface hardness test shall be made with a Brinell testing machine or a portable
hardness tester such as a Telebrineller using a 10 mm ball.
c) The hardness tests for the HAZ shall be made with the ball centered in the HAZ
(representing a composite of weld metal, HAZ, and base metal).
d) Surface preparation shall consist of filing, grinding, machining, or polishing with
abrasive material the areas to be tested so that the edge of the impression shall be
clearly defined to permit the measurement of the diameter to + 0.02 mm. Care
should be taken to avoid overheating or cold working the surface.
Adjacent reading shall be at least 2-1/2 diameter apart, edge to edge.
e) Should surface preparation or instrument applicable be difficult, a mockup with
identical condition shall be used.
f) Where hardness values are determined to be in excess of the allowable limit,
sufficient additional reading shall be taken to fully delineate the extent of the
deficiency.
g) Verification of hardness value shall be performed on the following points.
- Each cylinder circumferential seam: one hardness test per seam
- Each cylinder longitudinal seam: one hardness test per seam
- Sphere seams:
- One hardness test per seam at weld line intersection
- Fillet weld seam tested by mockup:
one hardness test per order for each welding process, filler metal, and technique
used

5.12 Dimensional Inspection

1) Dimensional tolerance other than specified in ASME Code Section VIII, Division 1
shall be in accordance with the attached drawings in Figure 1. In addition to the
above, the dimensional tolerances specified in TEMA shall be applied to heat
exchangers.

2) Nozzle flange dimensions shall be within the tolerance of the pertinent standards for
flanges.

3) Agitator mounting flanges shall be machined after welding to shell and the flange
face shall be parallel with the indicated plane in any direction + 0.05°.

5.13 Welding Procedure Specifications and Procedure Qualification Records

1) Before starting to weld, welding procedure specification (WPS) and procedure

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SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

qualification record (PQR) shall be submitted to the Purchaser for approval. The
formats shall be Form QW-482 and QW-483 of ASME Code Section IX or
equivalent.

2) PQR on carbon steel and other materials for which hardness limit is specified shall
include hardness measurement across the weld metal, HAZ and base metal to
assure that the WPS is adequate for producing the allowable hardness.

3) The WPS/PQR shall meet the requirements of ASME Code Section IX.

4) Weld maps shall be attached to WPS and PQR. The maps shall show the
traceability of WPS No. to the weld line of each vessel.

5) Weld repair procedures shall be submitted to the Purchaser for approval, before
starting of repair work.

5.14 Surface Finishing

When surface finishing such as buff finishing and electro polishing is specified, the
finishing of each component shall be visually inspected before assembling by
comparing with sample pieces accepted in advance by the Purchaser.
Three sample pieces shall be submitted for approval. (Sample piece size : 100 mm
x 100 mm x 3 or 6 mm thick, or 4 in. x 4 in. x 1/8 or 1/4 in. thick)

5.15 Tubular Heat Exchangers

1) Actual inside diameter of exchanger shells shall be measured completely around
three cross sections of the shell. Maximum diameter shall not exceed design
diameter by more than 3.2 mm (1/8 inch) as determined by circumferential
measurement.
2) Transverse baffle to shell clearances greater than specified in TEMA Table R-4.3
shall not be used.
3) A template consisting of two discs with diameters equal to baffle diameters, rigidly
fixed on a shaft and spaced not less than 304 mm (12 inches) apart, shall pass
completely through the shell after completion of all welds and post weld heat
treatment(PWHT).
4) After fabrication and PWHT, the deviation from a plane for tubesheet and girth
flange gasket surface, including peripheral and pass partition sections, shall not
exceed 0.8 mm, as measured with dial indicators.
5) All matching nozzle of stacked exchangers must be within 3.2 mm (1/8 inch) in any
direction. Matching gasket faces including tubesheet surface must be parallel to
within 0.8 mm (1/32 inch).
6) All nondestructive examinations for final welds required by the purchaser shall be
performed after PWHT, if PWHT is specified.
7) Shell flanges, channel flanges, channel covers, tube sheets and split rings shall
have the manufacturer's serial number applied with steel stencils.
8) Seal welds or strength welds between tubes and tube sheets shall be examined by
the liquid penetrant method according to Appendix 8 of the ASME Code, Section
VIII, Division 1.

5.16 PNEUMATIC TESTING

5.16.1 All reinforcing plates shall be tested at the air pressure not less than 3.4 bar g.
Reinforcing plates and other attachments with vent holes on vessels subject to

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post weld heat treatment shall be pneumatically tested before and after post weld
heat treatment.

5.16.2 Sleeve lined nozzles in clad vessels shall be tested at the air pressure not less
than 3.4 bar g.

5.16.3 Strip lined plates shall be tested at the air pressure specified in the data sheets.

5.16.4 If specified in the data sheets, vessels shall be subject to a leakage test at the air
pressure specified in the data sheets after hydrostatic test.

6. DOCUMENT SUBMITTAL
The documents prescribed in the Section A above.

6.1 Detailed Inspection and Test Procedure

Unless otherwise specified, the Contractor shall submit the Detailed Inspection and
Test Procedure for the Purchaser's approval within 12 weeks after the date of
purchase order or by 8 weeks in advance of the date of the first inspection,
whichever is earlier.
The Procedure shall cover at least the following items and shall meet requirements
of all inquiry and purchase documents, including related Contractor's and
Purchaser's correspondence.
1) Inspection and test agenda
2) Specific test methods including test equipment
3) Acceptance criteria
4) Test report and test certificate to be submitted (See Table 3)

6.2 Welding Procedure Specifications and Procedure Qualification Records

Welding procedure specifications including for the applicable equipment and the
procedure qualification records shall be prepared in accordance with Paragraph 5.9
of this specification by the manufacturer.
WPS/PQR with Weld Map shall be submitted and approved before starting
fabrication and not necessary to be included in QC Dossier.
For welding procedures already qualified, the certified records may only be
reviewed.

6.3 Fabrication Procedure

Fabrication procedure including hot forming procedure and post weld heat treatment
procedure shall be submitted for approval of the Purchaser prior to the start of
fabrication.

6.4 Welder Qualification Records

Welder qualification records and qualified welders list for this job shall be prepared
by the manufacturer. They shall be available to Purchaser's Inspector at fabrication
shop.

6.5 QC Dossier (Test and Inspection Reports)

After final inspection, all test records and/or test certificates for inspection and test
given in Table 3 shall be issued as a form of QC Dossier.

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 GUJARAT NARMADA VALLEY FERTILIZERS COMPANY LIMITED
50000 MTPA PAC PROJECT
SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

Figure 1a STANDARD TOLERANCES FOR PRESSURE VESSELS

(EXCEPT SHELL AND TUBE HEAT EXCHANGERS)

1 PASS

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 GUJARAT NARMADA VALLEY FERTILIZERS COMPANY LIMITED
50000 MTPA PAC PROJECT
SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

TRAY SUPPORT Unit .

Figure Ib STANDARD TOLERANCES FOR PRESSURE VESSELS

(EXCEPT SHELL AND TUBE HEAT EXCHANGERS)

DIMENSION TO BE MEASURED TOLERANCES (UNIT mm)

(NOTE1)
1. FROM T.L. TO T.L. LARGER OF ± 13 OR 1.5/m
MAX. ± 25
2. FROM T.L. TO C.L. OF MANHOLES + 10
3. INCLINES OF MANHOLE FLANGES FROM 1 Deg
INDICATED PLANE IN ANY DIRECTION
4. FROM INSIDE OF VESSELS TO MANHOLE + 10
FLANGES
5. FROM T.L. TO C.L. OF NOZZLES + 10
6. INCLINES OF NOZZLE FLANGES FROM ½ Deg
INDICATED PLANE IN ANY DIRECTION
7. FROM OUTSIDE OF VESSELS TO NOZZLE +5
FLANGES
8. FROM BOTTOM OF DOWNCOMER TO +3
TRAY FLOORS
9. HEIGHT OF WEIR + 1.5
(ABOVE DOWNCOMER SUPPORT)
10. FROM C.L. OF HEAD TO C.L. OF NOZZLES +6
11. ORIENTATION OF NOZZLES AND OTHER +6
ATTACHMENTS
12. FROM TRAY TO TRAY +3
13. LEVEL OF SUPPORT RINGS (NOTE 2)
Upto 1200 mm ID INCL 2
From 1201 to 2100 3
From 2101 to 4000 4
From 4001 to 6000 6
From 6001 to 8000 8
From 8001 to 10000 10
14. FROM T.L. TO TRAY SUPPORT RINGS + 10
15. FROM TRAYS TO NOZZLE C.L. OF NOZZLES +3
16. OUT-OF-ROUNDNESS OF CYLINDRICAL SHELL
a. VESSELS WITH TRAYS + 0.5 % ID
b. VESSELS WITH TIE-ROD TRAYS + 0.5 % ID min + 3
c. VESSELS WITHOUT TRAYS +1 % (Note 3)
INSIDE DIAMETER AS MEASURED BY
EXTERNAL STRAPPING
Upto 1200 mm ID INCL +3
From 1201 to 2100 + 4.5
From 2101 to 4000 + 6.0
From 4001 to 6000 +7
From 6001 to 8000 +8
From 8001 to 10000 + 10
17. Head A & B Outside I.D. X 1.2

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 GUJARAT NARMADA VALLEY FERTILIZERS COMPANY LIMITED
50000 MTPA PAC PROJECT
SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

Inside I.D. X 0.625%

18. Deviation from Straight applied to LESS THAN 6 PER 6000 AND
Shell. LESS THAN 20 PER TOTAL
LENGTH
19. Skirt Length +6
20. From TL to Lug +6

Figure Ic STANDARD TOLERANCES FOR PRESSURE VESSELS

(EXCEPT SHELL AND TUBE TYPE SHELL AND TUBE HEAT EXCHANGERS)

DIMENSION TO BE MEASURED TOLERANCES (UNIT mm) (NOTE 1)

21. LEVEL OF BASE PATE &
SUPPORT
Up to 1200 mm ID INCL 3
From 1201 to 2100 4.5
From 2101 to 4000 6
From 4001 to 6000 7
From 6001 to 8000 8
From 8001 to 10000 10

22. B.C.D. OF ANCHOR BOLTS

UPTO 2100 INCL +3
Over 2100 +6

23. SUPPORT FOR HORIZONTAL VESSELS

a. PITCH OF BOLT HOLES
UPTO 2100 INCL +3
Over 2100 +6
b. FROM T.L. TO CENTER OF ANCHOR +3
BOLTS
c. HEIGHT OF SUPPORT +3

24. FROM T.L. TO FLANGE OF BOTTOM OR TOP + 10

25. NOZZLES FOR LEVEL GAUGES
a. PITCH +2
b. ALIGNMENT LESS THAN 1
c. ALIGNMENT OF ORIENTATION LESS THAN 2
26. ROTATION OF FLANGES 1.5
27. LOCATION OF PLATFORMS, LADDERS, ELE + 10
PIPE SUPPORTS AND LUGS (E.L.)
28. DEVIATION FROM VERTICAL PLANE ON + 20
TRUE CENTER LINE FROM BASE TO TOP OF
VESSEL

NOTE 1: TOLERANCES ARE NOT CUMULATIVE

NOTE 2: MAX. 6 FOR THE PORTION OF SUPPORT RING THAT WEIR IS
ATTACHED.
NOTE 3: WHEN THE CROSS SECTION PASSES THROUGH AN OPENING,
THE PERMISSIBLE DIFFERENCE IN INSIDE DIAMETERS MAY
BE INCREASED BY TWO PERCENT OF THE DIAMETER OF
OPENING.

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 GUJARAT NARMADA VALLEY FERTILIZERS COMPANY LIMITED
50000 MTPA PAC PROJECT
SECTION 6 ANNEXURE 4.9
INSPECTION PHILOSOPHY FOR STATIC EQUIPMENT

Table – 3 INSPECTION & TEST AGENDA AND DOCUMENTS TO BE ISSUED

TEST & INSPECTION TEST TEST

AGENDA CATEGORY REPORT REMARKS
_______________________________________________________________________________

MATERIAL TEST (INCLUDING R REQD

BY MILL TEST
UT & IMPACT) REPORT
(Note 2)
________________________________________________________________________________
FORMED VISUAL INSP & W - TOGETHER WITH
HEAD DIMENSIONAL MEAS SHELL
ULTRASONIC EXAM R REQD ONLY FOR CLAD
________________________________________________________________________________
WELDED FIT UP, EDGE PREP, W - BY SAMPLING
JOINT BACK CHIPPING
RADIOGRAPHIC EXAM R REQD FILM CHECK
LIQ PEN EXAM W REQD BY SAMPLING
M.P. EXAM W REQD BY SAMPLING
________________________________________________________________________________
IMPACT TEST W REQD
HARDNESS TEST W REQD
________________________________________________________________________________
VISUAL INSP & DIMENSIONAL
MEASUREMENT OF BODY W REQD NOTE 3
________________________________________________________________________________
VISUAL INSP & DIMENSIONAL
MEASUREMENT OF INTERNAL W REQD
________________________________________________________________________________
POST WELD HEAT TREATMENT R REQD BY CHART
PNEUMATIC TEST FOR REINF PAD R REQD
HYDROSTATIC TESTING W REQD
PNEUMATIC TEST W REQD
________________________________________________________________________________
MANUFACTURER’S DATA REPORT R REQD ASME FORM
RUBBING (COPY) OF NAMEPLATE R REQD.

Table 3 INSPECTION AND TEST AGENDA AND DOCUMENTS TO BE ISSUED (Cont'd)

Note 1) W: Witness Inspection

R: Review of the manufacturing test report
Test Category: Purchaser's inspection

Note 2) Provide "Sketch of Materials" or "List of Materials"

Mill test reports for the following parts, but not limited to, shall be submitted.
- Shells, shell flanges, shell covers, channels, and channel flanges
- Tube sheets, Tubes
- Nozzles, nozzle flanges, and reinforcing plates for nozzles
-Parts integrated with the pressure parts
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 GUJARAT NARMADA VALLEY FERTILIZERS COMPANY LIMITED
FEED STOCK CONVERSION

SECTION 6.4.9 – INSPECTION PHILOSOPHY

-Bolts and nuts for shells, shell covers and channel flanges
Note 3) The following inspection shall be conducted as the interim witness inspection for shell and
tube heat exchangers:
- Use of specified gaskets and means of holding them in place
- Ease of bundle insertion
- Bolt makeup and loading
- Assembly of stacked exchangers, if any.

PART C - INSPECTION PHILOSOPHY FOR COLUMN TRAYS

1. GENERAL
Inspection Philosophy for trays shall be read in conjunction with Section A &
Section B of the Inspection Philosophy, Section 6.4.9 of the ITB.

2 CODES AND STANDARDS

2.1 Only the latest editions of regulations, codes, and standards in force at the time of
order placement shall be applied, unless otherwise specified.
2.2 The requirements in the following codes and standards form a part of the
requirements of this specification:
(1) National standards in regard to materials of the countries from which the materials
are supplied.
These standards shall, however, be previously approved by the Purchaser.
(2) Other codes and standards specified in each individual specification.

3. WITNESS INSPECTION
3.1 All trays shall be subject to inspection, at the option of the Purchaser, under
witness by the Purchaser or designated representative of the Purchaser at any
reasonable time and place before, during, and after manufacture/fabrication.
3.2 Witness inspection and test agenda shall be in accordance with Table 1,
3.3 The owner has the right of access to the Vendor's or Subvendor's shops for
inspection matters.
If the vendor received any instruction from the Owner's Inspector, the Vendor
should report to the Purchaser before making any changes.

4. INSPECTION AND TEST AGENDA

4.1 Material
1) Material shall be verified to conform to the specified materials by mill test reports
or material certificates.
2) Mill test reports or material certificates for such main parts as tray floor, down
comer, weir, seal pan and tray support beam and for other specified parts shall be
submitted.
3) For other parts than specified above, mill test report or material certificates for
corrosion resistant austenitic stainless steel and higher grade material shall be
also submitted.

4.2 Visual Inspection

1) All parts shall be visually checked for workmanship.
2) Surface shall be confirmed to have no harmful effect such as creases or chap.
3) Cutting face and punched hole shall be confirmed not to be stripped greatly.
4) Slag and spatter caused by welding shall be confirmed to be removed
5) When surface finishing such as buff finishing and electro polishing is specified, the

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 GUJARAT NARMADA VALLEY FERTILIZERS COMPANY LIMITED
FEED STOCK CONVERSION

SECTION 6.4.9 – INSPECTION PHILOSOPHY

finishing shall be visually inspected by comparing with sample pieces accepted in

advance by the Purchaser. Three sample pieces shall be submitted for approval.
(Sample piece size : 100 mm x 100 mm x 3 or 6 mm thick, or 4 in. x 4 in. x 1/8 or
1/4 in. thick)

4.3 Dimensional Inspection

Dimensional measurement shall be performed against certified dimensional
drawings.
Unless otherwise specified, tolerances shall be as follows:
(1) Tray Floor
(a) Length
Up to 1000 mm, incl. ±2.0 mm
Over 1000 mm - up to 2000 mm, incl. ±2.5 mm
Over 2000 mm ±3.5 mm
(b) Width ±2 mm
(c) Flatness ±1.5 mm per 1000 mm
at any place
(2) Downcomer and Weir
(a) Straightness for upper line of weir
and lower line of down comer ±1 mm

(b) Length
Up to 1500 mm, incl. ±2.5mm
Over 1500 mm ±4.5 mm
(c) Width ±1.5 mm
(d) Flatness ±1.5 mm per 1000 mm
at any place

(3) Punched hole for perforated tray

Diameter +0.3 mm

4.4 Temporary Assembly Inspection

All stages of tray shall be temporarily assembled at the Vendor's or Sub vendor's
shop to confirm fit-up without trouble about pitch of bolt holes.

Main dimensions shall be within the following tolerances.

Diameter of Tray
(1) Inside diameter specified of tower
Up to 2000 mm, incl. +0 mm -4 mm
2001 mm and over +0 mm -5 mm
(2) Flatness of tray floor +1.5 mm per 1000 mm at any place
(3) Height of weir above the upper
surface of tray floor ±1.5 mm

5. DOCUMENT SUBMITTAL
The documents prescribed in the following paragraphs shall be submitted in
accordance with Section A – Inspection Instruction to the Vendors above.

5.1 Detailed Inspection and Test Procedure

Unless otherwise specified, the vendor shall submit Detailed Inspection and Test
Procedure for the Purchaser's approval within 12 weeks after the date of purchase
order or 8 weeks in advance of the date of the first inspection, whichever is earlier.

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 GUJARAT NARMADA VALLEY FERTILIZERS COMPANY LIMITED
FEED STOCK CONVERSION

SECTION 6.4.9 – INSPECTION PHILOSOPHY

The procedure shall cover at least the following items and shall meet requirements
of all inquiry and purchase documents, including related vendor's and Purchaser's
correspondence.
1) Inspection and test agenda
2) Specific test methods including test equipment
3) Acceptance criteria
4) Test report and test certificate to be submitted

5.2 QC Dossier (Test and Inspection Reports)

After final inspection, all test records and/or test certificates for inspection and test
given in Table 1 shall be issued as a form of QC Dossier.

Table 1 INSPECTION AND TEST AGENDA AND DOCUMENTS TO BE ISSUED

Inspection & Test Test Category Test Report Remarks

Material Test R Required By Mill Test

Report/Material
Certificate

Visual Inspection W Required Incl.inspection of

Buff Finishing
Dimensional Insp. W Required

Temp. Assembly Insp. W Required

Note: 1) W: Witness
R: Review of manufacturing test report
Test Category : Purchaser’s Inspection

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