INSPECTION & TEST PLAN

ADVANCE VALVES
BUTTERFLY VALVES
Client: Plant Engineering General Trading & Contracting Co. W.L.L. Product :- All products & all models ITP NO. :ITP/AVG/18BDGN0006

Doc. Ref.:- QAD-P-01 TO 09,_Issue.02/Rev.00, API 609-2016, API 598-

PO NO: PEC-PO-1576/2019 Project : Rev. No. : 00 Date: 09/03/2019
2016, ASME B16.34-2017, PI-KNPC-05-VALVES
1 2 3 4 5 6 7 8 9 10
Execution by REMARK
COMPONENTS / QUANTUM OF FORMAT OF Sub-
SL. CHARACTERISTICS TYPE OF CHECK Scope REFERENCE DOCUMENTS ACCEPTANCE NORMS AV- KNPC
OPERATIONS CHECK RECORDS Supplier
QC/QA TPI
/ Prod.
PRE MANUFACTURING STAGE

Products Quality All the client's requirements related to his Review of PO and All the contractual
A. 100% PO and specifications PO and specifications Review Sheets - - -
Requirements product on order specifications requirements

Review of PO and Procedures,

B. Document Submission ITP & Drawings As required by client 100% PO and specifications PO and specifications - - -
specifications Drawings etc.

Review of Sl. A in presence of client's

Review of PO and
C. Pre Inspection Meeting representatives and finalizing the As applicable in project 100% PO and specifications PO and specifications MOM and ITP - - -
specifications
inspection & testing requirements

RAW MATERIAL RECEIVING STAGE INSPECTION

a) Chemicals Analysis Verify the chemistry M H R

All MTCs to be
Verify the Mechanical 100% review and ASTM A216 Gr. WCB , ASTM B ASTM A216 Gr. WCB , ASTM
b) Mechanical Properties reviewed. Lab Test MTC / Test M H R Body Casting MTC to be as per
Properties testing as per 148 UNS 95500 AB2 & PI-KNPC- B 148 UNS 95500 AB2 & PI-
required on sampling Reports EN 10204 3.1,
sampling 05-VALVES KNPC-05-VALVES
basis
Castings (Body & Disc) c) Heat Treatment Verify the HT details M H R

Measurement w.r.t. casting, Review of foundry I.I.R. (QAD-F-

1.0 d) Dimensions reports and dimension One sample per Casting / Component Drg. Casting / Component Drg. M H -
machining drawing 01_Issue.02)
h k size per class per
Visual & Marking, Flow Review of MTC and materials MSS SP 55 - 2011, MSS SP 25 - MSS SP 55 - 2011, MSS SP I.I.R. (QAD-F-
e) Visual Inspection M H -
Direction visual check 2013, Component Drg. 25 - 2013, Component Drg. 01_Issue.02)

a) Chemicals Analysis Verify the chemistry All MTCs to be M H R

100% review and
reviewed. Lab Test ASTM B 148 UNS C95500(AB2) ASTM B 148 UNS MTC / Test
Retaining Ring, Shaft testing as per MTC to be as per EN 10204 2.2.
Verify the Mechanical required on sampling & Monel K500 C95500(AB2) & Monel K500 Reports
b) Mechanical Properties sampling M H R
Properties basis

ASME B16.34/Approved PT
On exterior and PI-KNPC-05- ASME B16.34/Approved PT For all non magnetic castings. Or
LIQUID PENETRATION Procedure/QAD-W- QAD-F-
Surface Quality Penetrant Testing accessible interior VALVES Procedure/QAD-W- M H R where MT is not possible.
TESTING (PT) 07_Issue.02, PI-KNPC-05- 04_Issue.02
surface of raw castings REFER NOTE-2 07_Issue.02 Operator Qualification L-II
VALVES

ASME B16.34/Approved MT ASME B16.34 Appendix-

On exterior and PI-KNPC-05- QAD-F-
Magnetic Particle Procedure/QAD-W- II/Approved MT For all megnetic castings.
Surface & Sub-surface defects Magnetic Particle Testing accessible interior VALVES 04_Issue.02/ M R R
Testing (MT) 08_Issue.02, PI-KNPC-05- Procedure/QAD-W- Operator Qualification L-II
surface of raw castings REFER NOTE-2 MT Report
VALVES 08_Issue.02

PI-KNPC-05- Extent of RT may go up as per

Radiographic Testing / On critical area of body QAD-W-05 Rev.08/ASME ASME B16.34 Appnex-I RT Films &
Radiography (RT) Inside Defects / Volumatric defects VALVES M R R approved Project ITP
Review of RT films raw castings B16.34, PI-KNPC-05-VALVES /QAD-W-05_Rev.0 Reports
REFER NOTE-2 Operator Qualification L-II

Other elements may be as per

Alloy Verification Alloy Steel, SS, Duplex 100% & Refer QAD-F-
2.0 Alloy Verification (Ni, Cr and Mo.) PMI CHECK QAD-W-09_Rev.0 QAD-W-09_Rev.0 M H R project requirements. Equipment
Testing SS, Nickle note-3 05_Issue.02
limiations apply.

All dimensions as per MFG-F-

a) Dimensions Measurement 100% Mfg. Drg. Mfg. Drg. M H ----
component drawing 10_Issue.02

Inprocess Inspection:
Complete internal and QAD-W-31_Issue.01, QAD-W-31_Issue.01, MFG-F-
4.0 Machining Of b) Visual Inspection Visual 100% M H ----
external surfaces Component Drg. Component Drg. 10_Isse.02
Components
QAD-W-10_Issue.01, 3 mm
Per approved Project QAD-W-10_Issue.02 and QAD- Spark Testing-100%W, Shore
c) Rubber Lining Inspection Visual, Spark Testing, Hardness 100% minimum at flat surface or IR M H R
ITP/QAP W-31_Issue.02 Hardness Test-5%W
as per Project ITP

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 INSPECTION & TEST PLAN
ADVANCE VALVES
BUTTERFLY VALVES
Client: Plant Engineering General Trading & Contracting Co. W.L.L. Product :- All products & all models ITP NO. :ITP/AVG/18BDGN0006

Doc. Ref.:- QAD-P-01 TO 09,_Issue.02/Rev.00, API 609-2016, API 598-

PO NO: PEC-PO-1576/2019 Project : Rev. No. : 00 Date: 09/03/2019
2016, ASME B16.34-2017, PI-KNPC-05-VALVES
1 2 3 4 5 6 7 8 9 10
Execution by REMARK
COMPONENTS / QUANTUM OF FORMAT OF Sub-
SL. CHARACTERISTICS TYPE OF CHECK Scope REFERENCE DOCUMENTS ACCEPTANCE NORMS AV- KNPC
OPERATIONS CHECK RECORDS Supplier
QC/QA TPI
/ Prod.

FINAL INSPECTION STAGES

Per approved Project MFG-F- Equipment calibration to be

a) Dimensions Measurement 100% Mfg. Drg. & approved GAD M H ----
ITP/QAP 10_Issue.02 checked.
5.0 Inspection at Assembly
Per approved Project MFG-F-
b) Visual Inspection Visual 100% QAD-W-31_Rev.0 QAD-W-31_Rev.0 M H ----
ITP/QAP 10_Issue.02
All installation
a) Flange OD, Thickness, PCD, Bolt Hole dimensions and QAD-F-
Measurement 100% Appd. GAD Appd. GAD M H R
Final Visual & Dia, No. of Holes, Valve F/F, dimensions which may 58_Issue.02
6.0
Dimensional Inspection f
b) Surface Defects, Flow direction & All Valves before MSS SP 55 - 2011, Appd. QAD-F- Flow direction should be marked
Visual Check 100% MSS SP 55 - 2011, Appd. GAD M H R
mountings painting GAD 58_Issue.02 on valves

Per approved Project QAD-F-

a ) Shell Test Hydrostatic test 100% M H R
ITP/QAP 7_Issue.02 Calibrated Pressure Gauges with
QAD-W-02_Rev.0/Issue.02 / Approved Procedure/ API
appropriate range to be used.
Functional / Pressure API 598-2016 /Appd. Drg. 598-2016 /Appd. Drg./
7.0 Per approved Project QAD-F-
Testing b) Low Pressure Closure Test Pneumatic Test @ 06Kg/cm2 100% M H R
ITP/QAP 7_Issue.02

Open Close of Plates / Disc Per approved Project QAD-W-02_Rev.0 / API 598- QAD-F-
c) Performance 100% Smooth Operation M H R
with operator ITP/QAP 2016 / Appd. Drg. 7_Issue.02

QAD-F-
a) Surface roughness & profile Visual & Profile All Blasting Lots All Lots ---- ---- ----
Inspection at Shot 17_Issue.02
8.0 QAD-W-04_Rev.0, QAD-W-04_Rev.0,
Blasting & Coating
Per approved Project QAD-F-
b) Coating Thickness Visual Check, DFT, Color 100% ---- ---- ---- Refer Note -6
ITP/QAP 17_Issue.02

a) Name Plate, Tag Plate, Code Stamp Per approved Project QAD-W-17A_Rev.0, MSS SP 25 - QAD-W-17A_Rev.0, MSS SP QAD-F-
Correctness & Traceability 100% M H R
Plate ITP/QAP 2013, 25-2013 19_Issue.02
Inspection of Marking Visual Check, QC & TPI All valves before final QAD-P-06_Issue.02/Rev.0, QAD-P-06_Issue.02/Rev.0, QAD-F-
9.0 b) Valve Finishing & Product Release 100% M H ----
& Packing reviewed docs check packing QAD-W-31_Rev.0 QAD-W-31_Rev.0 19_Issue.02
STR-W-02_Rev.0 / 03_Rev.0 / STR-W-02_Rev.0 / 03_Rev.0
c) Packaging Visual 100% IR M H R
04_Rev.0 / 04_Rev.0

a) Inspection Reports, MTCS,Test Records Review 100% As per ITP As per approved ITP & GAD As per approved ITP & GAD ---- ---- M R

FINAL REVIEW OF PO, ITP,ASTM Spec, Approved PO, ITP,ASTM Spec,

b) Conformance of Certificates Review 100% As per ITP COC ---- M R
10.0 DOCUMENTS & ISSUE Drg. Approved Drg.
OF IRN
PO, ASTM Spec, PO, ITP,ASTM Spec, Approved PO, ITP,ASTM Spec,
c) Inspection Release Note Verification 100% IRN ---- ---- H
Approved Drg. Drg. Approved Drg.

LEGEND : NOTES:

Prod. - Advance Valves Production Department IR - Inspection Reports 1. All the MTCs of pressure containing parts shall be as per EN 10204 3.1 type, rest of the components as per 3.1/2.2 type.
2. NDE Extent shall be as per PI-KNPC-05-VALVES, according to PI-KNPC-05-VALVES RT not required to carbon steel for Class 150 & 300 &
AV - Advance Valves I.I.R. - Incoming Inspection Report MPT requied 5% for class 150 for carbon steel body & LP required SS body only.
3. 100% PMI performed by vendor prior to assemble and after assembly PMI perforemd on accessible area of SS/AS, Inconel
QC - Advance Valves Quality Control Department DFT - Dry Film Thickness Alloy items of valves only
QA - Advance Valves Quality Assurance Department OD - Outer Dia 4. TPI is not applicable, refrence of Inspection level PO for carbon steel as per annexure-1 PI-KNPC-05-VALVES-.

5. Manufacturer to provide all applicable MTC's and all applicable internal inspection documents to KNPC for review & approval.
KNPC TPI- Velosi PCD - Pitch Circle Diameter
6. Coating system as floowing for carbon steel as per advance valves Painting procedure-QAD-W-04.
MTC - Material Test Certificates, F/F - Face to Face Dimension of Valve a. Primer-Resist 86-Inorganic Zinc Silicate- 50μm DFT(Min)
b.Intermediate Coat-Solvalitt Aluminium - Silicone Acrylics - 25μm (min)
MOM - Minutes of Meeting W2- 10% witness
c. Solvalitt Aluminium - Silicone Acrylics -25μm (min)
MTC - Material Test Certificates M - Monitor Total DFT 100(Min)-Final Color- Aluminium (RAL 9006) & same color on mounted bracket & gear also.
W - Witness
7. Color Coating-No color coding on Carbon steel as per ANNEXURE –III, COLOUR CODING SPECIFICATION
R - Review of documents

Prepared By: Dev Brat Dwivedi Checked By : Sanjeev Kumar

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