Fired Heater Inspection and Test Plan
This content provides you with a sample Fired Heater Inspection and Test Plan. This is a draft fired heater ITP and must be modified based on your purchase order requirements.
| Fired Heater Inspection and Test Plan Task | Vendor | TPI Inspection | Client |
|---|---|---|---|
| Pre-inspection meeting, when specified by Purchaser | H | H | H |
| (Furnace Coils (Wrought carbon or alloy steel pipe) | - | - | - |
| Mill test reports | H | R | R |
| (Fittings) | - | - | - |
| Mill test reports | H | R | R |
| (Finning and/or Studding) | - | - | - |
| Mill test reports | H | R | R |
| Visual and dimensional inspection | H | W/R | R |
| (Shop Fabrication of Coils) | - | - | - |
| Materials identifications and markings | H | W/R | R |
| WPS/PQR, Welders qualifications (records or welder's list) | H | W/R | R |
| Weld preparation and fit-up | H | S | R |
| Execution of major repairs, when issued NCR | H | H | R |
| Visual and dimensional inspection prior to heat treatment, if applicable | H | W | R |
| Heat treatment record review | H | R | R |
| Non-destructive testing (RT, UT, MT and/or PT) (Review of all radiographs) | H | S | R |
| Hardness measurements in final condition | H | S | R |
| Visual and dimensional inspection for pre-fabricated coil (overall) prior to hydrostatic test | H | W | R |
| Hydrostatic test,when coil assembled as Harp(Not witness each coil before assembling) | H | H | R |
| Surface preparation prior to painting, coating, lining | H | W | R |
| Final visual inspection (including Painting (if applicable), coating, preservation, lining, picking, nameplate, tagging, marking, and Aux items like spare parts, bolts, etc.) | H | H | R |
| Documentation review prior to release at local shop(Final activity of Technical Inspection) | H | H | R |
| Pre-shipment Inspection | H | H | R |
| (Steel Structure, Casing Panels and Stack) | - | - | - |
| Mill test reports | H | R | R |
| Materials identifications and markings | H | W/R | R |
| WPS/PQR, Welders qualifications (records or welder's list) | H | R | R |
| Weld preparation and fit-up | H | S | R |
| Ultrasonic examination for strength welds | H | W | R |
| Visual and dimensional inspection | H | W | R |
| Temporary assembled inspection inclu. Pre-fabricated structure (overall) | H | S | R |
| Surface preparation prior to painting, coating, lining | H | S | R |
| Painting, coating, preservation, lining, pickling & passivating | H | S | R |
| (Refractory & Anchor) | - | - | - |
| Material testing record (Material supplier's) | H | R | R |
| Visual and dimensional inspection | H | W | R |
| Castable material tests (by installer) | H | W | R |
| Refractory & Anchoring Prosess | H | S | R |
| (Burners) | - | - | - |
| Mill test reports (major parts) | H | R | R |
| Firing test, when it is Proto-type | H | W | R |
| Firing test, when it is Conventional type | H | W | R |
| Visual and dimensional inspection | H | W | R |
| Painting, coating, preservation, lining, pickling & passivating | H | S | R |
| (Tube Supports (Cast & Plate)) | - | - | - |
| Mill test reports | H | R | R |
| Visual and dimensional inspection | H | W | R |
| Liquid penetrant examination on the critical surface (for Cast Supports) | H | S | R |
| (Spring Supports) | - | - | - |
| Mill test reports (major parts) | H | R | R |
| Visual and dimensional inspection | H | W | R |
| Calibration records | H | W | R |
| Painting, coating, preservation, lining, pickling & passivating | H | S | R |
| (Instruments) | - | - | - |
| Calibration report | H | R | R |
| Visual and dimensional inspection | H | W | R |
| (Soot Blowers) | - | - | - |
| Mill test reports (major parts) | H | R | R |
| Rotation and/or retractable test for lance | H | W | R |
| Visual and dimensional inspection | H | W | R |
| Painting, coating, preservation, lining, pickling & passivating,if applicable | H | S | R |
| (Local Panel) | - | - | - |
| Visual and dimensional inspection | H | W | R |
| Painting, coating, preservation, lining, pickling & passivating | H | S | R |
| Function test,if applicable | H | H | R |
| (Damper) | - | - | - |
| Mill test reports (major parts) | H | R | R |
| Visual and dimensional inspection | H | W | R |
| Painting, coating, preservation, lining, pickling & passivating | H | S | R |
| (IDF/FDF) | - | - | - |
| As per Fans & Blowers ITP's | - | - | - |
| (Air Preheater) | - | - | - |
| As per Pressure Vessel ITP | - | - | - |
| (General) | - | - | - |
| Final visual inspection (including Painting (if applicable), coating, preservation, lining, picking, nameplate, tagging, marking, and Aux items like spare parts, bolts, etc.) | H | S | R |
| Documentation review prior to release at local shop (Final activity of Technical Inspection) | H | H | R |
| Pre-shipment Inspection | H | H | R |
Fired Heater Inspection and Test Plan Points
H: Hold Point implies that relevant production activities shall not proceed until the continuation of work is permitted by Purchaser. (Notification req'd)
W: Witness point implies that Purchaser intends to witness the designated inspection feature. If Purchaser decides not to witness the relevant feature, production can proceed without permission of Purchaser. (Notification req'd)
S: Witness, but spot check basis. Initial operation will be witness point and subsequent operation will be witnessed at discretion of Purchaser considering the results of previous inspection. (Random Inspection : Notification not req'd)
R: Review fired heater inspection and test plan records (Notification not req'd)
General Note for Fired Heater Inspection and Test Plan:
1) Fired Heater witness/hold point by Code Inspector, when applied by Code Stamp/Local Regulation, is to comply with its requirements and to specify in Vendor's ITP.
2) Type of Inspection by Fired Heater Purchaser may be changed according to equipment criticality and vendor QC evaluation at job stage.
3) When requested in the requisition, detailed Fired Heater ITP shall be submitted by Vendor.
4) Monitoring/Observation of Fired Heater Vendor shop daily routine works (i.e. Storage of materials & welding consumables, Adherence to approved procedures, Testing tool calibration check, Welder/NDE Operator performance & qualification, workmanship, cleanliness and etc.) shall be done by Purchaser during inspection visit.
5) Final Fired Heater Visual Inspection/Documentation Review/Pre-Shipment Inspection may be combined within one time visit.
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