CONTRACTOR TITLE BLOCK FORMAT

Duqm Refinery Project EPC Package One

Duqm Refinery Project EPC Package One

PROJECT NO: 10121 UNIT: 120-HCU

PURCHASE ORDER NUMBER (RFP): 1012004010 EQUIPMENT: 120E-004AB

REVIEW RESPONSE BY PURCHASER:

Purchaser review and comments do not indicate either responsibility or liability for accuracy and completeness of this document or alter any
contractual terms and conditions:

DATE: 20-dec-2019

VENDOR IDENTIFICATION: TEMA INDIA LTD.

DOCUMENT TITLE: QUALITY ASSURANCE PLAN FOR 1STSTAGE REACTOR FEED / EFFLUENT EXCHANGER

VENDOR DOCUMENT No.: ITP / 17-263 / 001 REV: 7 CODE: PLN-0001

CONTRACTOR DOCUMENT No.: REV: 7 DOCUMENT CLASS: 1

DRP001-PUC-TEM-Q93-120E-004A-0001

DRP001-PUC-PRO-U-000-014-Tmp01
 Page 2 of 15

QUALITY ASSURANCE PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Document No. ITP / 17-263 / 001. Rev. 7

CLIENT : TRD / DUQM EQUIPMENT NO. : 120E - 004 A/B.

PROJECT : DUQM REFINERY & PETROCHEMICAL IND. COM. , OMAN TYPE : D-MODIFIED / E / U (HORIZONTAL)
P.O. NO./ DATE : LOA 1012004010, DTD.: 26.10. 2018 INSPECTION BY (TPI) : TPI / AI

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL Contractor Company
TIL AI AI SIGN Contractor Company Remark
SIGN Sign Sign
1 Quality Assurance Plan Stages of inspection & testing ASME Sec. VIII Div. 2. ASME Sec. VIII Div. 2. Signed and Approved QAP
CLASS2 CLASS2
Specification : DRP001-PUC- Specification : DRP001-PUC-
PRO-N-000-004. Rev. A1 PRO-N-000-004.Rev. A1
IAP No.: 10121-EA000-01/02. IAP No.: 10121-EA000-01/02. H* H A A
Approved Drawing, Approved Drawing,

2 PE certified UDS, PE Design Calculation & Drawings PO/ MR, ASME Sec. VIII Div. 2, 1.Approved Drawing &
certified MDER & Drawing Data Sheet, & TEMA-R, Calculation record
Design code PO/ MR 2.MDER Annex-2B H* R A R

3 Pre inspection meeting PO / Specification : DRP001- PO / Specification : DRP001- PIM MOM

PUC-PRO-N-000-004. Rev.A1 PUC-PRO-N-000-004.
/ PIM Agenda Rev. A1 / PIM Agenda H* -- H H

4 Approval of documents
4.1 NDE procedures RT , UT , PT , MT. ASME Sec. VIII Div. 2, ASME Sec. VIII Div. 2, Approved procedure
CLASS2 , ASME Sec. V, CLASS2 , ASME Sec. V,
Specification : DRP001-PUC- Specification : DRP001-PUC-
SPE-W-000-006. SPE-W-000-006. H* R A R
Project Specification : DRP001- Project Specification : DRP001-
PUC-SPE-V-000-001. PUC-SPE-V-000-001.

4.2 Inspection & testing Hydro testing / Pneumatic test / Surface ASME Sec. VIII Div. 2, ASME Sec. VIII Div. 2, Approved procedure
Procedures preparation & painting / PMI / Pickling CLASS2 , ASME Sec. V, CLASS2 , ASME Sec. V,
and pssivation / Hardness test / Base line Specification : DRP001-PUC- Specification : DRP001-PUC-
thickness measurement / PWHT / Local SPE-W-000-006. SPE-W-000-006. H* R A A
PWHT / Impact testing of Production Project Specification : DRP001- Project Specification : DRP001-
Test coupon etc. PUC-SPE-V-000-001. PUC-SPE-V-000-001.

4.3 Welding & Testing Plan Welding & Testing Plan ASME Sec. VIII Div. 2, ASME Sec. VIII Div. 2, Approved Welding &
CLASS2 , ASME Sec. IX, CLASS2 , ASME Sec. IX, Testing Plan
Specification : DRP001-PUC- Specification : DRP001-PUC-
SPE-W-000-006. SPE-W-000-006. H* R A R
Project Specification : DRP001- Project Specification : DRP001-
PUC-SPE-V-000-001. PUC-SPE-V-000-001.

4.4 WPS / PQR WPS / PQR Qualification. ASME Sec. VIII Div. 2, ASME Sec. VIII Div. 2, Approved WPS/PQR
CLASS2 , ASME Sec. IX, CLASS2 , ASME Sec. IX,
Specification : DRP001-PUC- Specification : DRP001-PUC- ** Witness
SPE-W-000-006. SPE-W-000-006. For new
H* R W** / R A
WPS/PQR
Project Specification : DRP001- Project Specification : DRP001-
PUC-SPE-V-000-001 , API PUC-SPE-V-000-001 , API
RP934A RP934A
4.5 Welders/ Welding Operators WPQ Qualification. ASME Sec. IX, ASME Sec. IX Welder List
H* R R R
 Page 3 of 15

QUALITY ASSURANCE PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Document No. ITP / 17-263 / 001. Rev. 7

CLIENT : TRD / DUQM EQUIPMENT NO. : 120E - 004 A/B.

PROJECT : DUQM REFINERY & PETROCHEMICAL IND. COM. , OMAN TYPE : D-MODIFIED / E / U (HORIZONTAL)
P.O. NO./ DATE : LOA 1012004010, DTD.: 26.10. 2018 INSPECTION BY (TPI) : TPI / AI

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL Contractor Company
TIL AI AI SIGN Contractor Company Remark
SIGN Sign Sign

5 MATERIAL CONTROL

5.1 Material Control at receipt stage

5.1.1 Plates Review of MTC / MTR TDC , ASME Sec. VIII Div. 2, TDC , ASME Sec. VIII Div. 2, Mill test Reports
CLASS2 , ASME Sec.II A CLASS2 , ASME Sec.II A Refer Note 1 R -- -- -- -- -- --

Certificate of compliance as per code & II B. & II B.

Project Specification : DRP001- Project Specification : DRP001- R -- -- -- -- -- --
PUC-SPE-V-000-001. PUC-SPE-V-000-001.
Verification of compliance of
requirements as per TDC / Project R -- -- -- -- -- --
specifications.
PMI check Form QC/01 A
( For LAS / SS / NF as applicable ) H* -- -- W -- --

Visual & Dimension inspection and

marking inspection, correlation with H* -- -- -- -- -- --
MTC / MTR
5.1.2 Forgings Review of MTC / MTR TDC , ASME Sec. VIII Div. 2, TDC , ASME Sec. VIII Div. 2, Mill test Reports
CLASS2 , ASME Sec.II A CLASS2 , ASME Sec.II A Refer Note 1 R -- -- -- -- -- --
& II B. & II B.
Certificate of compliance as per code Project Specification : DRP001- Project Specification : DRP001-
PUC-SPE-V-000-001. PUC-SPE-V-000-001.
R -- -- -- -- -- --

Verification of compliance of
requirements as per TDC / Project R -- -- -- -- -- --
specifications.
PMI check Form QC/01 D
( For LAS / SS / NF as applicable ) H* -- -- W -- --

Visual & Dimension inspection and

marking inspection, correlation with H* -- -- -- -- -- --
MTC / MTR
5.1.3 U ' Tubes Review of MTC / MTR TDC , ASME Sec. VIII Div. 2, TDC , ASME Sec. VIII Div. 2, Mill test Reports
R -- -- -- -- -- --
SA213 TP321 (SEAMLESS) CLASS2 , ASME Sec.II B. CLASS2 , ASME Sec.II B. Refer Note 1
Certificate of compliance as per code Project Specification : DRP001- Project Specification : DRP001-
R -- -- -- -- -- --
PUC-SPE-V-000-001. PUC-SPE-V-000-001.
Verification of compliance of DRP001-PUC-SPE-W-000-007. DRP001-PUC-SPE-W-000-
requirements as per TDC / Project 007.
R -- -- -- -- -- --
specifications.

PMI Check at receipt stage 10% per heat / Form QC/01

lot
H* -- -- W -- --

Visual, dimensional and marking

inspection, correlation with MTC / MTR H* -- -- -- -- -- --
5% per box
 Page 4 of 15

QUALITY ASSURANCE PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Document No. ITP / 17-263 / 001. Rev. 7

CLIENT : TRD / DUQM EQUIPMENT NO. : 120E - 004 A/B.

PROJECT : DUQM REFINERY & PETROCHEMICAL IND. COM. , OMAN TYPE : D-MODIFIED / E / U (HORIZONTAL)
P.O. NO./ DATE : LOA 1012004010, DTD.: 26.10. 2018 INSPECTION BY (TPI) : TPI / AI

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL Contractor Company
TIL AI AI SIGN Contractor Company Remark
SIGN Sign Sign
5.1.4 Fasteners Review of MTC / MTR TDC , ASME Sec. VIII Div. 2, TDC , ASME Sec. VIII Div. 2, Mill test Reports
R -- -- -- -- -- --
CLASS2 , ASME Sec.II A. CLASS2 , ASME Sec.II A. Refer Note 1
Certificate of compliance as per code Project Specification : DRP001- Project Specification : DRP001-
PUC-SPE-V-000-001. PUC-SPE-V-000-001. R -- -- -- -- -- --

Specific requirement as per material

purchase specification (TDC) R -- -- -- -- -- --

PMI Check Form QC/01 E

H* -- -- W -- --

Visual, dimensional and marking

inspection, correlation with MTC / MTR H* -- -- -- -- -- --
minimum 5%
5.1..5 Gaskets Review of MTC / MTR TDC , ASME Sec. VIII Div. 2, TDC , ASME Sec. VIII Div. 2, Mill test Reports P -- -- -- -- -- --
CLASS2 , CLASS2 , Refer Note 1
Certificate of compliance as per code
Project Specification : DRP001- Project Specification : DRP001- P -- -- -- -- -- --
PUC-SPE-V-000-001.fications / PUC -SPE-V-000-001.fications
Specific requirement as per material Codes & Standards. / Codes & Standards.
purchase specification (TDC) R -- -- -- -- -- --

Visual, dimensional and marking Form QC/01 F

H* -- -- -- -- -- --
inspection, correlation with MTC/ MTR
5.1.6 Welding Consumables Review of test certificates ASME Sec. II C ASME Sec. II C Test Certificates
Refer Note 1 R -- -- -- -- -- --

PMI (Alloy Verification) PMI Procedure PMI Procedure Form QC / 13.

H* -- -- R R

5.2 MATERIAL IDENTIFICATION

5.2.1 Material Identification of Review of MTC / MTR / Check test ASME Sec. II A, ASME Sec. ASME Sec. II A, ASME Sec. Material identification
Pressure parts & Non- report VIII Div. 2, Approved VIII Div. 2, Approved Report H* R R M
Pressure parts welded to Drawing Drawing
pressure parts. Dimensions
( Plates , Forgings , Tubes H* R W M
etc. )
Visual & Verification of Identification
marking. H
(For
plates)
H* W M
R
(For
others)

Gasket face finish of flanges ( as per

drawing) H* R R R

Certificate of compliance as per code

H* R R R

5.2.2 Material Identification of Review of MTC / MTR / Check test ASME Sec. II A, ASME Sec. ASME Sec. II A, ASME Sec. Job Card / Material
Non-Pressure parts. report VIII Div. 2, Approved VIII Div. 2, Approved identification Report H* R R R
( Baffles , Tie rods , Spacers , Drawing Drawing
Visual & Dimensions.
Structure etc. ) H* R R R
Verification of Identification marking.
H* R R R
 Page 5 of 15

QUALITY ASSURANCE PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Document No. ITP / 17-263 / 001. Rev. 7

CLIENT : TRD / DUQM EQUIPMENT NO. : 120E - 004 A/B.

PROJECT : DUQM REFINERY & PETROCHEMICAL IND. COM. , OMAN TYPE : D-MODIFIED / E / U (HORIZONTAL)
P.O. NO./ DATE : LOA 1012004010, DTD.: 26.10. 2018 INSPECTION BY (TPI) : TPI / AI

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL Contractor Company
TIL AI AI SIGN Contractor Company Remark
SIGN Sign Sign

6 MANUFACTURING OF MAIN SHELL ASSEMBLY

6.1 HEMI HEAD FORMING
6.1.1 Forming Verification of Dimensions / Shape / ASME Sec. VIII Div. 2, ASME Sec. VIII Div. 2, Report
( Before Weld overlay ) Minimum Thickness. NACT Approved Drawing, & Approved Drawing, &
PT of inside & outside surface before Applicable PFHT Procedure Applicable Procedure & Project
PFHT ( PFHT/17-263/001) & Project Specification. H* -- -- R R
Specification.
DRP001-PUC-SPE-V-000-001.
Review of Heat treatment Chart. HT Chart
H* R R R

6.1.2 NDT PT of inside & outside surface of Hemi NDE Report

head after PFHT
H* R W R

6.1.3 Visual Inspection Visual check of surfaces. Report

H* R W R

6.1.4 Shape / Dimension Verification of Dimensions / Shape / Report

Minimum Thickness.
H* W W W

6.1.5 Simulation Testing Deleted

6.2 WELD OVERLAY INSIDE OF MAIN SHELL , HEMI HEAD

6.2.1 Weld Overlay Inside of Hemi Check WPS / Welder Qualification Approved WPS / PQR , Approved WPS / PQR , Report / NDE Report /
head. ( Barrier layer ) WTP , Drawing , NDE WTP , Drawing , NDE IPC / DHT Record H* --- R R
procedure procedure
6.2.2 DHT after barrier layer
--- R R

6.2.3 NDE As per WTP after barrier layer M

--- M

6.2.4 Weld Overlay Check WPS / Welder Qualification

H* --- R R
( Final layer )
6.2.5 Weld Visual
H* W W R
6.2.6 Thickness of weld overlay.
H* --- W R

6.2.7 NDE As per WTP after Final layer H* R M M

6.2.8 PMI PMI Procedure. PMI Procedure. Form QC / 13.

H* --- W W During final inspection
 Page 6 of 15

QUALITY ASSURANCE PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Document No. ITP / 17-263 / 001. Rev. 7

CLIENT : TRD / DUQM EQUIPMENT NO. : 120E - 004 A/B.

PROJECT : DUQM REFINERY & PETROCHEMICAL IND. COM. , OMAN TYPE : D-MODIFIED / E / U (HORIZONTAL)
P.O. NO./ DATE : LOA 1012004010, DTD.: 26.10. 2018 INSPECTION BY (TPI) : TPI / AI

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL Contractor Company
TIL AI AI SIGN Contractor Company Remark
SIGN Sign Sign

6.3 CIRCULAR SEAM JOINT OF MAIN SHELL TO MAIN SHELL & HEMI HEAD.

6.3.1 Set Up Verification of Identification marking, Approved WPS / PQR , Approved WPS / PQR , Form QC/21,
weld geometry, offset. Production Test Approved Drawing. Approved Drawing. Inspection progress chart
Coupon H* R M M
( As Applicable )

6.3.2 NDE As per WTP WTP / Applicable Procedure WTP / Applicable Procedure NDE reports
H* R M M

6.3.3 Tack Welding Check WPS / Welder Qualification , Approved WPS / PQR , Approved WPS / PQR , Report
Welding Parameters. Approved Drawing. Approved Drawing. H* -- -- M M

6.3.4 Visual Inspection Visual Inspection of Tack weld / Fit up Approved WPS / PQR , Approved WPS / PQR , Report
Approved Drawing , WTP & Approved Drawing , WTP & H* -- -- M M
Approved applicable Approved applicable
6.3.5 In Process Welding NDE as per WTP Procedures Procedures Report
H* -- -- M M

6.3.6 Complete Welds ISR ISR Chart

H* -- -- R M

Weld visual ASME Sec. VIII Div. 2 , ASME Sec. VIII Div. 2 , Report / Inspection progress
CLASS 2 CLASS 2 chart H* W W W During final inspection
Approved Drawing , WTP & Approved Drawing , WTP &
6.3.7 NDE As per WTP NDE Procedures NDE Procedures
H* R M R

6.3.8 Clad Restoration Check WPS / Welder Qualification Approved WPS and WPQ Approved WPS and WPQ Report
H* -- -- R R

6.3.9 DHT after barrier layer DHT Record

H* -- -- R R
6.3.10 Weld visual Approved Drawing Approved Drawing Report
H* W -- M M During final inspection

6.3.11 Dimension Approved Drawing Approved Drawing Report

( Thickness of Weld overlay ) H* R -- M M

6.3.12 NDE as per WTP WTP / Applicable Procedure WTP / Applicable Procedure NDE Report
H* -- -- M M
6.3.13 PMI PMI Procedure. PMI Procedure. Form QC / 13.
H* --- W W
During final inspection
6.3.14 Ferrite Check ( FN 5 - 10 ) TEMA'S General Procedure No. TEMA'S General Procedure Form QC / 13. Before PWHT
TIL-INS-PROC-08. No. TIL-INS-PROC-08. H* -- -- W W
 Page 7 of 15

QUALITY ASSURANCE PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Document No. ITP / 17-263 / 001. Rev. 7

CLIENT : TRD / DUQM EQUIPMENT NO. : 120E - 004 A/B.

PROJECT : DUQM REFINERY & PETROCHEMICAL IND. COM. , OMAN TYPE : D-MODIFIED / E / U (HORIZONTAL)
P.O. NO./ DATE : LOA 1012004010, DTD.: 26.10. 2018 INSPECTION BY (TPI) : TPI / AI

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL Contractor Company
TIL AI AI SIGN Contractor Company Remark
SIGN Sign Sign

6.4 NOZZLE TO MAIN SHELL JOINT.

6.4.1 Set Up Verification of Identification marking, Approved WPS / PQR , Approved WPS / PQR , Form QC/21,
weld geometry, offset, Orientation , Approved Drawing. Approved Drawing. Inspection progress chart H* R M M
Projection.

6.4.2 NDE As per WEP WTP / Applicable Procedure WTP / Applicable Procedure NDE reports
H* R M M

6.4.3 Tack Welding Check WPS / Welder Qualification , Approved WPS / PQR , Approved WPS / PQR , Report
Welding Parameters. Approved Drawing. Approved Drawing. H* -- -- M M

6.4.4 Visual Inspection Visual Inspection of Tack weld / Fit up Approved WPS / PQR , Approved WPS / PQR , Report
Approved Drawing , WTP & Approved Drawing , WTP & H* -- -- M M
Approved applicable Approved applicable
6.4.5 In Process Welding NDE as per WTP after Back Chipping Procedures Procedures Report
H* -- -- R R

6.4.6 Complete Welds ISR WTP , WPS / PQR WTP , WPS / PQR ISR Chart
H* -- -- R R

Weld visual ASME Sec. VIII Div. 2 , ASME Sec. VIII Div. 2 , Report / Inspection progress
CLASS 2 CLASS 2 chart H* W W W During final inspection

6.4.7 NDE As per WTP Approved Drawing , WTP & Approved Drawing , WTP & # PAUT is applicable when ISR
PAUT # NDE Procedures NDE Procedures is carried out Locally (By heat
H* R M R resistance coil)

6.4.8 Clad Restoration Check WPS / Welder Qualification Approved WPS and WPQ Approved WPS and WPQ Report H* -- -- R R
6.4.9 DHT after barrier layer DHT Record H* -- -- R R
6.4.10 Weld visual Approved Drawing Approved Drawing Report
H* W -- W W During final inspection
6.4.11 Dimension Approved Drawing Approved Drawing Report
( Thickness of Weld overlay ) H* R -- M M

6.4.12 NDE as per WTP WTP / Applicable Procedure WTP / Applicable Procedure NDE Report
H* -- -- M M

6.4.13 PMI PMI Procedure. PMI Procedure. Form QC / 13. H* --- W W

During final inspection
6.4.14 Ferrite Check ( FN 5 - 10 ) TEMA'S General Procedure No. TEMA'S General Procedure Form QC / 13. Before PWHT
TIL-INS-PROC-08. No. TIL-INS-PROC-08. H* -- -- W W

6.5 MAIN SHELL TO SADDLE SUPPORT AND OTHER ATTACHMENT.

Verification of Identification marking ASME Sec. VIII Div. 2, CLASS ASME Sec. VIII Div. 2, CLASS Inspection progress chart
H* R R R
2 2 NDE Reports / DHT Record
6.5.1 Identification Visual, dimensions, weld edge TEMA-R, TEMA-R,
preparation Approved Drawing, Approved Drawing, H* R M R
WTP, & WTP, &
6.5.2 Welding Check WPS / Welder Qualification ,
NDE Procedures NDE Procedures H* R M R
Welding Parameters.
DHT after welding H* -- R R
6.5.3 Visual Inspection Weld visual and size of fillet
H* R W M During final inspection

6.5.4 NDE NDE as per WTP

H* R M M
 Page 8 of 15

QUALITY ASSURANCE PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Document No. ITP / 17-263 / 001. Rev. 7

CLIENT : TRD / DUQM EQUIPMENT NO. : 120E - 004 A/B.

PROJECT : DUQM REFINERY & PETROCHEMICAL IND. COM. , OMAN TYPE : D-MODIFIED / E / U (HORIZONTAL)
P.O. NO./ DATE : LOA 1012004010, DTD.: 26.10. 2018 INSPECTION BY (TPI) : TPI / AI

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL Contractor Company
TIL AI AI SIGN Contractor Company Remark
SIGN Sign Sign

7 PWHT OF MAIN SHELL ASSEMBLY ( Furnace )

7.1 Close out of Non Conformity Verification of Close out of any Non NCR NCR Form QC / 32 ,
Conformity H* H H -- --

7.2 Visual Inspection before Visual Check for Surface Defects ASME Sec. VIII Div. 2 , ASME Sec. VIII Div. 2 , Report
PWHT CLASS 2 CLASS 2
TEMA - R , Approved TEMA - R , Approved H* H H H
Drawing. Drawing.
7.3 Dimensional Inspection Dimensional Verification Approved Drawing Approved Drawing Report
H* W H H

7.4 NDE As per WTP NDE Procedure NDE Procedure NDE Report
H* R M M --

7.5 Gauge Passing before PWHT Gauge Passing Insertion into Shell Insertion into Shell Report
H* -- -- R -- --

7.6 PMI Alloy Verification PMI Procedure. PMI Procedure. Form QC / 13.
H* --- W W

7.7 Ferrite check Ferrite Check ( FN 5 - 10 ) TEMA'S General Procedure No. TEMA'S General Procedure Form QC / 13.
TIL-INS-PROC-08. No. TIL-INS-PROC-08. H* -- -- W W

7.7a Chemical Analysis Verification of alloying elements Procedure for chemical analysis Procedure for chemical analysis Test records
DRP001-PUC-TEM-P40-120E- DRP001-PUC-TEM-P40-120E-
004A-0011 004A-0011 H* R R

7.8 Initial Thickness As Built Thickness Verification Thickness monitoring location Thickness monitoring location Report
Measurement (TML) procedure (TML) procedure H* -- -- W W

7.9 Production Test coupon Verification of test results. Impact testing of production Impact testing of production Production test coupon *Testing witness
test coupon procedure DRP001- test coupon procedure DRP001- result
PUC-TEM-P40-120E-004A- PUC-TEM-P40-120E-004A- H* R W* W* --
0007 ( IT / 17-263 / 001 ) 0007 ( IT / 17-263 / 001 )

7.10 Heat Treatment of Complete Thermocouples Location Drawing and approved Heat Drawing and approved Heat Charge Card
Assembly Treatment Procedure Treatment Procedure H* -- W R

Calibration of Thermocouples/ Recorder, HT Chart

Chart Review, Loading etc. H* R R -- --

7.11 Visual Inspection after Visual Check for Surface Defects ASME Sec. VIII Div. 2 , ASME Sec. VIII Div. 2 , Report
PWHT CLASS 2 CLASS 2
TEMA - R , Approved TEMA - R , Approved H* W W W DELETED
Drawing. Drawing.
7.12 NDE After PWHT A s per WTP WTP , NDE Procedures WTP , NDE Procedures NDE Report
H* R M R
7.13 Hardness Hardness of Weld & HAZ. Drawing , Procedures for Drawing , Procedures for Form QC / 14.
hardness check. hardness check. H* -- W W
 Page 9 of 15

QUALITY ASSURANCE PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Document No. ITP / 17-263 / 001. Rev. 7

CLIENT : TRD / DUQM EQUIPMENT NO. : 120E - 004 A/B.

PROJECT : DUQM REFINERY & PETROCHEMICAL IND. COM. , OMAN TYPE : D-MODIFIED / E / U (HORIZONTAL)
P.O. NO./ DATE : LOA 1012004010, DTD.: 26.10. 2018 INSPECTION BY (TPI) : TPI / AI

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL Contractor Company
TIL AI AI SIGN Contractor Company Remark
SIGN Sign Sign

8 CHANNEL FABRICATION
8.1 WELD OVERLAY ON INSIDE OF CHANNEL BARREL & NOZZLES
8.1.1 Weld Overlay Check WPS / Welder Qualification Approved WPS / PQR , Approved WPS / PQR , Report / NDE Report /
H* --- R R
( Barrier layer ) WTP , Drawing , NDE WTP , Drawing , NDE IPC / DHT Record
8.1.2 DHT after barrier layer procedure procedure
H* --- M R
8.1.3 NDE As per WTP after barrier layer
H* --- M R
8.1.4 Weld Overlay Check WPS / Welder Qualification
H* --- R R
( Final layer )
8.1.5 Weld Visual
H* W W W During final inspection

8.1.6 Thickness of weld overlay.

H* --- W M
8.1.7 NDE As per WTP after Final layer
H* R M R
8.1.8 PMI PMI Procedure. PMI Procedure. Form QC / 13.
H* --- W W During final inspection

8.2 NOZZLE TO CHANNEL BARREL JOINT

8.2.1 Set Up Verification of Identification marking, Approved WPS / PQR , Approved WPS / PQR , Form QC/21,
weld geometry, offset, Orientation , Approved Drawing. Approved Drawing. Inspection progress chart H* R M M
Projection.
8.2.2 NDE As per WEP WTP / Applicable Procedure WTP / Applicable Procedure NDE reports
H* R M M

8.2.3 Tack Welding Check WPS / Welder Qualification , Approved WPS / PQR , Approved WPS / PQR , Report
Welding Parameters. Approved Drawing. Approved Drawing. H* -- -- M R

8.2.4 Visual Inspection Visual Inspection of Tack weld / Fit up Approved WPS / PQR , Approved WPS / PQR , Report
Approved Drawing , WTP & Approved Drawing , WTP & H* -- -- M M
Approved applicable Approved applicable
8.2.5 In Process Welding NDE as per WTP after Back Chipping Procedures Procedures Report
H* -- -- M M

8.2.6 Complete Welds ISR WTP , WPS / PQR WTP , WPS / PQR ISR Chart
H* -- -- R R
Weld visual ASME Sec. VIII Div. 2 , ASME Sec. VIII Div. 2 , Report / Inspection progress
CLASS 2 CLASS 2 chart H* W W M During final inspection

8.2.7 NDE As per WTP Approved Drawing , WTP & Approved Drawing , WTP &
Phased array ultrasonic testing NDE Procedures NDE Procedures
(PAUT) H* R M R

8.2.8 Clad Restoration Check WPS / Welder Qualification Approved WPS and WPQ Approved WPS and WPQ Report
H* -- -- R R
8.2.9 DHT after barrier layer DHT Record H* -- -- R R
8.2.10 Weld visual Approved Drawing Approved Drawing Report
H* W -- W W During final inspection

8.2.11 Dimension Approved Drawing Approved Drawing Report

( Thickness of Weld overlay ) H* R -- M M

8.2.12 NDE as per WTP WTP / Applicable Procedure WTP / Applicable Procedure NDE Report
H* -- -- M M
 Page 10 of 15

QUALITY ASSURANCE PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Document No. ITP / 17-263 / 001. Rev. 7

CLIENT : TRD / DUQM EQUIPMENT NO. : 120E - 004 A/B.

PROJECT : DUQM REFINERY & PETROCHEMICAL IND. COM. , OMAN TYPE : D-MODIFIED / E / U (HORIZONTAL)
P.O. NO./ DATE : LOA 1012004010, DTD.: 26.10. 2018 INSPECTION BY (TPI) : TPI / AI

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL Contractor Company
TIL AI AI SIGN Contractor Company Remark
SIGN Sign Sign

8.3 CHANNEL BARREL TO SADDLE SUPPORT AND OTHER ATTACHMENT

Verification of Identification marking ASME Sec. VIII Div. 2, CLASS ASME Sec. VIII Div. 2, CLASS Inspection progress chart H* R R -- --
2 2 NDE Reports / DHT Record
8.3.1 Identification
Visual, dimensions, weld edge TEMA-R, TEMA-R, H* R R -- --
preparation Approved Drawing, Approved Drawing,
8.3.2 Welding Check WPS / Welder Qualification WTP, & WTP, & H* R R -- --
NDE Procedures NDE Procedures
DHT after welding H* -- R -- --
8.3.3 Visual Inspection Weld visual and size of fillet H* R W -- -- During final inspection

8.3.4 NDE NDE as per WTP H* R M -- --

9 PWHT OF CHANNEL ASSEMBLY
9.1 Close out of Non Conformity Verification of Close out of any Non NCR NCR Form QC / 32 ,
H* H H -- --
Conformity
9.2 Visual Inspection before Visual Check for Surface Defects ASME Sec. VIII Div. 2 , ASME Sec. VIII Div. 2 , Report
PWHT CLASS 2 , TEMA - R , CLASS 2 , TEMA - R , H* H W W
Approved Drawing. Approved Drawing.
9.3 Dimensional Inspection Dimensional Verification Approved Drawing Approved Drawing Report H* W W -- --
9.4 PMI Alloy Verification PMI Procedure PMI Procedure Form QC / 13. H* -- -- W W
9.5 Ferrite check. Ferrite Check ( FN 5 - 10 ) TEMA'S General Procedure No. TEMA'S General Procedure Form QC / 13.
(As weld / Machined condition TIL-INS-PROC-08. No. TIL-INS-PROC-08. H* -- -- W W
prior to PWHT)
9.5a Chemical Analysis Verification of alloying elements Procedure for chemical analysis Procedure for chemical analysis Test records
DRP001-PUC-TEM-P40-120E- DRP001-PUC-TEM-P40-120E-
004A-0011 004A-0011 H* -- -- R R

9.6 NDE As per WTP NDE Procedure NDE Procedure NDE Report H* R M -- --
9.7 Initial Thickness As Built Thickness Verification Thickness monitoring location Thickness monitoring location Report
H* -- -- W -- --
Measurement (TML) procedure (TML) procedure
9.8 Heat Treatment Calibration of Thermocouples/ Recorder, Drawing and approved Heat Drawing and approved Heat HT Chart
H* R R -- -- DELETED
Chart Review, Loading etc. Treatment Procedure Treatment Procedure
9.8a Production Test coupon Verification of test results. Impact testing of production Impact testing of production Production test coupon *Testing witness
test coupon procedure DRP001- test coupon procedure DRP001- result
PUC-TEM-P40-120E-004A- PUC-TEM-P40-120E-004A- H* R W* W*
0007 ( IT / 17-263 / 001 ) 0007 ( IT / 17-263 / 001 )

9.9 Visual Inspection Visual Check for Surface Defects ASME Sec. VIII Div. 2 , ASME Sec. VIII Div. 2 , Report
CLASS 2 , TEMA - R , CLASS 2 , TEMA - R , H* W W -- --
Approved Drawing. Approved Drawing.
9.10 NDE After PWHT A s per WTP WTP , NDE Procedures WTP , NDE Procedures NDE Report H* R M -- --
9.11 Hardness Hardness of Weld & HAZ. Drawing , Procedures for Drawing , Procedures for Form QC / 14.
H* -- W W
hardness check. hardness check.
9.12 Inspection of Channel barrel Verification of Identification marking TEMA-R, TEMA-R, Report / Job Card,
H* R R -- --
after machining Approved Drawing, & Approved Drawing, & NDE reports
Visual, dimensions NDE Procedures NDE Procedures H* R M -- --
Weld Edge preparation - As Applicable
H* R M -- --
Finish of gasket face (As per drawing) -
H* R R -- --
As Applicable
PT of threads after machining H* R W -- --
 Page 11 of 15

QUALITY ASSURANCE PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Document No. ITP / 17-263 / 001. Rev. 7

CLIENT : TRD / DUQM EQUIPMENT NO. : 120E - 004 A/B.

PROJECT : DUQM REFINERY & PETROCHEMICAL IND. COM. , OMAN TYPE : D-MODIFIED / E / U (HORIZONTAL)
P.O. NO./ DATE : LOA 1012004010, DTD.: 26.10. 2018 INSPECTION BY (TPI) : TPI / AI

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL Contractor Company
TIL AI AI SIGN Contractor Company Remark
SIGN Sign Sign

10 MANUFACTURING OF TUBE BUNDLE

10.1 Tube sheet final inspection Visual and dimensions TEMA-R, TEMA-R, Form QC/08
after drilling and machining Tube hole finish, Go-No Go check, weld Approved Drawing Approved Drawing
groove, hole layout, Ligament, tie rod H* W W -- --
holes, Impingement rod holes
Finish of gasket face
(As per drawing) H* R R -- --

10.2 Inspection of baffles, Support Visual and dimensions. TEMA-R, TEMA-R, Form QC/11
plates after drilling and (Tube hole finish, hole layout & size, Approved Drawing Approved Drawing
chamfer, notch, tie rod holes, cut H* R R -- --
machining
orientation)
10.3 Skeleton for tube bundle Visual & dimensions TEMA-R, TEMA-R, Form QC/10 &
H* R W -- --
Approved Drawing Approved Drawing Job card
Cleaning of tube holes, tube loading &
tube projection H* R R -- --

Baffle orientation arrangement

H* R R -- --
10.4 Tube to Tube sheet joint Tube tube sheet MOCK UP TEMA-R, ASME SEC-IX TEMA-R, ASME SEC-IX Report / Job Card,
Approved Drawing, NDE Approved Drawing, NDE NDE reports H* R H M

Weld visual and NDE (PT) after root run Procedure Procedure
welding as per WTP H* R M M

Weld visual and NDE (PT) after final run

welding as per WTP H* W W M

Pneumatic test of tube to tube sheet joint Pneumatic Test Procedure Pneumatic Test Procedure Report
before expansion at DRP001-PUC-TEM-P80-120E- DRP001-PUC-TEM-P80-120E- H* R W M
1.25 Kg/cm² g 004A-0004 004A-0004

7 Helium leak test of Tube to tube sheet Helium leak test procedure Helium leak test procedure Report
joint (Before expansion) H* -- W W

Expansion of Tubes TTJ Mock-up TTJ Mock-up Report

Expansion Ratio ( 3 to 6 % ) H* R M -- --

NDE (PT) after Expansion NDE Procedure NDE Procedure NDE Report
H* R M -- --

10.2 Tube Bundle final inspection Completeness of Bundle & visual TEMA -R, TEMA -R, Form QC/19 , Form QC/13
inspection Approved Drawing, & Approved Drawing, & NDE Report H* W W -- --

Dimensions PMI Procedure PMI Procedure

H* R W W
Sharp corners rounding off
H* R W -- --
NDE as per WTP H* R M -- --
Ring passing through bundle H* R R -- --
Positive material identification (PMI)
H* -- W W

Closing of Non Conformance Report.

(if any) H* R H -- --
 Page 12 of 15

QUALITY ASSURANCE PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Document No. ITP / 17-263 / 001. Rev. 7

CLIENT : TRD / DUQM EQUIPMENT NO. : 120E - 004 A/B.

PROJECT : DUQM REFINERY & PETROCHEMICAL IND. COM. , OMAN TYPE : D-MODIFIED / E / U (HORIZONTAL)
P.O. NO./ DATE : LOA 1012004010, DTD.: 26.10. 2018 INSPECTION BY (TPI) : TPI / AI

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL Contractor Company
TIL AI AI SIGN Contractor Company Remark
SIGN Sign Sign

11 CHANNEL BARREL ASSEMBLY TO MAIN SHELL JOINT

11.1 Set Up Verification of Identification marking, Approved WPS / PQR , Approved WPS / PQR , Form QC/21,
weld geometry, offset, Orientation , Approved Drawing. Approved Drawing. Inspection progress chart
Production test coupon as applicable. H* R M M

11.2 NDE As per WTP WTP / Applicable Procedure WTP / Applicable Procedure NDE reports
H* R M M
11.3 Tack Welding Check WPS / Welder Qualification , Approved WPS / PQR , Approved WPS / PQR , Report
H* -- -- M -- --
Welding Parameters. Approved Drawing. Approved Drawing.
11.4 Visual Inspection Visual Inspection of Tack weld / Fit up Approved WPS / PQR , Approved WPS / PQR , Report
H* -- -- M -- --
Approved Drawing , WTP & Approved Drawing , WTP &
11.5 In Process Welding NDE as per WTP Approved applicable Approved applicable Report
Procedures Procedures H* -- -- M -- --
11.6 Complete Welds ISR ISR Chart H* -- -- R -- --
Weld visual ASME Sec. VIII Div. 2 , ASME Sec. VIII Div. 2 , Report / Inspection progress
H* W W W
CLASS 2 CLASS 2 chart
11.7 NDE As per WTP Approved Drawing , WTP & Approved Drawing , WTP &
H* R M -- --
NDE Procedures NDE Procedures
11.8 Clad Restoration Check WPS / Welder Qualification Approved WPS and WPQ Approved WPS and WPQ Report H* -- -- R -- --
11.9 DHT after barrier layer DHT Record H* -- -- R -- --
11.10 Weld visual Approved Drawing Approved Drawing Report H* W -- W W
11.11 Dimension Approved Drawing Approved Drawing Report
( Thickness of Weld overlay ) H* R -- M M

11.12 NDE as per WTP WTP / Applicable Procedure WTP / Applicable Procedure NDE Report H* -- -- M -- --
11.13 PMI Alloy Verification PMI Procedure PMI Procedure Form QC / 13. H* -- -- W W
11.14 Ferrite check. Ferrite Check ( FN 5 - 10 ) TEMA'S General Procedure No. TEMA'S General Procedure Form QC / 13.
( As weld / Machined TIL-INS-PROC-08. No. TIL-INS-PROC-08. H* -- -- W W
condition prior to PWHT )
11.14a Chemical Analysis Verification of alloying elements Procedure for chemical analysis Procedure for chemical analysis Test records
DRP001-PUC-TEM-P40-120E- DRP001-PUC-TEM-P40-120E-
H* -- -- R R
004A-0011 004A-0011

11.15 Production Test coupon Verification of test results. Impact testing of production Impact testing of production Production test coupon *Testing witness
test coupon procedure test coupon procedure result
DRP001-PUC-TEM-P40-120E- DRP001-PUC-TEM-P40-120E- H* R W* W*
004A-0007 004A-0007
( IT / 17-263 / 001 ) ( IT / 17-263 / 001 )
11.16 Local Heat Treatment of Calibration of Thermocouples/ Recorder, Drawing and approved Heat Drawing and approved Heat HT Chart
Channel Barrel to Main shell Chart Review, Loading etc. Treatment Procedure Treatment Procedure H* R R -- --
Joint.
11.17 NDE As per WTP WTP , NDE Procedure WTP , NDE Procedure NDE Report H* R WS -- --
11.18 Hardness Hardness of Weld & HAZ. Drawing , Procedures for Drawing , Procedures for Form QC / 14.
H* -- W W
hardness check. hardness check.
11.19 Visual examination Visual examination & overall dimension ASME Sec. VIII Div. 2 , ASME Sec. VIII Div. 2 , Report
of complete assy. before Bundle insertion CLASS 2 , TEMA - R , CLASS 2 , TEMA - R , H* W W W
Approved Drawing. Approved Drawing.
11.20 Pickling and Passsivation of Pickling and Passivation of Weld overlay Pickling and Passsivation Pickling and Passsivation Report
H* --- R -- --
complete assembly Surface Procedure Procedure
Visual examination after Pickling and
H* --- W M
Passivation
 Page 13 of 15

QUALITY ASSURANCE PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Document No. ITP / 17-263 / 001. Rev. 7

CLIENT : TRD / DUQM EQUIPMENT NO. : 120E - 004 A/B.

PROJECT : DUQM REFINERY & PETROCHEMICAL IND. COM. , OMAN TYPE : D-MODIFIED / E / U (HORIZONTAL)
P.O. NO./ DATE : LOA 1012004010, DTD.: 26.10. 2018 INSPECTION BY (TPI) : TPI / AI

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL Contractor Company
TIL AI AI SIGN Contractor Company Remark
SIGN Sign Sign

12 Manufacturing of Internal Cylinder (Non Pressure retaining part) and other items used for Internal Assembly
12.1 a) Long Seam Joint Verification of Identification marking, Approved Drawing, Approved Drawing, Form QC/21,
set up weld geometry, offset, circumference and WTP, & WTP, & Inspection progress chart H* R R -- --
ovality NDE Procedures NDE Procedures (Welded Joint) ,
Visual of tack welds, visual of weld edges NDE reports
& dimensions H* R R -- --

NDE (PT of WEP) as per WTP

H* R M M

b) In process welding NDE (PT) as per WTP after back Approved Drawing, ASME Sec. VIII Div. 1, Inspection progress chart
chipping WTP, & NDE Procedures Approved Drawing, & (Welded Joint), H* R R -- --
NDE Procedures NDE reports
c) Complete welds Weld visual ASME Sec. VIII Div. 2, ASME Sec. VIII Div. 1, Inspection progress chart
Approved Drawing, WTP, & Approved Drawing, NDE (Welded Joint), H* W W M
NDE Procedure Procedures NDE reports
NDE (PT) as per WTP
H* R M -- --

12.2 End plate , Seal Ring , and Verification of Identification marking, Approved Drawing, Approved Drawing, Form QC/21,
partition plate set up and weld edge preparation WTP, & WTP, & Inspection progress chart H* R R -- --
welding NDE Procedures NDE Procedures (Welded Joint),
Visual of tack welds, visual of weld edges NDE reports
& dimensions H* R R -- --

NDE (PT of WEP) as per WTP

H* R W M

Dimensional inspection of complete Report

assembly H* -- R -- --

12.3 PMI Alloy Verification PMI Procedure PMI Procedure Form QC / 13.
H* -- -- W W

13 Inspection of Machined Verification of Identification marking TEMA-R, TEMA-R, Job Card,

Components Approved Drawing Approved Drawing NDE reports H* R R -- --
a) Internal cylinder NDE Procedures NDE Procedures
b) Internal flange Visual, dimensions
H* R R -- --
c) Internal sleeve
d) Compression rings Finish of gasket face.(as per drawing) --
e) Channel cover As applicable H* -- -- R -- --
f) Threaded lock ring
PMI
H* -- -- W W

PT of thread portion of lock ring

H* -- -- W M

14 Closing of all NCR Verification of close out of Non NCR NCR Form QC / 32
( If any ) Conformity H* H H -- --

15 Fasteners and all other Positive material identification Approved Drawing, Approved Drawing, FORM.QC/13
applicable components PMI Procedure PMI Procedure H* -- W W

15a Clearance for Verification of Dim., NDE and Visual --- --- Signed Reports
Hydro Static Test reports H* --- R R
 Page 14 of 15

QUALITY ASSURANCE PLAN (INSPECTION AND TEST PLAN)

SHELL & TUBE HEAT EXCHANGER
Document No. ITP / 17-263 / 001. Rev. 7

CLIENT : TRD / DUQM EQUIPMENT NO. : 120E - 004 A/B.

PROJECT : DUQM REFINERY & PETROCHEMICAL IND. COM. , OMAN TYPE : D-MODIFIED / E / U (HORIZONTAL)
P.O. NO./ DATE : LOA 1012004010, DTD.: 26.10. 2018 INSPECTION BY (TPI) : TPI / AI

INSPECTION BY AND SIGNATURE

S. No. Activity Description Reference Document Acceptance Criteria Format of Report
TIL Contractor Company
TIL AI AI SIGN Contractor Company Remark
SIGN Sign Sign

16 TESTING
16.1 Hydrostatic Test. Shell side hydro test including TTJ at Approved Drawing , Approved Drawing , FORM. QC / 18
differential test pressure Approved Testing Procedure. Approved Testing Procedure. H* H H -- --

Shell side and Tube side simultaneous

hydro test after Complete assembly at
full Pressure ( Ensuring that pressure
between the two side at no time exceeds H* H H H
differntial pressure.)

Tube side hydro test at differential test

pressure (No pressure drop on pressure H* H H -- --
gauge)
NDE as per WTP & MT/PT of temporary WTP , NDE Procedures WTP , NDE Procedures NDE Report
attachment removal area after Hydro test H* R M -- --

17 As built drawings -- ASME Sec.VIII Div.2 ASME Sec.VIII Div.2 As Built Drawings
CLASS 2 CLASS 2 H* R R -- --

18 Draining & Drying Both Shell side & Tube side Approved Drawing , Approved Approved Drawing , Approved Report
procedure procedure H* -- -- W -- --

19 Surface Preparation Blasted surface examination Drawing, Surface preparation Drawing, Surface preparation Form QC/17
** Final DFT and
& Painting DFT & Visual after Painting and painting Procedure and painting Procedure H* -- -- **W **W
Visual

20 Nitrogen filling Leakage at bolted joints & Pressure gauge Approved Drawing, Approved Drawing, Report
H* -- -- R -- --
(1.0 kg/cm2 ) protection Approved procedure Approved procedure
21 Shipping preparation Name plate details verification & Approved Drawing Approved Drawing. Rub- offs,
inspection and Dispatch Authorised to stamp ASME certification Spares List, MTC &
Clearance. Mark with U-2 Designator and National MDR. H* H --- -- --
Board Registration.
Attachment of ASME name plate on
H* H H -- --
Vessel
Verification & Attachment of Warning
plate / Manufacturer Name plate. H* -- -- W -- --

Review of MDR & signing off

H* H R -- --
Visual , dimension check , MTC review
for spares & Accessories. H* -- -- W M
( Scope of Supply items )
22 Inspection Release Issurance of Inspection Release PO , Applicable Project PO , Applicable Project IRC
H* -- -- H -- --
Certificate Certificate Specification. Specification.
23 Release Note Issurance of Inspection Release Note Release Note
H* -- -- H H

24 Documentation Document Folder. Approved MRB Index Approved MRB Index QC Dossier
H* -- -- R -- --
 Page 1 of 4

Annexure - 1 to ITP NO : ITP / 17-263 / 001. Rev.7

FABRICATION SEQUENCE ( EQUIPMENT NO. 120E-004 AB )

A) MAIN SHELL ASSEMBLY :

1. Complete Fabrication of main shell assembly
2. NDE : RT & Manual UT of Category A , B , D.
3. NDE : WFMT / MT / PT of all welded joints.
4. Ensure completeness of sub assembly including Visual , dimensions , NDE etc. as per ITP before releasing
the items for PWHT.
5. PWHT in Furnace.

B) CHANNEL BARREL ASSEMBLY :

1. Complete Fabrication of Channel Barrel assembly.
2. NDE : RT & Manual UT of Category D.
3. NDE : WFMT / MT / PT of all welded joints.
4. Ensure completeness of sub assembly including Visual , dimensions , NDE etc. as per ITP before releasing
the items for PWHT.
5. PWHT in Furnace.
 Page 2 of 4

Annexure - 1 to ITP NO : ITP / 17-263 / 001. Rev.7

FABRICATION SEQUENCE ( EQUIPMENT NO. 120E-004 AB )

C) MACHINING OF CHANNEL BARREL AFTER PWHT :

1. Machining of Channel Barrel.
2. Inspection of Channel Barrel after maching as per ITP.

D) MAIN SHELL to Channel Barrel JOINT.

1. Complete Fabrication of Joint.
2. NDE : RT & Manual UT.
3. NDE : WFMT / MT / PT of all welded joints.
4. Ensure completeness of Joint including Visual , dimensions , NDE etc. as per ITP before releasing
the items for PWHT.
5. Local PWHT of joint.
 Page 3 of 4

Annexure - 1 to ITP NO : ITP / 17-263 / 001. Rev.7

FABRICATION SEQUENCE ( EQUIPMENT NO. 120E-004 AB )

E) FINAL INSPECTION OF COMPLETE ASSEMBLY AFTER PWHT AND BEFORE TUBE BUNDLE INSERTION :
1. Complete Fabrication of assembly
2. NDE : RT & Manual UT of Category A , B , D.
3. NDE : WFMT / MT / PT of all welded joints.
4. Ensure completeness of assembly including Visual , dimensions , NDE , Review of PWHT charts etc. as per
ITP before releasing the assembly for Tube bundle insertion.

F) TUBE BUNDLE FINAL INSPECTION :

1. Ensure the clearance of previous stages for Tube sheet , baffles , Tie rod etc.
2. Ensure completeness of tube bundle assembly including Visual , dimensions , NDE etc. as per ITP before
releasing the tube bundle for insertion into main shell.

G) FINAL INSPECTION OF INTERNAL CYLINDER AND INTERNALS :

1. Final Inspection of internal cylinder.
2. Visual and dimension inspection of internals after machining.
 Page 4 of 4

Annexure - 1 to ITP NO : ITP / 17-263 / 001. Rev.7

FABRICATION SEQUENCE ( EQUIPMENT NO. 120E-004 AB )

H) TUBE TO TUBE SHEET JOINT PNEUMATIC TEST :

1. Tube bundle insertion into main shell.
2. Assembly of internal cylynder.
3. Pneumatic test of Tube to Tube sheet joint before expansion.
4. Helium Leak test of Tube to tube sheet joint before expansion.
5. Tube to tube sheet joint Expansion.
6. Inspection of tube to tube sheet joint expansion as per ITP.
7. Cleaning and NDE of Tube to tube sheet joint as per ITP.

I) TESTING :
1. Ensure the completion / clearance of all previous stages prior to testing as per ITP.
2. Shell side Hydro test to check Tube to tube sheet at differntial pressure.
3. Assembly of Channel cover , Threaded lock ring etc.
4. Shell side & Tube side simultaneous hydro test after complete assembly.
5. Tube side Hydro test at differntial pressure.

SL. No. - 2 SL. No. - 4

SL. No. - 5

J) DESPATCHED :
1. Draining , Drying , surface preparation , Painting , N2 purging , Shipping Preparation & readiness for
despatch.
 ANNEXURE-2
MATERIAL WELD WELDING AWS PREHEAT INTERPASS
JOINT NO(S)
COMBINATION THK. PROCESSES
WPS NO.
CLASSIFICATION
GAS / FLUX
MIN. (°C) MAX. (°C)
PWHT NON DESTRUCTIVE EXAMINATION (NDE)

106, WPS/17-263/03A Rev.A E 9016 B3 + (S3)

P5A TO P5A SMAW+SAW PF-200D 200 300 YES JOINT NO(S) (S1) (S2) (S4) (S5) (S7)
63 (To be qualified) EB3R (S6)
A1, B1-B3 GROUP NO After Flame After Root After Barrier / 1st Layer After Completion After Hydro
WPS/17-263/15A Rev.A E 309Nb-16 150 (Barrier) 250 (Barrier) Completion of Extent of After PWHT
Overlay restoration 7 SMAW --- YES TYPES Cutting & Beveling Pass / back Gouging E of WOL of WOL Test(If any)
(To be qualified) E 347-16 25 (Subsequent) 170 (Subsequent) welding examination(%)
153, WPS/17-263/02A Rev.A VT, #4 MT, VT,MT,PT*,
P5A TO P5A SMAW E 9016 B3 --- 200 300 YES A1,B1-B3 1 1a MT MT #2 100% 1 --- --- MT*
106 (To be qualified) RT,UT#1 RT,UT,UT#3
D1 - D4
WPS/17-263/15A Rev.A E 309Nb-16 150 (Barrier) 250 (Barrier) F1,F3-F6,F8,F9,F14,F15,
Overlay restoration 7 SMAW --- YES 10 1a --- --- MT 100% --- --- --- MT MT*
(To be qualified) E 347-16 25 (Subsequent) 170 (Subsequent) F19,F20-F43
7
WPS/17-263/01A Rev.A
F9,F14 P5A TO P5A --- GTAW ER 90S G --- 200 300 YES WOL-1,WOL-2,WOL-3 --- --- --- --- --- 100% --- PT PT,UT PT,UT#3 PT**
(To be qualified)
WPS/17-263/02A Rev.A VT, #4 WFMT, VT,WFMT,PT*,
F15 P5A TO P5A --- SMAW E 9016 B3 --- 200 300 YES D1-D4 1 1a MT MT #2 100% 1 --- --- MT*
(To be qualified) RT,PAUT RT,PAUT,UT#3
WOL-1 WPS/17-263/15A Rev.A E 309Nb-16 150 (Barrier) 250 (Barrier)
SS347 WOL on P5A 7 SMAW --- YES F16, F17,F2,F7 10 1a --- --- PT --- --- --- --- --- ---
(Restoration,corners,repairs) (To be qualified) E 347-16 25 (Subsequent) 170 (Subsequent)
7
WOL-2 WPS/17-263/16A Rev.A ER 309L 150 (Barrier) 250 (Barrier)
SS347 WOL on P5A 7 SAW(String) Automelt S33 YES A2,A3 1 1a PT PT PT --- --- --- --- --- ---
(Nozzle ID etc) (To be qualified) ER 347 25 (Subsequent) 170 (Subsequent)
WOL-3 SAW-Strip WPS/17-263/17A Rev.A EQ 309Nb Record INT 150 (Barrier) 250 (Barrier) Internal Cylinder(Note-5)
SS347 WOL on P5A 7 YES 7 --- 1b --- --- PT --- --- --- --- --- ---
(Shell & Barrel ID) (Multilayer) (To be qualified) EQ 347 109 25 (Subsequent) 170 (Subsequent) F10-F13,A7
SS347 WOL TO P8 WPS/17-263/30 Rev.A
T1 --- GTAW ER 347 Argon 25 150 NO A6 1 1b --- PT PT,RT 100% --- --- --- --- ---
(Tube to tube sheet joint) (To be qualified)
Tube Bundle skeleton
P8 TO P8 --- GTAW WPS/17-263/12 Rev.1 ER 347 Argon 25 150 NO D5,A7 7 7 1b --- PT PT 100% --- --- --- --- ---
(Note-4)
Internal Cylinder ER 347+ Argon
P8 TO P8 --- GTAW+SMAW WPS/17-263/12 Rev.1 25 150 NO C1 9 1b --- --- PT --- --- --- --- --- ---
(Note-5) F10-F13 E 347-16 ---
E 347-16+ ---
A6, D5, C1 P8 TO P8 36 SMAW,SAW WPS/17-263/14 Rev.0 25 150 NO D6-D9 7 1a PT PT PT, UT 100% --- --- --- --- ---
ER 347 Automelt S33
SS347 Buttering on
D6-D9, F17 P1 TO P1 32 SMAW WPS/17-263/11 Rev.1 E 7018 --- 100 300 NO 1b --- --- --- 100% --- PT PT PT ---
P5A
F2,F3,F6,F7,F8 P1 TO P1 --- SMAW WPS/17-263/39 Rev.A E 7018 100 300 YES(At 690°) B4-B7 SS347 Buttering on P1 1b --- --- --- 100% --- PT PT --- ---
WPS/17-263/40A Rev.A SS 347 buttering to
F1,F5 P5A TO P1 --- SMAW E 9015 B3 --- 200 300 YES 1b PT PT PT,RT,UT Spot RT --- --- --- --- ---
(To be qualified) SS 347 buttering
F16 P5A TO P1 --- GTAW WPS/17-263/07A Rev.0 ER 90S G --- 200 300 NO T1 e 1b --- PT PT*** 100% --- --- --- --- ---
E 309CB-16 150 250 Bundle skeleton
SS347 Buttering on P5A 10 SMAW --- YES --- 1b --- --- PT --- --- --- --- --- ---
E 347-16 27 170 (Note-4)
WPS/17-263/41 Rev.A E 309CB-16 100 250
B4-B7 SS347 Buttering on P1 --- SMAW --- NO APPLICABLE NDE PROCEDURE
(To be qualified) E 347-16 27 170
SS 347 buttering to ER 347+ Argon,
--- GTAW+SMAW 27 150 NO
SS 347 buttering E 347-16 ---

1)NDE-17-263-001-(TEMA/QA/RT-1 Rev.13)
REMARKS : 2)NDE-17-263-002-(TEMA/QA/UT-2 Rev.11)
3)NDE-17-263-003-(TEMA/QA/MT-2 Rev.9)
1) All welding joints shall require 100% visual examination to the maximum extent possible 4)NDE-17-263-005-(TEMA/QA/PT-1 Rev.12)
5)NDE-17-263-007-(TEMA/QA/MT-4 Rev.2)
2) MT Shall be carried out on all arc strikes and locations where temporary attachments have been removed .

3) If PT/MT and RT /UT to be carried out at same stage PT/MT to be done prior to RT,UT
4) If MT is not accessible / feasible; PT to be carried out. PRODUCTION TEST COUPON (PTC) DETAIL ( PTC testing shall be as per the procedure No.:IT/17-263/001)
5) (a)*MT on all external pressure retaining weld and attachment weld (Including temporary attachment weld removal area) that are accessible without disassembling the heat exchanger. IMPACT TESTS
STRUCTURE
TENSILE TEST BEND TEST
(b)**PT on weld overlaid surface that are accessible without disassembling the heat exchanger. REPRESENTING LENGTH WELD HEAT AFFECTED. ZONE EXAMINATION HARDNESS INSPECTION.
PTC NO. NDE
(c) * PT on overlaid surface after PWHT. JOINTS (MM) TEST BY
(d) UT #1 shall be carried out for internal(TEMA) purpose only. NUMBER NUMBER LOCATION TEMP.(°C) LOCATION TEMP.(°C) MACRO MICRO
(e) PT shall be carried out for each layer of overlay weld deposit(V-000-001, A7.3.1)
(f) *** PT shall be carried out after final Expansion. PTC requirement & testing shall be as per the procedure No.:IT/17-263/001
g) #4 For Wet H2s service (i)WFMT shall be performed on all internal weld surfaces and 2” (50mm) either side of weld (If feasible), MT shall be perform on outside welds
(ii) WFMT & UT for all D-Joints (Both side if feasible).
6) MT #2 shall be carried out in preheating condition by yoke technique.

7) Ferrite , PMI & Hardness shall be carried out as per the approved procedure.

8) UT shall be carried out on Lifting lug fillet welds. LEGENDS :

9) UT#3 shall be carried out on all overlay after PWHT MDMT : Minimum Design Metal Temperature. WFMT : Wet Fluorescent Magnetic Particle Test. WPS : Welding Procedure Specification

10) Prior to WOL, all weld surfaces shall be MT tested as per V-000-002 Para 4.4.3, if feasible otherwise PT. T : Joint Thickness TEMP. : Temperature PT : Penetrant Test RT : Radiographic Test.

UT : Ultrasonic Test PAUT: Phase Array Ultrasonic Test MT : Magnetic Particle Test. PWHT : Post Weld Heat Treatment.

DTN : Drawing Transmittal Note TOFD: Time of Flight Diffraction ROH : Rate Of Heating I / S : Inside O / S : Out Side

E : Joint efficiency WOL : Weld Overlay ROC : Rate Of Cooling

INSPECTION BY : TPI / AI MDMT : 5°C Reviewed By

CODE OF CONSTRUCTION RADIOGRAPHY

ASME SEC VIII DIV-2 CLASS-2 Edition 2017 ,
NOTES :- 1) All attachment welds including joints in non presure parts on shell side & barrel side shall be made using WPS/17-263/02A Rev.A TEMA CLASS-R 9th Edn. + API 660 9th Edn., 2015.
SHELL SIDE TUBE SIDE

2) All tack welds during joint set-up shall be made using the appropriate WPS of the respective joint & qualified welder. --- 100% 100%

3) For any weld joint repair, the WPS shall be used as specified for that Joint ,refering the Repair Procedure . REF. DRAWING(DRG) NO.: SDB/E/182474-1 SHT NO.1 OF 9

4) Baffle plate to sealing strip, tie rod,seal rod and impingement rod etc welding by using WPS No. : WPS/17-263/12 Rev.0. MANUFACTURER'S SERIAL NO. T/E/18/0168 for 120E-004 A

5) Internal Cylinder assembly welding by using WPS No. : WPS/17-263/12 Rev.0. T/E/18/0169 for 120E-004 B

6) P5A :-SA387 GR.22 CL2,SA336 GR.F22 CL3, P8 : -SA965 F321, SA240 Type 321, SA213 TP321, SA479 Type321 P1 : SA516 GR.70, SA105
7) PWHT shall be carried out as per approved PWHT procedure.
CLIENT : DUQM REFINERY & PETROCHEMICAL IND. COMPANY
HEAT TREATMENT
MAX ROC UP TO
TYPE OF HEAT MAX ROH ABOVE HOLDING MIN HOLDING APPROVED BY A. Sinha
PART DESCRIPTION 300 °C (°C / PROCEDURE NO. TITLE : 1ST STAGE REACTOR FEED/EFFLUENT EXCHANGER
TREATMENT 300ºC(ºC/HOUR) TEMP (°C) TIME 2 19/03/2019 1 Third Issue PREPARED &
HOUR) B. Sahu
Main shell Assembly PWHT 56 690 ( ±10) 5.5 hours 56 PWHT/17-263/01 CHECKED BY
CLIENT P. O. NO. : L.O.A.No.-1012004010 Dated.26/10/2018
Channel Shell Assembly PWHT 56 690 ( ±10) 6.02 hours 56 PWHT/17-263/01 APPROVED BY A. Sinha
B1 - Joint Local PWHT 56 690 ( ±10) 5.5 hours 56 PWHT/17-263/02 1 22/01/2019 0 Second Issue PREPARED &
B. Sahu TEMA WORK ORDER NO. : 17 – 263
CHECKED BY
APPROVED BY A. Sinha
EQUIPMENT NO. : 120E-004 A/B
WELD MAP : REFER ANNEXURE - 1 0 27/11/2018 0 First Issue PREPARED &
B. Sahu
WPS-PQR LIST : REFER ANNEXURE - 2 CHECKED BY SHT
NDE PLAN IN QAP (Rev. 7)
WTP. REV. DATE DRG. REV. DESCRIPTION OF REVISION SIGNATURE 1 OF 1
QC / 26 Rev.5