Comprehensive inspection and test plan is something that an ASME certificate holder would already have in their Quality manual. Most ASME certificate holders that I have audited over the years have specific process/fabircation procedures, hold points for the AI, and NDT procedures.


Hartford Steam Boiler used to provide clients and sell a page fold out for pressure vessels including applicable reference to nozzle openings and NDT requirements related to ASME Section I and Section VIII, Div 1.

You might want to visit the web site below for more details or contact HSB directly using their web site;

http://www.hsb.com/index.asp

Here is the HSB ,as mentioned above, bookstore page. Look under "reference materials". What used to be free now cost money.

http://bookstore.hsbct.com/


Here are couple of simple forms that sort of set the schedule for inspection of new vessels. The biggest problem that I've encountered is fabricators honoring hold and witness points. Make sure this is spelled out specifically in the contract, not just in general terms.
 
http://www.gepower.com/about/suppliers/en/downloads/insp_and_test_plan_eg_rev2.pdf

http://www.safetyfire.com/pdf/plan.pdf

Thank you gentlemen

The scenario is that vessels, heat exchangers and tube bundle replacements have been ordered and fabrication started without any quality documents provided for review (ITP,s, Welding dossiers, Inspection (NDT, hydrotest) procedures, cleaning, coating and painting procedures). As a member of the QC & MR (materials reliability) group my leader has assigned me the task of compiling a generic ASME VIII ITP for a vessel which we shall supply yo our Engineering & Procurement Depts. so that they can understamd what is required for review prior to placing a firm order.

Perhaps we should take the view that the fabricators are the specialists in their field and should know what they are doing. Maybe fabricators with a skimpy radiography procedure are actually doing a top job and vice versa. Fabricators go through so many audits and document reviews surely they must be refined to perfection by now. I would relish the opportunity to review a completed order, from receiving inspection, dimensional and functional checks to Data Book Review to see how many deviations and NCR's could or should have been raised. However specialisation has its downside and I dont think I shall have that opportunity.

Thanks again for your asssistance

Nigel Armstrong
Karachaganak Petroleum
Kazakhstan

ndeguy;

Quote:

The scenario is that vessels, heat exchangers and tube bundle replacements have been ordered and fabrication started without any quality documents provided for review (ITP,s, Welding dossiers, Inspection (NDT, hydrotest) procedures, cleaning, coating and painting procedures).

RECOMMENDATION:
Perform an audit of any and all facilities that will be fabricating the components mentioned above. The fact that a customer shows up for a technical audit provides that much more attention to your contract. Don't assume anything with shop fabrication! Prior to the audit, request for review the items you listed above.

Also, don't fall into the trap of thinking that the AI will inspect in quality.  From the wording, you are really looking for a vendor document checklist as opposed to an ITP (or quality plan) in the ISO 29001 sense.  One of the documents that the vendor should be submitting up front is the ITP/quality plan.  The first thing to look for will be that the vendor has altered their 'standard' ITP to reflect the specific order requirements of KPO.  I'm surprised that none of the partners in KPO can't come up with a prior example from a manufacturing record book that they will have in their possession somewhere.  And, from bitter experience, you won't want to get involved with the deviations/NCR's that you WILL find when reviewing the databook which, typically, only arrives 3 months after the vessel has been installed - also taking into account that you will, of course, have deployed a reputable inspection company to release the vessels in the first place!

Steve Jones
Materials & Corrosion Engineer
http://www.pdo.co.om/pdo/

Thank you all for your assistance. Steve, I think your suggstion of a vendor document checklist is nearer the mark for what would be useful to our contracts & procurement people, with a specific ITP for our mark-up being first on that list.

Nigel Armstrong
Karachaganak Petroleum
Kazakhstan