Section 8 — Heat Transfer Equipment
TEMA Shell and Tube Heat Exchangers Inspection Checklist
IPE Engineering Practice IPE-EP-8-1-1C
Document number: IPE-EP-8-1-1C · Section: 8 — Heat Transfer Equipment
THE MANUFACTURER OF EQUIPMENT PURCHASED BY IPE COMPANY SHALL BE RESPONSIBLE FOR MEETING ALL APPLICABLE REQUIREMENTS OF THE IPE ENGINEERING PRACTICE AND OTHER DOCUMENTS REFERENCED THEREIN REGARDLESS OF WHETHER THE ITEMS ARE INSPECTED BY A IPE REPRESENTATIVE.
REFERENCES
THE LATEST EDITION OF THE FOLLOWING STANDARDS AND PUBLICATIONS ARE REFERRED TO HEREIN
IPE ENGINEERING PRACTICES
EP 7-1-1 PRESSURE VESSELS
EP 7-1-3 HEAVY WALL AND SPECIAL SERVICE PRESSURE VESSELS EP 7-1-4 SUPPLEMENTAL REQUIREMENTS FOR PRESSURE VESSELS EP 7-1-5 WELDING REQUIREMENTS FOR PRESSURE VESSELS
EP 7-1-6 METAL LINING AND CLADDING EP 7-1-7 PRESSURE VESSEL DETAILS
EP 8-1-1 TEMA SHELL AND TUBE HEAT EXCHANGERS EP 8-1-8 TUBE TO TUBESHEET JOINTS
EP 8-1-9 TUBE MATERIAL AND SELECTION
EP 10-2-2 SUPPLEMENTAL REQUIREMENTS FOR METALLIC MATERIALS EP 10-2-3 MATERIAL HARDNESS REQUIREMENTS
EP 10-3-1 SHOP PAINTING
EP 10-3-7 INTERNAL LINING AND RESIN REPAIR
EP 15-1-4 POSITIVE MATERIAL IDENTIFICATION (PMI)
FREQUENCY OF CONTACT BY THE INSPECTOR (CHECK ONE)
LEVEL L: ON CALL BY FABRICATOR LEVEL 2: ONCE EVERY TWO WEEKS LEVEL 3: EVERY WEEK
LEVEL 4: DAILY
LEVEL 5: RESIDENT
LEVEL 6. OTHER, SPECIFY
LEVEL OF INSPECTION BY THE INSPECTOR (CHECK ONE)
LEVEL L: PREFABRICATION MEETING, DOCUMENT REVIEW, AND FINAL INSPECTION
LEVEL 2: PREFABRICATION MEETING, DOCUMENT REVIEW. REVIEW ITEMS. AND FINAL INSPECTION LEVEL 3: PREFABRICATION MEETING. DOCUMENT REVIEW, REVIEW ITEMS. WITNESS POINTS, AND FINAL
INSPECTION
LEVEL 4: PREFABRICATION MEETING, DOCUMENT REVIEW, REVIEW ITEMS, WITNESS POINTS, HOLD POINTS, AND FINAL INSPECTION
LEVEL 5. OTHER, SPECIFY
DOCUMENT REVIEW (SHOP INSPECTOR SHALL REVIEW)
| DOCUMENT DESCRIPTION (REFERENCES TO EP 7-1-1, UNLESS OTHERWISE NOTED) |
INSPECTOR’S INITIALS (REVIEW COMPLETE) | DATE | |
|---|---|---|---|
| IPE PURCHASE DOCUMENTS | |||
| DRAWINGS AND SPECIFICATIONS | |||
| DOCUMENTATION (EP 7-1-4, 6.0) | |||
| QUALITY CONTROL MANUAL (EP 7-1-4: 5.3) | |||
| QUALITY CONTROL PLAN (5.0, EP 7-1-4: 5.3.3) | |||
| MATERIAL RECEIVING SIGN-OFF | |||
| MATERIAL REQUISITIONS (6.1) | |||
| MATERIAL TEST REPORTS | |||
| UT REPORT OF PLATE (EP 7-1-3: 6.2) | |||
| UT REPORTS OF FORGINGS AND THICK PLATE (EP7-1-3:6.2) | |||
| TEST EQUIPMENT CALIBRATION CERTIFICATIONS | |||
| WELDING PROCEDURE SPECS (EP 7-1-5:7.0) | |||
| WELDER QUALIFICATION RECORDS (EP 7-1-5: 9.0) | |||
| NDE PROCEDURES | |||
| NDE TEST REPORTS | |||
| NDE PERSONNEL CERTIFICATION | |||
| FAB. PLAN/SHOP TRAVELER | |||
| IDENTIFICATION OF CRITICAL DIMENSIONS | |||
| DAILY COATING INSPECTION REPORT (EP 10-3-1) | |||
| SUB-CONTRACTOR Q/C REPORTS | |||
| AS-BUILT DATA SHEET (4.1) | |||
| NAME PLATE RUBBINGS AND/OR CODE | |||
| PRESSURE VESSEL DATA BOOK (EP 7-1-4:6.3) | |||
| PWHT PROCEDURES ( 8.5) | |||
| AUTHORIZED WAIVERS AND/OR DEVIATIONS REVIEW | |||
| REVIEW OF SUBORDERS OF UNPRICED PURCHASE ORDERS TO SUB-VENDORS FOR COMPLIANCE WITH IPE ENGINEERING PRACTICE | |||
GENERAL FABRICATION INSPECTION REQUIREMENTS (ALL FABRICATED EQUIPMENT)
R CHECK: THE SHOP INSPECTOR SHALL REVIEW DOCUMENTED RESULTS OF INSPECTION PERFORMED BY VENDOR'S INSPFCTOR OR SUBCONTRACTED INSPECTOR.
W CHECK: INDICATES THE SHOP INSPECTOR SHALL WITNESS ITEMS DURING FABRICATION SHOP SHALL NOTIFY INSPECTOR 2 DAYS IN ADVANCE OF FABRICATION POINT BUT NEED NOT HOLD PRODUCTION FOR INSPECTION.
H CHECK: INDICATES THE SHOP INSPECTOR SHALL INSPECT ITEMS DURING HOLD ON FABRICATION. SHOP SHALL NOTIFY INSPECTOR FIVE DAYS IN ADVANCE OF FABRICATION POINT AND SHALL NOT CONTINUE AFFECTED PRODUCTION UNTIL INSPECTOR PERFORMS AND IMPROVES FABRICATION AFTER INDICATED INSPECTION.
| R | W | H | INSPECTION/TESTING ACTIVITY (REFERENCES TO EP 7-1-1 UNLESS OTHERWISE NOTED) | INSPECTOR’S INITIALS (REVIEW COMPLETE) | DATE |
|---|---|---|---|---|---|
| SPECIAL MATERIAL REQUIREMENTS (EP 10-2-2) | |||||
| PWHT SEP COOLING REQUIREMENTS (EP 10-2-2) | |||||
| SPECIAL MATERIAL TENSILE AND IMPACT TESTING REQUIREMENTS (EP 10-2-2) | |||||
| FIT-UPS WELD ROOTS/WELD BEVELS | |||||
| SPECIAL FORGINGS TESTING REQUIREMENTS | |||||
| GENERAL FABRICATION CHECKS (8.1) | |||||
| GENERAL WELDING FABRICATION CHECKS (8.2) | |||||
| HEAD AND TRANSITION SECTION THICKNESS REQUIREMENTS (8.3) | |||||
| REINFORCING PAD GAP ALLOWANCE (8. 3) | |||||
| SPECIAL FORGING FORMING REQUIREMENTS (8.4) | |||||
| PWHT PREPARATIONS (8.5) | |||||
| REVIEW OF COLD WORKED PARTS PWHT REQUIREMENTS | |||||
| NAMEPLATE REQUIREMENTS (8.6) | |||||
| DIMENSIONAL CHECKS (8.7) | |||||
| TEMPLATE CHECK (8.7) | |||||
| CLEANLINESS CHECK PRIOR TO FINAL INSPECTION (9.1) | |||||
| PMI OF ALL APPLICABLE MATERIALS (EP 15-1-4) | |||||
| RT LOCATION SELECTION | |||||
| RT REVIEW (9.2) | |||||
| RT OF WELDS IN COLD WORKED PARTS (9.2) | |||||
| UT OF NOZZLES IN THICK SHELLS (9. 3) | |||||
| WFMT OF WELDS IF VESSELS IN AES (9.4) | |||||
| MT/PT OF DOUBLE WELDED GROOVE JOINTS (9.4) | |||||
| MT/PT OF SPECIFIED AREAS (9.4) | |||||
| MT/PT OF SPECIFIED AREAS OF 100% RT VESSEL (9.4) | |||||
| NOZZLE REQUIREMENTS (7.7) | |||||
| GIRTH FLANGE CONTACT SURFACE REQUIREMENTS (7.11.1) | |||||
| NON-STANDARD FLANGE GASKETING REQUIREMENTS (7.11.1) | |||||
| FLANGE REQUIREMENTS FOR CLAD VESSELS (7.11.1) | |||||
| MT/PT OF UNRADIOGRAPHICABLE NOZZLES (9.4) |
GENERAL FABRICATION INSPECTION REQUIREMENTS (ALL FABRICATED EQUIPMENT)
| R | W | H | INSPECTION/TESTING ACTIVITY (REFERENCES TO EP 7-1-1 UNLESS OTHERWISE NOTED) | INSPECTOR’S INITIALS (REVIEW COMPLETE) | DATE |
|---|---|---|---|---|---|
| ALL MAJOR REPAIRS PERFORMED IN ACCORDANCE WITH ACCEPTED PROCEDURES (10.0) | |||||
| ALL OTHER REPAIRS PERFORMED IN ACCORDANCE WITH ACCEPTED PROCEDURES (10.0) | |||||
| HYDROSTATIC LEAK TEST (11.0) | |||||
| CHLORIDE CONTENT OF HYDROTEST FOR STAINLESS STEEL (11.0) | |||||
| REINFORCING PAD PRESSURE TEST (11.0) | |||||
| PROGRESSIVE FORMING/MACH. | |||||
| ASSEMBLY AND MATCH MARKS | |||||
| REMOVAL OF TEMPORARY ATTACH. AND NDE INSPECTION OF AFFECTED AREA | |||||
| SURFACE CLEANLINESS/PROFILE | |||||
| FINAL SHIPPING PREPARATION/CLEANLINESS/PRESERVATION (EP 7-1-4: 5.5) | |||||
| STAMPING AND MARKING (EP 7-1-4: 5.4) | |||||
| WELDING INSPECTION (SEE EP 7-1-5) | WELDING INSPECTION (SEE EP 7-1-5) | WELDING INSPECTION (SEE EP 7-1-5) | WELDING INSPECTION (SEE EP 7-1-5) | WELDING INSPECTION (SEE EP 7-1-5) | WELDING INSPECTION (SEE EP 7-1-5) |
| WELDING PROCESS REQUIREMENTS (6.0) | |||||
| WELDER PERFORMANCE QUALIFICATION TESTS (7.0) | |||||
| WELD JOINT DESIGN (8.0) | |||||
| PREHEAT AND INTERPASS REQUIREMENTS (9.1) | |||||
| FILLER METAL REQUIREMENTS (9.0) | |||||
| WELDING TECHNIQUE REQUIREMENTS (9.0) | |||||
| WELDER IDENTIFICATION (9.0 | |||||
| PRODUCTION TEST PLATE QUALIFICATION (9.0) | |||||
| PWHT REPORT - ASME CODE (10.0) | |||||
| PWHT - AES SERVICE (11.0) | |||||
| WELD HARDNESS REQUIREMENTS AFTER PWHT (EP 10-2-3) | |||||
SHELL AND TUBE HEAT EXCHANGER INSPECTION AND TESTING
| R | W | H | INSPECTION/TESTING ACTIVITY (REFERENCES TO EP 8-1-1 UNLESS OTHERWISE NOTED) | INSPECTOR’S INITIALS (REVIEW COMPLETE) | DATE |
|---|---|---|---|---|---|
| TUBE SHEET DRILLING/MACHINE PROCESS (EP 8-1-8) | |||||
| TUBE EXPANSION/ROLLING PROCESS(EP 8-1-8: 6.0) | |||||
| TUBE STRENGTH WELDS WITH THROAT THICKNESS EQUAL TO TUBE THICKNESS (EP 8-1-8: 7.4.4) | |||||
| TUBE BUNDLE INSERTION/REMOVAL CHECK (8.1) | |||||
| WELDED TUBE ROLL LEAK TEST (EP 8-1-8: 8.4) | |||||
| EXCHANGER HYDROSTATIC TEST REQUIREMENTS (8.2) | |||||
| VERIFY UNIT DRYOUT AFTER HYDROTEST | |||||
| CLADDING AND WELD OVERLAY INSPECTION WHEN REQUIRED (EP 7-1-6) | CLADDING AND WELD OVERLAY INSPECTION WHEN REQUIRED (EP 7-1-6) | CLADDING AND WELD OVERLAY INSPECTION WHEN REQUIRED (EP 7-1-6) | CLADDING AND WELD OVERLAY INSPECTION WHEN REQUIRED (EP 7-1-6) | CLADDING AND WELD OVERLAY INSPECTION WHEN REQUIRED (EP 7-1-6) | CLADDING AND WELD OVERLAY INSPECTION WHEN REQUIRED (EP 7-1-6) |
| INSPECTION REQUIREMENTS FOR CLAD PLATE (11.0) | |||||
| REQUIREMENTS FOR CLAD PLATE (5.0) | |||||
| PT OF WELD OVERLAY OF SEAMS (11.0) | |||||
| RT OF MAIN SEAM AFTER WELD OVERLAY (11.0) | |||||
| VERIFICATION OF WELD OVERLAY THICKNESS (11.0) | |||||
| PMI OF WELD OVERLAY (11.0) | |||||
| PT OF 1ST LAYER OF WELD OVERLAY (11.0) | |||||
| FINAL PT EXAMINATION OF OVERLAY (11.0) | |||||
| RT OF P3, P4, AND P5 FOLLOWING PWHT (11.0) | |||||
| FERRITE CONTENT OF OVERLAYS (11.0) | |||||
| INSPECTION REQUIREMENTS FOR STRIP LINING (11.0) | |||||
HEAVY WALL AND SPECIAL SERVICE VESSEL INSPECTION WHEN REQUIRED
| R | W | H | INSPECTION/TESTING ACTIVITY (REFERENCES TO EP 7-1-3 UNLESS OTHERWISE NOTED) | INSPECTOR’S INITIALS (REVIEW COMPLETE) | DATE |
|---|---|---|---|---|---|
| VESSEL ATTACHMENT WELD REQUIREMENTS (5.4) | |||||
| SUPPLEMENTAL UT OF PLATE MATERIAL (6.2) | |||||
| SUPPLEMENTAL UT AND MT OF FORGINGS (6.2) | |||||
| REPAIRS OF PLATES AND FORGINGS (6.2) | |||||
| SUPPLEMENTAL RT REQUIREMENTS (8.1) | |||||
| SUPPLEMENTAL UT REQUIREMENTS (8.2) | |||||
| SUPPLEMENTAL MT AND PT REQUIREMENTS (8.3) | |||||
| AE REQUIREMENTS (9.0) | |||||
| PRODUCTION TEST PLATE QUALIFICATIONS (EP 7-1-5) | |||||
| EXTERIOR COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-1) | EXTERIOR COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-1) | EXTERIOR COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-1) | EXTERIOR COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-1) | EXTERIOR COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-1) | EXTERIOR COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-1) |
| SAND BLASTED SURFACES (10.0) | |||||
| COATINGS PREPARATION (10.0) | |||||
| WET FILM THICKNESS MEASUREMENTS (10.0) | |||||
| DRY FILM THICKNESS MEASUREMENTS (10.0) | |||||
| HOLIDAY TESTING OF COATING (10.0) | |||||
| REPAIR AND FINAL INSPECTION | |||||
| INTERNAL COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-7: 12.0) | INTERNAL COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-7: 12.0) | INTERNAL COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-7: 12.0) | INTERNAL COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-7: 12.0) | INTERNAL COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-7: 12.0) | INTERNAL COATING INSPECTION WHEN REQUIRED (SEE EP 10-3-7: 12.0) |
| INITIAL SURFACE INSPECTION | |||||
| SAND BLASTING OPERATION | |||||
| SURFACE PREPARATION PRIOR TO APPLICATION | |||||
| CONDITION FOR APPLICATION OF COATING | |||||
| DRY FILM THICKNESS MEASUREMENT | |||||
| HOLIDAY TESTING OF COATING | |||||
| REPAIR AND FINAL INSPECTION | |||||
| INSPECTOR SIGN-OFF | INSPECTOR SIGN-OFF | INSPECTOR SIGN-OFF | INSPECTOR SIGN-OFF |
|---|---|---|---|
| INITIALS | NAME | COMPANY | SOCIAL SECURITY NUMBER |
| EQUIPMENT ID | JOB NO. | DOCUMENT NO. | REV. |
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| SUMMARY: |
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