OWNER: CONTRACTOR:

BUSHEHR PETROCHEMICAL COMPANY

HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 1 of 28

Inspection and Test Plan

for Heat Exchangers

B00 30-Sep-21 Approved for Design H.Sadeghiyan M.Osta M.Alavi

AC
Rev. Date Purpose of Issue (P.O.I) Prepared Checked Approved
Code
Class: 1 Phase: BE

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 2 of 28

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whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

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Project Document Number : BU40 000 EQ ITP 0002
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Table of Contents

1.  Purpose .......................................................................................................................4 

2.  Applicable Documents ................................................................................................4 
3.  Definitions ...................................................................................................................4 
3.1  General definitions ......................................................................................................... 4 
3.2  Abbreviations ................................................................................................................. 5 
4.  General Requirements ................................................................................................5 
5.  Definition of CONTRACTOR and CLIENT / TPI Involvement ....................................5 
6.  VENDOR’s Quality Manual and Quality Control Plan (VQCP) ...................................7 
7.  Inspection Activities ....................................................................................................8 
8.  Attachments ................................................................................................................8 
8.1  Attachment #1: ITP for Shell and Tube Heat Exchanger (3 Sheets) ............................. 8 
8.2  Attachment #2: Test Sequence Standards with reference to TEMA Type of Shell and
Tube Heat Exchangers (13 Sheets) ......................................................................................... 8 

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 4 of 28

1. Purpose
The inspection and test plan is an engineering document, which defines the type and
extent of CONTRACTOR and CLIENT involvement in each phase of fabrication, control
and testing requirements and inspection.

The inspection and test plan may under no circumstances be used as a substitute for
the VENDOR's Quality Manual and/or Quality Control Plan. The VENDOR shall in any
case conduct all the tests required by contractual documents, specifications, codes and
standards, and keep the relevant documentation.

CONTRACTOR and CLIENT shall be entitled to send their inspectors to attend

inspection in the VENDOR’s workshop.

This inspection and test plan shall be used as a basis for the definition of the material
inspection plan during pre-inspection meeting.

2. Applicable Documents
ASME Sec. II Material
ASME Sec. VIII Div. 1 Rules for Construction of Pressure
Vessels
ASME Sec. VIII Div. 2 Rules for Construction of Pressure
Vessels, Alternative Rules
ASME Sec .V Non-Destructive Examination
ASME Sec. IX Welding and Brazing Qualifications
TEMA Standard Tubular Exchanger Manufacturers
Associations
API 660 Shell & Tube Heat Exchangers
BS EN 10204 (3.1) Material Certificates

All Standards and Specifications listed in the Requisition

3. Definitions

3.1 General definitions

Project Title  : BUSHEHR PETROCHEMICAL COMPANY HDPE PLANT

PLANT : HDPE PLANT

OWNER : BUSHEHR PETROCHEMICAL COMPANY

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whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 5 of 28

CONTRACT : Agreement Between OWNER and its CONTRACTOR

MANAGING : Joint Venture (JV) of Samto Soo Tose’e Iranian (SSTI)

CONTRACTING AND
(MC) Namavaran Delvar Engineering and Construction
Company
(NDEC)
CONTRACTOR : Joint Venture of SAZEH Consultants and SAZEHPAD
TEHRAN (SZP)

3.2 Abbreviations

Abbreviation Meaning

NDT None Destructive Test

WPS/PQR Welding Procedure Specification/Procedure Qualification Record

VQCP Vendor’s Quality Manual and Quality Control Plan

ITP Inspection and Test Plan

TPI Third Party Inspector

PIM Pre Inspection Meeting

4. General Requirements
The VENDOR shall inspect all the manufactured items to ensure that materials and
workmanship are in accordance with applicable codes, standards and specifications
indicated in the relevant Purchase Order.

All the manufactured items shall be inspected according to CONTRACTOR’S

requirements. However, the acceptance of any work and/or release of them by the
CONTRACTOR shall in no way relieve the VENDOR of any responsibility for carrying
out all the provisions of the codes and specifications.

The CONTRACTOR and CLIENT or their authorized Inspectors/Representatives shall

have free access at all reasonable time to all shops of the VENDOR or Sub-VENDOR
for inspection/witnessing of work.

5. Definition of CONTRACTOR and CLIENT / TPI Involvement

The nature of CONTRACTOR and CLIENT involvement is indicated against each
activity of fabrication and testing by means of the letters H, W, SW, R and A with the
following definitions:
This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
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HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

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Project Document Number : BU40 000 EQ ITP 0002
B00 6 of 28

H: (Hold) Point
The VENDOR cannot carry out the specified controls and tests without CONTRACTOR
and CLIENT attendance and witnessing. The VENDOR must notify CONTRACTOR by
fax of the dedicated inspection activity at least twenty (20) Calendar days in advance
and consequently CLIENT will be informed by CONTARACTOR. The VENDOR cannot
deviate from this rule unless written approval has been given by CONTRACTOR.

W:(Witness)
The VENDOR must notify CONTRACTOR of the dedicated inspection activity at least
twenty (20) Calendar days in advance and consequently CLIENT will be informed by
CONTARACTOR. Although CONTRACTOR and CLIENT witnessing is not mandatory.
If CONTRACTOR does not elect to be present, the VENDOR may proceed with his own
inspection, provided controls and test records are made available to CONTRACTOR for
review.

SW: (Spot Witness)

Spot Witness denotes to random attendance of inspector without any invitation from the
VENDOR and without advance notification by the CONTRACTOR to the VENDOR.

R: (Review) – Review of Documents

The VENDOR has either to submit to CONTRACTOR for review and comments the
documents required prior to the performance of the dedicated activity or to transmit or
make available for the review of CONTRACTOR the result of the controls and tests
conducted, as the case may be. Consequently CLIENT will be informed by
CONTARACTOR.

A: (Approval) – Approval of Documents

The VENDOR has either to submit to CONTRACTOR for comments and approvals the
documents required prior to the performance of the dedicated activity or to transmit or
make available for the approval of CONTRACTOR the result of the controls and tests
conducted, as the case may be. VENDOR is not allowed to proceed the work before
receipt of CONTRACTOR approval on the required documents.

Levels of Inspection:

Inspection levels shall be based on the criticality and complexity of the equipment, as
determined by engineering.

Level 1: Full scope inspection

In addition to the visits required for formal witness points, the inspector shall visit the
VENDOR on a regular basis to monitor work in progress. The frequency of visits will
depend on the complexity and size on the order and the quality history of the VENDOR.

Level 1*: Modified Full scope inspection

The visits required for formal witness points are to be performed.
This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

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Project Document Number : BU40 000 EQ ITP 0002
B00 7 of 28

Level 2: Limited Scope Inspection

The inspector shall visit the VENDOR to inspect a limited number of pre-determined
witness points.

Level 3: Final inspection prior to Shipment

The inspector shall provide specific instructions to the VENDOR defining the activities to
be witnessed or the details to be verified.

Level 4: No source inspection required.

The inspector shall review and accept VENDOR’s certifications, test reports and QC
data book documentation.

Level of inspection for this particular ITP is considered as level ‘1’ or ‘1*’. Level of
inspection of Long Lead Items are exception and in any case are being treated as level
‘1’.

6. VENDOR’s Quality Manual and Quality Control Plan (VQCP)

The VENDOR’s Quality Control Plan is a document, which defines in a chronological
manner the list of the operations, controls and tests in accordance with his own “know-
how” and with the requirements specified in CONTRACTOR’s requisition.

The VENDOR must issue a Quality Control Plan for each type or category of material
and component and the following information shall be clearly specified against each
operation:

Reference documents (drawings, procedures, etc …)

Acceptance criteria (code, etc …)
Recording documents for control and tests.

Involvement of the Quality Control department of the VENDOR and/or his Sub-
VENDOR.

The VQCP will have to include all CONTRACTOR and CLIENT inspection activities
defined in inspection and test plan as well as all inspection activities scheduled by the
third party inspection company.

For component of inspection levels 1 and 2 the VENDOR’s VQCP shall be submitted
compulsorily to CONTRACTOR and CLIENT for comments before the Pre-Inspection
Meeting or starting the manufacturing. Vendor’s Quality Manual shall also be submitted
to CONTRACTOR upon request.

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

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Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 8 of 28

7. Inspection Activities
For detail of inspection activities, see relevant inspection and test plan in attachment # 1
as minimum requirements which shall be finalized during PIM.

8. Attachments

8.1 Attachment #1: ITP for Shell and Tube Heat Exchanger (3 Sheets)

8.2 Attachment #2: Test Sequence Standards with reference to TEMA Type of Shell
and Tube Heat Exchangers (13 Sheets)

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 9 of 28

Attachment # 1
ITP for Shell and Tube Heat Exchanger
(3 Sheets)

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 10 of 28

Table: Inspection Activities

APPLICABLE
INSPECTION ACTIVITIES CLIENT / TPI
DOCUMENTS CONTRACTOR

VENDOR’s
VENDOR’s Quality Control Plan R R
Document

Pre-Inspection Meeting Agenda H H

Material Test Certificate BS EN 10204 (3.1) R R

Checking The Material With Requirements of

Requisition W W
Requisition

Inspection of Sub Ordered Components Requisition W W

VENDOR’s
Material identifications and markings W W
Approved Procedure

VENDOR’s
Storage of materials and welding consumables R R
Approved Procedure

Design Code,
WPS/PQR R/A R
ASME Sec IX

Welder’s Qualifications
ASME Sec. IX R/A R
(Note 1)

Design Code,
NDT Personnel’s Qualification ASME Sec V, R/A R
ASNT Lev.II or eqv.

VENDOR’s
Material Traceability W W
Approved Procedure

Dimensional check (before forming & rolling) Approved Drawings W W

Cutting, Forming, Rolling, Punching, Drilling,

Approved Drawings W W
Tacking and Fit up

Inspection of Back Gouged portions of edges Design Code,

W W
prepared for welding by MT or PT ASME Sec V

Tube Expanding / Tube to tubesheet Welding Approved Drawings W W

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 11 of 28

APPLICABLE
INSPECTION ACTIVITIES CLIENT / TPI
DOCUMENTS CONTRACTOR

Tube to Tubesheet joint test (Notes 5) Approved Procedure W W

Design Code,
Welding W R
ASME Sec IX

Bundle Assembly Approved Drawings W R

Confirmation of NDT Results VT, RT, UT, MT, PT Design Code,

W/A R
(Review of all Radiographs) ASME Sec V

Preparation of Production Test Plate Requisition W R

ASME Sec II,

Mechanical Testing of Production Test Plate W R
Requisition

ASME Sec II,

Chemical Analysis of Production Test Plate W R
Requisition

Execution of Major Repair Requisition W W

Completeness check Approved Drawings H H

PWHT/ Stress Relieve

Design Code R/A R
(Note 2)

NDTafter PWHT/ Stress Relieve Requisition R/A R

Roughness checking (Flange Facing, Internal

Approved Drawings W R
Surface, etc.)

Confirmation of Hardness Measurement in Final Design Code,

W R
Condition, if applicable ASME Sec V

Approved Drawings
Final Visual and Dimensional Check H W
and Standards

Reinforcing Pad air-soap test Requisition W W

Leakage Test/Hydrotest Requisition H H

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

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Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 12 of 28

APPLICABLE
INSPECTION ACTIVITIES CLIENT / TPI
DOCUMENTS CONTRACTOR

Complete Draining and drying, N2/VPT/desiccant

Requisition W W
filling, (which applicable)

Surface Preparation, Anti-Corrosion / Painting Requisition W W

Pickling & Passivation (where applicable) Requisition W W

Name plate, Cleanliness, Tagging and Marking Requisition W W

Auxiliary Items (Spare Parts, Bolts, Nuts, etc.) Requisition W W

Packing / Preparation for Shipment Requisition W W

Check Identification and Destination Marking Requisition W R

Pre Shipment Inspection (PSI) Including Packing,

Requisition H H
Marking and Review of Documents

Non Conformities Treatment Requisition W W

Design Code,
NDT Documents R/A R
ASME Sec V

Documentations Requisition A W/R

Control of Packing List - H W

Deviations - H W/R

Final Inspection / Data Book Requisition H/A W/R

Release Note - H H

Notes:
1- If Inspector doubts welder’s ability, Inspector may request Welder for new qualification test.
2- Inspector has right to request VENDOR to witness if he/she deems necessary.
This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
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HDPE PLANT

Inspection and Test Plan

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Project Document Number : BU40 000 EQ ITP 0002
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3- All shop tests shall be done by VENDOR or his SUB-VENDOR.

4- Qualification of sub-VENDORs shall be approved by CONTRACTOR.
5- For lethal / toxic services: Hold Point of CONTRACTOR to be considered.

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
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HDPE PLANT

Inspection and Test Plan

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Attachment # 2
Test Sequence Standards with reference to TEMA Type of Shell and
Tube Heat Exchangers
(13 Sheets)

Hydrostatic test procedure and test ring requirement for Shell and Tube Heat Exchangers: U
tube, Floating head and Fixed Tubesheet are as specified sketches.

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

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for Heat Exchangers

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Project Document Number : BU40 000 EQ ITP 0002
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Fig. 1-1 : Standard for Floating Head Exchangers

Case 1- Shell pressure ≥ bundle pressure

Tests made : Figs 1,3,4

Elements tested:

Fig. 1 - Extra tubular space

a. Tube to tube-sheet joints

b. Tube failure

Fig 3 - Test of removable head

g. Channel
h. Gasket between channel and channel cover
f. Gasket between channel and tube-sheet
d. Floating head cover to tube-sheet

Fig 4 - Test of shell

j. Gasket between shell cover and shell

l. Gasket between channel and tube-sheet
c. Shell + cover

Case 2- bundle pressure > shell pressure

Test made: Figs. 1 (Note 1), 2,3,4

Elements tested:

Fig. 1 - See Case 1

Fig. 2 - Intratubular space

a. Tube to tube-sheet joints

b. Tube failure

Fig. 3 - See Case 1

Fig. 4 - See Case 1

Notes:
(1) This test is made only when the tubes are welded
to the tube-sheet.
(2) For tubes welded to the tube-sheet, a dye-penetrant
examination or test with ammonia must be

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

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Project Document Number : BU40 000 EQ ITP 0002
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Fig. 1-2: Standard for Floating Head Exchangers (Continued)

Case 1- Shell pressure ≥ bundle pressure

Tests made : Figs 1,3,4

Elements tested:

Fig. 1 - Extra tubular space

a. Tube to tube-sheet joints

b. Tube failure

Fig 3 - Test of channel and floating head

c. Channel
d. Gasket between channel and channel cover
e. Gasket between channel and tube-sheet

Fig 4 - Test of shell cover

f. Gasket between shell cover and shell

g Gasket between channel and tube-sheet
h. Shell + cover

Case 2- bundle pressure > shell pressure

Test made: Figs. 1 (as per floating head 1), 2,3,4

Elements tested:

Fig. 1 - See Case 1

Fig. 2 - Intratubular space

a. Tube to tube-sheet joints

b. Tube failure

Fig. 3 - See Case 1

Fig. 4 - See Case 1

Notes:

(1) For tubes welded to the tube-sheet, a dye-penetrant

examination or test with ammonia must be
conducted before and after the hydraulic test to
locate any cracking.

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
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B00 17 of 28

Fig. 1-3: Standard for Floating Head Exchangers (Continued)

Case 1- Shell pressure ≥ bundle pressure

Tests made : Figs 1,3,4

Elements tested:

Fig. 1 - Extra tubular space

a. Tube to tube-sheet joints

b. Tube failure

Fig 3 - Test of channel and floating end

g. Channel and floating end

h. Gasket between channel and channel cover
f. Gasket between channel and tube-sheet

Fig 4 - Test of shell cover

j. Gasket between shell cover and shell

k. Gasket between channel and tube-sheet
l. Shell + cover

Case 2- bundle pressure > shell pressure

Test made: Figs. 1 (Note 1), 2,3,4

Elements tested:

Fig. 1 - See Case 1

Fig. 2 - Intratubular space

a. Tube to tube-sheet joints

b. Tube failure

Fig. 3 - See Case 1

Fig. 4 - See Case 1

Notes:

(1) This test is made only when the tubes are welded
to the tube-sheet.
(2) For tubes welded to the tube-sheet, a dye-penetrant
examination or test with ammonia must be
conducted before and after the hydraulic test to

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

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Fig. 1-4: Standard for Floating Head Exchangers (Continued)

Case 1- Shell pressure ≥ bundle pressure

Tests made : Figs 2,4 (Note 1)

Elements tested:

Fig. 2 - Intratubular space

a. Tube to tube-sheet joints

b. Tube failure
c. Gasket of floating head
d. Gasket of channel
e. Test of channel and floating head

Fig 4 - Test of shell and shell cover

f. Gasket between shell and channel

g. Shell
h. Shell cover
j. Gasket between channel and tube-sheet

Case 2- bundle pressure > shell pressure

Test made: Figs. 1,3,4

Elements tested:

Fig. 1 – Extra tublar space

a. Tube to tube-sheet joints

b. Tube failure

Fig. 3 - Intratubular space

c. Gasket of floating head

d. Gasket between channel and channel
cover
e. Channel and floating head
Fig. 4 – Test of shell and shell cover : See Case 1

Notes:

(1) Test 1 is made only when the tubes are welded

to the tube-sheet.
(2) Provide blind nuts and gaskets for floating tubeshee
(3) For tubes welded to the tube-sheet, a dye-penetran
examination or test with ammonia must be
conducted before and after figures 1 or 2 tests to
This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
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Rev.: Page
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This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
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HDPE PLANT

Inspection and Test Plan

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Fig. 1-5: Standard for Floating Head Exchangers (Continued)

In all cases:
I
Tests made : Figs. 1,2,3
T
Elements tested:
E
Fig. 1 - Extra tubular space
F
a. Tube to tube-sheet joints
b. Tube failure a
c. Floating head and gasket b
c
Fig 2 - Extra tubular space
F
d. Shell
e. Gasket between shell and tube-sheet

Fig 3 - Test of channel

F
f. Gasket between channel cover and channel
Gasket between channel and tube-sheet f
g. Test of channel
g

Notes:
N
(1) If the shell pressure is higher than the channel
Pressure, continue test 1 to the (
shell pressure if possible so as to check
a, b and c.

(2) For tubes welded to the tube-sheet, a dye-

penetrant examination or test with ammonia (
must be conducted before figure 1 test and
after figure 2 test to check the welds and.
locate any cracks.

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 21 of 28

Fig. 1-6: Standard for Floating Head Exchangers (Continued)

In all cases:

Tests made : Figs. 1,3,4 (in the case of welded

tubes, test 2 shall also be made).

Elements tested:

Fig. 1 - Intratubular space

a. Tube to tube-sheet joints
b. Tube failure
c. Floating head and gasket

Fig 2 - Extra tubular space

a. Tube to tube-sheet joints

b. Tube failure

Fig 3 - Testing of shell

d. Shell
e. Gasket between shell and tube-sheet

Fig 4- Testing of channel

f. Testing of channel
g. Gasket between channel and tube-sheet

Notes:

(1) For tubes welded to the tube-sheet, a

dye-penetrant examination or test with
ammonia must be conducted before
figure 1 test and after figure 2 test to
check the welds and locate any cracks.

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 22 of 28

Fig. 2-1: Standard for U-Tube Exchangers

Tests made : Fig. 1,2 (Note 2),3,4

Elements tested:

Fig. 1 - Intratubular space

a. Tube to tube-sheet joints

b. Tube failure

Fig 2 - Extra tubular space

g. Shell
h. Test of Gasket between shell and tube-sheet
j. Tube to tube-sheet joints
k. Tube failure

Fig 3 - Test of channel

c. Test of channel
d. Test of gasket between channel and channel
cover and tube-sheet

Fig 4- Test of shell

f. Test of Gasket between shell and tube-sheet

g. Test of shell

Case 2- bundle pressure > shell pressure

Test made: Figs. 2,3

Elements tested:

Fig. 2 - See Case 1

Fig. 3 - See Case 1

Notes:
(1) For tubes welded to the tube-sheet, a dye-
penetrant examination or test with ammonia must
be conducted before and after figures 1 or 2 tests to
check and to locate any cracks.

(2) This test is made only when the tubes are welded
This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 23 of 28

Fig. 2-2: Standard for U-Tube Exchangers (Continued)

Case 1- Shell pressure ≥ bundle pressure

Tests made : Figs. 2,3,4

Elements tested:

Fig. 2 - Extra tubular space

a. Tube to tube-sheet joints

b. Tube failure

Fig 3 - Test of channel

c. Channel
d. Test of gasket between channel and tube-sheet

Fig 4 - Test of shell

e. Test of shell
f. Test of gasket between shell and tube-sheet

Case 2- Bundle pressure > shell pressure

Test made: Figs. 1,2 (Note 2),3,4

Elements tested:

Fig. 1 - Intratubular space

a. Tube to tube-sheet joints
b. Tube failure

Fig. 2 - See Case 1

Fig. 3 - See Case 1

Fig. 4 - See Case 1

Notes:

(1) For tubes welded to the tube-sheet, a dye-

Penetrant examination or test with ammonia must
be conducted before and after the hydraulic test to
locate any cracking
This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 24 of 28

Fig. 2-3: Standard for U-Tube Exchangers (Continued)

Case1-Shell pressure ≥ bundle pressure

Tests made : Figs. 2,3

Elements tested:

Fig. 2 - Extra tubular space

a. Tube to tube-sheet joints
b. Tube failure
c. Gasket between shell and channel
d. Shell

Fig 3 - Intratubular space

e. Tube to tube-sheet joints
f. Gasket between channel and
channel cover

Case2-Bundle pressure > shell pressure

Tests made : Figs. 1,2

Fig. 1 - Intratubular space

a. Tube to tube-sheet joints

b. Tube failure
c. Channel
d. Gasket between channel and
channel cover

Fig 2 - Extra tubular space

c. Gasket between shell and channel

d. Shell

Notes:

(1) For tubes welded to the tube-sheet, a

dye-penetrant examination or test with
ammonia must be conducted before
figure 1 test and after figure 2 test to
check the welds and locate any cracks.

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 25 of 28

Fig. 2-4: Standard for U-Tube Exchangers (Continued)

Case 1- Shell pressure ≥ bundle pressure

Tests made : Figs. 2,3,4

Elements tested:

Fig. 2 - Extra tubular space

a. Tube to tube-sheet joints
b. Tube failure

Fig 3 - Test of channel

c. Channel
d. Test of gasket between channel and tube-sheet

Fig 4 - Test of shell

e. Test of shell
f. Test of gasket between shell and tube-sheet

Case 2- Bundle pressure > shell pressure

Test made: Figs. 1,2 (Note 2),3,4

Elements tested:

Fig. 1 - Intratubular space

a. Tube to tube-sheet joints
b. Tube failure

Fig. 2 - See Case 1

Fig. 3 - See Case 1

Fig. 4 - See Case 1

Notes:

(1) For tubes welded to the tube-sheet, a dye-penetrant

examination or test with ammonia must be
conducted before and after figure 2 tests to check
the welds and locate any cracks.

(2) This test is made only when the tubes are welded
This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 26 of 28

Fig. 2-5: Standard for U-Tube Exchangers (Continued)

Case1-Shell pressure ≥ bundle pressure

Tests made : Figs. 1,2,3

Elements tested:

Fig. 1 - Intratubular space

a. Tube to tube-sheet joints

b. Tube failure

Fig 2 - Extra tubular space

a. Tube to tube-sheet joints

b. Tube failure
c. Test of shell
d. Test of gasket between shell and tube-sheet

Fig. 3 - Test of channel

e. Test of channel
f. Test of gasket between channel and stationary
tube-sheet, and between channel and
channel cover

Case2-Bundle pressure > shell pressure

Tests made : Figs. 2,3

Elements tested:

Fig. 2 - See Case 1

Fig. 3 - See Case 1

Notes:

(1) For tubes welded to the tube-sheet, a

dye-penetrant examination or test with
ammonia must be conducted before
figure 1 test and after figure 2 test to
check the welds and locate any cracks.

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 27 of 28

Fig. 3-1: Standard for Fixed Tube sheets Exchangers

Case1-Shell pressure ≥ bundle pressure

Tests made : Figs. 1,2

Elements tested:

Fig. 1 - Extra tubular space

a. Shell
b. Tube to tube-sheet joints
c. Tube failure

Fig 2 -Intratubular space

d. Stationary head-bonnet
e. Gasket between bonnet and shell
f. Gasket between shell and channel
g. Channel
h. Gasket between channel and channel cover

Case2-Bundle pressure > shell pressure

Same tests as Case 1, but for figure 2 tests:

- Do not drain after the test of the shell (figure 1 tests)

- Fit a glass tube onto an obturator in an upper nozzle

of the shell.

- Continue filling the shell until the water appears in

the glass tube.
- Pressurize the channel and channel cover and note
the water level in the glass tube.

Any leaks at the tube to tube-sheet joints will be

indicated by the change of level in the glass tube.

Notes:

(1) For tubes welded to the tube-sheet, a dye-penetrant

examination or test with ammonia must be
conducted before and after the hydraulic test to
locate any cracking.

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.
OWNER: CONTRACTOR:
BUSHEHR PETROCHEMICAL COMPANY
HDPE PLANT

Inspection and Test Plan

MC :
for Heat Exchangers

Plant No. Unit Discipline Doc. Type Serial No. Contract No : 52-00/500

Rev.: Page
Project Document Number : BU40 000 EQ ITP 0002
B00 28 of 28

Fig. 3-2: Standard for Fixed Tube sheets Exchangers (Continued)

Case1-Shell pressure ≥ bundle pressure

Tests made : Figs. 1,2

Elements tested:

Fig. 1 - Extra tubular space

a. Shell
b. Tube to tube-sheet joints
c. Tube failure

Fig 2 -Intratubular space

d. Bonnet
e. Gasket between bonnet and
bonnet cover
g. Channel
h. Gasket between channel and
channel cover
Case2-Bundle pressure > shell pressure

Same tests as Case 1, but for figure 2 tests:

- Do not drain after the test of the shell

(figure 1 tests)
- Fit a glass tube onto an obturator in an
upper nozzle of the shell.

- Continue filling the shell until the water

appears in the glass tube.
- Pressurize the channel and channel cover
and note the water level in the glass tube.

Any leaks at the tube to tube-sheet joints

will be indicated by the change of level in
the glass tube.

Notes:

(1) For tubes welded to the tube-sheet,

a dye-penetrant examination or test with
ammonia must be conducted before and
after the hydraulic test to locate any cracking.

This document with all its rights is the property of B.U.P.C. and must be held in confidence. No disclosure, reproduction or other use of the document in
whole or a portion is to made without the prior consent of B.U.P.C.