PAGE

PT. TRUBA JAGA CITA

PT. VALE PROJECT, SOROWAKO - SOUTH SULAWESI 1 OF 6

INSPECTION AND TEST PLAN

ELECTRIC FURNACE-4 REBUILD MAIN CONSTRUCTION

CONTENTS
STRUCTURAL WORKS
INSTALLATION OF FEED TUBE REFRACTORY LINING
DOC. NO: W-TJC-C3101-QAC-146- CWP-040506-L-2090 FURNACE#4 MAJOR REBUILD

ORIGINATED BY REVIEWED BY APPROVED BY DISTRIBUTION

SDCC : Original
QA/QC : Copy
BECA/ : Copy
PVI
Constr : Copy

Al Gazali Nur Wahdam Nuari Wardiansyah

QA/QC Site Co. Project Coordinator Branch Manager BECA/VALE
ISSUED EFFECTIVE
REV NO. BRIEF OF REVISION
DATE DATE

0 August , 9 2021 August , 9 2021

 Page 2 of 6

ITP NO. : W-TJC-C3101-QAC-146

LEGENDS, ABBREVIATIONS, REMARKS OF ITP Rev. No. :
Date : August, 9 2021

PROJECT NAME : ELECTRIC FURNACE # 4 REBUILD MAIN CONSTRUCTION REFERENCES : Scope of work, Drawing, Site queries, PT. VALE Spec ,
OWNER : PT. Vale Indonesia - Sorowako
CLIENT : PT. Vale Indonesia - Sorowako
TJC JOB NO. : C-3101
DESCRIPTION : INSTALLATION OF FEED TUBE REFRACTORY LINING

I LEGEND INSPECTION / SURVEILLANCE CODES

NOTIFICATION : Inspection Request in writing and require a minimum of 24 hours notice of impending inspection / test.
H - HOLD POINT : As notification point, however work may not proceed beyond this point without acceptance or formal waiver from Inspection
Authority ( Client / Owner )
W - WITNESS : Witness of inspection by Client / Owner and Sub-Contractor may proceed if Client / Owner not appearance at the pointed time.
Witness point shall be given by Notification
SW - SPOT WITNESS : Witness of inspection by Client / Owner and to be done at spot or random ( random sample )
R - REVIEW : Review of verifying certificate / Review a document to ensure compliance with specification/Review of inspection report or proc.
A - APPROVAL : Approval documentation ( Procedure, Work instruction, Inspection report, etc. ) or Control document required to be approved
IR : Issued report or documents required (i.e Inspection Report, Mill Certificate, Fabrication Completed Certificate, Etc.)
Note;
1. Inspection and test items covered by this list and applicable requisition and specifications are TJC's general requirements. If any conflict arise
between this list and individual requisition and specifications, the requirements in individual requisition and specification shall govern.
2. The legend used throughout this list shall have the meaning denoted and can be changed to suit with Client or Owner Comments.

II ABBREVIATIONS
AWS AMERICAN WELDING SOCIETY NCR NON CONFORMANCE REPORT RT RADIOGRAPHY TEST
ASTM AMERICAN SOCIETY TESTING OF MATERIAL RFI REQUEST FOR INFORMATION UT ULTRASONIC TEST
DIN DEUTCHES INSTITUT FUR NORMUNG MDR MANUFACTURER'S DATA REPORT PT PENETRANT TEST
WPS WELD PROCEDURE SPECIFICATION NDT NON DESTRUCTIVE TESTING MT MAGNETIC PART. TEST
PQR PROCEDURE QUALIFICATION RECORD PWHT POST WELD HEAT TREATMENT
WQTR WELDER QUALIFICATION TEST RECORD Proc. PROCEDURE
N/A NOT APPLICABLE
III REMARKS
1) Ref. Approval Section of Document.
a : Where there is a Subcontractor element, the Subcontractor involved will sign the approval of the activity.
b : Where there is no Subcontractor element, TJC will sign approval of activity and present to the Client.
2) Inspection and Test Plan (ITP) Status
It is to be understood that the Inspection and Test Plan forms an integeral part of the control/verification documentation.
However, where no other documents are required or exit " The Inspection and Test Plan " only will be understood to be
the control/verification document.
 Page 3 of 6

ITP NO : W - TJC - C 3101 - QAC - 146

REV. NO :
INSPECTION & TEST PLAN (ITP)
DATE : August, 9 2021

PROJECT NAME : ELECTRIC FURNACE # 4 REBUILD MAIN CONSTRUCTION REFERENCES :Scope of work, Drawing, Site queries, PT. VALE Spec ,

CLIENT : PT. Vale Indonesia - Sorowako AWS D1.1

JOB NO : C-3101

DESCRIPTION : ELECTRIC FURNACE # 4 REBUILD MAIN CONSTRUCTION

INSTALLATION OF FEED TUBE REFRACTORY LINING
Inspection Activities
Inspection / Test Activities Verifying
Reference Acceptance Depart.
No Documents /
Process Operation/ Documents Criteria Involve TJC/or Subcon Vale/Client
Characteristic Reports*
Description
I General - Documentation

1 Documentation Specification

Engineering Calculation(if any)

PTI Specification Approved Design,
Drawings (PTVI Drawing) Code/Satndard ( AWS Calculation, Drawing, Approval Document Eng/Cons./QC R R&A
D1.1, SSPC) Procedure
Shop Drawing (TJC Fabrication Drawing)

Procedure and Work Instruction

2 Welding Control WPS Approved WPS & PQR

AWS D1.1, Mill WPS & PQR, WPQR,
Certificate, Welding Material Receiving Approved WPQR
Welder Performance Qualification Test QC,WH/MC H H, R & A
Certificate, Drawing, Inspection Report, Mill (existing/new welder)
Specification Certificate
Welding Consumable As per WPS-AWS

3 NDE Control NDT Procedure AWS Part C C6.10 PT.MT.

SOP, Personnel
AWS D1.1, ASNT Approval Document QC H H, R & A
Qualification Certificate
NDT Personnel Qualification (MT/PT Report)

Material Receiving
4 Verified BOM
Inspection & Storage
BOM, Mill certificate,
Material Receiving Correct as per BOM/
Mill Certificate Code/Standard, Mat’l QC,WH/MC H H, R & A
Inspection Report drawing
spec.
Packing list, etc.

Material Receiving
5 Inspection & Storage (if Verified BOM
supply by TJC) BOM, Mill certificate,
Material Receiving Correct as per BOM/
Code/Standard, Mat’l QC,WH/MC H H, R & A
Mill Certificate Inspection Report drawing
spec.

Packing list, etc.

 Page 4 of 6

Inspection Activities
Inspection / Test Activities Verifying
Reference Acceptance Depart.
No Documents /
Process Operation/ Documents Criteria Involve TJC/or Subcon Vale/Client
Characteristic Reports*
Description
II General Works

1 Civil Works

Refractory Preparation Form work (Location, Dimension,

Orientation, Elevation/Verticality, Pre-Castable Report
Oil/Cleanliness) Drawing, Site query, Correct as per
Cons., QC W&R SW, R & A
Refractory Instruction drawing/site query
Embededment item (Location,
Pre-Castable Report
Dimension, Orientation)
2 Construction Works

Craneage (Rigging & Lifting) (if

Section I.2 See Section I.2 Approval Document Cons., HSE M H, R & A
required)
III INSTALLATION OF FEED TUBE REFRACTORY LINING

1 Pre-Shutdown Work

Prepare a refractory installation and dry

out plan for each feed tube Drawing, Scope of Work, Correct as per
1. Installation PlanninG - Cons., M M
section. Have this approved by the Site Query/CWP drawing/site query
refractory installation specialist.

Set up ventilated work area for

Drawing, Scope of Work, Correct as per
2. Area Preparation Refractory Ceramic Fibre (RCF) board - Cons., M M
Site Query/CWP drawing/site query
preparation.

Drawing, Scope of Work, Correct as per

Set up refractory mixer. - Cons., M M
Site Query/CWP drawing/site query
Set up diesel burner (including stack) Drawing, Scope of Work, Correct as per
- Cons., M M
for firing. Site Query/CWP drawing/site query

Request feed tubes (fabricated by PT

Vale Fabrication Shop) from
project warehouse excluding all feed
3. Request and
tubes requiring field fits and last Drawing, Scope of Work, Correct as per
Identification of feed - Cons., M M
straight top section of each feed system Site Query/CWP drawing/site query
tubes
assembly (these will be cast
after field fitting has been completed
during the shutdown).

Identify each of the feed tubes and Drawing, Scope of Work, Mechanical Checklist Correct as per
Cons., M M
check the dimensions. Site Query/CWP Report drawing/site query

Cut the RCF Board into 50mm wide

strips, apply heat resistant adhesive and
4. Installation of RCF Drawing, Scope of Work, Correct as per
install the RCF board tight against the - Cons., M M
board Site Query/CWP drawing/site query
internal perimeter surface of the feed
tubes and the top and bottom flanges.

Coat RCF board with sodium silicate and

leave to dry. Ensure that
Drawing, Scope of Work, Correct as per
the sodium silicate coating has dried - Cons., M M
Site Query/CWP drawing/site query
prior to installing the castable
refractory.

Rods in the rod gate spool pieces are to

Drawing, Scope of Work, Correct as per
5. Casting of Refractory be fitted prior to the installation of the - Cons., M M
Site Query/CWP drawing/site query
refractory lining.
 Page 5 of 6

Inspection Activities
Inspection / Test Activities Verifying
Reference Acceptance Depart.
No Documents /
Process Operation/ Documents Criteria Involve TJC/or Subcon Vale/Client
Characteristic Reports*
Description

Identify relevant polystyrene formwork

for each feed tube, make sure the Drawing, Scope of Work, Mechanical Checklist Correct as per
Cons., M M
refractory castables has not expired or Site Query/CWP Report drawing/site query
damaged.

Install the polystyrene formwork in the

center of the feed tubes and
support with a 1.5" NB pipe, pre-cut Drawing, Scope of Work, Correct as per
- Cons., M M
plywood for the stop end at the Site Query/CWP drawing/site query
bottom and the centralizing jig at the
top.

Mix the refractory as per the refractory

suppliers procedure.

Level the feed tube section so the top Drawing, Scope of Work, Correct as per
Inspection Report Cons.,QC W&R SW, R & A
flange is in the horizontal Site Query/CWP drawing/site query
position and install castable refractory
into the feed tube sections through one
continuous pour.

Once casting is complete cover the feed

Drawing, Scope of Work, Correct as per
tube and allow to air cure for - Cons., M M
Site Query/CWP drawing/site query
24 hours prior to firing.

6. Drying Out of Castable

Assemble feed tube sections for drying.
Refractory

Dry out the feed tube sections as per Drawing, Scope of Work, Mechanical Checklist Correct as per
Cons.,QC W&R SW, R & A
the castable manufacturers dry Site Query/CWP Report drawing/site query
out schedule to remove all of the free
water and the majority of the
combined water.

2 Shutdown Work

Feed Tubes (excluding field fit items)

1. Field Fit Tube Drawing, Scope of Work, Correct as per
are installed in the field under - Cons., M M
Refractory Installation Site Query/CWP drawing/site query
the reference CWP

Feed tube sections requiring field fit

shall be requested from project Drawing, Scope of Work, Correct as per
- Cons., M M
warehouse and taken to site for field Site Query/CWP drawing/site query
measurement.

Field fit feed tube sections shall then be

Drawing, Scope of Work, Correct as per
transported to the refractory - Cons., M M
Site Query/CWP drawing/site query
shop for casting.

Install refractory (including RCF board)

Drawing, Scope of Work, Correct as per
in the field fit sections by Inspection Report Cons.,QC W&R SW, R & A
Site Query/CWP drawing/site query
repeating steps 3.2 to 6.2.

Final
Pre-Handover Activities Scope of work, Inspection(inclu
IV Task completed Punch list Completed work
(Start up & Commisioning) Drawing ding as built
drawing)

W&R W, R & A
 Page 6 of 6

Inspection Activities
Inspection / Test Activities Verifying
Reference Acceptance Depart.
No Documents /
Process Operation/ Documents Criteria Involve TJC/or Subcon Vale/Client
Characteristic Reports*
Description
W&R W, R & A
Up date all
records Review
for Compliance
forward to PM

Notes: * All Inspection Report/Checklist will be issued base on the Section II - Steel Structutal Works item (Civil/Structural Works) unless otherwise specified.