SUPPLY VERIFICATION ITP-SV-M- PIPEWORK

PIPEWORK
INSPECTION & TEST PROCEDURE

A) INTRODUCTION

The following procedure is intended to ensure that the quality of procured product and its associated
activities are completed by competent persons and:
1. Comply with current and applicable specified requirements (including Corporation specifications /
contract terms and conditions, national / international standards, manufacturer’s
recommendations and industry best practices.
2. Are conducted in a safe and professional manner.
3. Provide an audit trail for verification of Quality Assurance and Quality Control compliance.

This procedure is for all PIPEWORK of various materials of construction inclusive of fittings and gaskets.
This may include carbon steel, mild steel cement lined (MSCL), ductile (DICL) and cast iron cement lined
(CML), galvanised steel, stainless steel (SS) , copper, cast and ductile iron (DI), polymer based
(ABS/PE/HDPE/PVC-U/PVC-M) and fibreglass (GRP).

Competent personnel shall complete all inspection / construction activities and record all activities on
Water Corporation Document (ITP-SV-M- PIPEWORK) for each asset inspected. Note a welding and
corrosion /coating inspector maybe required particularly for prefabricated welded pipe specials/spools.

NOTE:
 Please ensure that all ITP documents are completed by a competent person and that all Water
Corporation SAFETY and operational requirements are to be complied with at all times in
relation with Water Corporation and Australian Standards where applicable.

B) COMPLETED DOCUMENTS

Completed documents are to be scanned and saved as a .pdf file in the relevant AQUA folder utilising
the following naming convention:

LOCATION - DISCIPLINE - ASSET – ASSET TYPE – VENDOR NAME – DOCUMENT TYPE – P&ID
TAG – REVISION NUMBER

E.g. RavenswoodPS_M_Valve_Butterfly_Tyco_SV_1000BV3422_1

The commissioning manager shall coordinate incorporation of completed ITPs in conjunction with the
CAMEL.

Feedback on improvements to ITPs should be directed to MESB Mechanical for incorporation into future
versions.

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AQUADoc No: 6259963 Document Custodian: Team Leader – Mechanical
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INSPECTION & TEST PROCEDURE

* All Supply Verification documents shall contain the following sections (1 – 2) which capture generic asset
information

1. REFERENCE INFORMATION
INSPECTION DATA ASSET DATA
PROJECT NAME: MANUFACTURER:

LOCATION: MF SERIAL NO:

INSPECTION DATE: WC FLER / TAG NO:

INSPECTOR NAME: TYPE / MODEL NO / SIZE:

PROJECT / CONTRACT NO: DESIGN CRITERIA:

ATTENDEES:

2. INSPECTION PREPARATION
OSH compliance requirements.
Obtain QA / QC documentation (review outstanding items).
Relevant Water Corporation standards.
Relevant Australian Standards.
Supporting contract documentation / approved drawings.
Provision of required test equipment.
Provision of required test reports and certificates; i.e. hydrostatic test, material certificates, etc.

*Contents of Section 3 (Inspection) and Section 4 (Test) are Asset Specific and shall reflect relevant SPS /
Australian Standard(s) where practicable. Entries shall also be worded to reflect the procedures involved in
a step-by-step manner; i.e. “Conduct visual inspection and ensure pre-start photographs are taken”,
“Extract bearing housing covers to expose bearings and full shaft length”.

3. INSPECTION YES NO N/A COMMENTS/DETAILS

GENERAL
Check:
Locate and verify that pipework label details
1 match specification and contract Design Standard/Nominal Bore
Diameter/Design Pressure/Type of Fluid/Max
requirements Surge Pressure

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INSPECTION & TEST PROCEDURE

Confirm if datasheets have been provided Hardcopy / softcopy? (please circle)

2
(hardcopy / softcopy)

MATERIALS AND ARRANGEMENT

Verify construction materials with material Check:

3
certs, specification and relevant drawings Material Type/Grade/Standard
Attach a copy of the pipework drawing to this
Confirm major key dimensions correct per
4 record sheet highlighting on the drawing
drawing which dimensions were checked.
Ensure a welding consultant is engaged and
5 Verify that all welds meet WS-1 requirements all associated welding documents are
obtained

Pipes

6 External coating meet specification? Coating Type: Sintakote/Painted

Check suitability on the basis of:

1. Corrosivity
Check material for suitability for fluid or gas
7 2. Temperature
characteristics 3. Hazard level of fluid/gas
4. Water quality issues
Check suitability on the basis of:
1. Above Ground or Buried
Check material for suitability for
8 2. Soil corrosivity
environmental conditions 3. Exposure to sunlight
4. Dissimilar metal corrosion
For carbon steel pipe confirm it is seamless
9
or electric resistance welded (ERW)
For cement mortar lined piping (MSCL or
Thickness:…………mm
10 CML) confirm the uniformity and thickness of
lining meets WC specifications
Confirm the cement lining is profiled to match
11 any machinery interface such as pump
suction nozzles
Confirm the cement lining is free of
12 excessive cracking and porosity especially
around tapping points
For H2S attack prone application is the
13
cement lining coated to prevent corrosion
Confirm cement lining will not interfere with
14
operation of valves
Check tapping points are located correctly Ensure air venting points are located at the
15 highest locations
and plugs are installed were applicable
16 Confirm earthing studs are fitted
Ensure anode brackets and ribbons are fitted
17
and secure
Temporary internal bracing installed for Applicable to large diameter thin walled
18 MSCL pipework
transport if applicable?
Applicable to:
For Polymer based pipes check for external HDPE/PE/PVC-O/PVC-M/PVC-U/ABS
19
cracking, kinks and sun-damage Note pipe maybe supplied on a reel which will
require unrolling to allow thorough inspection

20 For ABS and PVC-U/M, confirm the pipework

is not subject to cyclic loading such as those
related to multiple pump starts/stop and
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valve opening/closing
Ensure where ABS joins to PVC piping that
21 the solvent cement is compatible to both
materials
Confirm PVC-U is not being used on
22
compressed air lines
For copper pipe check for signs of work
23
hardening, kinks and zinfication
For copper confirm the pipe is designed to
24 accommodate capilliary or compression cone
fittings
For galvanise steel confirm pipe has been
25
hot dipped galvanised
For GRP piping confirm the nominal stiffness
26
(SN) is 5000 or greater
For buried ductile iron (DI) pipe confirm
internals are CML and external is cold
27
applied bituminous paint (short term) and
external polyethylene sleeve (long term)
For polyethylene pipe (PE) ensure it is either
Note the colour and striping of the pipe for
28 medium or high density with a PN12.5 or identification
greater rating
For stainless steel pipe (SS) confirm the
29 schedule is 10S or greater and low grade
carbon content when welding is required
For spiral welded (SS) pipe confirm this has
30 been TIG welded and used only upto 75mm
pipe
Confirm stainless steel pipework has been
31
pickled and passivated
Threaded/Flanged/Victaulic/Welded/
/Compression/Camlock/Bevelled/Elastomeric
Confirm end connections are correct to suit
32 Seal Joint/Solvent Cement Welding/ Rubber
fittings Ring joints

Flanges
33 Design Standard: AS……../EN…….….
Confirm flange standard correct
34 Weldneck/Plate/Slip-
Check flange type is correct On/Threaded/Loose/Socket Weld/Blind
35 Raised/Flat
Ensure flange facing and finish is correct
36 Check flange thickness is correct Thickness: ……..mm
37 Confirm outside diameter is correct Class:
38 Confirm pitch circle diameter is correct PCD: _____________ mm
39 Ensure number and diameter of drilled bolt No.:______ Dia.:________ mm
holes are correct
40 Check number and diameter of threaded bolt No.:______ Dia.:________ mm
holes are correct
41 Check threads on holes are free of defects Use GO/NO-GO gauge if applicable
42 Confirm spot facing on bolt head landings
Elbows/Bends/Tees/Reducers/Strainers
43 Confirm end connection correct ? Threaded/Flanged/Victaulic
/Compression/Camlock

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INSPECTION & TEST PROCEDURE

44 Diameter correct? DN_____mm

45 Angle of fitting correct? Degrees:___
46 Aperture of strainers correct to suit process Aperture: ____ mm
fluid expected filtrate?
Pipe Supports/Restraints
47 Confirm support/restraint type is suitable for Fabricated/Clamp Stye/Free-sliding/
intended pipe
48 Confirm fabricated support/restraint key
dimensions are correct
49 For “off the shelf” supports check details These may include Binder engineered
match drawings and specification supports
50 Confirm mounting baseplate matches
drawings and specification
51 Check mounting baseplate squareness
relative pipe centreline and mounting surface
52 Confirm pipe supports for stainless steel pipe
is made of either stainless or hot dipped
galvanised
Pipe Specials/Flange Matching Piece
53 Confirm pipe special’s dimensions are
correct
54 Threaded/Flanged/Victaulic
Check end connection details are correct /Compression/Camlock/Bevelled

55 Confirm flange detail is correct in-line with

previous checklist items above
56 Confirm cement motor lining meets WC
standards
57 Lifting eyes/lugs correctly located and fitted Ensure a welding consultant is engaged and
all associated welding documents are
or welded? obtained
58 Anode brackets and ribbons fitted and
secure?
59 Confirm crotch plate detail is correct
Joints and Fittings
60 For copper pipe confirm the fittings are either
capilliary or compression cone type
61 For copper capilliary long engagement
sockets, silver solder shall be used
62 For copper capilliary short engagement
sockets, brazing alloy shall be used
63 For ABS pipe joints confirm the use of
solvent cleaner and cement shall be used
64 For duct iron pipe confirm the use of flanged
or socketed joints
65 For MSCL pipework confirm welded bands
provided meet WC specifications
66 Low Pressure
Male: BSPT-R series
For stainless steel (SS), fittings should be Female: BSPP –RP series
screwed High Pressure
NPT
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Gasketing
67 Confirm compressed fibre gasket are utlised
in-lieu of o-rings and reinforced fabric
gaskets
68 For compressed fibre gaskets confirm Thickness normally 1.5mm to 3mm
thickness is as specified
69 Where natural rubber or EPDM is being used
confirm hydrocarbons are not present in the Use NBR in high hydrocarbon applications
gas or liquid
70 Confirm for gaseous chlorine and chlorine
solution lines that gaskets are made of FPM
(Viton)
71 Confirm the gasket is correctly full or narrow
faced to suit pressure rating and pipework
size

4. TEST PASS FAIL N/A COMMENTS/DETAILS

1 Confirm Material certificates are acceptable
Confirm welding documentation (incl NDT)
2
are acceptable
Confirm heat treatment certificates are
3
acceptable
Confirm pickling and passivation evidence
4 documentation is acceptable for stainless
steel

*Contents of Section 5 to be retained where applicable; i.e. if coatings inspection is required. Sections 6-9
to be retained in all ITPs.

5. COATINGS INSPECTION YES NO N/A COMMENTS/DETAILS

Verified construction materials with specification and
1 Substrate material:
relevant drawings
Review surface pre-treatment and/or preparation
2 procedure (circle PH: Epoxy Coating on Steel/Cast PA / OTHER _________________
Iron or state Other)
Verify coating system and specification ensuring that
3
product is approved for purpose
Ensure that surface preparation was acceptable and
free from contaminants prior to coating/complies to Class of surface finish (if known):
spec1 Consider dust and spent abrasive, oil and
4
contamination, flash rusting, slag, porosity, weld Profile (if known):
spatter, sharp edges, free from laminations, free Coating application (if known):
from burrs etc
5 Consider if conditions acceptable for testing2. Conditions:
Surface temperature should be least 3ºC above dew
point and relative humidity less than 85 % before

1
Refer to AS/NZS 1627 series for Metal Finishing – Preparation and Pretreatment of Surfaces
2
Refer to AS/NZS 3894.7 for practical procedure for Determination of Surface Temperature of metal surfaced (pre-coating)
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AQUADoc No: 6259963 Document Custodian: Team Leader – Mechanical
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testing
Fully cured coating system should be adherent while
6 Failure force (if known):
in their service condition (Method AS/NZS 3894.9)
Assess degree of cure and hardness of coating is
acceptable (method AS 3894.4). Allow sufficient
7 drying and curing of the coating prior conducting Method used:
testing. The length of time shall be obtained from
the coating manufacture.
Checked that flange faces are clean and are free
8 from any defects resulting from corrosion or any
other cause
Visually inspect surfaces and ensure is adequately
9 Method/chemicals used:
clean and dry prior to testing
Check internal coating type and verify in accordance
with relevant specification (circle PH: Epoxy Coating
10 PA / PH / OTHER _____________
on Steel/Cast Iron or state, PA: Protective Coating
on Steel/Cast Iron or state Other)
Visually inspect condition of internal coating
appearance including uniformity, colour and free
11
from any defect that could impair performance
and/or appearance of coating.
Check external coating type and verify in accordance
with relevant specification (circle PH: Epoxy Coating
PA / PH / PS/ OTHER
12 on Steel/Cast Iron or state, PA: Protective Coating
_____________
on Steel/Cast Iron or state, PS: Inorganic zinc
silicate primed two pack acrylic coating or Other )
Visually inspect condition of external coating
appearance including uniformity, colour and free
13
from any defect that could impair performance
and/or appearance of coating.
Calibrate thickness tester to standard of uniform and Method/instrument used3:
14 calibrated thickness, covering appropriate range of
film thicknesses to be measured
Visually inspect and measure4 dry film thickness (DFT) in at least 10 locations on coated surfaces. Record
15 values, ensure compliance with spec and record in table below (note that Flange Thickness is not considered
acceptable if not within minimum – maximum range)
Ensure coating fully cured prior continuity testing by
Temp/time:
16 checking datasheet for required time to full cure or
Test method:
other appropriate test method
Calibrate holiday detector (spark tester) electrode
with appropriate volt meter which has been
17 laboratory calibrated within the last 2 years to Brand/model used:
proposed voltage. Record brand and model of spark
tester to be used.
18 Carry out spark test on internal coating in Test Voltage: V
accordance to AS/NZS 3894.1 Continuity testing of

3
Refer to AS/NZS 3894.3 methods for Determination of Dry Film Thickness
4
Method AS 3894.3 refers Determination of Dry Film Thickness
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non-conductive coating – High Voltage (brush)

method. Specify voltage at which test is carried out.
Carry out spark test on external coating accordance
to AS/NZS 3894.1 Continuity testing of non-
19 Test Voltage: V
conductive coating – High Voltage (brush) method.
Specify voltage at which test is carried out.
Asset passes continuity testing with zero defects
(including pinholes, holidays, cracks and other
discontinuities) detected in finished coating for
20
immersed/buried conditions and/or subsequent
repairs have been carried out before being placed in
service.

Coating Complies
Internal (micrometers): External (micrometers): Flange (micrometers ):
Thickness: with Spec?
Specified min N/A
Specified max N/A
Measured 1
Measured 2
Measured 3
Measured 4
Measured 5
Measured 6
Measured 7
Measured 8
Measured 9
Measured 10
Average
Note any comment or variation to test procedure that will assist in interpretation of results:

Refer to AS/NZS 1627 series for Metal Finishing – Preparation and Pretreatment of Surfaces
2
Refer to AS/NZS 3894.7 for practical procedure for Determination of Surface Temperature of metal surfaced (pre-coating)
3
Refer to AS/NZS 3894.3 methods for Determination of Dry Film Thickness
4
Method AS 3894.3 refers Determination of Dry Film Thickness

TARGET
6. REMARKS / REMEDIAL / FOLLOW UP ACTIONS ACTION BY STATUS
DATE

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AQUADoc No: 6259963 Document Custodian: Team Leader – Mechanical
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7. SIGNOFFS
NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

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AQUADoc No: 6259963 Document Custodian: Team Leader – Mechanical
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POST TRANSPORTATION INSPECTION

 Inspection to be completed at point of delivery

 If a supply verification was not completed at the manufacturer, both supply verification and post
transportation inspection should be completed at point of delivery.

8. POST TRANSPORTATION REMARKS / REMEDIAL / FOLLOW UP TARGET

ACTION BY
ACTIONS DATE

9. SIGNOFFS
NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

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AQUADoc No: 6259963 Document Custodian: Team Leader – Mechanical
Version Date: 30/12/2015 Next Review Date: 30/12/2017