033-itp for piping installation ag and ug.pdf
TRANSCRIPT
-
Pearl GTL Project
LINDE ENGINEERING
Shell Project No: HP-3000-QAT Contractor Project No: 5887
Project Document Number: T- 4.250.918 Project Rev.: A Page 2 of 10
Purchase Order Number:
2MH127
Tag/Item Number(s): N/A
Unit(s): ASU
PCWBS: Z
-
QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION
D A 27.07.08 Ready for Construction AB EO AG RFC
C O 23.12.07 Issued for Company comments BR AU/MC ZG ICC
B 15.12.07 Issued for Review BR AU/MC ZG IFR
A 02.12.07 Issued for Internal Review BR AU/MC ZG IIR
GAMA Rev.
Project Rev
Date Description Prepared
By Checked
By
Approved By
Status
No. No. ORIGINATOR
LINDEGINEERING AG
Document Title:
INSPECTION TEST PLAN FOR PIPING INSTALLATION A/G AND U/G
Contractor
Gama Qatar Co. W. L. L.
Document No. LOC470
GAM ITP QAC GTL 033 D
Org.
Code
Doc.
Type
Disc. Code
Geogr. Area
Seq.
No
Rev. No
Vendor Code
Project Document Number: T-4.250.918
Rev No: A
-
QSGTL PEARL PROJECT Document No.: GAM-ITP-QAC-GTL-033
C2 ASU Construction Works
ITP FOR PIPING INSTALLATION -AG/UG (FSI) DATE: 27.07.08 REV. D
S. GAMA QATAR X. CONTRACTOR QC C. COMPANY A. THIRD PARTY (TPI)
I: INSPECTION / TEST R: DOCUMENT ISSUED/REPORT REVIEW S: SURVEILANCE H: HOLD POINT (Notification Required and Presence Mandatory). W: WITNESS (Notification Required but Presence not Mandatory)
Item Activity Test
Frequency Reference Document Acceptance Criteria
Responsible Party
Verifying Documents S X C A
T-4.250.918 Rev.A Page 4 of 10
1.0
DOCUMENTATION
1.1 Contractor isometric drawings / Spool drawings
100%
T.4.234.542;T.4.250.935; T.4.250.936
RFC QCI RFC H R R
1.2 Approved W.P.S.
100%
T.4.251.025; T.4.250.938
DEP 30.10.60.18;ASME SEC IX;ASME B31.3;
T.13.377.441;T.13.377.433E;
WI GAM-QCR-QAC-GTL-106 H H R
1.3 Approved PQRs 100% T.4.251.025; T.4.250.938 WI GAM-QCR-QAC-GTL-105 H H S H
1.4
Welder Performance Qualifications
100%
T.4. T.4.250.939 WI
GAM-QCR-QAC-GTL-100 WSD-QC 2
WSD-QC 3
H H W
1.5 Verify calibration of inspection, measuring and test equipment
100%
T.4.250.915 DEP 30.10.60.18; T.13.377.433E;
T.13.377.441; T.13.377.437E QCI Calibration certificate H I / R R
2.0 MATERIALS
2.1 Receiving inspection / Verification of Material
100% T.4.250.927;T.4.250.928; T.13.376.797E; T.13.377.438E QCI LINDE MRCR SYSTEM H I R
2.2 Storage & Segregation of Material
100%
T.4.250.927;T.4.250.928; T.4.250.932
T.13.377.454E; T.13.377.438E QCI H I R
2.3 Welding consumable control & storage procedure
100%
WPSs / PQRs; T.4.250.931
ASME SEC II PART C
DEP 30.10.60.18; T.13.377.433E; T.13.377.437E
T.13.377.441;T.4.096.687
WI Test certificate 3.1 B H I I / R
-
QSGTL PEARL PROJECT Document No.: GAM-ITP-QAC-GTL-033
C2 ASU Construction Works
ITP FOR PIPING INSTALLATION -AG/UG (FSI) DATE: 27.07.08 REV. D
S. GAMA QATAR X. CONTRACTOR QC C. COMPANY A. THIRD PARTY (TPI)
I: INSPECTION / TEST R: DOCUMENT ISSUED/REPORT REVIEW S: SURVEILANCE H: HOLD POINT (Notification Required and Presence Mandatory). W: WITNESS (Notification Required but Presence not Mandatory)
Item Activity Test
Frequency Reference Document Acceptance Criteria
Responsible Party
Verifying Documents S X C A
T-4.250.918 Rev. A Page 5 of 10
2.4 Cutting /Transfer of heat No.s
100% Drawings;T.4.250.928
DEP 30.10.60.18; ASME B 31.3 T.13.377.433E; T.13.376.815E
DEP 31.38.01.11; DEP 31.38.01.31; T.13.376.796E;
QCI GAM-QCR-QAC-GTL-072 H I S
2.5 PAMI 100% T.4.250.934;T.4.250.938 WI WSD-QC 4 H I S
3.0 WELDING
3.1 Welder identification and
performance verification 100% T.4.250.938;T.4.250.939
DEP 30.10.60.18; T.13.377.433E ; T.13.377.441 ASME B 31.3
WI WSD-QC 2 H I I / R
3.2 Issue of welding consumable to welder
100% T.4.250.931: T.4.250.938 WI GAM-QCR-QAC-GTL-060 H I S
3.3 Fit-up and tack welding 100% T.4.250.938;T.4.250.936
WPSs / PQRs
DEP 30.10.60.18;ASME B 31.3 T.13.377.433E; DEP 31.38.01.31;
T.13.376.796E; T.13.377.441 WI
GAM-QCR-QAC-GTL-098
H I S
3.4 Root pass visual inspection
100% T.4.250.938;T.4.250.935; T.4.250.937
DEP 30.10.60.18; ASME B31.3 T.13.377.433E; T.13.377.441
WI I I S
3.5
Root pass magnetic check for
Stainless steel materials
100%
T.4.250.938
DEP 30.10.60.18 T.13.377.433E
WI GAM-QCR-QAC-GTL-098 H I S
3.6
Dissimilar joint welding
100% WI GAM-QCR-QAC-GTL-107 H H H
-
QSGTL PEARL PROJECT Document No.: GAM-ITP-QAC-GTL-033
C2 ASU Construction Works
ITP FOR PIPING INSTALLATION -AG/UG (FSI) DATE: 27.07.08 REV. D
S. GAMA QATAR X. CONTRACTOR QC C. COMPANY A. THIRD PARTY (TPI)
I: INSPECTION / TEST R: DOCUMENT ISSUED/REPORT REVIEW S: SURVEILANCE H: HOLD POINT (Notification Required and Presence Mandatory). W: WITNESS (Notification Required but Presence not Mandatory)
Item Activity Test
Frequency Reference Document Acceptance Criteria
Responsible Party
Verifying Documents S X C A
T-4.250.918 Rev. A Page 6 of 10
3.7
Inter pass temp controlling /
cleaning
100%
T.4.250.938 DEP 31.38.01.31;ASME B31.3
T.13.376.796E; WI AS PER WPS I I S
3.8
Arc strike control and repair 100% T.4.250.938 DEP 30.10.60.18;ASME B 31.3
T.13.377.433E; T.13.377.441
WI GAM-QCR-QAC-GTL-042 GAM-QCR-QAC-GTL-043
I I S
3.9 Weld identification and marking
100% T.4.250.938;T.4.250.935 WI GAM-QCR-QAC-GTL-098 I I S
3.10
Welding, purge log (St-steel), process parameter monitoring
100%
T.4.250.938; T.4.250.901 WPSs / PQRs
DEP 30.10.60.18;ASME B31.3 T.13.377.433E; T.13.377.441 DEP
31.38.01.31; T.13.376.796E; WI GAM-QCR-QAC-GTL-090 I I S
3.11 Visual Inspection of Welds 100% T.4.250.931 DEP 30.10.60.18; ASME B31.3 T.13.377.433E; T.13.377.441
WI GAM-QCR-QAC-GTL-098 H H S
4.0 POST WELD HEAT TREATMENT
4.1 PWHT 100%
T.4.250.913;T.4.250.938 DEP 30.10.60.18;ASME B31.3
T.13.377.433E DEP 31.38.01.31; T.13.376.796E; T.13.377.441
WI GAM-QCR-QAC-GTL-083 I I I
4.2
HARDNESS Test (if required)
100% WI WSD-QC 5 S/R S/R S/R
5.0 NON DESTRUCTIVE EXAMINATION
5.1 Radiographic Film Interpretation/
ultrasonic examination 100% T.4.250.914;T.4.250.938
DEP 31.38.01.31; ASME B31.3 T.13.376.796E;
WI WSD-QC 6 WSD-QC 7
H I / R I / R
-
QSGTL PEARL PROJECT Document No.: GAM-ITP-QAC-GTL-033
C2 ASU Construction Works
ITP FOR PIPING INSTALLATION -AG/UG (FSI) DATE: 27.07.08 REV. D
S. GAMA QATAR X. CONTRACTOR QC C. COMPANY A. THIRD PARTY (TPI)
I: INSPECTION / TEST R: DOCUMENT ISSUED/REPORT REVIEW S: SURVEILANCE H: HOLD POINT (Notification Required and Presence Mandatory). W: WITNESS (Notification Required but Presence not Mandatory)
Item Activity Test
Frequency Reference Document Acceptance Criteria
Responsible Party
Verifying Documents S X C A
T-4.250.918 Rev. A Page 7 of 10
5.2
Liquid Penetrant 100%
T.4.250.909;T.4.250.938 WI WSD-QC 9 H I / R I / R
5.3 Magnetic particle 100% T.4.250.911;T.4.250.938 WI WSD-QC 8 H I / R I / R
5.4 FERRITE CHECK 100% T.4.250.933 DEP 30.10.60.18; T.13.377.433E
;T.13.377.441 WI WSD-QC 10 H I / R I / R
6.0 REPAIR CONTROL
6.1 Repair authorization 100% T.4.250.940 DEP 30.10.60.18; T.13.377.433E WI
GAM-QCR-QAC-GTL-097
H H I / R
6.2
Removal of defects 100% T.4.250.940 ASME B31.3 WI H I I
6.3 Repair welding 100% T.4.250.940; T.4.250.901 DEP 30.10.60.18;ASME B31.3 T.13.377.433E;T.13.377.441
WI H W I
6.4
PWHT control 100% T.4.250.913 DEP 30.10.60.18;ASME B31.3
T.13.377.433E; T.13.377.441 DEP 31.38.01.31; T.13.376.796E;
WI GAM-QCR-QAC-GTL-083 S/R S/R S/R
6.5 Hardness test (if required) 100% T.4.250.912 WI WSD-QC 5 H I / R I / R
6.6 NDE of repaired weld 100% T.4.250.940;T.4.250.938 DEP 31.38.01.31;ASME B 31.3
T.13.376.796E; WI SAME AS ACTIVITY 5.0 H I / R I / R
6.7 NDE (TRACERS) 100% T.4.250.940;T.4.250.938 ASME B 31.3 WI WSD-QC 11 H I / R I / R
7.-0 FINAL INSPECTION
7.1 Dimensional check 100% T.4.250.936;
Spool Drawings
ASME B 31.3;DEP 31.38.01.31; T.13.376.796E;DEP 31.38.01.11;
T.13.376.815E QCI GAM-QCR-QAC-GTL-091 H I W
7.2 Flanges Alignment 100% T.4.250.936 DEP 31.38.01.11; T.13.376.815E; ASME B 31.3;DEP 31.38.01.31; T.13.376.796E;DEP 61.10.08.11
QCI GAM-QCR-QAC-GTL-058 H W I
-
QSGTL PEARL PROJECT Document No.: GAM-ITP-QAC-GTL-033
C2 ASU Construction Works
ITP FOR PIPING INSTALLATION -AG/UG (FSI) DATE: 27.07.08 REV. D
S. GAMA QATAR X. CONTRACTOR QC C. COMPANY A. THIRD PARTY (TPI)
I: INSPECTION / TEST R: DOCUMENT ISSUED/REPORT REVIEW S: SURVEILANCE H: HOLD POINT (Notification Required and Presence Mandatory). W: WITNESS (Notification Required but Presence not Mandatory)
Item Activity Test
Frequency Reference Document Acceptance Criteria
Responsible Party
Verifying Documents S X C A
T-4.250.918 Rev. A Page 8 of 10
7.3 Torquing of bolts 100% T.4.250.936 DEP 31.38.01.11; T.13.376.815E QCI GAM-QCR-QAC-GTL-041 H W W
7.4 Hydraulic Tensioning of bolting in special flanges/components
100% T.4.250.936 DEP 31.38.01.11; T.13.376.815E QCI GAM-QCR-QAC-GTL-041 H H W
7.5 Piping properly supported
100% T.4.250.936
DEP 31.38.01.11;ASME B 31.3 T.13.376.815E;DEP
31.38.01.29:T.13.376.807E QCI GAM-QCR-QAC-GTL-091 H H W
7.6 Installation of spring supports
100% T.4.250.936
DEP 31.38.01.11; T.13.376.815E; DEP 31.38.01.29; T.13.376.807E
QCI GAM-QCR-QAC-GTL-093 H H W
7.7 Installation of cold/special supports
100% T.4.250.936 QCI GAM-QCR-QAC-GTL-092 H W W
7.8 Support base grouting (if required)
100%
T.4.250.935 DEP 34.19.20.31;
T.13.376.815E;ASME B 31.3 QCI GAM-QCR-QAC-GTL-086 H W I
7.9 Painting of support
100% T.4.250.916 DEP 30.48.00.31; T.13.376.799 QCI/WI GAM-QCR-QAC-GTL-055 H W S
7.10 Inspection and verification of
orifice meter run installation 100% T.4.250.936
DEP 31.38.01.11; T.13.376.815E DEP 61.38.10.10;T.13.375.791E
QCI GAM-QCR-QAC-GTL-095 H W W
7.11 Valve installation (direction of
flow) 100% T.4.250.936
DEP 31.38.01.11; T.13.376.815E ASME B 31.3
QCI GAM-QCR-QAC-GTL-091 H W / R I
7.12 Installation of bellows 100% T.4.250.936 QCI GAM-QCR-QAC-GTL-094 H W W
7.13 Installation of inline items 100% T.4.250.936 QCI GAM-QCR-QAC-GTL-091 H I / R I
7.14 Test pack preparation and
submission 100%
T.4.250.908;Test Pack
DEP 31.40.40.38;DEP 61.10.08.11
QCI H H I
7.15 Preparation of pre-test punch
list 100% QCI GAM-QCR-QAC-GTL-066 H H H
-
QSGTL PEARL PROJECT Document No.: GAM-ITP-QAC-GTL-033
C2 ASU Construction Works
ITP FOR PIPING INSTALLATION -AG/UG (FSI) DATE: 27.07.08 REV. D
S. GAMA QATAR X. CONTRACTOR QC C. COMPANY A. THIRD PARTY (TPI)
I: INSPECTION / TEST R: DOCUMENT ISSUED/REPORT REVIEW S: SURVEILANCE H: HOLD POINT (Notification Required and Presence Mandatory). W: WITNESS (Notification Required but Presence not Mandatory)
Item Activity Test
Frequency Reference Document Acceptance Criteria
Responsible Party
Verifying Documents S X C A
T-4.250.918 Rev. A Page 9 of 10
7.16 Clearance of pre-test punch
list 100% QCI H H H
7.17 As-built documentation 100% T.4.250.908;T.4.250.936 DEP 31.40.40.38;T.13.377.441 QCI H H I / R
7.18 Material traceability records 100% T.4.250.928 T.13.377.438E QCI GAM-QCR-QAC-GTL-072 H W I
7.19 Check of welding / NDE
records 100% T.4.250.908; T.4.250.938 DEP 31.40.40.38 WI
GAM-QCR-QAC-GTL-087 NDE REPORTS
H H R
7.20 Calibration verification and Installation of safety / Relief valves
100%
T.4.250.936; T.4.250.915 DEP 31.38.01.11; T.13.376.815E QCI GAM-QCR-QAC-GTL-111 H H W
7.21 Pressure test 100%
T.4.250.908 DEP 31.38.01.11; T.13.376.815E; ASME B 31.3;DEP 31.38.01.31;
T.13.376.796E QCI
GAM-QCR-QAC-GTL-065 GAM-QCR-QAC-GTL-112
H H H
7.22 Preparation of post test punch list
100%
T.4.250.908 DEP 61.10.08.11 QCI GAM-QCR-QAC-GTL-067 H H I
7.23 Post test punch list clearance 100%
T.4.250.908 QCI GAM-QCR-QAC-GTL-067 H H W
7.24 Flawless Start-up Initiative (FSI) - Cleanliness
Internal
Cleaning
T.13.377.360 Rev E
&T.4.096.688
No external materials inside the pipe & Internal Cleaning shall be
done before erection the pipe
Site Eng
Visual I H I
7.25 Flawless Start-up Initiative (FSI) - Tightness
a) Loose Bolt
b) Wrong Type of
Bolt c) Bolt
tightening
T.13.377.360 Rev E,
DEP 31.38.01.11- Gen Full Tight without leak Site Eng
Joint Integrity Control Procedure T.13.377.453 , T.13.376.815 & Flaw
List
I H I
-
QSGTL PEARL PROJECT Document No.: GAM-ITP-QAC-GTL-033
C2 ASU Construction Works
ITP FOR PIPING INSTALLATION -AG/UG (FSI) DATE: 27.07.08 REV. D
S. GAMA QATAR X. CONTRACTOR QC C. COMPANY A. THIRD PARTY (TPI)
I: INSPECTION / TEST R: DOCUMENT ISSUED/REPORT REVIEW S: SURVEILANCE H: HOLD POINT (Notification Required and Presence Mandatory). W: WITNESS (Notification Required but Presence not Mandatory)
Item Activity Test
Frequency Reference Document Acceptance Criteria
Responsible Party
Verifying Documents S X C A
T-4.250.918 Rev. A Page 10 of 10
7.26 Turn over of quality documents 100%
T.4.250.908: T.4.251.035 QCI QC DOSSIER H I / R