P18136 Sonatrach Exhg Unit Project: Inspection And Test Plan

Inspection and Test Plan Project

:

P18136 Sonatrach exHg unit project

Scope

:

Design, Fabrication, Testing Testing and Supply of inlet and outlet Skid Assembly Assembly (Skid, piping and assembly)

Project Number

:

PRJ0010068

Tag Number

:

10068-1,10068-2,10068-3; Client Tag number: PS-PXE-SERVPACK-01, PS-PXE-SERVPACK-02 PS-PXE-SERVPACK-02

Client

:

Expro Production

Document Number

:

EP-18136-Q-ITP-0002-SPS (10068-ITP-SKD-01)

Client Purchase order number :

:

4500751807

By George Morris at 9:01 am, Nov 14, 2018

:

C

11 Nov 2018

Client comments incorporated

SR

KKN

RMS

B

07 Nov 2018

Issued for approval

SR

KKN

RMS

A

30 Oct 2018

Internal discipline check check

SR

KKN

RMS

Revision Number

Date

Description of revision

Prepared Prepared by

Reviewed Reviewed by

Approved by

Warning: The Warning: The controlled copy of this document is stored on Specialist Services server under (S:\forms\2 qa forms). If you are using a hard copy of this document it is uncontrolled and needs to be compared with the controlled copy at the time of use to ensure that it is up to date. This document is the property of the Specialist Services Group. It may not be copied, reproduced or used wholly or in part in any way without the written permission of Specialist Services. Form QA 26, Rev. 5, Page 1 of 10

ABU DHAB I I DUBAI I JUBAIL I YANBU I DELHI I ABERDEEN I ROTTERDAM I SINGAPORE I HOUSTON

www.specserve.com

Inspectio n and Test Plan

Item number

A A1

Description of operation and inspection activity

Document Number :

EP-18136-Q-ITP-0002-SPS

Level / type of involvement in inspection and testing

Reference document / Acc eptan ce cr iter ia

Record

Customer PO

ITP

QC Engineer

H

H

Project paint specification PS 1112

Painting procedure/ paint system

QC Engineer

H

H

ASME B31.3

Leak test procedure

QC Engineer

H

H

Responsibility

SS

TPI / CA

Client

Documents Inspection and Test plan

A2

Painting procedure

A3

Leak test procedure for assembly Structural

A4

Welding documents WPS, PQR and WPQ

AWS D1.1

Approved WPS,PQR/WPQ

QC Engineer

H

R/A

A5

Review of NDE Procedures (sub- contractor’s) MT

AWS D1.1

Approved NDE Procedures

QC Engineer

H

R/A

A6

NDE Operator Qualification (sub-contractors)

ASNT-SNT-TC-1A

NDE Level II certificate

QCI

H

R

Piping A7

Welding documents WPS, PQR and WPQ

ASME Section IX

Approved WPS,PQR and WPQ

QC Engineer

H

R/A

A8

NDE Procedures (Sub-contractors) RT,MT

ASME Section V ASME B31.3

Approved NDE procedures

QC Engineer

H

R/A


Item number


Document Number :


Record

NDE Operator Qualification (sub-contractors)

ASNT-SNT-TC-1A

NDE level II certificate

A10

Hydrostatic test procedure

ASME B31.3 AFC drawings

Hydrostatic test procedure

GA drawing

AFC drawings

Purchase order , Material specification, International standards

Purchase order, Material specification, International standards

Design

B1

Issuance of fabrication drawings

C

Material

Level / type of involvement in inspection and testing SS

A9

B

Responsibility

EP-18136-Q-ITP-0002-SPS

TPI / CA

Client

H

R

H

R/A

Design Engineer/ Project Engineer

H

-

Material test certificate

Storekeeper / QCI

H

S

Material test certificate

Storekeeper / QCI

H

S

QCI QC Engineer

Structural materials (Steel sections, plates...) C1

C2

D

Incoming material inspection -Physical verification and review of material certificates Piping and assembly materials (Pipes, flanges, fitti ngs, valves, instruments...etc.) Incoming material inspection -Physical verification and review of material certificates Fabrication and Inspection Structural


Item number


D1

Fit-up Inspection (inspection of weld edge preparation, transfer of material marking)

D2

Material traceability

D3

Welding

D4

Visual inspection of Welds -100%

D5

Dimensional Check


Document Number :

Record

Responsibility

EP-18136-Q-ITP-0002-SPS


TPI / CA

Client

AFC drawings

Weld inspection report

Fabrication Supervisor/QCI

H

S

AFC drawings

Material traceability record


H

R

AWS D1.1 WPS

Weld inspection report

Welding Supervisor/QCI

H

S

AWS D1.1

Weld Inspection report


H

W

AFC drawings

Dimensional inspection report


H

W

MT procedure AWS D1.1

MT Reports

QCI

H

S

AFC drawing, Load test procedure, API RP 2A

Load test report

Rigging Supervisor/QCI

H

W

QCI

H

W

NDT D6

MT -100% Primary structure and lifting pad eye welds -10% MT on secondary structure welds Load Test

D7

Load test, 4 point load test on pad eyes, (1.5 X R)

D8

NDE (MT) on pad eyes (after load test) Painting

MT procedure

MT report


Item number


Document Number :


Record

Responsibility

EP-18136-Q-ITP-0002-SPS


TPI / CA

Client

D9

Surface preparation (Check surface profile, cleanliness)


Paint report

Painting Supervisor/ QCI

H

W

D10

Inspection of primer coat


Paint report


H

S

D11

Inspection of 2nd coat


Paint report


H

S

D12

Inspection of final coat(Verification of final colour, DFT)


Paint report

Painting Supervisor/QCI

H

W

E

PIPING

E1

Fit up inspection

AFC drawings

Weld Inspection Report

Fabrication Supervisor

H

S

E2

Material traceability

AFC drawings

Material traceability record


H

R

E3

Welding

ASME Section IX / WPS



H

S

E4

Dimensional Inspection

AFC drawings

Dimensional Inspection Report


H

W

E5

Weld Visual

ASME B31.3


Welding Supervisor/QCI

H

W

E6

NDE Inspection as per drawing -RT- 10% of total welds on butt joints - MT or PT -10% of total welds on fillet joints

ASME B31.3 NDE Procedures

NDE Reports

QCI

H

R/A


Item number


Document Number :


Record

Responsibility

EP-18136-Q-ITP-0002-SPS


TPI / CA

Client

W

H

E7

Hydrostatic Test

Hydrostatic test procedure ASME B31.3

Hydrostatic Report


H

E8

Cleaning and drying after hydro test

Spools cleaned and dried properly

-

Fabrication Supervisor / QCI

H

S

Painting procedure Paint system

Paint Report

Painting Supervisor / QCI

H

S

H

S

H

S

Surface preparation and paintin g E9

Surface preparation (Check surface profile, cleanliness)

E10

Inspection of primer coat

E11

Inspection of 2nd coat

E12

Inspection of final coat(Verification of final colour, DFT)

F

Painting procedure Paint system Painting procedure Paint system

Paint Report Paint Report

Painting Supervisor / QCI Painting Supervisor / QCI

Painting procedure Paint system

Paint report

Painting Supervisor / QCI

H

W

Ass embl y Skid assembly

F1

Assembly of pipe spools, valves and instruments on skid as per drawing

GA/P&I drawings

Check list

Assembly Supervisor

H

S

F2

In process inspection Verification of stud bolts and nuts, gaskets, tightening of bolted joints (bolt torque) as per drawing

P & ID Drawings

Check list

Assembly supervisor/QCI

H

S


Item number



Record

P & ID Drawings

Check list

Leak test procedure Drawings No Leakage

Leak Test Report

Leak test procedure Dried and cleaned assembly

Check list

P & ID Drawings

Check list

F3

Verification of valves, instruments as per drawing

F4

Final assembly water leak test

F5

Drying and cleaning of assembly after water leak test

F6

Installation and testing of instrument line as per drawing

F7

Leak test of instrument line

Test procedure

F8

Verify calibration of instruments

G G1

Electrical and Instrumentation installation Installation and verification of cable trays, power cables, junction boxes

Document Number :

Responsibility

EP-18136-Q-ITP-0002-SPS


TPI / CA

Client

H

W

H

H

H

S

Instrument Supervisor / QCI

H

S

Check list

QCI

H

H

Valid calibration

Calibration certificate

QCI

H

R

AFC drawings

checklist

Electrical supervisor

H

S

AFC drawings

checklist


H

S

QCI Assembly Supervisor / QCI Assembly Supervisor / QCI

G2

Installation and verification of transmitters

G3

Cable laying and cable termination

AFC drawings

ITP


H

S

G4

Earthing of E&I equipment on skid

AFC drawings

ITP


H

S

G5

Cable continuity and insulation resistance testing

Test procedure

Test report

Electrical Supervisor/QCE

H

W


Item number


H

Final Inspection

H1

Final visual inspection, markings, name plate verification of the skid

H2

Weigh the unit & Issue weight report

H3

Inspection Release Note

I

Documentation

I1

Manufacturing Data Book(MDB)

Document Number :

EP-18136-Q-ITP-0002-SPS

Level / type of involvement in inspection and testing


Record

AFC drawings

Name plate photo

QCI

H

W

AFC drawings

Weight report

Rigging Supervisor / QCI

H

R

ITP / All activities as required as per ITP are completed & accepted

Inspection Release Note

Project Engineer / QC Engineer

H

A

MDB index

Completed MDB

Document controller / Project Engineer

H

R/A

Responsibility

SS

TPI / CA

Client

TERMINOLOGY OF QC SURVEILLANCE POINTS H-

HOLD

W-

Inspection points which require acceptance by the designee prior to the continuation of the work. Designee shall b e formally notified about the approaching hold point. Work shall not proceed until hold point is signed off. WITNESS Inspection points which require acceptance by the designee prior to the continuation of the work. The work proceeds if the de signee does not attend and gives his consent. Designee shall be formally notified on approaching witness points.

M/S -

MONITOR / SURVEILLA NCE Random check, by direct or indirect inspection, to ensure conformance of the item or activity.

R-

REVIEW


Item number



Document Number :

Record

Responsibility

EP-18136-Q-ITP-0002-SPS


TPI / CA

Client

Review of documents/records in line with specified requirements. A -

APPROVAL Approval of documents/records to authorize start of activity or process (e.g. final release for shipment, approval to start the inspection activities, system completion and hand-over etc.).

List of applicable forms WP 2.1 WP 2.46 WP 2.15

Weld Inspection Report Welding Inspection Request / Report Weight Report

WP 4.1 WP 8.1

Paint report Pressure testing of piping

WP 7.24

Electrical installation certificate

List of procedures 1. OP06.1 – Procedure for incoming material inspection and testing 2. OP06.2 – Procedure for in process and final inspection 3. WI-AM-0039 – Works instruction for load testing 4.

Welding Procedures

5.

WI-QHSE-0013 rev.0 – Work instruction for Hydrostatic test

6. 7.

WI-AM-0038 rev.0 – Work instruction for Bolt torque NDE Procedures

Abb rev iat ion s us ed in ITP CA

Certification Authority

PT

Liquid Penetrant Testing

UT

Ultrasonic Inspection


Item number

MT


Magnetic Particle Inspection


PWHT QAP

Document Number :

Record

Post Weld Heat Treatment

NCR

Non-Conformance Report

NDE

Non-Destructive Examination

QC

Quality Control

OP PO PQR

Operating Procedure Purchase Order Procedure Qualification Record

QCI RT TPI

Quality Control Inspector Radiographic Inspection Third party inspection

Quality Assurance Procedure

Responsibility

EP-18136-Q-ITP-0002-SPS


WI WPS

TPI / CA

Client

Work instructions Welding Procedure Specification

List of applicable specifications 1.

ASME Sec V – Non Destructive Examination

2.

ASME Sec IX - Qualification standard for welding Brazing Procedures

3.

D1.1 – Structural Welding Code

4.

ASME B31.3 –Process piping

App li cabl e Exp ro GQC GQC 2, GQC 3(P&ID, GA, ISO, Name plates), GQC 5, GQC 7, GQC 12,GQC 13(height of weld letters as per space availability),GQC 1 4(for instruments PSVs and control valves),GQC 17, GQC 18(as per API RP 2A -load factor 1.5 times for onshore application), GQC 21 (as applicable),GQC 32,GQC 37,GQC 44, GQC 54(as applicable),GQC 57

P18136 Sonatrach Exhg Unit Project: Inspection And Test Plan

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