046-ITP for INSTALLATION OF MAC-BAC-ST MACHINERY UNIT.pdf

Pearl GTL Project Shell Project No: HP-3000-QAT Project Document Number: T- 4.234.557

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

Unit(s):

ASU

PCWBS:

Z

LINDE ENGINEERING

Contractor Project No: 5887

Project Rev.: O

Page 2 of 17

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

D

O

11.02.09

Company Comments Incorporated

SK

EO

AG

CCI

C

O

27.01.09

Issued for Company Comments

SK

EO

AG

IFR

B

27.01.09

Issued for Review

SK

EO

AG

IFR

A

12.01.09

Issued for Internal Review Review

SK

EO

AG

IIR

Date

Description

GAMA Rev.

Project Rev

No.

No.

Prepared Checked Approved By By By

Status

ORIGINATOR ORIGINATOR

Document Title:

LINDEGINEERING AG

INSPECTION TEST PLAN FOR INSTALLATION OF MAC/BAC/ST MACHINERY UNIT Document No.

Contractor

Gama Qatar Co. W. L. L.

GAM

ITP

QAC

GTL

046

D

Org.

Doc. Type

Geogr. Area

Seq.

Code

Disc. Code

Rev. No

Project Document Number: T-4.234.557

No

LOC470 Vendor Code

Rev No: O

QSGTL PEARL PROJECT ITP NO: GAM-ITP-QAC-GTL-046 GAM-ITP-QAC-GTL-046

C2 ASU Construction Works

ITP FOR INSTALLATION OF MAC/BAC/ST MACHINERY UNIT S. GAMA QATAR

X. CONTRACTOR QC

C. COMPANY

DATE:

11.02.09-REV. D

A. VENDOR (MAN)

I: INSPECTION / TEST R: DOCUMENT ISSUED/REPORT REVIEW S: SURVEILANCE H: HOLD POINT (Notification Required and Presence Mandatory). W: WITNESS(Notification WITNESS (Notification Required but Presence not Mandatory) Item

1.0

Activity

Test Frequency

Reference Document

Acceptance Criteria

Responsible Party

Verifying Documents

S

A

X

C

DOCUMENTATION

1.1

Contractor drawings, project specifications, manuals, codes

100%

-

-

TECHINICAL OFFICE

-

H

R

R

1.2

Lifting studies (For Heavy Equipments)

100%

T.4.234.084,T.4.129.859

-

HSSE

-

H

R

R

2.0

EQUIPMENTS

2.1

Receiving inspection (Including nameplate verification) & Open Box Inspection during unpacking

100%

T-4.250.945;T.4.250.927

Packing list DEP 31.29.00.10 DEP 31.10.03.10

STORE INCHARGE

2.2

Storage, preservation and documentation(FSI) documentation(FSI)

100%

T.13.377.360E;T.4.250.932

Approved drawing, DEP 31.29.00.10;DEP 70.10.70.11 T.13.377.454E; Vendor instruction, instruction,

FSI

2.3

Inspection measuring and test equipment calibration

100%

T.4.250.915

-

QCI

3.0

INSTALLATION

3.1

Foundation complete and accepted

T-4.095.567, T-4.250.945

DEP 34.19.20.31; T.13.376.358 DEP 31.29.00.10,

QCI

GAM-QCR-QAC-GTL-080

I

S

I

S

I

R

S

S

Calibration certificates

H

R

R

R

Ref. ITP 023; MC certificates

H

R

R

R

GAM-QCR-QAC-GTL-069

MC documents,

T-4.234-557 REV-O

100%

Page 4 of 17




X. CONTRACTOR QC

C. COMPANY

DATE:

11.02.09-REV. D

A. VENDOR (MAN)


Activity

Reference Document

100%

T-4.095.805, T-4.250.945

Sole plates spindles/wedges or Installation

3.3

Erection of pre alignment of coolers/wash water unit/steel structure of skid/ oil system

100%

T-4.095.567, T-4.250.945,

3.4

Installation/levelling of struts for base frame

100%

T-4.095.567, T-4.250.945, T-4.233.680

3.5

Installation & alignment of skid on steel structure

100%

T-4.095.567, T-4.250.945, T-4.233.680

3.6

Check alignment of gear box (soft foot, coupling, slope etc.)

100%

T-4.095.567, T-4.250.945, T-4.233.680

3.7

Steam Turbine alignment / coupling check

100%

T-4.095.567, T-4.250.945, T-4.233.680

3.8

MAC Alignment turbine

100%

T-4.095.805, T-4.250.945, T-4.233.680

3.9

BAC Alignment to gear box

100%

T-4.095.805, T-4.250.945, T-4.233.680

T-4.234-557 REV-O

steel

steam

Acceptance Criteria

Responsible Party

Approved drawings,

3.2

to

and shims

Test Frequency

T-4.260.824 DEP 31.29.00.10,

QCI

Approved drawings, T-4.260.824 DEP 31.29.00.10,

QCI


QCI


QCI

Verifying Documents

GAM-QCR-QAC-GTL-169 Surveyor report GAM-QCR-QAC-GTL-169 Surveyor report GAM-QCR-QAC-GTL-038

GAM-QCR-QAC-GTL-169

S

A

X

C

I

I

S

S

I

I

S

S

H

I

S

S

H

I

I

I

H

I

I

S


QCI

GAM-QCR-QAC-GTL-170


QCI

Linde/MAN Report

H

I

I

S

QCI

Linde/MAN Report

H

I

I

S

QCI

Linde/MAN Report

H

I

I

S

Approved drawings, T-4.260.824 DEP 31.29.00.10, Approved drawings, T-4.260.824 DEP 31.29.00.10,

Page 5 of 17




X. CONTRACTOR QC

C. COMPANY

DATE:

11.02.09-REV. D

A. VENDOR (MAN)


Activity

Test Frequency

Reference Document

3.10

Pre alignment of coolers MAC/BAC to machine skid and ACC Condensate Piping to steam turbine

100%

T-4.095.805, T-4.250.945, T-4.233.680

3.11

Oil Unit foundation

100%

T-4.095.451, T-4.209.390, T-4.250.945

Alignment

on

3.12

Alignment of Motor – Pump for oil unit

100%

T-4.250.927, T-4.209.390, T-4.248.567

3.13

Grouting Release for all unit contents

100%

T-4.095.567, T-4.250.945, T-4.233.680

3.14

Recheck grouting

100%

T-4.095.805, T-4.250.945, T-4.233.680

Alignment

after

3.15

All piping installation, installation, alignment, & connection without any objectionable load

3.16

Verification of piping pressure test acceptance – Prior to final alignment

3.17

Erection Damage(Equipments)

T-4.234-557 REV-O

Acceptance Criteria

Responsible Party

Verifying Documents

S

A

X

C

QCI

Linde/MAN Report

H

I

I

S

H

I

I

S

H

I

I

S

H

I

I

S

I

I

I

R


QCI

GAM-QCR-QAC-GTL-115


QCI

Linde/MAN Report

QCI

Ref. ITP 024


QCI

GAM-QCR-QAC-GTL-115

Ref. ITP 033 (T-4.250.918 Rev. A)

Ref. ITP 033 (T-4.250.918 Rev. A)

100%

T.4.251.035

-

QCI

GAM-QCR-QAC-GTL-127

Page 6 of 17




X. CONTRACTOR QC

C. COMPANY

DATE:

11.02.09-REV. D

A. VENDOR (MAN)


Activity

Test Frequency

Reference Document

4.0

FINAL INSPECTION INSPECTION

4.1

Final alignment checks

100%

T-4.095.805, T-4.250.945, T-4.233.680

4.2

FSI Checks preservation)

100%

T-4.095.805, T-4.250.945, T-4.233.680

4.3

MC Inspections

100%

T-4.095.805, T-4.250.945, T-4.233.680

4.4

Installation Completion , signoff quality records and hand over to Linde MC Dept

100%

T-4.250.945

T-4.234-557 REV-O

(cleaning,

Acceptance Criteria

Responsible Party


QCI

Approved drawings, T-4.260.824 DEP 31.29.00.10

FSI

Verifying Documents

GAM-QCR-QAC-GTL-117

GAM-QCR-QAC-GTL-0 GAM-QCR-QAC-GTL069

S

A

X

C

I

I

S

S

I

I

S

S

Approved drawings, T-4.260.824 DEP 31.29.00.10

QCI

Linde MC Records

I

S

I

S

T.13.377.555G

QCI

All Reports

H

R

R

R

Page 7 of 17

C2 ASU PEARL GTL PROJECT RASLAFFAN INDUSTRIAL CITY STEEL STRUCTURES ELEVATION REPORT

( BASED ON SURVEY REPORT) Subcontract Ref.:

Report No.:

Item Description: Description:

Inspection Date:

Item Location / Area:

Test Code No.:

Subsystem:

ITP No.:

Ref. DWG / Documents: Used Measuring and test equipment ref. (if applicable): INSPECTIONS Column No

Planned Level

Actual Level

Level/Difference

Plumb 0 Degree

ORGANIZATIONS y B d e t p e c c A

THIRD PARTY REP. GAMA REP. LINDE REP. QSGTL OR its PMC REP.

GAM-QCR-QAC-GTL-038 Rev. O

DATE

NAME

90 Degree

SIGNATURE

FORM NO:

STORAGE, PRESERVATION AND NITROGEN PURGING REPORT

SHT:

PROJECT: C2 ASU PEARL GTL PROJECT, RAS LAFFAN INDUSTRIAL CITY

EQUIP. TAG.NO.:

DESCRIPTION:

LOCATION:

MANUFACTURER:

DRG.NO.:

RFI NO:

MONTH ACTIVITY

1 Month

Date Checked Check all internal and accessories storage is acceptable Visual Check : Is there any damage Check for protective covers on all the openings Check all warning labels,like N2 warning plate are existent Actual Pressure level level Required Pressure Level

GAMA SIGN WITH DATE LINDE SIGN WITH DATE QSGTL or its PMC NOTE:

GAM-QCR-QAC-GTL-069 GAM-QCR-QAC-GTL-069 Rev. O

2

3

4

5

6

7

8

9

10

11

12

C2 ASU PEARL GTL PROJECT RAS LAFFAN INDUSTRIAL CITY

EQUIPMENT RECEIPT CHECK SHEET

ITEM No:

PO No:

UNIT No:

MANUFACTURER :

ITEMS TO BE CHECKED

REQ No:

INSPECTOR INITIAL

REMARKS

1 Name Plate 2 Preparation and painting 3 Desiccant installed 4 Moisture present 5 Nozzle flange faces acceptable 6 Temporary nozzle protection acceptable 7 Internals and accessories complete and storage acceptable 8 Purge - pressure: Purge monitoring date: Date of initial inspection:

Name and signature of Inspector:


Pressure

EQUIPMENT LEVELLING & ALIGNMENT REPORT

Report No: Date:

PROJECT: C2 ASU ASU PEARL GTL PROJECT-RAS LAFFAN INDUSTRIAL CITY

Tag No:

Manufacturer:

Drg. No:

Equip. Description No. of reading

Orientation

ORIENTATION : LEVELLING GRADIENT / SLOPE

Elevation

Plumpness

ACCEPTED

Tolerance

Remarks

REJECTED

REQUIRED

ACTUAL

ACC

REJECTED

REQUIRED

ACTUAL

ACC

REJECTED

GAM-QCR-QAC-GTL-115

Rev. O

PAGE 1 OF 2

REMARKS: ……………………………………………………… ……………………………………………. .

……………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………

GAMA

LINDE

QSGTL or its PMC

Name Sign Date

GAM-QCR-QAC-GTL-115

Rev. O

PAGE 2 OF 2


Q A A T A A R

TURBINE INSTALLATION PROCESS SHEET

Item No:

Report No:

Item Description:

Date:

Drawing No:

Area:

Item No

Description

Signature & Date Gama Linde QSGTL

1.

Foundation complete, Level & Accepted.

2.

Sole plates level

3.

Align base

4.

Align casing

5.

Align rotor

6.

Anchor bolts tight

7. 8.

Piping complete co mplete & connected with no objectionable loads or strains on the flanges Verify pressure test accepted

9.

Coupling face gap checked & acceptable

10.

Final alignment checked

11.

Coupling set screws tight

12. 13. 14.

Accessories Installed & Ready for service (i.e,Vents,Drains,strainers,etc) Auxiliary System Complete(i.e. lube system, Water cooling etc) Lubrication system flushed & recharged with appropriate lubricant

15.

Turbine rolls freely, By hand

16.

Governor Mechanism: Linkages checked Manual Trip Level Free

17. Relief valves checked & installed 18. Expansion bellows for condensing turbines installed properly Remarks:

The Installation of the above compressor has been satisfactorily completed in accordance with the Drawings & Specifications ORGANIZATIONS GAMA QATAR REP

LINDE REP QSGTL REP GAM-QCR-QAC-GTL-117 Rev. O

DATE

NAME

SIGNATURE

REPORT NO.:

SITE INSPECTION REPORT PROJECT:

DATE:

C2 ASU PEARL GTL PROJECT –RAS LAFFAN INDUSTRIAL CITY

Originator

Date of observation:

Location / Area:

Unit No :

Discipline:

SYSTEM NUMBER:

Drawing / Specification Numbers

Description of Discrepancy/Observation (Be specific, events, time, date, location, etc :)

Corrective Action:

Originator: Name: _____________________________Signat ure: _____________________Date: ________________ NCR Required

YES

NO

(Circle one)

CTQ to Contractor Required

YES

NO

(Circle one)

Remarks if any:

Site Engineer:

Name:

______________________ _ Signature: ________________ Date: ______________

QA/QC Manager: Name:

_________________________ Signature: _______________ Date: ______________

Discrepancy Corrected/Remarks:

GAMA Representative:

Name: ____________________

Close-out of Corrective Action - Remarks:

Site Engineer:

Name:

Signature:

______________ Date: ________________

NCR No.: ___________________

___________________

Signature: __________________ Date: ___________

DISTRIBUTION (Original QA/QC file)

QA/QC Manager

Site Manager

Site Engineer

Project Manager

Construction Manager

Originator


CTQ No: ______________


Q A A T A A R

MAC/BAC/ST MACHINERY UNIT INSTALLATION PROCESS SHEET

Item/Tag No:

Report No:

Item Description:

Date:

Drawing No:

Area:

System No:

Subsystem No:

Item No

Description

Signature & Date Gama Linde QSGTL

1.

Foundation complete, Level & Accepted.

2.

Sole plates and spindles/wedges or shims installation accepted

3. 4.

Erection of pre alignment of coolers/wash water unit/steel structure of skid/oil system Skid alignment accepted

5.

Alignment of all equipment accepted

6. 7.

Piping complete & connected with no objectionable loads or strains on the flanges Verify pressure test accepted

8.

Coupling Installation (face gap checked & acceptable)

9.

Final alignment checked

10. 11.

Accessories Installed & Ready for service (i.e. Vents, Drains, strainers, etc) Auxiliary System Complete(i.e. lube oil system, Water cooling etc)

12. 13.

Turbine rolls freely, By hand Governor Mechanism

13.1

Linkages checked

13.2

Manual Trip Level Free

14.

Expansion bellows for condensing turbines installed properly

Remarks:

The Installation of the above Machinery Unit has been satisfactorily completed in accordance with the Drawings & Specifications ORGANIZATIONS GAMA QATAR REP

LINDE REP QSGTL REP GAM-QCR-QAC-GTL-169 Rev. O

DATE

NAME

SIGNATURE

Report No:

GEAR BOX LEVELLING & ALIGNMENT REPORT

Date: System No:

PROJECT: C2 ASU ASU PEARL GTL PROJECT-RAS LAFFAN INDUSTRIAL CITY

Tag No:

Manufacturer:

Drg. No:

Equip. Description: No. of reading

Orientation

Elevation

Plumpness

Tolerance

SOFT FOOT :

ACCEPTED

REJECTED

ORIENTATION :

ACCEPTED

REJECTED

LEVELLING GRADIENT / SLOPE

Remarks

REQUIRED

ACTUAL

ACC

REJECTED

REQUIRED

ACTUAL

ACC

REJECTED

GAM-QCR-QAC-GTL-170

Rev. O

PAGE 1 OF 2

REMARKS: ……………………………………………………… ……………………………………………. .

……………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………

GAMA

LINDE

QSGTL or its PMC

Name Sign Date

GAM-QCR-QAC-GTL-170

Rev. O

PAGE 2 OF 2

046-ITP for INSTALLATION OF MAC-BAC-ST MACHINERY UNIT.pdf

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