84501-9200-9P-006_R2

CONOCOPHILLIPS INDONESIA INC. LTD. PROJECTS PROJECTS DEPARTM ENT ENT SPECIFICATION DOCUMENT NUMBER REV

TITLE INSPECTION AND TESTING REQUIREMENTS FOR EQUIPMENT AND MATERIAL

8450184501 -9200-9P-006

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REVISION CONTROL SHEET LATEST REV

DATE ISSUED

PREPARED

REVIEWED

APPROVED

COMMENTS

0

1 Oct 2002

B. Burn

R.Ford R.For d

A.McIntosh

Issued For Use

1

1 Mar 2003

B. Burn

R.Ford R.For d

A.McIntosh

Department Name Change

Cino Calfino

Section 7.4 AML Number corrected

2

8 March Marc h 04

B. Burn

R. Ford

Paper Copies are UNCONTROLLED - Check with Document Control for latest available –

CONOCOPHILLIPS INDONESIA INC. LTD. PROJECTS PROJECTS DEPARTM ENT ENT SPECIFICATION DOCUMENT NUMBER REV


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REVISION CONTROL SHEET LATEST REV

DATE ISSUED

PREPARED

REVIEWED

APPROVED

COMMENTS

0

1 Oct 2002

B. Burn

R.Ford R.For d

A.McIntosh

Issued For Use

1

1 Mar 2003

B. Burn

R.Ford R.For d

A.McIntosh

Department Name Change

Cino Calfino

Section 7.4 AML Number corrected

2

8 March Marc h 04

B. Burn

R. Ford


CONOCOPHILLIPS INDONESIA INC. LTD. PROJECTS PROJECTS DEPARTM ENT ENT


SPECIFICATION DOCUMENT NUMBER REV 8450184501 -9200-9P-006

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T ABLE OF CONTENTS

1.

INTROD INT RODUCT UCTION ION ................................................................ ................................................................................................ ................................................ ................4 4

2.

SCOPE SCO PE ............................................ .................................................................. ........................................... ........................................... ..........................................4 ....................4

3.

PURPOSE............................................................................................................................4

4.

DEFINITI DEFI NITIONS ONS .......................................... ................................................................ ............................................ ......................................................4 ................................4

5.

RESPONSIBILITIES..........................................................................................................6

6.

APPLICATION....................................................................................................................7

7.

PROC PR OCED EDUR URE E FOR FO R PRO PR OCUREMENT.............................................. CURE MENT................................................................ .............................. ............8 8

8.

PROCEDUR PROC EDURE E SITE FABRICATION/I FABRICAT ION/INSTA NSTALLATION LLATION ........... ................ ........... ........... .......... ............ ............. .........9 ...9 APPEND APP ENDIX IX 1 .......................... .................................................... ................................................... ....................................... ........................................10 ..........................10 APPEND APP ENDIX IX 2 .......................... .................................................... ................................................... ....................................... ........................................12 ..........................12 APPEND APP ENDIX IX 3 .......................... .................................................... ................................................... ....................................... ........................................13 ..........................13 APPEND APP ENDIX IX 4 .......................... .................................................... ................................................... ....................................... ........................................21 ..........................21 APPENDI APPEN DIX X 5 .......................... .................................................... ................................................... ....................................... ........................................22 ..........................22 APPEND APP ENDIX IX 6 .......................... .................................................... ................................................... ....................................... ........................................26 ..........................26 APPEND APP ENDIX IX 7 .......................... .................................................... ................................................... ....................................... ........................................29 ..........................29 APPEND APP ENDIX IX 8 .......................... .................................................... ................................................... ....................................... ........................................30 ..........................30 APPEND APP ENDIX IX 9 .......................... .................................................... ................................................... ....................................... ........................................31 ..........................31 APPEND APP ENDIX IX 10 ........................................... ................................................................. ........................................... ......................................... .............................33 .........33


CONOCOPHILLIPS INDONESIA INC. LTD. PROJECTS DEPARTM ENT


1.

SPECIFICATION DOCUMENT NUMBER REV 84501-9200-9P-006

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INTRODUCTION This procedure, in addition to Project Procedure 84501-9200-9P-005, (Equipment Criticality Rating),shall be used to establish project quality and certification and program requirements

2.

SCOPE This procedure is restricted to Contractors responsible for engineering and design, procurement and construction activities.

3.

PURPOSE The purpose of this procedure is to provide guidance in the determination of inspection requirements for inclusion in the following documents produced by the Contractor:

4.

•

Purchasing Inspection Specifications and Plans

•

Site Fabrication, Erection/Installation Specifications

•

Site Inspection and Testing Plan

DEFINITION For the purpose of this procedure, the following definitions apply: Shall - Denotes a mandatory action Should - Denotes a strongly recommended action Contractor - Each organization that carries out all or part of the detailed engineering and design and procurement of project equipment and materials. Owner – ConocoPhillips Indonesia Inc. Ltd Project – Quality Plan - A document produced by the Supplier and Contractor summarizing the specific activities relevant to a Suppliers and Contractors scope of work. The document shall reference those activities pertinent to the purchase order scope and identify procedures appropriate to the management and control of those activities. Procurement Inspection Plan - A document produced by the Contractor outlining the overall inspection requirements pertinent to the procurement of Paper Copies are UNCONTROLLED - Check with Document Control for latest available –




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equipment and materials. The plan shall ensure appropriate reference to or incorporate Belanak Project inspection requirements. Purchase Order Supplier Quality Control/Inspection Plan - A document defining the requirements for the specific inspections to be performed during manufacture, and test. Site Inspection and Test Plan - A document produced by the Contractor defining specific inspection and test activities relevant to site fabrication, installation and test. Positive Material Identification (PMI) - The ability to trace material to a Material Test Report (MTR). Alloy Verification (AV) - Physical verification of material composition using material analyzers. It is used to supplement PMI in order to verify a Material Test Report. Material Test Report (MTR) - A document issued and authenticated by the material manufacturer defining the chemical composition and mechanical properties of a material. Material Traceability - Ability to trace material to a material trac eability report during any stage of procurement, manufacture, storage or installation. Certificate of Conformance (COC) – A document issued by a relevant organization certifying that the products supplied conform in every respect to the purchase specifications. Inspection Certificate - A document certifying the satisfactory completion of a stage inspection, final inspection or test. The document is authenticated by the purchaser's appointed inspection authority and, where required by the design code, also signed by an independent inspection authority. Concession Request - A formal document raised by a Supplier or Contractor requesting the purchaser's permission to deviate from a purchase specification. Positive Material Identification (PMI) Program - A document produced by the Contractor defining the extent of PMI to be performed on specific materials in order to enable verification and traceability of material to MTR's during any stage of supply, storage, manufacture or final installation Project Specifications - The project engineering standards those are developed for a Specific Project incorporating requirements for specific inspections and tests to be performed in the procurement, fabrication, installation and commissioning of equipment, systems and materials.





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Specification Deviation Request - A formal document issued by the Contractor to request permission to deviate from a specification or Project inspection requirement. 5.

RESPONSIBILITIES

5.1

Contractor

5.1.1 The Contractor is responsible for maintaining a documented system to ensure that required inspection activities are planned, performed, witnessed and verified and to provide adequate assurance that all equipment, materials fabrication, installation and tests fully comply with the requirements of this procedure and project specification and design code requirements. 5.1.2 The system shall provide an auditable trail verifying that inspection and certification requirements satisfy quality and safety standards indicative of equipment or system criticality as determined b y the Contractor. 5.1.3 Other responsibilities shall include the following:Preparation of the overall Procurement Inspection Plan for approval by Company. Documenting the inspection practices to be considered in association with procurement of equipment and materials. The Plan and associated Contractor's procedures shall clearly define responsibilities within the Contractors organization for specifying and approving inspection plans and performing inspection activities.

5.2

-

approval of agreed Supplier or Inspection Plans prior to manufacture, fabrication, installation and test.

-

performing necessary inspection and verification activities to ensure equipment, materials and installation conform in every respect with relevant approved Project specifications and design codes.

-

the review of Inspection Requirements to ensure requirements are incorporated in the final inspection plans.

-

issue of Deviation Requests for approval by the Project Team where deviations from Project Inspection requirements are requested.

-

ensuring that inspection requirements are cost effective and fully comply with relevant Project design codes.

the

necessary

Specific Project Development

5.2.1 The Contractors Engineering Manager shall be responsible for the maintenance, revision, implementation and update of this pro cedure.



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5.2.2 The Specific Project Team shall be responsible for providing guidance in the interpretation of inspection and certification requirements to Contractors and undertaking technical assessments and audits to ensure compliance with requirements. 5.2.3 The Contractors engineering function shall be responsible for approving deviations to Project Inspection Plans and communicating such concessions to the Company for approval 5.2.4 When a deviation is deemed to be of a general nature and affects all Contractors, this shall be notified accordingly to the Company the Project team shall be responsible for ensuring that inspection requirements, particularly on systems or equipment interfacing with other packages, are consistent. 5.3

Quality Assurance

5.3.1 The responsibilities defined in this section apply to both Company Project Team and Contractors. 5.3.2 Quality Assurance shall be responsible for ensuring that systems and programs employed by the Contractor's engineering, procurement, and construction organizations demonstrate that quality objectives and Project requirements, as defined in the contract document and described in this procedure, are being achieved. 5.3.3 Contractors Quality Assurance shall perform and document assessment, and audits relevant to engineering and design, procurement and construction activities to provide assurance that the Project Quality Assurance Program and contract requirements are being implemented by all organizations contracted to supply products or services to the Project. 5.4

Safety

5.4.1 As a function of the Project Safety Reviews, shall ensure that in review and implementation of the Contractors systems for control of design, procurement, and construction activities that quality systems and inspection requirements are consistent, documented, and provide confidence in the design and operational safety of the facilities. 6.

APPLICATION

6.1

This procedure is for INTERNAL project use by Contractors, and shall not be issued to Suppliers or Sub-Contractors.

6.2

This procedure shall be used by all Contractors following the establishment of criticality ratings as a guidance document in the determination of Inspection Paper Copies are UNCONTROLLED - Check with Document Control for latest available –




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requirements pertaining to, Material Certification, Material Traceability, Positive Material Identification requirements. 6.3

The Inspection requirements detailed in Appendices 3-10 defines the basis for the inspection activities to be incorporated in supplier and site inspection plans. They are NOT an instruction to Contractors to perform an inspection task.

6.4

The determination of Purchaser, Supplier and Site Inspection involvement is the responsibility of each Contractor and will demonstrate to the Company that adequate inspection tasks are being performed by the Contractor to provide assurance of the integrity of equipment and the completed facilities.

6.5

Site inspection activities will be documented and agreed in appropriate Inspection Plans and indicate the level of Inspection involvement performed by the company, Contractor.

6.6

Certification shall be produced to certify satisfactory acceptance of products during all stages of manufacture, fabrication, installation and testing.

6.7

Certification requirements shall be defined by the Contractor and shall satisfy the requirements of the Contract document.

6.8

It shall be the Contractor's responsibility to ensure that requirements of any Independent Inspection Authority, Company Project and applicable design codes are defined in the appropriate Purchase Orders.

6.9

Requirements for Site Inspection and Testing are described in more detail in Contractors Procedures.

7.

PROCUREMENT PROCEDURE

7.1

Following award of Criticality Rating and determination of Quality Program requirements for an item of equipment (reference Project Procedures 845019200-9P-005), the Contractor shall use this procedure as a basis for advising the supplier of the Inspection and Certification requirements associated with the purchase order.

7.2

Appendices 2-10 shall be used to assist in preparing the appropriate documentation to advise the Contractors Supplier of the required inspection, material certification, Material traceability and positive material identification requirements.

7.3

Depending on the equipment or material, the final clarification and agreement of inspection and certification requirements with the supplier; the levels of purchaser and any Independent Inspection Authority involvement will be determined by the



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Contractor and prior agreement with Company or at Supplier pre-production meeting or by return of an agreed QC Inspection Plan.

7.4

The originator of the material requisition or equivalent document shall determine the extent of inspection in accordance with the requirements of 84501-9200-9P005 Equipment Criticality Rating to be imposed on supplier of bulk materials or standard "off the shelf" items. Requirements for such suppliers to submit detailed Quality Assurance Plans will be determined by the Contractor but such suppliers should have demonstrated an ability to comply with appropriate project quality requirements and be included on the Company Approved Manufacturers List. 84501-9400-9W-001

8.

SITE FABRICATION AND INSTALLATION PROCEDURES

8.1

The Contractor shall reference Appendices 2-10 to assist in the determination of Site Inspection, Testing and Certification requirements for Project Site Fabrication and Installation Specifications.

8.2

The Site Fabrication and Installation Specifications shall form the basis against which Site QC and Inspection Plans are developed for each Sub-Contractor. The Site Inspection, Test and Certification Requirements describe the requirements, procedures, documentation and certification requirements to be utilized to verify the acceptance of the prescribed site inspection activities.

8.3

Completed system certification packages are coming together with Suppliers Certification in Fabrication Dossiers to form System Handover Packages.

8.4

The System Handover Packages are subsequently referenced in the appropriate completion certificates prepared by the Contractor for Project Company acceptance.


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APPENDIX 1 GENERAL NOTES FOR DETERMINING INSPECTION AND CERTIFICATION REQUIREMENTS 1.

It is the Contractors ultimate responsibility to ensure adequate levels of inspection and test are performed and that certification and traceability provide adequate verification to certify products and systems have been manufactured, installed and tested to the satisfaction of the Company. The Company shall perform such inspections and audits as desired to monitor activities of Contractor, Suppliers

2.

Appendices 3 through 8 define the basis for the determination of Inspection Requirements with respect to the categories listed.

3.

For equipment, Criticality Rating 1 or Criticality Rating 2, these requirements shall be mandatory as relevant to the type of equipment being considered and shall be incorporated in appropriate manufacturing or fabrication inspection plans.

4.

These requirements do NOT preclude the Contractor from incorporating additional requirements where considered necessary to provide assurance that levels of equipment integrity have been achieved.

5.

The difference between levels of inspection for Criticality Rating 1 and Criticality Rating 2 items are determined by the Contractor. These levels shall clearly demonstrate that the percentage of inspection, non-destructive testing, leak and pressure testing performed reflect the significance of the item being considered.

6.

Detailed requirements where listed on the attached inspection plans for Criticality Rating 1 and Criticality Rating 2 equipment, supplement requirements outlined in the present specification's. All present specification requirements for Inspection, Testing, and Certification shall be complied with where referenced in Appendices 2 through 10.

7.

Facility to deviate from Project specifications and minimum inspection and certification requirements as referenced herein shall be permitted where cost effectiveness can be demonstrated without loss or risk to equipment or system integrity. Contractor's deviations to inspection requirements on Criticality Rating 1 and Criticality Rating 2 equipment will be by exception only and must be fully supported.

8.

For the purpose of satisfying the requirements of this procedure the Contractors responsible for ensuring that requirements for deliverables, approvals, inspection, documentation, traceability and certification, comply with those sections of the





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contract document pertinent to the engineering, procurement construction activities that may not be specifically stated in this document.

and

9.

It shall be deemed by the Company that the Contractor has considered and incorporated all relevant inspection, test and certification requirements as required by this and referenced documents contained herein and in all purchase orders issued either by Contractor or by organizations acting on his behalf. The Contractor shall also ensure that orders placed by suppliers comply with the primary requirements.

10.

The Contractors system shall ensure that ALL concessions deviating from Project Specifications are documented and controlled.

11.

Where necessary or considered appropriate by Company the requirements of this procedure and shall also apply to modifications, refurbishment or tie-ins to existing equipment.

12.

Requirements for Material Traceability, Material Test Reports (MTR's), Positive Material Identification (PMI), and Alloy Verification (AV) apply to all engineering disciplines and should be read in conjunction with the relevant sections of Appendices 2-7




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APPENDIX 2 MINIMUM INSPECTION REQUIREMENTS CIVIL, ARCHITECTURAL, STRUCTURAL, HVAC

1.

Minimum inspection requirements for this category shall comply with the relevant Project specifications; Project approved standards and design codes as stated in the Contract document. These may be supplemented by Contractors established codes, standards, and practices where approved by Company NOTE:

Refer to Appendices 8-10 for Material Traceability, Certification and Positive Material Identification requirements.




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APPENDIX 3 MINIMUM INSPECTION REQUIREMENTS VESSELS/EXCHANGERS/TANKAGE GENERAL NOTES: 1.

The supplementary inspection requirements as defined in this Appendix only apply to equipment with Criticality Rating 1 and Criticality Rating 2. In distinguishing the requirements for levels of inspection between the two groups, refer to General Notes Appendix 1, Paragraphs 1. and 5.

2.

The requirements of this Appendix cover the minimum engineering quality control/inspection requirements for vessels, tankage and heat exchangers whether individual or part of a package unit and supplement Project specifications and Design Code Requirements.

3.

Where necessary, the requirements of this Appendix shall apply both o t new items and to modifications or refurbishment to existing equipment.

4.

Requirements for site erected tanks or fabricated equipment shall comply with all relevant inspection requirements and supplemented by activities specific to the type of equipment

5.

As a minimum, inspection requirements for Criticality Rating 3 equipment shall comply with Project specifications and Project Approved design codes. Deviations are subject to Company approval and should be sought where cost effectiveness and proven established practices can be justified.

6.

Above equipment groups classified as Criticality Rating 4 shall satisfy the Contractors purchasing specification requirements as defined by the Contractor. Standard equipment or off the shelf items, which are tested and certified as conforming to the product purchase specification would be acceptable. NOTE:


INSPECTION ACTIVITY REF. DESCRIPTION OF INSPECTION ACTIVITY 1.

Pre-production visit to Supplier's works to monitor the Contractors adherence the following: -

Supplier has relevant Standards and Specifications.

-

Final drawings approved before manufacture commences.




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-

Suppliers sub-orders have been placed and copies forwarded to Purchaser.

-

Quality Control/Stage Inspection Plan agreed.

-

Schedule of Welding Procedures production commences.

available

and

approved

before

COMMENTS:

2.

3.

4.

-

Record Specification and drawing numbers and status.

-

Copies of sub-orders where indicated in Quality Program and Purchase Order to Contractor.

-

Review to include suppliers Quality Control Plans where indicated in Quality Program.

Following materials inspected and positively identified against material test certificates: -

Plates, pressings, tubes, forging, castings and joint materials necessary for pressure containment.

-

Materials forming internals welded to pressure containment parts,

-

Materials forming external appendices, e.g., compensating pads, saddles, doubling plates where welded directly to pressure containing parts.

-

Alloy verification of above by portable material analyzer as per Contractors “PMI “ positive material identification program.

Check material control implemented at following stages and that identification and traceability are maintained: -

Stores inward (include free issue material)

-

During storage.

-

Fabrication through to final acceptance

-

Control of weld consumables.

Undertake full dimensional checks on: -

Receipt of materials

-

Following set up of strakes/shell sections

-

On completion of welding of strakes

-

Prior to heat treatment, if applicable




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COMMENTS:

5.

-

Dimensional check shall ensure manway/nozzle/ flange orientations, hold-down orientations are in accordance with AFC drawings, actual dimensions where different are noted on As Built drawings.

-

On columns, checks to include: (a) Spacing and level of tray supports. (b) Distance between downcomer and tray levels. (c) Weir heights.

Witness welding procedure qualifications and welder qualifications (to include all Mechanical Tests/NDT and test plates as required. N.B.

Existing qualifications may be acceptable if they are current and valid in accordance with code requirements. Review/approve WPS/PQR.

6.

Inspect welding set ups of longitudina l and circumferential seams.

7.

Check welding being performed in accordance with procedure and inspect: -

Root pass

-

Filler runs

-

Final after capping run

-

Grinding back to sound metal where second side weld required. COMMENTS: -

Check to include:

-

Application of preheat and inter-pass temperature

-

Correct type and size of electrode or wire for root and capping runs

Each weld to carry welder's identification (method of identification to be agreed with Purchaser for alloy, austenitic and low temperature steel plus non-ferrous material). 8.

Inspect during fabrication and check shape and workmanship of dished head manufacture as 5. through 7. above. Note minimum thickness at knuckle radius.

9.

Inspect branch connections before welding. Particularly for excessive root gap, misalignment with hole penetration in plate/tube; surface condition of weld preparation. Note: Flame cut holes to have all heat affected areas removed by grinding.

10.

Inspection of completed branch attachment welds and flange/neck welds. Check no flange face distortion or damage to joining faces. Ensure that where



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compensating pads are fitted, API tapped vent holes are provided (provision for vent holes in slip-on flanges where speci fied). 11.

Inspection of completed external attachment welds. Ensure API tapped vent holes are provided on saddles/ doubling plates which cross main longitudinal or circumferential shell welds. N.B. Where vessel to be insulated, all tapped holes to be fitted with extension tube extending beyond insulation prior to shipment from works.

12.

Check and approve NDT operator qualification meets NDT criteria. Where Contractor has own NDT facility, check competence of operator and assess facilities/ equipment.

13.

Check and approve NDT procedures:

14.

-

Dye penetrant

-

Magnetic particle

-

Ultrasonic

-

Radiographic

Witness following NDT: Dye Penetrant: -

Root run (including second side if applicable)

-

Completed weld

-

After heat treatment

-

Review all reports

Magnetic Particle: -

Root run (including second side if applicable)

-

Completed weld

-

After heat treatment

-

Review all reports

Ultrasonic Examination: -

Review examination report

Radiography: -

Interpret radiographs

-

Review report




NB -


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percentage radiography to include a random sample from each welder for spot R.T.




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COMMENTS: -

MT of all seam/nozzle/ branch and internal attachment welds in ferrous materials.

-

Review all required radiographs.

-

All seams covered by compensating pads on doubling plates to be radiographed prior to their attachment.

15.

Visual examination; all external and internal attachment welds to the pressure shell complete/ acceptable; (before stress relieving if applicable).

16.

Review Heat Treatment Procedures.

17.

Witness soapy water/air test on compensating and doubling plates (before stress relieving where applicable). 10% witnessing as a minimum requirement and review test reports.

18.

Check suitability and calibration records of thermal measurement equipment and positioning of temperature probes.

19.

Review Heat Treatment Record chart for compliance with ASME Code and P.O. specifications.

20.

Witness hydrotest. During test check for any undue deflections, pressure drops/variations, water temperature and chlori de content.

21.

Verify nameplate detail correct and stamped with relevant Inspection Authority stamp when required. Ensure correct weight indicated and verified.

22.

Witness vessel draining; ensuring adequate venting and vessel fully drained prior to shipment.

23.

Final external, internal inspection and dimensional check. Before final close check that all relevant bolts and gaskets are in place and that vessel internals are supported and protected to avoid damage in transit, e.g., dip pipes. All internal bolts are tightened and locked. All external openings are protected and sealed.

24.

Inspect painting s ystem or other protection specified. Ensure preparation, application, thickness and paint specification in accordance with specified requirements.

25.

Inspect insulation, ensure where vent holes have been provided in vessel external attachments that vent pipes are fitted. Check vapour barrier, insulation and cladding grade, thickness. All seams or apertures in cladding sealed with mastic.





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26.

Review, approve and countersign Manufacturing Data Books and Fabrication Data Dossiers.

27.

Inspect shipment preparation, packing, opening protection, dry-out, purging and marking.

28.

Additional minimum requirements for site erected tankage only. -

Vacuum box test floor

-

MT/DP floor to shell welds internal/external

-

Air on water roof test.

Additional Requirements for Heat Exchangers 29.

Tube end weld procedure approved and in accordance with Contractors specification (if applicable).

30.

Tube roll expansion procedure approved and in accordance with Contractors specification.

31.

Inspect weld procedure qualification test blocks for tube end welding process and approve mechanical testing and NDT results. (to include any shift test block requirements where specified)

32.

Review and approve results of ultrasonic examination of tube-sheet before drilling and following explosive cladding where applicable.

33.

Inspect tube-sheets following machining and check ligament size, weld preparations and detail of rolling grooves in accordance with appropriate TEMA classification. Tube holes to be checked for ovality, diameter, tolerance and surface finish. NOTE: Check minimum of 10%

34.

Inspect bellows assembly following welding of; -

Root pass

-

Final capping run

-

Second side where applicable

35.

Witness dye penetrant/MT examination of bellows assembly finished weld.

36.

Review NDT reports, DP, MT, radiographic, other, bellows assembly. -

Interpret radiographs





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37.

Check and inspect test rings/glands available for leak and hydrostatic testing where applicable; i.e.; "U" tube and floating head exchangers (will be supplied as specified in Purchase Order).

38.

Material inspected and positively identified against material certificate.

39.

Examine assembly of tubes, baffles, tie rods, spacers. Note provision of sliding strips on floating head and 'U' tube exchangers. Check tolerances before tube end welding or expansion is performed; baffle clearance correct, tube/tube hole clearances in baffles correct; tube/tube-sheet is fully de-greased prior to welding.

40.

Where measured tube expansion is specified check tube ends for scoring or damage after expansion. NOTE: Examine a minimum of 50%

41.

Inspect during tube expanding or tube end welding for compliance with procedure. NOTE: Examine as necessary to determine compliance.

42.

Witness dye penetrant examination of tube end welds. -

Final

NOTE: Examine 100% 43.

Witness leak test of tube end welds (before and after post weld tube expansion if called for) before hydrotest. Assess results of test and if leaks exceed 1% of the tube welds per tube-sheet refer to Contractor for full investigation.

44.

Check gasket material and installation is correct prior to assembly for test. Also conduct following test if bundle removed. In such cases, new gaskets to be fitted.

45.

Witness shell side hydrostatic test (tube sheets exposed).

46.

Witness tube side hydrostatic tests including channels and covers.

47.

Ensure all exchanger test rings/glands, etc. as specified on purchase order are available for shipment with exchanger. Test rings should be those incorporated in final hydrostatic test.

48.

Witness tubing bundle insertion to assure no undue strain is imposed.




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APPENDIX 4 MINIMUM INSPECTION REQUIREMENTS PIPING 1.

Minimum inspection requirements for piping systems incorporating all pipe, valves, flanges, fittings etc. shall be in accordance with ANSI B31.3 supplemented by any additional requirements defined in Company specifications.

2.

All piping system specifications shall be reviewed by Company to ensure consistency in application of inspection and certification requirements with respect to piping classes, components, material and duty. This requirement is particularly important on piping systems interfacing with other Contractors where consistency of requirements is essential both on safety grounds and also to facilitate system handover.

3.

Procurement specifications for bulks shall, as a minimum, comply with the requirements of the Contract documents.

4.

Procurement specifications for valves shall comply with Project approved codes and standards and should be consistent with respect to Contractors piping classes, duty and materials of construction.

5.

Requirements for supplementary inspection and certification as referenced in applicable codes and standards shall be determined by the Contractor. NOTE:

Refer to Appendices 8-10 for Material Traceability and Certification and Positive Material Identification requirements.




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APPENDIX 5 MINIMUM INSPECTION REQUIREMENTS MACHINERY 1.

The supplementary inspection requirements as defined in this Appendix only apply to machinery in Criticality Rating 1 and Criticality Rating 2. In distinguishing the requirement for levels of inspection between the two classifications, refer to the General Notes, Appendix 1 Notes 1. and 5.

2.

The requirements of this Appendix cover the minimum engineering QC/ Inspection requirements for machinery whether individual or part of a package unit.

3.

As a minimum, all Criticality Rating 3 machinery shall comply Project specifications Deviations are subject to Company approval and should be sought where cost effectiveness and proven established practice can be justifi ed.

4.

Machinery classified as Criticality Rating 4 shall satisfy the Contractors procurement specification requirements. Standard equipment or off the shelf items as determined by the Contractor, which have been tested and certified as conforming with the product purchasing specification would be acceptable. NOTE: Refer to Appendices 8-10 for Material Traceability, Certification and Positive Material Identification requirements.

INSPECTION ACTIVITY 5.

Pre-production visit to Supplier's works to check the following: -

Supplier has and understands all relevant standards and specifications.

-

Drawings approved before manufacture commences.

-

Any special manufacturing process as defined by the Contractors or suppliers specification or standards are approved.

-

Sub orders have been placed and contain relevant specifications, standards, and drawings as appropriate.

-

Manufacturing commences

-

Documentation, certification, mechanical data and fabrication data dossier requirements defined.

quality

control

plan

approved

before

manufacture

COMMENTS: -

Check and record all document/drawing numbers and revision status.




6.

7.

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-

Special manufacturing procedures should typically include:

-

Welding procedures

-

NDT procedures

-

Heat treatment procedures

-

Hard facing/coating procedures

-

Forming procedures unique to manufacturing process.

-

Function and Performan ce Test procedures.

Inspect material and verify compliance with certification, design and specification requirements for: -

Chemical analysis and physical properties

-

Material tests

-

Heat treatment

-

NDT examinations

-

Alloy verification (portable material analyzer)

Check that material control implemented at following stages and that identification and traceability are maintained: -

Stores inward

-

During storage

-

During manufacture through to final acceptance

-

Control of welding consumables

8.

Check material in accordance with Purchaser's specification; i.e.; ASTM, API; schedule/rating, welded or screwed connections.

9.

Witness welding procedure qualification (to include all mechanical tests, NDT and test plates as required by code). Review/approve “WPS” weld procedure specification and procedure qualification record

“WPQR” weld

N.B. existing weld procedures may be acceptable if they are current and valid as determined by applicable code. 10.

Verify welder qualifications current and applicable to approved procedure.

11.

Dimensional check of: -

Major static/rotating components




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Bearing/sleeve/thrust/seal sizes; clearances

-

Nozzle elevation/orientations

-

Bed-plate/hold down bolt hole location

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12.

Verify NDT operators' qualifications are current and applicable to NDT scope. Where supplier has own NDT facility, assess suitability and operator competence.

13.

Witness following NDT activities of castings or welded fabricated components: -

Dye penetrant

-

Magnetic particle

-

Ultrasonic (Review reports only)

-

Radiography (Interpret radiographs and review reports, only) COMMENTS: -

Machined components only; extent of NDT examination to be in accordance with procurement specification and as agreed on Suppliers manufacturing quality plan.

-

NDT requirements for ancillary equipment and pipe work to be in accordance with this section of the procedure.

14.

Check surface finish in accordance with specification requirements on critical components, i.e.; bearings, journals, thrust collars, and fitted bonnets.

15.

Witness balancing of rotating element:

16.

-

Couplings

-

Impellers

-

Gearwheels

-

Rotor and rotor assembly

Witness over-speed checks on rotating components: -

Impellers

17.

Where applicable, check heat treatment procedure approved; verify calibration and location of temperature probes correct. (stress relieving of fabricated components)

18.

Where applicable, check heat treatment record chart, verify treatment controlled within parameters.





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19.

Hydrostatic test of machine casing, to include where applicable, all ancillary pipe work and equipment.

20.

Mechanical running test of machine and auxiliaries when specified.

21.

Performance test, when specified on equipment data sheet.

22.

Strip test - bearing and seal examination.

23.

String test (complete unit test) when specified on equipment data sheet.

24.

Witness and verify noise level measurement complies with contractor's specification.

25.

Witness and verify vibration levels within limits as defined in Contractors specification.

26.

Final inspection and cleanliness check prior to shipment. Ensure all machine surfaces protected, openings sealed, paint coatings applied where specified; all nameplates fitted and correctly labelled (including ancillary components). Ensure any temporary transportation restraints, supports secure and clearly identified.

27.

Review and approve Mechanical Data and Fabrication dossiers, Operating and Maintenance Manuals, Spares Schedules.

28.

NPSH test to API and ANSI standard, as required.

29.

Operational tests of lube oil console, including cleanliness test. (API) standard minimum supplemented by Contractor's standard.)

30.

Final dimensional check for field corrections in relation to anchor bolt holes, grade, etc are per approved outline drawing.

31.

Electrical function test to NEMA and order specifications.

32.

Witness gas leak test when specified. (API standard)




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APPENDIX 6 MINIMUM INSPECTION REQUIREMENTS ELECTRICAL 1.

The supplementary inspection requirements as defined in this Appendix only apply to electrical equipment such as motors, transformers, variable speed drives and switch gear in Criticality Rating 1 and Criticality Rating 2. In distinguishing the requirements for levels of inspection between the two classifications, refer to the General Notes, Appendix 1 notes 1. and 5.

2.

The requirements of this section cover the minimum engineering quality control/inspection requirements for classes of electrical equipment as defined in 1.0 above and whether individual or part of a package unit.

3.

As a minimum, inspection requirements for all Criticality Rating 3 electrical equipment shall comply with appropriate “IEEE” Institute of Electric al and Electronic Engineers inc. regulations, Contractor's specifications and Deviations are subject to Company approval. Company approval should also be sought where cost effectiveness and proven established practice can be justifi ed.

4.

Electrical equipment classified as Criticality Rating 4 shall satisfy the Contractors procurement specification requirements. Standard proprietary equipment or off the shelf items as determined by the Contractor, and which has been tested and certified as conforming with the product purchasing specification would be acceptable.

5.

For major electrical machines, refer also to Appendix 5, Machinery inspection Requirements. NOTE:

Refer to Appendices 8 and 9 for Material Traceability and Certification Requirements.

INSPECTION ACTIVITY 6.

Pre-production visit to Supplier's works to check the following: -

Supplier has and understands all relevant standards and specifications.

-

Drawings approved before manufacture commences when required in the purchase order.

-

Any special manufacturing process as defined or supplier's specification or standards are approved.

-

Sub orders have been placed and contain relevant specifications, standards, and drawings as appropriate.




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-

Manufacturing quality control plan approved commences (including those of sub suppliers).

before

manufacture

-

Documentation, certification, data dossier and QC dossier requirements defined. COMMENTS: -

Check and record all document/drawing numbers and revision status.

7.

Audit/examine material and verify compliance with material certification, design, specification and IEEE regulations as defined in the Contractors specification. Review manufacturers test certificate.

8.

Where specified, check that material control is implemented and that identification and traceability are maintained throughout manufacture and final acceptance.

9.

Pre-assembly components inspection, ensure all components which make up a complete item/system are inspected and checked to ensure:

10.

-

Traceability maintained

-

Rating in accordance with specifications

-

Components are free from injurious defects.

Where specified in Contractors specification or IEEE regulations ensure all pressure containment components are hydrostatically tested. -

Review certificate of test only. COMMENTS: Where ancillary items or pipe work are used to provide cooling, etc., these shall be subjected to hydrostatic test -

Associated motor oil coolers, etc.

-

Electrical items such as oil reservoirs on transformers.

11.

Initial assembly and function test (including all calibration checks, tests as defined in the Contractors specifications, engineering standards and IEEE regulations referred to therein).

12.

Final acceptance test.

13.

Review and approve Mechanical Data and Fabrication dossiers, Operating and Maintenance Manuals and Spares Schedules.




14.


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Preparation of shipment, ensure all machine surfaces are protected, openings are sealed, paint coatings are applied where specified; all nameplates are fitted and correctly labelled, including hazard warning labels. Ensure that all temporary transportation restrain ts and supports are secure and clearly identified.




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APPENDIX 7 MINIMUM INSPECTION REQUIREMENTS INSTRUMENTATION 1.

The minimum inspection requirements for standard instruments shall comply with relevant Company specifications and Contractors procedures and sta ndards.

2.

Instrument "specials" i.e. items which are not normal supply, or are unique to the process design requirements shall be identified on a specific list copied to the Company. Such instrumentation particularly where manufacturing processed involve specialized techniques, i.e. specialized castings, welding, NDT or heat treatment, adequate levels of inspection and test in the purchase order specifications. NOTE:





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APPENDIX 8 MATERIAL TRACEABILITY REQUIREMENTS To be read in conjunction with Appendices 9 and 10. Refer to the Contract document for definition of Material Traceability. 1.

Material traceability is the ability to trace to Material Test Reports (MTR's) at any stage from purchase to installation.

2.

The scope of Material Traceability required is outlined in Appendices 9 & 10.

3.

Marking of materials shall as a minimum comply with relevant US codes and standards and be transferred to off cuts where appropriate to maintain required levels of traceability.

4.

Individual Contractors shall be responsible for implementing their own systems to achieve required levels of material traceability. The system shall demonstrate that material control, segregation, marking and traceability is planned and documented to provide the necessary level of assurance to the Company that installed materials of construction are certified and fully comply with the applicable code and specification requirements.

5.

Where Material Test Reports are required, heat numbers will be traceable to the individual material component.

6.

Where Material Test Reports are not required, marking shall be in accordance with relevant Codes and Standards.

7.

The Contractors system for Material Traceability during site fabrication shall facilitate compliance with requirements of the Contract document with respect to system acceptance certification.

8.

Material color coding requirements shall comply with Project specifications requirements.




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APPENDIX 9 MATERIAL TEST REPORT REQUIREMENTS To be read in conjunction with Appendices 8 and 10. Refer to the Contract document for definition of Material Test Reports (MTR's). 1.

General Notes: Section A: For ANSI/ASME P1 Material Grades I.

MTR's will only be required if specifically requested in Contractors specifications. Approved design codes or purchase orders. Typically the following examples would be advised: -

carbon steel vessels where temperature equipment.

metallurgy

is

critical

i.e.

low

-

boiler code piping; SA 106

-

materials are required to satisfy NACE standards in H2S or other similar duties where composition and metallurgy of finished condition is critical.

-

materials restricted to maximum carbon content below standard.

II.

Contractor will be clearly defined in the appropriate design and purchase documents.

III.

For vessels fabricated in accordance with ASME rules, the Authorized Inspection may require MTR's for other specific cases in which case they will be provided.

IV.

Other standard carbon steel products will require a certificate of conformance issued by the organization qualified to certify that products comply with specified requirements.

Section B: For ANSI/ASME materials higher than P1 V.

MTR's shall be required for all materials higher than P1, i.e. alloy steels, stainless steel grades, etc.

VI.

Exceptions to the above may be referred to the Project Specialist where use of the material is not relevant to process design conditions or for safety reasons but constitutes Contractors or manufacturers normal standard i.e. instrumentation components. Such concessions shall be documented in accordance with the Company specifications.



TITLE



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Section C: Form of Certificates VII.

Standard Material Test Report/Material Certificates satisfying the applicable Code requirements are acceptable. The European requirements for type A, B, or C material certificates shall not be mandatory.

VIII.

The form of the certificate shall contain a record of chemical composition, supplied condition and physical properties, including the results of any specific tests required by the purchase order or specification; i.e. hardness values, Charpy impact test results etc.

IX.

Such MTR's shall be furnished and authenticated by the material manufacturers and traceable to individual components. Copies of original MTR's are acceptable.

Section D: Civil X.

As a minimum, the Contractor shall provide MTR's for structural assemblies employing critical materials of construction. The scope shall be determined by the Contractor but should typically include for: - primary structural steel - lifting devices, runway beams, gantries, cranes, etc. - equipment anchor bolts where critical to security of the item.

Section E: Electrical XI.

As a minimum, the Contractors system shall ensure certification is available for electrical equipment consistent with an item's electrical rating and classification in compliance with hazardous zone ratings. Certification is to be verified during installation and site acceptance.

Section F: Bolting XII.

`The Contractors system for the inspection and verification that bolting materials comply with specified requirements shall ensure incorrect or rogue bolting materials are rejected at the suppliers or prior to receipt in module yard or site stores.





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APPENDIX 10 POSITIVE MATERIAL IDENTIFICATION REQUIREMENTS To be read in conjunction with Appendices 8 and 9 for definition of Positive Material Identification (PMI) and Alloy Verification (AV). 1.

Attention is drawn to the need for each Contractor to read and familiarize itself with the Contract Document.

2.

Alloy materials shall as a minimum comply with the Project requirements for PMI, which includes the requirements of MTR's, marking, traceability and AV.

3.

Specific traceability to as built drawings will not be required by the Company as part of the final handover documentation; refer to Project Procedure 84501-92009L-002

4.

The Contractors PMI program shall demonstrate that the system for tracing material to MTR's provides for simple traceability during purchasing, stores control, fabrication and installation. The following sections provide guidance to the Contractor for the determination of PMI requirements, but does not relieve the contractor from its obligation to include any additional materials in the PMI programme where it considers this to be justified or necessary.

5.

Components subject to PMI:

5.1

Vessels and Piping Systems All pressure retaining parts. PMI for internals as determined by the Contractor and defined in procurement documentation.

5.2

Machinery: Pressure containing casing. PMI of ancillary components and internals as determined by the Contractor and defined in procurement documentation.

5.3

Instruments: As determined by the Contractor.

5.4

Bolting: As determined by the Contractor, but as a minim um: -

to include sampling check of all bulk alloy steel stud bolts included in the ASTM A-193 classification.

-

alloy bolts critical to and used in equipment subject to PMI.


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