SOUTH PARS GAS FIELD DEVELOPMENT (PHASES 9&10) Inspection & Test Plan for Atmospheric Tank Work GS / OIEC/ IOEC CONSORTIUM
Doc. No. : ONS-09-0-PR-5254
Rev. No. : 3 Class : 1
TABULATION OF REVISED PAGES PAGE
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South Pars Gas Field Development (Phases 9 & 10)
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SOUTH PARS GAS FIELD DEVELOPMENT (PHASES 9&10) Inspection & Test Plan for Atmospheric Tank Work GS / OIEC/ IOEC CONSORTIUM
Doc. No. : ONS-09-0-PR-5254
Rev. No. : 3 Class : 1
TABULATION OF REVISED PAGES PAGE
1 2 3 4 5 6 7 8 9 10
Rev.0 * * * * * * * * *
Rev.1 Rev.1 * * * * * * * * * *
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Rev.3 Rev.3 * *
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South Pars Gas Field Development (Phases 9 & 10)
Page 2 of 10
SOUTH PARS GAS FIELD DEVELOPMENT (PHASES 9&10) Inspection & Test Plan for Atmospheric Tank Work GS / OIEC/ IOEC CONSORTIUM
Doc. No. : ONS-09-0-PR-5254
Rev. No. : 3 Class : 1
CONTENTS
Page 1. PURPOSE
……………………………
2. TERMS AND DEFINITIONS 3. REFERENCES
4
……………
4
……………………………
4
4. RESPONSIBILITY
……………
5. ATTACHMEN TTACHMENTS TS ……………………………
South Pars Gas Field Development (Phases 9 & 10)
5 5
Page 3 of 10
SOUTH PARS GAS FIELD DEVELOPMENT (PHASES 9&10) Inspection & Test Plan for Atmospheric Tank Work GS / OIEC/ IOEC CONSORTIUM
Doc. No. : ONS-09-0-PR-5254
Rev. No. : 3 Class : 1
1. PURPOSE
The purpose of this Inspection & Test Plan (ITP) is to describe the methods and establish the Quality Plan for the Inspection & Test Plan for Atmospheric Tank Work Activities for South Pars 9&10 Project. 2. TERMS AND DEFINITIONS
COMPANY: NATIONAL IRANIAN OIL COMPANY(NIOC) / Pars Oil and Gas Company(POGC) or his nominated representative. CONTRACTOR: The party (GS/OIEC/IOEC CONSORTIUM) which entered under Contract Agreement with COMPANY for the Design, Engineering, Procurement and Construction of the Onshore and Offshore Facilities regarding the South Pars Field Development Project 9&10. SUBCONTRACTOR: shall mean any company, firm or person with whom CONTRACTOR enters into a subcontract. TPA (Third Party Authorities): any inspection service person or company who is independent from COMPANY, CONTRACTOR AND SUBCONTRACTOR. SITE: The location for installation of the facilities at ASSALUYEH or the vicinity thereof in the IRAN. 3.
REFERENCES 3.1 Specification & Procedure RP-6340S-999-6600-001 RP-6340S-999-2500-001 RP-6340S-999-6300-0001 RP-6340S-999-P332-003 COM-07-0-PR-0002 ONS-09-0-PR-5300 ONS-09-0-PR-5400 ONS-09-0-PR-4505 ONS-09-0-PR-5208 ONS-09-0-PR-5210 ONS-09-0-PR-4600 ONS-09-0-PR-5200,1,2,3,4,7 ONS-09-0-PR-5211 ONS-09-0-PR-5252 ONS-09-0-PR-4503 ONS-O9-0-PR-4506 3.2 Standards API 650 API 620
API 2000
South Pars Gas Field Development (Phases 9 & 10)
Shop and Field Painting Specification Cylindrical Storage Tanks Small and Medium Size Welding of Pressure Containing Piping and Equipment Field Erection Pressure Testing Field Material Control Procedure Work Instruction for Material Receiving Material Control Procedure Flushing Procedure Work Procedure for Welder and Welding Operator Qualification Work Procedure for Welding Qualification Work Procedure for Blasting & painting Application NDT Procedures PWHT Procedure Inspection & Test Plan for Tank Lining Work Work Procedure for Pressure Test Welding Consumable Control Procedure Welded Steel Tanks for Oil Storage Design and Construction of Large, Welded Low-Pressure Storage Tanks Venting Atmospheric and Low-Pressure Storage Tanks
Page 4 of 10
SOUTH PARS GAS FIELD DEVELOPMENT (PHASES 9&10) Inspection & Test Plan for Atmospheric Tank Work GS / OIEC/ IOEC CONSORTIUM 4.
Doc. No. : ONS-09-0-PR-5254
Rev. No. : 3 Class : 1
RESPONSIBILITIES
4.1
SUBCONTRACTOR Field QA/QC Manager is responsible for Quality Control for all kinds of Equipment Installation Work Activities.
4.2
SUBCONTRACTOR Field QC Inspector is responsible as follows: a) Prepare & Implement details of the field inspection requirements or activities in accordance with the Project Specifications and the other code and standards of the Contract . b) Perform inspection and document review. c) Comply with any instructions or comments by the COMPANY’s Mechanical Supervisor and Field Inspector/CONTRACTOR’s field inspector and Issue all field inspection reports to the COMPANY/CONTRACTOR for review/information. d) Maintain regular contact with the COMPANY/CONTRACTOR, including reporting all field inspection activities. e) Prepare ITP or Procedures (if required).
f) Prepare an updated list of Inspection/Test status and schedule. g) Request the inspection & witness to COMPANY’s Mechanical Supervisor and Field Inspector /CONTRACTOR’s field inspector as per the ITP required for inspection on witness and hold point(At least one day in advance). h) Perform Inspection. i) Submit to COMPANY/CONTRACTOR the inspection/test records showing that all required inspection/test activities are completed. 4.3
5.
SUBCONTRACTOR Construction superintendent/supervisor implementing in Accordance with this procedure requirements.
has
the
responsibility
ATTACHMENTS
1. Inspection & Test Plan tables --2. Inspection Report Forms ------
5 Sheets 24 Sheets
South Pars Gas Field Development (Phases 9 & 10)
Page 5 of 10
for
INSPECTION & TEST PLAN FOR ATMOSPHERIC TANK WORK Doc. No. : ONS-09-0-PR-5254 DISCIPLINE : TANK
INSPECTION & TEST PLAN FOR SITE
SUBCON.
:
Rev. : 3
DESCRIPTION OF WORK : TANK NO.
PARTICIPATION BY REPORTING FORMAT SUBCON. CONTRACTOR COMPANY TPA
Applicable Spec. or Procedure
DESCRIPTION OF INSPECTION / TEST
A
MATERIAL VERIFICATION
1
Verify the material condition before installation , & Vendor Manual & Material MRI-001/EQPWelding Consumable Control 016 Control Procedure
X
W
SW
B
Foundation Inspection
X
W
SW
X
W
SW
X X X X X
W W W R/SW R
W W W R/SW R
REMARK
Related Drawing
EQP-020,EQP009
RP-6340S-999-2500-001,
1 2 3 4 5
Levelness of Ring Wall Center Point and Radius Flatness & Slope Orientation(Zero point, Drain sump) Anchor bolts(Distance, Projection,etc.) as required
C
Erection and Fabrication
1
Welding ONS-09-0-PR1) WPS/PQR 5208,5210,4506 2) Welder/Welding operator qualification RP-6340S-999-63003) Welding Process (Baking Electrode/Preheat/Weld ) 0001,ASME Sec. IX,API 650 4) NDT (if applicable) ONS-09-0-PR-5200,1,2,3,4,7 5)
Related DWG’s , API 650
WPS-001 PQR-001~003 WQT-001
NDT Operator Qualification Cert. Check
LEGEND :
R : Review
SW : Spot Witness
W : Witness
H : Hold
W W W R R
X: Execution of Inspection & Test
South Pars Gas Field Development (Phases 9 & 10)
Page 6 of 10
INSPECTION & TEST PLAN FOR ATMOSPHERIC TANK WORK Doc. No. : ONS-09-0-PR-5254 DISCIPLINE : TANK
INSPECTION & TEST PLAN FOR SITE
SUBCON.
:
Rev. : 3
DESCRIPTION OF WORK : TANK NO.
DESCRIPTION OF INSPECTION / TEST
2 2.1
Erection Bottom and Annular Plate 1) Fit-up of bottom plates. . 2) Welding sequence implementation 3) Visual inspection of weldment 4) Vacuum box test of bottom plate 5) Annular plate orientation check 6) Fit - up & welding of annular plate 7) NDT of annular plate / Vacuum Test(If required) 8) Annular erection marking check
2.2
Shell plate 1) Fit-up & first course shell plate tack welding 2) Check of roundness / plumbness / Levelness 3) Fit-up & tack welding of second course shell Plate 4) Check of plumbness 5) Fit-up & tack welding of third course shell plate 6) Check of plumbness 7) Welding of first course after assembling of second & third course 8) Check of plumbness / banding / peaking 9) NDT ( if applicable)
PARTICIPATION BY REPORTING FORMAT SUBCON. CONTRACTOR COMPANY
Applicable Spec. or Procedure Approved Vendor ‘s Tank Erection Procedure RP-6340S-999-2500-001,
EQP-010
RP-6340S-999-63000001
API 650
EQP-011
Applicable DWG. .
.
EQP-017 EQP-010/017
X X X X X X X
W W W H W R/W W
SW SW SW W W R/W W
X X X
W H W
SW W SW
X X X X
W W W W
W SW W W
X X
H R/W
W R/W
R : Review
SW : Spot Witness
R
RP-6340S-999-2500-001 Approved Vendor’s Tank Erection Procedure
EQP-010 EQP-008,12,13 EQP-010
API 650 RP-6340S-999-2500-001
EQP-012 EQP-010
Applicable DWG.
EQP-012 EQP-011 EQP-012,014,015
ONS-09-0-PR5200,1,2,3,4,7
LEGEND :
TPA
W : Witness
H : Hold
X: Execution of Inspection & Test
R
REMARK
INSPECTION & TEST PLAN FOR ATMOSPHERIC TANK WORK Doc. No. : ONS-09-0-PR-5254 DISCIPLINE : TANK
INSPECTION & TEST PLAN FOR SITE
SUBCON.
:
Rev. : 3
DESCRIPTION OF WORK : TANK DESCRIPTION OF INSPECTION / TEST
2 2.1
Erection Bottom and Annular Plate 1) Fit-up of bottom plates. . 2) Welding sequence implementation 3) Visual inspection of weldment 4) Vacuum box test of bottom plate 5) Annular plate orientation check 6) Fit - up & welding of annular plate 7) NDT of annular plate / Vacuum Test(If required) 8) Annular erection marking check
2.2
Shell plate 1) Fit-up & first course shell plate tack welding 2) Check of roundness / plumbness / Levelness 3) Fit-up & tack welding of second course shell Plate 4) Check of plumbness 5) Fit-up & tack welding of third course shell plate 6) Check of plumbness 7) Welding of first course after assembling of second & third course 8) Check of plumbness / banding / peaking 9) NDT ( if applicable)
PARTICIPATION BY REPORTING FORMAT SUBCON. CONTRACTOR COMPANY
Applicable Spec. or Procedure
NO.
TPA
REMARK
Approved Vendor ‘s Tank Erection Procedure RP-6340S-999-2500-001,
EQP-010
RP-6340S-999-63000001
API 650
EQP-011
Applicable DWG. .
.
EQP-017 EQP-010/017
X X X X X X X
W W W H W R/W W
SW SW SW W W R/W W
X X X
W H W
SW W SW
X X X X
W W W W
W SW W W
X X
H R/W
W R/W
R
RP-6340S-999-2500-001 Approved Vendor’s Tank
EQP-010
Erection Procedure
EQP-008,12,13 EQP-010
API 650 RP-6340S-999-2500-001
EQP-012 EQP-010
Applicable DWG.
EQP-012 EQP-011 EQP-012,014,015
ONS-09-0-PR-
R
5200,1,2,3,4,7
LEGEND :
R : Review
SW : Spot Witness
W : Witness
H : Hold
X: Execution of Inspection & Test
South Pars Gas Field Development (Phases 9 & 10)
Page 7 of 10
INSPECTION & TEST PLAN FOR ATMOSPHERIC TANK WORK Doc. No. : ONS-09-0-PR-5254 DISCIPLINE : TANK
INSPECTION & TEST PLAN FOR SITE
SUBCON.
:
Rev. : 3
DESCRIPTION OF WORK : TANK NO.
Applicable Spec. or Procedure
DESCRIPTION OF INSPECTION / TEST
10) Welding of second course after assembling fourth course 11) Check of plumbness / banding / peaking 12) NDT (if applicable) 13) Fit-up & welding of other course 14) Check of plumbness / banding / peaking 15) NDT (if applicable) 16) Welding of shell plate to annular plate after welding of third course 15) Oil test of shell plate to annular plate 16) Check of manhole, nozzle & other accessories 16.1) orientation and location 16.2) welding & NDT ( if applicable) 16.3) air test of reinforcements 2.3 Roof Erection
REPORTING FORMAT
X
W
SW
EQP-012,014,015
X X X X X X
H R/W W H R/W W
W R/W SW W R/W W
EQP-017
X
H
W
EQP-018 EQP-019
X X X
H W H
W W W
EQP-010
X X
W H
W SW
X X
H W
W W
X
W
W
EQP-010 EQP-012,014,015 EQP-011
ONS-09-0-PR-
SUBCON. CONTRACTOR COMPANY
EQP-011
ONS-09-0-PR5200,1,2,3,4,7
PARTICIPATION BY
EQP-011
Approved Vendor’s Tank Erection Procedure RP-6340S-999-2500-001
R : Review
SW : Spot Witness
R
R
5200,1,2,3,4,7
2.3.1 Floating Roof API 650, 1) Check of deck plates & pontoon roof orientation 2) Fit-up & welding of deck plates , pontoon roof , Rim , Compart , Center plate, etc. 3) Oil test deck plates 4) Check of distance between primary seal & inside Applicable DWG. of shell plate 5) Arrangement of roof structure LEGEND :
TPA
W : Witness
H : Hold
EQP-017
X: Execution of Inspection & Test
R H
REMARK
INSPECTION & TEST PLAN FOR ATMOSPHERIC TANK WORK Doc. No. : ONS-09-0-PR-5254 DISCIPLINE : TANK
INSPECTION & TEST PLAN FOR SITE
SUBCON.
:
Rev. : 3
DESCRIPTION OF WORK : TANK NO.
Applicable Spec. or Procedure
DESCRIPTION OF INSPECTION / TEST
10) Welding of second course after assembling fourth course 11) Check of plumbness / banding / peaking 12) NDT (if applicable) 13) Fit-up & welding of other course 14) Check of plumbness / banding / peaking 15) NDT (if applicable) 16) Welding of shell plate to annular plate after welding of third course 15) Oil test of shell plate to annular plate 16) Check of manhole, nozzle & other accessories 16.1) orientation and location 16.2) welding & NDT ( if applicable) 16.3) air test of reinforcements 2.3 Roof Erection
PARTICIPATION BY
REPORTING FORMAT
SUBCON. CONTRACTOR COMPANY
EQP-011
X
W
SW
EQP-012,014,015
X X X X X X
H R/W W H R/W W
W R/W SW W R/W W
EQP-017
X
H
W
EQP-018 EQP-019
X X X
H W H
W W W
EQP-010
X X
W H
W SW
X X
H W
W W
X
W
W
ONS-09-0-PR5200,1,2,3,4,7
EQP-010 EQP-012,014,015 EQP-011
ONS-09-0-PR-
TPA
REMARK
R
R
5200,1,2,3,4,7 EQP-011
Approved Vendor’s Tank
R H
Erection Procedure RP-6340S-999-2500-001
2.3.1 Floating Roof API 650, 1) Check of deck plates & pontoon roof orientation 2) Fit-up & welding of deck plates , pontoon roof , Rim , Compart , Center plate, etc. 3) Oil test deck plates 4) Check of distance between primary seal & inside Applicable DWG. of shell plate 5) Arrangement of roof structure LEGEND :
R : Review
SW : Spot Witness
W : Witness
H : Hold
EQP-017
X: Execution of Inspection & Test
South Pars Gas Field Development (Phases 9 & 10)
Page 8 of 10
INSPECTION & TEST PLAN FOR ATMOSPHERIC TANK WORK Doc. No. : ONS-09-0-PR-5254 DISCIPLINE : TANK
INSPECTION & TEST PLAN FOR SITE
SUBCON.
:
Rev. : 3
DESCRIPTION OF WORK : TANK NO.
DESCRIPTION OF INSPECTION / TEST 6) 7) 8) 9) 10) 11) 12)
2.3.2
2.3.3
Applicable Spec. REPORTING or Procedure FORMAT
Welding of roof plates Check nozzles & other accessories orientation Cutting & welding of nozzle & other accessories Air test of roof plate Air test of reinforcements Roof Drain System Floating Roof Seal
EQP-011 EQP-018 EQP-011 EQP-019 EQP-019
Fixed Roof 1) Arrangement of roof structure 2) Check the roof plate & compression ring & roof structure orientation 3) Fit-up & welding compression ring & roof plate 4) Welding of roof plates 5) Check nozzles & other accessories orientation 6) Cutting & welding of nozzle & other accessories 7) Air test of roof plate 8) Air test of reinforcements
EQP-010 EQP-011 EQP-018 EQP-011 EQP-019 EQP-019
Miscellaneous Accessories 1) Location check and VT of weldment( Spiral Stairway / Ladder / Platform / Handrail / Anchor Chair / Earth Lug / etc.)
LEGEND :
R : Review
SW : Spot Witness
W : Witness
H : Hold
PARTICIPATION BY SUBCON.
CONTRACTOR COMPANY
X X X X X X X
W H W H W W W
W W SW W W W W
X X
W W
W W
X X X X X X
H W H W H W
SW W W SW W W
X
W
SW
X: Execution of Inspection & Test
TPA
H
H
REMARK
INSPECTION & TEST PLAN FOR ATMOSPHERIC TANK WORK Doc. No. : ONS-09-0-PR-5254 DISCIPLINE : TANK
INSPECTION & TEST PLAN FOR SITE
SUBCON.
:
Rev. : 3
DESCRIPTION OF WORK : TANK NO. 6) 7) 8) 9) 10) 11) 12) 2.3.2
2.3.3
Applicable Spec. REPORTING or Procedure FORMAT
DESCRIPTION OF INSPECTION / TEST Welding of roof plates Check nozzles & other accessories orientation Cutting & welding of nozzle & other accessories Air test of roof plate Air test of reinforcements Roof Drain System Floating Roof Seal
PARTICIPATION BY SUBCON.
EQP-011 EQP-018 EQP-011 EQP-019 EQP-019
Fixed Roof 1) Arrangement of roof structure 2) Check the roof plate & compression ring & roof structure orientation 3) Fit-up & welding compression ring & roof plate 4) Welding of roof plates 5) Check nozzles & other accessories orientation 6) Cutting & welding of nozzle & other accessories 7) Air test of roof plate 8) Air test of reinforcements
EQP-010 EQP-011 EQP-018 EQP-011 EQP-019 EQP-019
Miscellaneous Accessories 1) Location check and VT of weldment( Spiral Stairway / Ladder / Platform / Handrail / Anchor Chair / Earth Lug / etc.)
LEGEND :
R : Review
SW : Spot Witness
W : Witness
H : Hold
CONTRACTOR COMPANY
X X X X X X X
W H W H W W W
W W SW W W W W
X X
W W
W W
X X X X X X
H W H W H W
SW W W SW W W
X
W
SW
TPA
REMARK
H
H
X: Execution of Inspection & Test
South Pars Gas Field Development (Phases 9 & 10)
Page 9 of 10
INSPECTION & TEST PLAN FOR ATMOSPHERIC TANK WORK Doc. No. : ONS-09-0-PR-5254 DISCIPLINE : TANK
INSPECTION & TEST PLAN FOR SITE
SUBCON.
:
Rev. : 3
DESCRIPTION OF WORK : TANK NO.
DESCRIPTION OF INSPECTION / TEST
Applicable Spec. or Procedure
REPORTING FORMAT
PARTICIPATION BY SUBCON.
CONTRACTOR COMPANY
EQP-020~23 Approved Vendor’s Hydrostatic test / Seal check 1) Verify the welding work and NDE work before test Tank erection X H 2) Internal cleaning before test procedure, Approved X W 3) Verify shell opening and external piping condition Vendor’s Hydrostatic X W before test test, RP-6340S-9994) Water Filling P332-003, ONS-09-0X W 5) Hydro test(Water level/Holding time) PR-4505, ONS-09-0X H 6) Settlement check (Refer to applicable procedure) PR-4503 X H 7) Roof test (Pneumatic leak test) X W 8) Water discharge X W 9) Cleaning check X W 10) Seal check X W 11) Floating roof and roof support check X W 12) Air-foam water spray system check X W ONS-09-0-PR-4600 E Painting work PAI-006/007 . . 1) Painting material identification/check RP-6340S-999-6600X W MRI-001 2) Weather condition & Surface Preparation (Blasting) 001 X W 3) Primer Layer Inspection(Including Wet & Dry X W Thickness check) 4) Intermediate/Final Layer Inspection (Including Wet & X W Dry Thickness check) Applicable Code/ DWG. Tank Table X H F Tank Calibration (Marking & Measuring) Final Book X R G Final Inspection( Ensure the completion of all activities) LEGEND : R : Review SW : Spot Witness W : Witness H : Hold X: Execution of Inspection & Test
TPA
REMARK
D
W W W W W W W W W W SW W
H H H
SW W W SW/W W R
H
F.R.T Tanks
INSPECTION & TEST PLAN FOR ATMOSPHERIC TANK WORK Doc. No. : ONS-09-0-PR-5254 DISCIPLINE : TANK
INSPECTION & TEST PLAN FOR SITE
SUBCON.
:
Rev. : 3
DESCRIPTION OF WORK : TANK NO.
DESCRIPTION OF INSPECTION / TEST
Applicable Spec. or Procedure
REPORTING FORMAT
PARTICIPATION BY SUBCON.
CONTRACTOR COMPANY
EQP-020~23 Approved Vendor’s Hydrostatic test / Seal check 1) Verify the welding work and NDE work before test Tank erection X H 2) Internal cleaning before test procedure, Approved X W 3) Verify shell opening and external piping condition Vendor’s Hydrostatic X W before test test, RP-6340S-9994) Water Filling P332-003, ONS-09-0X W 5) Hydro test(Water level/Holding time) PR-4505, ONS-09-0X H 6) Settlement check (Refer to applicable procedure) PR-4503 X H 7) Roof test (Pneumatic leak test) X W 8) Water discharge X W 9) Cleaning check X W 10) Seal check X W 11) Floating roof and roof support check X W 12) Air-foam water spray system check X W ONS-09-0-PR-4600 E Painting work PAI-006/007 . . 1) Painting material identification/check RP-6340S-999-6600X W MRI-001 2) Weather condition & Surface Preparation (Blasting) 001 X W 3) Primer Layer Inspection(Including Wet & Dry X W Thickness check) 4) Intermediate/Final Layer Inspection (Including Wet & X W Dry Thickness check) Applicable Code/ DWG. Tank Table X H F Tank Calibration (Marking & Measuring) Final Book X R G Final Inspection( Ensure the completion of all activities) LEGEND : R : Review SW : Spot Witness W : Witness H : Hold X: Execution of Inspection & Test
TPA
REMARK
D
South Pars Gas Field Development (Phases 9 & 10)
W W W W W W W W W W SW W
H H H
SW W W SW/W W R
H
F.R.T Tanks
Page 10 of 10
