0 $
PIPE FABRICATION AND INSTALLATION WORK PROCEDURE
Onshore Maintain Potential Program one S!"B#$B %S!A"BA!& %S!A"BA!& Contra't No ( ))***++,-.
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Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
01 00 Rev
10 ,une 201 0 May 201 Date
(D Q(M (D Q(M Deve#o)e+ 3y
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Re3ision No0( *$
RE4ISION RECORD S!EET
Rev. No
Date
Reason fo! t"e !evision
00
May 7& 201
'o! ())!ova#
01
May 28& 201
'o! ())!ova#
Revision Detai#$%ocation
(s *n+icate+ 0 $
Document No.: P672-QCP-07
Page 2 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
INDE5
CONTENTS
Page No0
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Page 3 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201 16
P*P5 *N/(%%(/*N (3<5 RND
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Page 4 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
$0 INTRODUCTION(
Cont!o# of Pi)e faA!ication is an essentia# )a!t as )e! !eBui!ements of *nte!nationa# stan+a!+& c#ient& in )!o+uction )i)e faA!ication an+ insta##ation an+ minimiing 4astages& uninten+e+ use of mate!ia# as 4e## as cost effectiveness . 10 PURPOSE(
/"is +ocument +esc!iAes t"e )!ocess to Ae fo##o4e+ to Ae +efine t"e cont!o#s !eBui!e+ fo! )i)e faA!ication eecution an+ Bua#ity cont!o# Aefo!e& +u!ing an+ afte! 4e#+ing faA!ication to asce!tain- t"!oug" su)e!vision& su!vei##ance& ins)ection an+ testing E acce)taAi#ity of faA!ication s)oo#s an+ )i)e in acco!+ance 4it" a))#icaA#e co+e stan+a!+s an+ c#ient !eBui!ements . +0 SCOPE(
/"is )!oce+u!e cove!s a## s"o) $ fie#+ )i)ing 4e#+ing 4o!Fs using a))!ove+ 4e#+ing )!oce+u!es& a))!ove+ ND5 )!oce+u!es& a))!ove+ PM* )!oce+u!e an+ Bua#ifie+ 4e#+e!s fo! Ca!Aon stee# an+ tain#ess stee# use+ at ns"o!e Maintain Potentia# P!og!am Gone =3-13 =(3(= Cont!act No : 66000;97 -0 DEFINITION( • • • • • • • • • •
0 $
• • • • • • •
PQP QCP (/*P (5 (5P (*C (/R (MP/ (P*D PQR P *'C NCR ND5 R'* PM* =/
P!oHect Qua#ity P#an. Qua#ity Cont!o# P!oce+u!e. au+i (!amco /y)ica# *ns)ection P#an. au+i (!amco 5nginee!ing tan+a!+. au+i (!amco 5nginee!ing P!oce+u!e. au+i (!amco *ns)ection C"ecF %ist. au+i (!amco /est Re)o!ts. au+i (!amco P!oHect Management /eam. au+i (!amco P!oHect *ns)ection De)a!tment. PRC5DR5 Q(%*'*C(/*N R5CRD 5%D*N PRC5DR5 P5C*'*C(/*N *ssue+ 'o! Const!uction. Non Confo!mance Re)o!t. Non Dest!uctive 5amination. ReBuest 'o! *ns)ection. Positive Mate!ia# *+entification. =a!+ness /esting.
Page 5 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201 • •
• •
%P/ R/
%iBui+ Penet!ant /esting. Ra+iog!a)"ic /esting.
MP/ /
Magnetic Pa!tic#e /esting #t!asonic /esting
60 REFERENCE DOCUMENTS( Document NumAe!
Document /it#e
* ;001-2008
Qua#ity Management ystem ReBui!ements.
C=5D%5 IQJ
Minimum Qua#ity ReBui!ements.
( D1.1
t!uctu!a# e#+ing Co+e.
(M5 ec *?
e#+ing an+ 3!aing Qua#ification.
(M5 ec. **
Mate!ia# s)ecification.
(M5 3 1.9
Pi)e %ine /!ans)o!tation systems fo! =y+!oca!Aons an+ ot"e! #iBui+s.
(M5 31.8
as /!ansmission an+ Dist!iAution )i)ing systems.
(P* 1109
tan+a!+ fo! 4e#+ing of )i)e#ines an+ Re#ate+ 'aci#ities.
(5--012
e#+ing ReBui!ements fo! Pi)e#ine.
(5-%-10
Pi)e %ine C#asses.
(5-%-90
Const!uction of n-%an+ an+ Nea!- "o!e Pi)e#ine.
(5 -(-206
Positive Mate!ia# *+entification.
(/*P--12-01
e#+ing of )i)e#ines.
(/*P-%-0-08
"o) 'aA!ication E Pi)ing an+ Misce##aneous tee# t!uctu!es.
(/*P-%-90-0
C!oss Count!y (Aove !oun+ Pi)e #ine.
(*C--2019
(*C--2012
Revie4 =a!+ness /esting P!oce+u!e - (## ())#ications P#ant Pi)ing& Pi)e#ines&
/anFs
(*C-%-2009
Positive Mate!ia# *+entification P!oce+u!e.
(*C-%-2112
Mate!ia# ve!ification of Pi)e& 'ittings& )!efo!me+ Aen+s Co#+ > =ot 3en+s
(*C-%-209
Mate!ia# sto!age an+ "an+#ing.
Page 6 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201 Document NumAe!
Document /it#e
(*C-%-20
Cutting assemA#y fit-u).
SAIC-L-2036
Cold Bending
(*C-%-208
(*C- %-201
Revie4 > ())!ove Pi)ing 'aA!ication "o) ui+e - (ssu!e uccessfu# P!oHect ta!t-u)
)0 RESPONSIBILITIES( Pro7e't Manager
5nsu!e t"at t"e !eBui!ement of t"is )!oce+u!e a!e fu##y com)#ie+ 4it" Ay si+e o)e!ations )e!sonne#& t"at t"e si+e QC section a!e )!ovi+e+ 4it" t"e necessa!y faci#ities an+ co-o)e!ation f!om a## su)e!inten+ents& fo!eman an+ #aAou!& to enaA#e satisfacto!y ins)ection ve!ification of activities. Pi8ing S/8erinten9ent : S/8er3isor
5nsu!es com)#iance Ay a## fo!eman an+ #aAou! to t"e a))!ove+ )!oHect QCP& associate+ )!oce+u!e an+ s)ecifications& )!ovi+es t"e s"o) an+ site QC section 4it" t"e !e#evant +ocumentation !eBuest& 4it" sufficient notice to enaA#e stage ins)ection to com)#ete in a Bua#ity manne!. 2/alit; 'ontrol s/8er3isor
5nsu!es com)#iance Ay t"e s"o) an+ site )i)ing section to t"e a))!ove+ QCP an+ associate+ )!oce+u!e an+ s)ecifications. Monito! t"e QC Pe!sonne# in t"ei! +ai#y function an+ con+ucts !evie4s of +ocumentation an+ *ns)ection$
Monito!s +ai#y )i)ing activities an+ con+ucts ins)ection in acco!+ance 4it" t"e a))!ove+ )!oHect QCP& associate+ )!oce+u!e an+ s)ecification. P!e)a!e Bua#ity !eco!+s an+ fina# acce)tance +ocumentation 4"e!e !eBui!e+. Maintains c#ose 4o!Fing !e#ations"i) 4it" custome! !e)!esentative.
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Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
0
. SAFET"
$ • •
•
5nsu!e 4o!F )e!mit is va#i+ if a))#icaA#e. 5nsu!e Aa!!ica+es a!e )!esent. Minimum PP5 !eBui!ements s"a## Ae com)#ie+. Mac"ines a!e to Ae o)e!ate+ on#y Ay Bua#ifie+ an+ aut"o!ie+ )e!sonne#. @no4 t"e ca)acities of t"e mac"ine.
<0 PROCEDURE( Dra=ings an9 Do'/ments
(## )i)e4o!F action s"a## Ae con+ucte+ in acco!+ance 4it" t"e #atest !evision of t"e *'C +!a4ings& 4"ic" s"a## Ae +ist!iAution cont!o##e+. *t is essentia# t"at a## !e#evant inst!uction is avai#aA#e fo! !efe!ence at t"e 4o!F )#ace toget"e! 4it" t"e )e!tinent section of QCP. (## issues of t"ese +ocuments s"a## Ae cont!o##e+. Material Re'ei8t
Pi)ing mate!ia# s"a## Ae suAHecte+ to !ecei)t ins)ection. /"e eamination s"a## initia##y Ae con+ucte+ Ay mate!ia# cont!o# )e!sonne# fo! Bua#ity& com)#iance 4it" +e#ive!y note an+ ce!tification& 4"ic" s"a## Ae ve!ifie+ against cast numAe! i+entification. (n R'* s"a## Ae !aise+ fo! QC a))!ove+ of mate!ia# ce!tification& 4"ic" s"a## consist of a ve!ification of ce!tification ty)e i.e. o!igina# mi## o! ve!ifie+ !e+ stam)e+ an+ en+o!se+ su))#ie!s co)y. /"e mate!ia# ce!tificate s"a## Ae com)a!e+ 4it" t"e !eBui!ements of t"e i+entifie+ mate!ia#s ty)e& g!a+e an+ sie in t"e !efe!ence stan+a!+. n satisfacto!y conc#usion t"e QC ins)ecto! s"a## sign an+ !e+ QC stam) t"e ce!tificate an+ en+o!se t"e R'* noting acce)tance. 5ce)tion s"a## Ae custome! f!ee issue+ mate!ia#s. =o4eve! Buantity mate!ia# ty)e an+ f!ee f!om +amage s"a## sti## Ae a mate!ia# cont!o# staff function. P!e-faA!icate+ )i)e s)oo#s on !ecei)t s"a## Ae consi+e!e+ a "o#+ )oint unti# mate!ia# cont!o# eamines fo! +amage an+ Buantities as )e! +e#ive!y note. n
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Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
acce)tance an R'* s"a## Ae !aise fo! QC c#ea!ance. (cce)tance Re#ease s"a## Ae Ay !etu!n of en+o!se+ R'*. ReHection s"a## Ae Ay NCR issue. Pi)e s)oo#s !eceive f!om s"o) faA!ication faci#ities in ,uAai# faA s"o) s"a## Ae accom)anie+ Ay ins)ection !e#ease as )e! attac"e+ c"ecF#ist fo!m com)#ete+ sign Ay QC ins)ecto! an+ ot"e! aut"o!ity as +ictate+ Ay t"e cont!act Bua#ity cont!o# )#an. ( +ata )acF containing t"e fo##o4ing +ocuments 4"e!e a))#icaA#e s"a## Ae fo!4a!+e+ 4it" )i)e s)oo#s fo! fi##ing 4it"in site !eco!+s afte! Aeing ve!ifie+ Ay )!oHect site QC as )e! Ae##o4. 1.
e#+ summa!y !e)o!t.
2.
Mate!ia# test ce!tificates 4"e!e a))#icaA#e.
.
)oo# P!o+uction !+e! P.
9.
*somet!ic +!a4ing.
.
=eat /!eatment Reco!+s.
6.
PM* !eco!+s.
7.
=a!+ness !e)o!t.
8.
Coating !e)o!ts.
P!e-faA!ication )i)e s)oo#s !eceive+ as custome! f!ee issue s"a## Ae accom)anie+ Ay as )e! )!oHect ag!ee+ +ocuments. /"ese s"a## Ae suAHecte+ to t"e same !evie4s an+ ve!ification an+ as )e! @ent faA!ication s"o). /!aceaAi#ity of mate!ia# com)onents faA!ication an+ insta##ation 4i## Ae ca!!ie+ an+ ve!ifie+ on#y to t"e etent i+entifie+ in t"e cont!act s)ecification o! t"e a))!ove+ )!oHect QCP. (## mate!ia# s"a## Ae sto!e+ in t"e safe secu!e con+ition )aying )a!ticu#a! ca!e to !eBui!ements fo! )!otection& i.e. +amage& en+ )!otection an+ gene!a# c#imatic )!otection. (cce)te+ mate!ia# an+ faA!icate+ s)oo# +ocumentation s"a## Ae fi#e+ 4it"in +!a4ing sco)e in t"e QC section& an+ cont!o##e+ in t"e manne! +esc!iAe+ in QCP )!e)a!ation of Qua#ity Reco!+s. Page 9 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
(ny +isc!e)ancies +etecte+ +u!ing any of t"e mate!ia# an+ faA!icate+ !evie4s s"a## !esu#t in t"e !aising of a Non Confo!mance Re)o!t NCR Ay t"e !es)onsiA#e section in acco!+ance 4it" QCP Non Confo!mance an+ Co!!ective (ctions. ,0 MATERIAL TRACEBILIT"(
Mate!ia# Ce!tification& co#ou! co+ing& intaFe ins)ection& sto!age an+ mate!ia# "an+-out Ae st!ict#y cont!o##e+ to ec#u+e to !ogue mate!ia#s f!om eBui)ment an+ )#ant. /"e ven+o! s"a## o!ganise its manufactu!e )!ocess so t"at mate!ia# t!aceaAi#ity is ensu!e+& in 4"ic" case )ositive a##oy mate!ia# i+entification afte! mate!ia# assemA#y is not !eBui!e+. /o ensu!e mate!ia# t!aceaAi#ity t"e fo##o4ing s"a## Ae +ocumente+ in fu##y im)#emente+ an+ au+itaA#e faA!ication an+ $o! const!uction )!oce+u!e. te) 1
Mate!ia# P!ocu!ement. /"e )u!)ose o!+e! s"a## s)ecify t"at t"e ven+o! s"a## s"i) t"e mate!ia# ce!tificates toget"e! 4it" )!o)e!#y ma!Fe+ mate!ia#s.
te) 2
Mate!ia# ce!tification an+ i+entification. )on mate!ia# !ecei)t t"e cont!acto! s"a## ve!ify t"at mate!ia#s a!e )!o)e!#y ma!Fe+ an+ matc" t"e ce!tificates.
te)
t!ict se)a!ate mate!ia# sto!age Aase+ on mate!ia# g!a+e. /"e fo##o4ing ve!ification& t"e mate!ia# s"a## Ae sto!e+ Ay mate!ia# g!a+e an+ sie.
te) 9
Cont!o##e+ mate!ia# issue. 3u#F mate!ia# !eBui!e fo! const!uction $ faA!ication )u!)oses s"a## Ae su))#ie+ f!om t"ei! sto!age a!ea Ay means of mate!ia#s issue vouc"e! 4"ic" c#ea!#y i+entifies t"e !eBui!e+ mate!ia# sie an+ g!a+e fo! 4"ic" const!uction$faA!ication item it is !eBui!e+.
te)
st!ict se)a!ations of mate!ia# g!a+es. (t t"e const!uction$faA!ication site mate!ia# g!a+es s"a## Ae Fe)t st!ict#y se)a!ate an+ i+entifiaA#e unti# suc" time as t"e faA!icate+ Page 10 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
item is com)#ete an+ t"e #iFe#i"oo+ of !ogue mate!ia#s Aeing suAstitute+ is minimise+. Positive mate!ia# i+entification of t"e finis"e+ )!o+ucts s"a## Ae )e!fo!me+ if any of aAove ste) 1 t"oug" ste)s is not fo##o4e+ com)#ete#y. $*0 POSITI4E MATERIAL IDENTIFICATION %PMI&
*f mate!ia# t!aceaAi#ity is not com)#ete#y a+"e!e+ to& PM* test s"a## Ae )e!fo!me+ on com)#ete+ eBui)ment o! assemA#e+ )a!t of eBui)ment at suc" time as to ensu!e t"at no mate!ia# an+ const!uction$faA!ication c"ange a!e ma+e. (n a))!ove+ t"i!+ )a!ty cont!acte+ Ay t"e ven+o! o! Fent in- "ouse ins)ection faci#ities s"a## ca!!y out PM*. (n action )#an fo! PM* testing s"a## Ae suAmitte+ Ay t"e ven+o! fo! t"e a))!ova# of t"e )!inci)a#. (ny )o!taA#e ?-!ay emission ana#yse! o! eBuiva#ent 4it" com)ute!ise+ !ea+Eout is acce)taA#e. /"e cont!acto! s"a## ensu!e t"at au+itaA#e measu!e of Bua#ity assu!ance a!e in )#ace to ve!ify t"at 4e#+s ma+e 4it" t"e consumaA#e s)ecifie+ on t"e P a#so t"ese measu!e.
"a## ensu!e t"at as )e! (5-(-206 7. PM* testing of 4e#+ meta# s"a## Ae suAHecte+ to t"e same cove!age as fo! t"e Aase mate!ia#. 7.9 /aA#e No.1 an+ /aA#e No.2. n com)#etion of s)oo#s an+ afte! t"e satisfacto!y ins)ection Ay t"e +i!ect su)e!vision& R'* s"a## Ae !aise+ fo! fina# c#ea!ance ins)ection. /"is s"a## Ae fo!4a!+e+ 4it"out +e#ay to t"e QC section. 0
$$0 S!OP:SITE FABRICATION
$
>ENERAL
Pi)ing 4i## no!ma##y Ae faA!icate+ on t"e Aasis of I3i## of mate!ia#s fo! )i)ingJ 4"ic" inc#u+es isomet!ic +!a4ing& mate!ia# #ist 4"e!e necessa!y a++itiona# info!mation fo! t"e content of t"e 3i## of Mate!ia#s. C/tting an9 ?e3elling Cutting an+ Aeve##ing of )i)e may Ae +one Ay mec"anica# means: f#ame cutting& )#asma cutting o! t"e fo##o4ing s"a## a))#y: Page 11 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
-
'o! ca!Aon stee#& f#ame o! a!c cuts s"a## Ae !easonaA#e smoot" an+ a## oi+e s"a## Ae !emoving f!om t"e su!face Ay g!in+ing to A!ig"t meta#.
-
'o! #o4 a##oy stee#& afte! f#ame cutting a minimum of 2 mm of mate!ia# s"a## Ae !emove+ f!om t"e cut su!face Ay g!in+ing.
-
'o! stain#ess stee# f#ame cutting s"a## not Ae use+. /"e su!face s"a## Ae g!oun+ to A!ig"t meta# afte! )#asma cutting.
e#+ Aeve# fo! Autt 4e#+s of )i)e an+ fitting s"a## Ae in acco!+ance 4it" (M5 316.. "o)-Aeve##ing of fie#+ 4e#+s a!e not !eBui!e+ if a maFe-u) et!a #engt" fo! fie#+ cutting to sie is )!ovi+e+. *n t"is case& Aeve# s"a## Ae )!e)a!e+ afte! cutting t"e !e#evant )i)e s)oo# to !eBui!e+ #engt". Cutting oi# s"a## Ae !emove+. Pi)e fo! socFet 4e#+ Hoints s"a## Ae cut sBua!e an+ Au!!s !emove+. 0
@oint Pre8aration0
$
P!io! to sta!t any 4e#+ing 4o!Fs t"e @ent 4e#+ing fo!eman an+ 4e#+ing ins)ecto! s"a## ensu!e t"e fo##o4ing: •
•
•
Pi)ing Aeve# en+ s"a## Ae )!e)a!e+ fo! 4e#+ing o)e!ation Ay g!in+ing o! mac"ining 4it" an ang#e as in+icate in t"e a))#icaA#e P. *nte!na# misa#ignment of Autt Hoints s"a## Ae not ecee+ing 1. mm inte!na# ta)e!ing in acco!+ance 4it" (M5 3 1.9 o! 3 1.8 Ay mac"ining& AacF 4e#+ing& o! comAination may Ae use+ to co!!ect t"e misa#ignment. (ny tem)o!a!y 4e#+e+ attac"ments o! tem)o!a!y tacF 4e#+s s"a## Ae g!oun+ off. (ttac"ments may Ae cut off no c#ose! t"an mm to Aase meta# su!face& )!io! to t"e !eBui!e+ g!in+ing. (## +amage to t"e )a!ent meta# s"a## Ae )!e)a!e+ 4it" a Bua#ifie+ 4e#+ing )!oce+u!e. (!c st!iFes& gouges& an+ ot"e! in+ications of ca!e#ess 4o!Fmans"i) suc" as )o!osity& uneven 4e#+ )!ofi#e& an+ un+e!cut s"a## Ae !emove+ Ay g!in+ing. /"e !e)ai! s"a## Ae ve!ifie+ using a non-+est!uctive eamination )!oce+u!e Bua#ifie+ fo! t"e a))!o)!iate ty)e of ins)ection.
•
P!otection of coate+ )i)e an+ ot"e! com)onents.
Page 12 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
Coate+ su!face s"a## Ae )!otecte+ f!om t"e 4e#+ing a!c& associate+ 4e#+ s)atte!& an+ +amage f!om g!oun+ c#am)s o! ot"e! associate+ eBui)ment. Assem?l; o 8i8ing 'om8onents
'o! Autt 4e#+ing of a## )i)e com)onent e.g. )i)e en+s& fitting 4e#+ing necF f#anges& a unifo!m !oot ga) s"a## Ae )!ovi+e+ as t"e s)ecific in t"e !e#evant e#+ing P!oce+u!e )ecification. Refe! to (P* 1109 )a! 7.2 t"e a#ignment of aAutting en+s s"a## minimie t"e offset Aet4een su!faces. 'o! )i)e en+s of t"e same s)ecifie+ /"icFness& t"e offset s"ou#+ not ecee+ 1$8 in. mm. %a!ge! va!iations a!e )e!missiA#e )!ovi+e+ t"e va!iation is Cause+ Ay va!iations of t"e )i)e en+ +imensions 4it"in t"e )i)e )u!c"ase s)ecification to#e!ances& an+ suc"
/"e 4e#+ing fo!eman an+ QC Pi)ing$e#+ing *ns)ecto! s"a## monito! t"at 4e#+ing )!ocess in acco!+ance 4it" )!oHect stan+a!+ an+ s)ecification an+ t"at t"e
Page 13 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
4e#+ing is )e!fo!me+ in acco!+ance 4it" t"e a))!o)!iate P Ay suitaA#y Bua#ifie+ 4e#+e!s.
Wel9ing En3ironment
0 $
Prior to start an; =el9ing =ors the Kent =el9ing ins8e'tor shall ens/re the ollo=ing( •
•
Win9shiel9 or tents shall ?e /se9 =hen the =in9 is strong eno/gh to ae't ar' sta?ilit; or shiel9ing gas 'o3erage or =hen 9eeme9 ne'essar; ?; Aram'o0 >TAW shall not ?e /se9 or iel9 or ;ar9 a?ri'ation /nless a9e/ate =in9shiel9s are /se90 The =in9 3elo'it; in the =el9 area or >TAW shall no e'ee9 < 8h %101 m:s&0 Wel9ing shall not ?e 9one =hen s/ra'e are =et or 9am8 or e8ose9 to rain or sno= or =hen the =el9ers are e8ose9 to in'lement 'on9itions0 Contamination rom the en3ironment s/'h as =in9#?lo=n san9 shall ?e 8re3ente9 ?; the /se o a9e/ate shiel9ing0
Preheat
0 $
• •
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0
Preheat shall ?e in a''or9an'e =ith the a88ro3e9 =el9ing 8ro'e9/re0 !an9 hel9 Pro8ane gas tor'hes shall ?e /se9 to 8reheat Car?on Steel0 I a =el9 7oint is =et or has s/ra'e moist/re or 'on9ensation it shall ?e 9rie9 ?; heating or a 9istan'e o $** mm rom the =el9 7oint an9 shall ?e =arm to the han9 ?eore =el9ing0 Tem8erat/re#in9i'ating 'ra;ons thermo'o/8les or 'onta't 8;rometers shall ?e /se9 to meas/re 8reheat an9 inter 8ass tem8erat/re0 Tem8erat/re in9i'ation 'ra;ons shall not ?e /se9 or an; =el9 7oint that is to ?e 'oate9 or that =ill ha3e a heat#shrin slee3e installe9 on it0
In Pro'ess Ins8e'tion0
$ •
Maimum 4e#+ +e)osit Bua#ifie+ Ay PQR an+ in+icate+ on P fo! eac" 4e#+ing )!ocess an+ eac" )ass s"a## Ae oAse!ve+ Ay t"e 4e#+e! an+ ins)ecte+ Ay @ent 4e#+ing ins)ecto!.
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Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
•
•
0 $
Inter#Pass Tem8erat/re Cleaning
/"e QC Pi)ing$e#+ing *ns)ecto! s"a## monito! t"at 4"e!e !eBui!e+ P!e"eat an+ *nte!-)ass tem)e!atu!e a!e a))#ie+ an+ cont!o##e+ in acco!+ance 4it" t"e P. •
•
•
0
'o! no#es 4it" !einfo!cing )a+s& t"e no#es attac"ments 4e#+ s"a## Ae com)#ete+ an+ ins)ecte+ Ay @ent e#+ing ins)ecto! con+uct magnetic )a!tic#e ND/ )!io! to insta##ing t"e !einfo!cing )a+. @ent 4e#+ing ins)ecto! s"a## ensu!e t"at a## no#es& A!anc" an+ tee connections a!e ma+e 4it" fu## )enet!ation g!oove 4e#+s on#y.
n#ess s)ecifie+ ot"e!4ise& t"e maimum inte!-)ass tem)e!atu!e s"a## Ae 177 C fo! P-No 8& P-No. ? an+ P-No.9? mate!ia#s an+ 1C fo! P-No.1& P-No.& P-No.9 an+ P.No. stee#. 5ac" 4e#+ )ass s"a## Ae t"o!oug"#y c#eane+ an+ a## s#ag o! ot"e! fo!eign matte! !emove+ Aefo!e t"e net )ass is +e)osite+. (## s#ag& '#u an+ s)atte! s"a## Ae !emove+ f!om t"e com)#ete+ 4e#+ an+ su!!oun+ing a!eas.
Post =el9 Ins8e'tion
$
(## 4e#+ Hoint s"a## Ae 100
•
•
•
•
0
*!!egu#a! Aea+& ecess !einfo!cement& !oot )enet!ation if access )e!mitte+ u!face +efect suc" as c!acFs& un+e!cutting an+ #acF of fusion. /"e maimum a##o4aA#e 4e#+ Aea+ 4i+t" fo! 4e#+ ma+e Ay /( an+ M( )!ocess s"a## Ae times t"e co!e 4i!e o! fi##e! meta# +iamete!. Ma!Fe! use+ fo! )i)es s"a## Ae 4it"out c"#o!i+es an+ "a#i+es. e#+s 4i## Ae i+entifie+ 4it" a numAe! of eac" #ine. /"e numAe! 4"ic" is i+entifie+ on t"e 4e#+ ma) 4i## Ae t!ansfe!!e+ to t"e )i)e at a #ocation a+Hacent to t"e Hoint. Refe! Ae#o4 5%D *D5N/*'*C(/*N NM35R*N /5M.
Ta' =el9s
$ •
(## tacF 4e#+s s"a## Ae ma+e Ay Bua#ifie+ 4e#+e!s. Page 15 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
•
• •
•
•
•
•
•
•
(## tacFs o! tem)o!a!y 4e#+s s"a## Ae )e!fo!me+ 4it" t"e same ca!e& mate!ia#s& e#ect!o+e& minimum )!e"eat& an+ )!oce+u!es t"at a!e use+ fo! )e!manent 4e#+s. /acFs 4e#+ s"a## Ae of sufficient sie to maintain Hoint a#ignment. /acF 4e#+s t"at a!e to Ae inco!)o!ate+ in to t"e fina# 4e#+ s"a## Ae t"o!oug"#y c#eane+& )!e)a!e+ at eac" en+& an+ ins)ecte+ fo! c!acFs. (ny c!acFe+ tacFs s"a## Ae !emove+ Aefo!e 4e#+ing t"e Hoint. 3!i+ge tacFs #ocate+ aAove t"e !oot a!ea a!e acce)taA#e Aut suc" tacFs must Ae ma+e com)#ete#y 4it"in t"e 4e#+ g!ove an+ s"a## Ae com)#ete#y !emove+ )!io! to com)#etion of t"e 4e#+. (!c st!iFes& gouges& an+ ot"e! in+ications of ca!e#ess 4o!Fmans"i) suc" as su!face )o!osity& uneven& 4e#+ )!ofi#es& an+ un+e!cut s"a## Ae !emove+ Ay g!in+ing. (ny tem)o!a!y 4e#+e+ attac"ments o! tem)o!a!y tacF 4e#+s s"a## Ae g!oun+ off. (ttac"ments may Ae cut off no c#ose! t"an mm to t"e Aase meta# su!face& )!io! to t"e !eBui!e+ g!in+ing. *f any g!in+ing !e+uces t"e Aase meta# to #ess t"an t"e +esign minimum& t"e g!oun+ a!ea s"a## Ae !e 4e#+e+ an+ g!oun+ f#us" 4it" t"e o!igina# Aase meta# su!face o! t"e com)onent s"a## Ae !e)#ace. Re 4e#+ing s"a## Ae +one on#y 4it" t"e )!io! a))!ova# of (!amco. /em)o!a!y attac"ments& g!oun+ing #ugs& o! su))o!ts 4e#+e+ to any com)onent s"a## Ae ma+e 4it" a com)atiA#e mate!ia#. n+e! no ci!cumstances s"a## !eAa! o! ga#vanie+ stee# Ae use+. Coate+ su!face s"a## Ae )!otecte+ f!om t"e 4e#+ing a!c& associate+ 4e#+ s)atte! an+ +amage f!om g!oun+ c#ams o! ot"e! associate eBui)ment.
WELD IDENTIFICATION NUMBERIN> S"STEM0
/"e 4e#+ i+entification numAe!ing system s"a## Ae use+ to i+entify an+ t!acF )i)ing g!oove an+ Autt 4e#+ as minimum 4e#+ numAe!ing s"a## Ae consecutive in t"e +i!ection of f#o4 )e! #ine. 5ac" 4e#+ s"a## Ae i+entifie+ Ay Hoint numAe!& #ine numAe!& an+ s)oo# numAe!& P"ysica# ma!Fing of 4e#+s s"a## com)#y 4it" t"e a))#icaA#e (5(-- )ecification.in a++ition to t"e s)oo# numAe! an+ #ine numAe! i+entification& eac" 4e#+ s"a## Ae i+entifie+ as fo##o4s.
Page 16 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
-01
:
/"is numAe! Aeen given to 4e#+ )!io! to )!o+uction 4e#+ing. *f !eBui!e+ eamination is acce)te+ no c"ange is !eBui!e+.
-01R1
:
-01R2
:
/"e -01 4e#+ "as Aeen com)#ete+ an+ eamination "as !evea#e+ an unacce)taA#e +iscontinuity t"at 4as !eBui!e+. *f suAseBuent eamination is acce)te+ no c"ange is !eBui!e+. /"e -01R14e#+ !e)ai! "as Aeen com)#ete+ an+ eamination "as !evea#e+ an unacce)taA#e +iscontinuity. *f suAseBuent eaminations a!e acce)te+ no c"ange is !eBui!e+. No fu!t"e! !e)ai! is )e!mitte+ 4it"out e)!ess a))!ova# of au+i (!amco. *f )e!mitte+ t"e suffi R s"a## Ae use+.
0
-01R :
/"e unacce)te+ 4e#+ -01R2 "as Aeen cut out an+ t"e Hoint "as Aeen !e-4e#+e+. /"e i+entification met"o+o#ogy aAove is to Ae a))#ie+ s"ou#+ fu!t"e! 4e#+ !e)ai!s Ae necessa!y.
-01/1
:
/"e -01 4e#+ "as Aeen com)#ete+ an+ eamination "as !evea#e+.
-01/2
:
an unacce)taA#e 4e#+ +iscontinuity o! =/ tests "ave Aeen !eHecte+. P!og!essive sam)#ing is !eBui!e+ in Aot" cases an+ t"e It!ace!J 4e#+s 4i## Ae i+entifie+. *f suAseBuent test a!e acce)te+ no c"ange is !eBui!e+. Re)ai! on t!ace! 4e#+s 4i## !eBui!e fu!t"e! sam)#ing in 4"ic" case t"e suffi numAe!ing system s"a## )!og!ess acco!+ing#y.
-01(
:
/"is numAe! Aeen given to 4e#+ )!io! to (++itiona#$(s Aui#+ Hoint.
-01(1
:
/"is numAe! Aeen given to 4e#+ )!io! to secon+ (++itiona#$(s Aui#+ Hoint.
$
0 $
e#+s faA!icate+ in t"e fie#+ s"a## Ae )!efie+ 4it" t"e #ette! O' an+ 4e#+s faA!icate+ in a 4e#+ s"o) 4it" #ette! O. /"e aAove numAe!ing system s"a## Ae a))#ie+ as a minimum fo! a## ty)e of tests an+ ins)ections of )i)e 4e#+s. $10 POST WELD !EAT TREATMENT /"e QC Pi)ing$e#+ing ins)ecto! s"a## monito! t"at 4"e!e !eBui!e+ P=/ as )e! t"e P t"e a))!ove+ an+ associate+ +ocuments fo! )ost 4e#+ "eat t!eatments a))#ie+ acco!+ance 4it" Qua#ity Cont!o# ReBui!ement.
Page 17 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
$+0 NON DESTRUCTI4E TESTIN>
*n acco!+ance to 4e#+ing !eBui!ements fo! on-)#ot )i)ing (5--012 )a!ag!a)" 16 a## of t"e 4e#+s o! )a!t of t"e tota# 4e#+s s"a## Ae non-+est!uctive teste+& acco!+ing to t"e )e!centage #eve# of ins)ection !eBui!e+ Ay ND/ taA#e issue+ Ay (!amco 5nginee!ing. 5ac" ND/ ins)ection s"a## Ae !egiste!e+ on ND/ %og "eet fo! eac" #ine.
/"e minima# )!o+uction Bua#ification 4e#+s ins)ecte+ Ay !a+iog!a)"ic test R/ s"a## not Ae )a!t of t"e !egu#a! !eBui!e+ )e!centage fo! t"e )!oHect )!o+uction 4e#+. /"e !eHect !e)o!t s"a## Ae !e)o!te+ se)a!ate#y as 4e#+e!s Bua#ification !e)o!t an+ t"e !eHect )e!centage fo! eac" 4e#+e! s"o4n against "is initia# )!o+uction 4e#+. ND/ eamination !e)o!ts s"a## Ae i+entifie+ as fo##o4s: • • • •
R/ MP* P/ / -
Ra+iog!a)"ic /esting Magnetic Pa!tic#e *ns)ection Penet!ant /esting #t!asonic /esting
$-0 WELD REPAIR G PRO>RESSI4E E5AMINATION
Re)ai!s an+ )ena#ty Hoints s"a## Ae se#ecte+ in acco!+ance 4it" (M5 31.8& 31.9 an+ SAES#W#*$1 se'tion $. I'o! )!og!essive eamination !eBui!ement. ( %/ s"a## Ae +efine+ as a## t"e 4e#+s ma+e since t"e #ast acce)taA#e 4e#+& ec#u+ing )ena#ty. (ny 4e#+ !e)ai! s"a## Ae !e)o!te+ on e#+ing Dai#y Re)o!ts as a))#icaA#e& ,oints No. R1 'i!st Re)ai!& Hoint No.R2 econ+ Re)ai!& ,oint No. R cut > !e-4e#+. Re)ai! )e!centage fo!mu#a a))#icaA#e as )e! (5--12 Pa!a 16.7.1. (ny ins)ection )e!fo!me+ +ue to )!og!essive eamination !eBui!ement s"a## not count to4a!+s !eBui!e+ ove!a## eamination f!eBuency )e!centage. (## cut an+ !e-4e#+ s"a## Ae notifie+ a#!ea+y acce)te+ Ay visua# ins)ection& ND/& P=/& o! )!essu!e test s"a## notify to (@ an+ (!amco. $60 PIPE WORK INTERNAL CLEANLINESS
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Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
(## )i)e& )i)e fitting an+ )!e-faA!icate+ )i)e s)oo#s +e#ive!e+ to )!oHect #ocation s"a## Ae visua##y ins)ecte+ fo! c#ean#iness an+ s"a## "ave fo!eign mate!ia# !emove f!om t"e insi+e. /"e )i)ing su)e!viso! an+ QC )i)ing ins)ecto! s"a## monito! )!otection of )i)es& s)oo#s an+ f#anges +u!ing t"e insta##ation )"ase. 5ac" 4i## Ae A!us"e+ out& an+ en+ ca) fitte+ )!io! #ifting in !acFs. Du!ing #ifting fo! insta##ation& t"ese item 4i## Ae tit#e+ at one en+ ensu!e a## +eA!is "as Aeen !emove+& afte! 4"ic" en+ )!otection 4i## Ae !einstate+.
"e!e t"e )i)ing s)oo#s a!e to Ae #eft incom)#ete a## en+s must Ae c"ecFe+ Ay QC to ensu!e t"at a## o)enings !emain secu!e#y cove!e+& no en+ 4i## #eft o)en at any time. (fte! com)#etion of s)oo# 4e#+ing )!io! to c#osing )i)ing s)oo#s a fina# c"ecFe+ 4i## Ae ma+e to ensu!e t"at t"e inte!na#s "ave !emains f!ee f!om +eA!is o! fo!eign matte!. Com)!esse+ ai! s"a## Ae use+ to ensu!e !emove of #ig"t +i!t an+ #oose sca#e. /"is ai! must Ae f!ee f!om oi# moistu!e o! contaminations. (i! c#eaning s"ou#+ Ae com)#ete+ Ay c#eaning in a )!og!essive +o4n4a!+s +i!ection& sta!ting at t"e "ig"est o)ening )oint )ossiA#e +o4n to t"e #o4est eit )oint. 'ina# *ns)ection fo! Re#ease of 'aA!icate+ Pi)e an+ s)oo#s& !aise an R'* fo! QC fina# ins)ection as )e! (*C-%-208. $)0 PIPE INSTALLATION %ABO4E >ROUND&
(## mate!ia# o! )i)e s)oo#s fo! insta##ation s"a## "ave c#ea!e+ !eceive& o! faA!ication ins)ection& t"is s"a## Ae ve!ifie+ )!io! to any movement to t"e insta##ation a!ea. n#y t"e imme+iate#y !eBui!e+ mate!ia# s"ou#+ Ae "e#+ in t"e insta##ation a!ea. Pi)ing insta##ation s"a## Ae con+ucte+ in acco!+ance 4it" )!oHect s)ecification an+ inst!uction. (## 4e#+ing ins)ection 4i## Ae st!ict#y cont!o# an+ con+ucte+ in acco!+ance 4it" P an+ 4e#+ing ins)ection an+ t"e a))!ove+ QCP. /"e )i)ing su)e!vision an+ t"e QC )i)ing$4e#+ing ins)ecto! s"a## monito! t"at va#ve$gasFet ty)e& #ocation an+ o!ientation a!e in com)#ianceL an+ Ao#ting Page 19 of 21
Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
connections a!e com)#ete+ in acco!+ance 4it" t"e *'C +!a4ing an+ a))#icaA#e )!oHect stan+a!+s > s)ecifications. /"e )i)ing su)e!vision an+ t"e QC )i)ing$4e#+ing ins)ecto! s"a## monito! t"at )i)e c#am)s $c#i)s etc. a!e insta##e+ in acco!+ance 4it" t"e *'C +!a4ings an+ t"e )i)e Hoints$4e#+s a!e not ove! st!esse+ Ay t"e c#am)ing.
/"e )i)ing su)e!vision s"a## on com)#etion on +efine sco)e of 4o!F& com)#ete of fu## su!vey of t"e )a!ticu#a! insta##ation. nce satisfie+ t"at a## is com)#ete+ an+ in com)#iance 4it" t"e !es)ective +!a4ing "e s"a## !aise an R'* fo! QC fina# su!vei##ance. /"e QC )i)ing$4e#+ing ins)ecto! s"a## c"ecF t"e o!ientation an+ com)#eteness of )i)e s)oo#s an+ t"ei! insta##ations. '#ange Ao#t-"o#es& 4e#+-o-#ets an+ ot"e! )i)e fitting a!e in acco!+ance 4it" *'C +!a4ings. (cce)tance s"a## Ae note+ 4it" t"e QC ins)ecto!s en+o!sement on t"e R'*. *tem foun+ to Ae not acce)te+ s"a## Ae !aise NCR. Qua#ity Cont!o# Punc" %ist. /"e R'* s"a## i+entify t"e )unc" #ist seBuentia# numAe! an+ a co)y of Aot" s"a## Ae !etu!ne+ to t"e o!iginato!. C#ea!ance s"a## Ae Ay !e-suAmission of )unc" #ist an+ R'*. C#ea!e+ )unc" #ist o!igina#s s"a## Ae ente!e+ into QC +!a4ing sco)e fi#es. 5cessive )unc" #ist item s"a## initia##y Ae !eco!+e+ in t"e ins)ection #og AooF& )!oHect QC !e)o!ts. Continua# vio#ation s"a## !esu#t in an NCR Aeing !aise+. /"is measu!e is necessa!y to avoi+ misuse of t"e system. $.0 UNDER >ROUND SER4ICE
"e!e )i)e 4o!F is to insta##e+ un+e!g!oun+ t"e QC ins)ecto! civi#$st!uctu!a# s"a## c"ecF t!enc"ing 4o!F +imensiona#& o!ientation& t!enc" Ae+ a+eBuacy& a))ea!ance& )!ofi#e& +e)t"& s"o!ing& Aenc"ing s#o)ing as )e! *'C +!a4ing > s)ecification. /"e !eBui!ements fo! on-site faA!ication an+ insta##ation s"a## Ae acco!+ance 4it" section 10 an+ 1 of t"is )!oce+u!e. /"e QC ins)ecto! civi#$st!uctu!a# s"a## c"ecF AacF fi##ing to ensu!e com)#iance 4it" +!a4ing an+ a))#icaA#e )!oHect stan+a!+ > s)ecification& afte! fu## com)#iance 4it" +ocumente+ !eBui!ements an+ !e#ease Ay t"e )i)ing$4e#+ing QC ins)ecto!.
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Document No.: P672-QCP-07 Revision No.: 01 Date: 28 May 201
$<0 INSPECTION AND TEST STATUS
/"!oug"out any )i)ing faA!ication an+ insta##ation )!ocess& t"e QC Pi)ing$e#+ing *ns)ecto! s"a## ensu!e t"at ins)ection an+ test status ma!Fing is )e!fo!me+ in acco!+ance 4it" /est )!oce+u!e QCP *ns)ection an+ /est tatus > any s)ecific !eBui!ements of )!oHect s)ecifications. $,0 INSPECTION LO> BOOK
*ns)ection #og AooF ent!ies in acco!+ance 4it" %og !egiste! s"a## Ae use+ to i+entify an+ !eco!+ on-going ins)ection +ifficu#ties f!eBuent occu!!ence& o! ystematic $ )!oce+u!a# #acF of non-com)#iance s"a## !esu#t in an NCR Aeing !aise+. CONTROL OF NON CONFORMIN> PRODUCT
Non-confo!mances s"a## Ae !eco!+e+ on fo!m Non-confo!mance Re)o!t NCR an+ )!ocesse+ in acco!+ance 4it" @ent )!oce+u!e Non-confo!mance an+ Co!!ective (ctions. 1*0 INSPECTION RECORDS
/"e QC Pi)ing$ e#+ing *ns)ecto! un+e! t"e +i!ection of t"e QC u)e!viso! s"a## ensu!e a## !e)o!ts an+ test +ocuments a!e )!og!essive#y com)i#e+& !evie4e+ an+ en+o!se+ in an e)e+itious manne!. (## !eco!+s s"a## Ae ti+y an+ #egiA#e taFing a+vantage of com)ute+ gene!ation. /"e !eBui!ements of P!e)a!ation of Qua#ity Reco!+s s"a## Ae c#ose#y fo##o4e+. 1$0 ATTAC!MENTS( 1 Mate!ia# Receiving *ns)ection. 2 Dai#y Hoint fit-u) *ns)ection !e)o!t. Dai#y 4e#+ P!o+uction !e)o!t. 9 ND/ ReBuest fo!m. eeF#y 4e#+ !e)ai! !ate !e)o!t. ,oint Aasis. I) %inea! Aasis. II) 6 e#+e! )e!fo!mance Re)o!t. 7 e#+ summa!y !e)o!t an+ ND/ /!acFing system. 8 e#+e! continuity !eco!+. ; *ns)ection Re#ease c"ecF#ist. 10 *nte!na# *R *ns)ection ReBuest. 11 Pi)ing com)#etion Re)o!t. 12 *nte!na# NCR Page 21 of 21
