39 0 108KB
Boustead QUALITY PLAN BIH JOB: 704 CLIENT : Petrofac E&C Oman LLC. WHRU TITLE: 3 unit's of Hot Oil WHRU
CLIENT PO NO. :
CO-BPXO-12-0376
CLIENT REQUISITION NO. : WHRU TAG NO. :
1
KZ01-ME-REQ-53-0016
REVISION:
0
FAC1-H-804001/804002/804003
DATE:
The Quality Plan is compiled in accordance with BIH's BS EN ISO 9001 approved procedures, complying with BIH Procedure PEP 017. Covers the 'in-house' activities Covers process pressure part materials Covers instruments and controls Covers non-pressure part components Covers refractory materials Covers ancillaries Lists the minimum inspection and test requirements envisaged for the requisition packages of fabrication and equipment items. The detailed fabrication Inspection and Test Plans will be supplied by the relevant Supplier with provision for BIH and client mark-up.
ED 013 Rev.2
704 ETD-001/C
SHEET:
This Quality Plan is relative to the activities at BIH and relates to the engineering design and administration functions performed at/by BIH.
PART A PART B PART C PART D PART E PART F PART G
DOC NO:
of 15
8-May-15
ED 013 Rev.2
Boustead
DOC NO: SHEET:
704 ETD-001/C 2
INSPECTION AND TEST PLANS (ITP) ITPs for the following activities shall be issued under separate cover within fourteen (14) days of sub-order placement and shall form the working document for quality verification by the inspectors. REQUISITION 262 341
COMMODITY
DOCUMENT NO
Steel & Coil Fabrication Damper
704-262-103 704-341-103
The Inspection and Test Plan (ITP) shall be issued by the Supplier for review and approval prior to commencement of the pre-inspection meeting and fabrication. Reference shall be made to the minimum requirements to be included as detailed in part G of this plan, the Purchase Order Requisition noted above and the Customer's specifications listed on ED 002 SPECIAL NOTES 1) All supplier and sub-supplier shall be ISO 9001 accrediated. 2) WHRU Package (including damper) shall compliance to ATEX 95 Product Directive 94/9/EC to Zone 2.Self certification is acceptable. 3) WHRU Electrical shall be ATEX certified.ATEX product certification require to Zone 2, Gas Group II B, and Temperature Class T3. Self certification not acceptable. 4) WHRU Instrumentation shall be ATEX certified.ATEX product certification require to Zone 1, Gas Group II B, and Temperature Class T3.Self certification not acceptable. 5) Inspection, testing and measuring equipment and instruments shall be ISO 17025 or UKAS or equivalent national accreditation laboratories. 6) Damper E & I installation shall be inspect by CompEx certified personnel (in-house). 7) Damper E & I detail installation, inspection shall be done by Ex competent inspection body (Baseefa Ltd, Cenelec etc..) 8) All lifting equipments & tackles (eyebolts, spreader beams, slings, chains, shackles etc.. require a proof load test certificate issued by 3rd party.
ED 013 Rev.2
of 15
Boustead
DOC NO: SHEET:
704 ETD-001/C 3
KEY TO LEGENDS AP APPROVAL- Approval required of the applicable activity results or design document. H HOLD POINT-Work shall not proceed without attendance BIH/Petrofac. Notification is equired by BIH/Petrofac. R REVIEWReview of Documentation W WITNESS-An operation or process that requires witness by the BIH/Petrofac. Notification is required. I/W INITIAL WITNESS-Witness Initial Operations followed by ongoing surveillance. Notification required for the first operation. S SURVEILLANCE- Periodic surveillance by BIH/Petrofac. Notification is not required.
HOLD POINTS
are specific stages to be attended by the inspector. Work may not proceed without written authorisation by the Customer.
WITNESS POINTS are specific stages that, providing the notification has been given within the prescribed time, the non-attendance of the Customer's inspector will be construed as agreement to proceed with the inspection or test. Records of the inspection will be offered to the inspector or Customer as evidence of compliance. Note : Fourteen (14) working days notification required for all customer inspection HOLD and/or WITNESS POINTS.
KEY TO RESPONSIBLE PERSONNEL MD Managing Director ED Engineering Director PD Projects Director CD Contract Director SD Sales Director PEM Project Engineering Manager PRCD Procurement Director SDM Structural Design Manager PE Project Engineer DE Design Engineer SC Spares Controller DC Document Controller CM Construction Manager QM Quality Manager ED 013 Rev.2
of 15
ED 013 Rev.2
Boustead
QUALITY PLAN
PART A
DOC NO:
704 ETD-001/C Rev
SHEET:
Activity ref no 1
Activity Description
4
of 15
Controlling Document/Procedure
Acceptance Criteria
Verifying Document
Authorised Party Legend
Signatory
Contract Review of Customer Purchase Order
BS EN ISO 9001 - 5.2/7.2
Customer's P O
Signed Purchase Order
MD + SD
R
SD
to ensure:
Customer's Purchase Order CO-BPXO-12-0376
Conditions
ED 024 SD 002 P O Memo Handover Checklist
SD
R
PEM
PEM
R
PEM/PE
R
DE
R
QM
a) All contract requirements are adequately defined. SDP 003 b) Any requirements differing from those in tender are resolved.
CO-BPXO-12-0376 KZ01-ME-REQ-53-0016
c) BIH have the capability to meet all the contract requirements. d) Applicable specifications and engineering standards with editions are listed and complete. 2
Sales Handover
BS EN ISO 9001 - 7.2 SDP 003 PEP 004 PD 032-3
3
Review of Sales Handover documentation
BS EN ISO 9001 - 7.2 PEP 004 PEP 006
Customer's Purchase Order Conditions.
ED 002
4
Design (Process)
BS EN ISO 9001 - 7.3 PDP 001 PDP 002 DES 001 DO 002 KZ01-ME-REQ-53-0016 KZ01-ME-DAT-53-0064 KZ01-ME-SPE-53-0003 KZ01-PR-BOD-53-0002 KZ01-PI-BOD-53-0001 KZ01-EV-BOD-53-0001 KZ01-PI-SPE-53-0006
Customer's Purchase Order Conditions and Data Sheets ISO 13704 (API 530) ISO 13705 (API 560) ASME B31.3 ASME VIII Div.1 GIS 22-101
Tubewall & Hydrotest calcs DE ETD008/A Refractory Thickness calculation ETD005/B
Customers specs as listed on ED 002
5
ED.013 Rev.2
a) Review project spec to establish design basis b) Review latest revision of applicable codes c) Produce design calculations d) Review of computer calculations e) Check design calcs f) Amendments if required g) Check amendments h) Approval of calculations i) Complete WHRU Data Sheets j) Review of pink copy(Engineering Review)
SD 002 PDP 002 SD 002 PDP 002 PDP 002 PDP 002 PDP 002 PDP 002 PDP 002 PDP 002 PDP 002 DO 002
Obtain Third Party Design Approval Lifting equipment (spreader beam & lifting accessories)
BS EN ISO 9001 - 7.3
Calculation sheets Calculation sheets Calculation sheets Calculation sheets Calculation sheets Calculation sheets WHRU Data ETD002/A Pink copy PEP 019
Third party approval
Third party approval documentation.
PEM
0
Boustead
QUALITY PLAN
PART A
704 ETD-001/C Rev
DOC NO:
5
SHEET
Activity ref no 6
Activity Description Design (Structural)
of 15
Controlling Document/Procedure
Acceptance Criteria
Verifying Document
Authorised Party Legend
Signatory
BS EN ISO 9001-7.3 ENG 001 DO 002 Clause 2 DES 001 KZ01-ME-SPE-53-0003 KZ01-CV-BOD-53-0001 KZ01-CV-SPE-53-0003 GIS 22-101
Customer's Purchase Order Conditions and Data Sheets AWS D1.1 Eurocode 1990,1991, 1993,1994,1998 ISO 13705 (API 560)
Foundation & Structural calcs ETD003/D Tube Suport cacls ETD007/A
SDM
R
PEM
Customers specs as listed on ED 002 a) b) c) d) e) f)
Review project spec to establish design basis Review latest revision of applicable codes Produce structural design calculations Check mathematical correctness & content Approval of structural design calculations Review of structural design drawings
SD 002 ENG 001 ED 024 SD 002 ENG 001 ED 024 ENG 001 DES 001 ED 024 ENG 001 ENG 001 ENG 001
Calculation sheets/drawings Calculation sheets/drawings Calculation sheets/drawings Calculation sheets/drawings
7
Compilaton of Master Document List
BS EN ISO 9001 - 4.2.3 PEP 012 Customer SDRML
Contract document requirements KZ01-ME-REQ-53-0016 Annexure 2 KZ01-QA-PLN-53-0113 KZ01-DM-SDR-00-0001
ED010 ED 011/A
PEM/PE
R
PE
8
Preparation of production programme
BS EN ISO 9001 - 7.1 PEP 011
Customer PO Delivery Requirements
ETD-001/B
PEM
R
PEM
9
Supplier document control
BS EN ISO 9001 - 4.2.3 PEP 013 PEP 014 PEP 037 DC 002 DC 003
ED 011 KZ01-ME-REQ-53-0016 Annexure 2 KZ01-QA-PLN-53-0113 KZ01-DM-SDR-00-0001 KZ01-DM-SPE-00-0004 KZ01-DM-TEM-53-0002
Document History Report
PE
R
PE
10
Preparation of Material Requisitions and Specifications for manufacturing and fabrication.
BS EN ISO 9001 - 7.2 / 7.4 SDP 004 PEP 020 QA 034
Customer's Purchase Order Conditions KZ01-QA-PRO-53-0005 KZ01-QA-PLN-53-0113 KZ01-QA-SPE-53-0002 KZ01-ME-REQ-53-0016
Approved copy of requisition package.
PEM
R
PEM
BS EN ISO 9001 - 7.3 DO 002 QA 034 Customer SDDR
Customer's Purchase Order Conditions
Approved drawing
PEM
R
PE
Procurement of components and services.
BS EN ISO 9001-7.4 PD 032
Purchase Order Specifications KZ01-QA-PRO-53-0005
PRCD
R
PRCD
a) Procurement strategy meeting
PD032-3 PEP 007 PEP 011 PD032-2 QA004 PD032-4 PD032-4
a) Compilation of requisition packages for subsuppliers using approved drawings, contract documentation, specifications & standards b) Approval of the requisition package c) Issue to Procurement for enquiry/purchase 11
Production of Contract drawings. a) Drawings prepared based on design and contract specificatons b) Check of drawing details c) Circulation of pink copy (Engineering Review) d) Issue of drawings for approval
12
b) Supplier selection c) Preparation of bid tab and evaluation. d) Placement of Purchase Order
ED.013 Rev.2
Approved Supplier
Approved Suppliers list Bid tab Authorised PO
0
Boustead
QUALITY PLAN
PART A
704 ETD-001/C Rev
DOC NO:
6
SHEET
Activity ref no 13 14
Activity Description Spares Quotations (if applicable)
Acceptance Criteria
Verifying Document
Authorised Party Legend
Signatory
BS EN ISO 9001 - 7.4 PEP 021 SDP 005
Customer's Purchase Order Conditions
Approved copy of requisition package
SC
R
PE
QM
R
QM
Change Order Notice
PEM
R
PEM
PD 032-2.7
Process Control / Inspection & Testing
BS EN ISO 9001 - 5.4.2, 7.1, 7.5.2, 8.1, Client's Purchase Order 8.2.4, 8.3 PD032-5 QA034 PEP019 Conditions QC001 KZ01-ME-REQ-53-0016 (Criticality Rating : 3) KZ01-QA-PLN-53-0113 KZ01-QA-SPE-53-0002 KZ01-QA-PRO-53-0009 KZ01-PE-PRO-53-0005 KZ01-MT-SPE-53-0103 GIS 36-103
Expediting & Inspection Reports
a) b) c) d) e) f) g)
QA034 QC 001 PD032-5 PEP 019 QC 001 QC 001 QC 001
Approved procedures Minutes of meeting Procurement Status Inspection & Expediting reports PMI Reports NCR Report Release note
Review of Technical Documents PIM for major fabrications Material progress reports Review of Inspection & Expediting reports Alloy verification Control of non-conforming product Final inspections
of 15
Controlling Document/Procedure
DC011
PEP 033 QC 001 QA 035 PEP 029 PEP 019
15
Change Notification & Change Order control
BS EN ISO 9001 - 7.2.2 / 7.3.7 PEP 023 DO 002-4
16
Corrective Action
BS EN ISO 9001 - 8.5.2 QA 036 PEP 029
Compliance with concesson or Purchase Order conditions KZ01-PE-PRO-53-0005
Closed out NCR
PEM/QM
R
QM
17
Concessions
BS EN ISO 9001 - 8.3 / 8.5.2 PEP 032
Compliance with concesson or Purchase Order conditions KZ01-PE-PRO-53-0005
Approved concession report
PEM
R
PEM
18
Compilation of Data Dossiers
BS EN ISO 9001 - 4.2.4 QA 038
Customer's Purchase Order Conditions KZ01-DM-SDR-00-0001 KZ01-QA-PLN-53-0113 KZ01-QA-SPE-53-0002
ETD-105
QM
R
QM
19
Produce Erection Procedures
BS EN ISO 9001 - 6.3 / 7.1 / 7.5.1 PEP 026
Customer's Purchase Order Conditions
Approved Procedures ETD-070/A
PE
R
PEM
20
Commissioning, Start-up. Operating & Maintenance BS EN ISO 9001 Instructions 7.5.1 / 7.5.2 / 7.5.4 / 7.5.5 PEP 027
Customer's Purchase Order Conditions
Approved documents ETD-070/B
PE
R
PEM
21
Shipping. Handling & Storage Procedures
Customer's Purchase Order Conditions
Approved Procedures
PE
R
PE
BS EN ISO 9001 - 7.5.5 PD032-6 PEP 026 B-11
GPO-MP-SPE-00001 KZ01-QA-PRO-53-0003 KZ01-QA-PRO-53-0009
ED.013 Rev.2
22
Certified As-built drawings, specifications & Data Sheets
BS EN ISO 9001 - 4.2.4 / 7.3.7 PEP 030 DO002-6
Customer's Purchase Order Conditions
Approved documents
PE
R
PE
23
Marking documentation & shipping instructions
BS EN ISO 9001 4.2.3 / 7.5.1 / 7.5.3 / 7.5.5 PD032-6
Customer's Purchase Order Conditions GPO-MP-SPE-00001 KZ01-QA-PRO-53-0003 KZ01-QA-PRO-53-0009
Authorised shipping instructions
PEM/PRCD
R
PEM/PRCD
0
Boustead Activity ref no 24
Activity Description COIL MATERIALS (PRESSURE PARTS)
QUALITY PLAN
PART B
Controlling Document/Procedure
Acceptance Criteria
BS EN ISO 9001 - 4.2.4 / 7.4.3 / 7.5.1 /
Req as (10) above
704 ETD-001/C Rev
DOC NO: SHEET:
7
of 15
Verifying Document
Authorised Party Legend
Signatory
EN 10204 3.1
QM/PE
R
QM/PEM
Inspection, Acceptance & Release Certs
QM
R
QM/PEM
Release Note ED 014
QM/PE/PEM
R
QM/PEM
EN 10204 2.1/2.2 Certificates
QM
R
QM
Inspection, Acceptance & Release Certs
QM
R
QM/PEM
Release Note ED 014
QM/PE/PEM
R
QM/PEM
7.5.2 / 7.5.3 / 7.5.5 / 8.2.4 QC 001
Alloy Pipes Alloy Manifold Alloy Fittings Manifold Fittings Alloy Flanges Weldoflanges Extruded Manifolds See also 704-262-103AA - Steel & Coil Fabrication
Requisition: 101 121 139 145 178 188 250 262
24.1
Material Certification
24.2
Visual and Dimensional
24.3
Delivery Free issue to finning manufacture & fabricator
PD032-6
Finning Material for Tubes
BS EN ISO 9001 - 4.2.4 / 7.4.3 / 7.5.1 /
25
KZ01-QA-SPE-53-0002 Attachment 2
Req as (10) above
7.5.2 / 7.5.3 / 7.5.5 / 8.2.4 QC 001 Finning
ED.013 Rev.2
25.1
Material Certification
25.2
Visual Dimensional & Marking
25.3
Delivery Free issue to coil fabricator
Requisition 240 KZ01-QA-SPE-53-0002 Attachment 2
PD032-6
0
Boustead Activity ref no 26
Activity Description INSTRUMENTATION / CONTROLS
QUALITY PLAN
PART C
Controlling Document/Procedure
Acceptance Criteria
Verifying Document
BS EN ISO 9001 - 4.2.4 / 7.4.3 / 7.5.1 /
Requsition as (10) above
Manufacturers' Standards
KZ01-QA-SPE-53-0002 Attachment 2 KZ01-QA-PLN-53-0113 KZ01-EL-SPE-53-0001 KZ01-EL-SPE-53-0002 KZ01-IC-SPE-53-0003 Zone 1, Gas Group II B, T3.
7.5.2 / 7.5.3 / 7.5.5 / 8.2.4 QC 001
ED.013 Rev.2
Instrumentations
Requisitions 434
See also 704-341-103 - Damper
341
26.1
Material Certification
26.2
Visual Dimensional Manufacturer's Standard Test and Markings
26.3
Delivery Site
PD032-6
704 ETD-001/C Rev
DOC NO: SHEET:
8
of 15
Authorised Party Legend
Signatory
EN 10204 Certificates Hazardous Area Certificates ATEX Certification Ingress Protection Certificates Inspection & Test Reports
QM/PEM
R
QM/PEM
Inspection, Acceptance & Release Certificates
QM/PEM
R
QM/PEM
Release Notes ED 014
QM/PEM
R
QM/PEM
0
Boustead Activity ref no 27
WHRU COMPONENTS (NON-PRESSURE)
PART D
Controlling Document/Procedure
Acceptance Criteria
BS EN ISO 9001 - 4.2.4 / 7.4.3 / 7.5.1 /
Requisition as (10)
7.5.2 / 7.5.3 / 7.5.5 / 8.2.4 Requisitions
above
Bolts Plate Puller Expansion Joints Piping Insulation
191 278 294 344 540
See also 704-262-103AA - Steel & Coil Fabrication
262
27.1
Material Certification
27.2
Visual Dimensional & Markings
27.3
ED.013 Rev.2
Activity Description
QUALITY PLAN
Delivery to : Site / Fabricator
QC 001
KZ01-QA-SPE-53-0002 Attachment 2 KZ01-QA-PLN-53-0113
Verifying Document
Release Certificate ED 014
9
Authorised Party Legend
EN 10204 3.1 for QM/PEM Primary/Secondary Structural & Steel & Load Bearing Components EN 10204 2.1/2.2 for Tertiary Structural Steel & Non-functional Components
Inspection, Acceptance & Release Certs PD032-6
704 ETD-001/C Rev
DOC NO: SHEET:
of 15
Signatory
R
QM/PEM
QM/PEM
R
QM/PEM
QM/PEM
R
QM/PEM
0
Boustead Activity ref no 28
Activity Description REFRACTORY MATERIALS
QUALITY PLAN
PART E
Controlling Document/Procedure
Acceptance Criteria
BS EN ISO 9001 - 4.2.4 / 7.4.3 / 7.5.1 /
Requisition as (10) above
7.5.2 / 7.5.3 / 7.5.5 / 8.2.4 QC 001
ED.013 Rev.2
Refractory Studs Ceramic Fibre Internal Coating
Requisitions 381 524 531
See also 704-262-103AA - Steel & Coil Fabrication
262
28.1
Material Certification
28.2
Delivery to : Site / Fabricator
KZ01-QA-SPE-53-0002 Attachment 2 KZ01-QA-PLN-53-0113
PD032-6
704 ETD-001/C Rev
DOC NO: SHEET:
Verifying Document
10
Authorised Party Legend
of 15
Signatory
EN10204 3.1 for Insulation QM/PEM material (Ceramic Fiber) EN 10204 2.1/2.2 for other parts.
R
QM/PEM
Release Certificate ED 014
R
QM/PEM
QM/PEM
0
Boustead Activity ref no 29
Activity Description ANCILLARIES
QUALITY PLAN
PART F
Controlling Document/Procedure
Acceptance Criteria
Verifying Document
BS EN ISO 9001 - 4.6.4 4.8 4.9 4.10
Requsition as (10) above
Manufacturers' Standards
KZ01-QA-SPE-53-0002 Attachment 2 KZ01-QA-PLN-53-0113
4.12 4.15 4.16 QC 001
Name Plate Noise Study CFD
ED.013 Rev.2
29.1
Material Certification (where applicable)
29.2
Visual Dimensional & Markings (where applicable)
29.3
Delivery (where applicable) to Site
704 ETD-001/C Rev
DOC NO: SHEET:
11
of 15
Authorised Party Legend
Signatory
EN10204 2.1
QM/PEM
R
QM/PEM
Inspector's report
QM/PEM
R
QM/PEM
Release Certificate ED 014
QM/PEM
R
QM/PEM
Requisitions 620 641 648
PD032-6
0
Boustead
QUALITY PLAN PART G
704 ETD-001/C Rev 0 12 of 15
JOB NO SHEET
Shop inspection and test requirements Activity Ref No
Activity Description
Authorised Parties Note 1 Sub Vendor
BIH
Petrofac/ BP/ NIB PIB
H
R
AP
R
~
H
R
AP
R
~
H
R
AP
R
~
NoBo
Convection Coil & Manifold 1 Produce inspection and test plans Produce WPS/PQR (including repair if any) complete 2 with relevant lab test reports for the PQR tests carried out including Weld/NDE plan. 3 Produce applicable inspection,test,NDE procedures 4
Pre inspection meeting (PIM)/Pre Production Meeting (PPM) and QMS Audit if any- With Steelwork
H
H
H
W
~
5
Welder qualification test and NDE operator qualification as applicable
H
S/R
S/R
R
~
6
Materials inspection,identification,traceability and certification requirements (including weld consumables)
H
S/R
S/R
R
~
7 Welding controls-Fit up,tack, welding, weld repair 8 100% Visual and dimensional inspection-after welding
H H
S/R W
S/R W
R R
~ ~
9 Coil fabrication
H
H
W
R
~
H
S/R
S/R
R
~
H
S/R
S/R
R
~
H
S/R
S/R
R
~
13 Positive material identification (PMI)
H
S/R
S/R
R
~
14 Hydrostatic test 15 Dryness & Cleanliness of Coil internal side Surface treatment & Insulation
H H
H W
W I/W
W R
~ ~
H
W
I/W
R
~
H
H
H
W
~
and Shipping- Including handling, preservation, 18 Packing identificaton, loose items & spare etc..
H
W
I/W
R
~
19 Issue of Release Notes-IRN 20 Review of Data Book/Dossier (R01+R04+R05)
H H
H H
H H
R R
~ ~
9.1 Build Review (30%, 60% and 90%) of convection coil assembly
10
RT/UT 10.1 100% RT of all butt welds on convection coil & manifold 10.2 100% UT on fillet welds greater than 12mm.
MPI/LPI 11
11.1 100% of all butt & branch welds, attachment welds and grinding marks. 11.2 100% of area after removal of thermocouple attachments. 11.3 100% on groove weld preparation prior root pass welding.
Hardness- Max 225 HBW (HRB 97,6). 12
12.1 Base Metal (BM) 12.1.1 5% of heat (minimum 1 item), 1 test for every item in sample 12.2 Groove Welds (Weld Cap/Root/HAZ) 12.2.1 No PWHT or Furnace PWHT: 1 test per weld of 5% of the welds
13.1 10% on weld & base metal
16
16.1 Blasting, surface profile check 16.2 Primer Coat Inspection 16.3 Intermediate Coat Inspection 16.4 Finish Coat Inspection 16.5 Coating Inspection & Test
Final inspection / Cleanliness 17
17.1 Verification of punchlist completion. 17.2 Verfication of name plate marking & tagging detail. 17.3 Verify all inspection & test completed per approved ITP.
ED.013 Rev.2
Boustead
QUALITY PLAN PART G
704 ETD-001/C Rev 0 13 of 15
JOB NO SHEET
Shop inspection and test requirements Activity Ref No
Activity Description
Authorised Parties Note 1
Sub Vendor WHRU Casings and Structure (Ducts, Stacks, Platforms & Ladders) 1 Produce inspection and test plans Produce WPS/PQR (including repair if any) complete 2 with relevant lab test reports for the PQR tests carried out including Weld/NDE plan. 3 Produce applicable inspection,test,NDE procedures
BIH
Petrofac/ BP/ NIB PIB
NoBo
H
R
AP
R
~
H
R
AP
R
~
H
R
AP
R
~
4
Pre inspection meeting (PIM)/Pre Production Meeting (PPM) and QMS Audit if any- With Steelwork
H
H
H
W
~
5
Welder qualification test and NDE operator qualification as applicable
H
S/R
S/R
R
~
6
Materials inspection,identification,traceability and certification requirements (including weld consumables)
H
S/R
S/R
R
~
H H
S/R W
S/R W
R R
~ ~
H
H
W
W
~
H
S/R
S/R
R
~
H
S/R
S/R
R
~
H
S/R
S/R
R
~
H
S/R
R
R
~
H H H H H
S/R S/R S/R S/R H
R R R R W
R R R R R
~ ~ ~ ~ W
H
H
H
W
~
and Shipping- Including handling, preservation, 20 Packing identificaton, loose items & spare etc..
H
W
I/W
R
~
21 Issue of Release Notes-IRN 22 Review of Data Book/Dossier (R01+R04+R05)
H H
H H
H H
R R
~ ~
7 Welding controls-Fit up,tack, welding, weld repair 8 100% Visual and dimensional inspection-after welding Fabrication and assembly 9 9.1 Build Review (30%, 60% and 90%) of WHRU structural/duct/casing assembly
RT/UT [subject to geometry] 10.1 10% of full penetration butt welds in each frame or structure. 10
10.2 100% of full penetration butt welds in primary members including splice joints. 10.3 100% of full penetration lifting lugs welds (including pad eyes) 10.4 One radiograph of each junction and one intermediate shot of all longitudinal welds.Note 2
MPI/LPI
11
11.1 10% of full penetration butt welds in each frame or structure. 11.2 10% of all fillet welds in major/primary joints. 11.3 100% of full penetration butt welds in primary members including splice joints. 11.4 100% of full penetration lifting lugs welds (including pad eyes) 11.5 100% of weld rat holes corner joints.
Match drilling/Trial assembly c/w match marks 12
• Unit outside overall dimensions • Unit frame anchor bolt hole dimensions • Tie-in connections elevation; • Tie - in Flange rating, flange bolt hole orientation ( centre line straddling), flange face finish etc • Bolt torqueing where applicable
Surface treatment-Internal & External 13
14 15 16 17 18
13.1 Blasting, surface profile check 13.2 Primer Coat Inspection 13.3 Intermediate Coat Inspection 13.4 Finish Coat Inspection 13.5 Coating Inspection & Test 13.6 Galvanizing of ladders & platforms
Visual and dimensional of anchors/studs layout Hammer test of anchors/studs - 5% random Installation of ceramic fibre blanket Installation of insulation cladding plates Spreader Beam - Load test Final inspection / Cleanliness
19
19.1 Verification of punchlist completion. 19.2 Verfication of name plate marking & tagging detail. 19.3 Verify all inspection & test completed per approved ITP.
ED.013 Rev.2
ED.013 Rev.2
Boustead
QUALITY PLAN PART G
704 ETD-001/C Rev 0 14 of 15
JOB NO SHEET
Shop inspection and test requirements Activity Ref No
Activity Description
Authorised Parties Note 1 Sub Vendor
BIH
Petrofac/ BP/ NIB PIB
H
R
AP
R
~
H
R
AP
R
~
H
R
AP
R
~
H
H
H
W
~
H
S/R
S/R
R
~
H
S/R
S/R
R
~
H H
S/R W
S/R W
R R
~ ~
H
H
W
W
~
H
S/R
S/R
R
~
H
S/R
S/R
R
~
H
H
W
W
H
H
S/R
R
R
~
H H H H
S/R S/R S/R S/R
R R R R
R R R R
~ ~ ~ ~
H
H
W
W
H
H
H
S/R
R
~
H
H
W
W
~
H
H
H
W
~
22 Packing and Shipping- Including handling, preservation,
H
W
I/W
R
~
23 Issue of Release Notes-IRN 24 Review of Data Book/Dossier (R01+R04+R05+R13)
H H
H H
H H
R R
~ ~
NoBo
Dampers 1 Produce inspection and test plans Produce WPS/PQR (including repair if any) complete 2 with relevant lab test reports for the PQR tests carried out including Weld/NDE plan. 3 Produce applicable inspection,test,NDE procedures Pre inspection meeting (PIM)/Pre Production Meeting 4 (PPM) and QMS Audit if any Welder qualification test and NDE operator qualification 5 as applicable Materials inspection,identification,traceability and 6 certification requirements (including weld consumables, Electrical & Instrumentations) 7 Welding controls-Fit up,tack, welding, weld repair 8 100% Visual and dimensional inspection-after welding 9 Fabrication and assembly 9.1 Build Review (30%, 60% and 90%) of Damper assembly
RT/UT [subject to geometry] 10.1 10% of full penetration butt welds in each frame or structure. 10
10.2 100% of full penetration butt welds in primary members including splice joints. 10.3 100% of full penetration lifting lugs welds (including pad eyes)
MPI/LPI
11
11.1 10% of full penetration butt welds in each frame or structure. 11.2 10% of all fillet welds in major/primary joints. 11.3 100% of full penetration butt welds in primary members including splice joints. 11.4 100% of full penetration lifting lugs welds (including pad eyes) 11.5 100% of weld rat holes corner joints.
12 Inspection/certification of air reservoir
- incl hydrotest
Surface treatment-Internal & External 13
13.1 Blasting, surface profile check 13.2 Primer Coat Inspection 13.3 Intermediate Coat Inspection 13.4 Finish Coat Inspection 13.5 Coating Inspection & Test
Visual and dimensional of anchors/studs layout Hammer test of anchors/studs - 5% random Installation of ceramic fibre blanket Installation of insulation cladding plates Detailed inspections of installed equipment, systems 18 and installations- ATEX 95 Products Directive 94/9/EC 14 15 16 17
Pre-FAT
19
19.1 Wiring check-Insulation,loop, continuity, routing, earthing, tagging, cleanliness 19.2 Electrical/instument functional/calibration testing 19.3 Intruments tubing & fittings check- type & competencies 19.4 Completion check of mechanical, electrical & instruments installations 19.5 ATEX documentations verification
FAT 20.1 Wiring check-Insulation,loop, continuity, routing, earthing, 20
tagging, cleanliness 20.2 Electrical/instument functional/calibration testing 20.3 Intruments tubing & fittings check- type & competencies 20.4 Completion check of mechanical, electrical & instruments installations 20.5 ATEX documentations verification
Final inspection / Cleanliness 21
21.1 Verification of punchlist completion. 21.2 Verfication of name plate marking & tagging detail. 21.3 Verify all inspection & test completed per approved ITP. identificaton, loose items & spare etc..
ED.013 Rev.2
Boustead
QUALITY PLAN PART G
704 ETD-001/C Rev 0 15 of 15
JOB NO SHEET
Shop inspection and test requirements Activity Ref No
Activity Description
Authorised Parties Note 1 Sub Vendor
BIH
Petrofac/ BP/ NIB NIB
NoBo
KEY TO LEGENDS AP APPROVAL- Approval required of the applicable activity results or design H HOLD POINT-Work shall not proceed without attendance REVIEW- Review of Documentation by BIH/Petrofac. R WITNESS-An operation or process that requires witness by the BIH/Petrofac. Notification is required. W I/W INITIAL WITNESS-Witness Initial Operations followed by ongoing surveillance. Notification required for the first operation. S SURVEILLANCE- Periodic surveillance by BIH/Petrofac. Notification is not required. DPI MPI UT RT BIH Petrofac BP NoBo NIB PIB
DYE PENETRANT INSPECTION MAGNETIC PARTICLE INSPECTION ULTRASONIC TESTING RADIOGRAPHIC TESTING BOUSTEAD INTERNATIONAL HEATER Petrofac E&C Oman LLC. BP OMAN NOTIFIED BODY- European Community ATEX directive, ASME and or 3rd Party Inspection Body NOMINATED INSPECTON BODY- Appointed by Company-BP OMAN PURCHASER INSPECTON BODY- Appointed by Purchaser- Petrofac E&C Oman LLC
NOTE 1. All authorised parties are to sign and date the activities above on the respective locations of the supplier ITPs. 2. Applicable for Stack section only. Minimum Radiograph length shall be 250mm. 3. For random inspection "10%" the selection of joint shall represent each welding process, welders/Welding Operator for every week production.
ED.013 Rev.2
ED.013 Rev.2