Inspection & Test Plan [PDF]

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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

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22 Packing and Shipping- Including handling, preservation,

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23 Issue of Release Notes-IRN 24 Review of Data Book/Dossier (R01+R04+R05+R13)

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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