Inspection Test Plan (Itp) Rev.00: DOC - NO. OPR08-01 REV. No: 00 [PDF]

Zitiervorschau

DOCUMENT NO:

GSCC-ZS-PV-ITP-005-2014

REV.01

ITEM DESCRIPTION

PRESSURE VESSELS

ITEM NO / DRAWING NO:

PED-0246 & 0242 REV.1

PROJECT

RABIGH II REFINIG & PETROCHEMICALS (CP3 & CP4)

JOB NO: GSCC-MD-2014-356

INSPECTION TEST PLAN (ITP) REV.00

1

Revised to incorporate client and PIM comments

QA/QC ENGG GSCC

QA/QC MANAGER GSCC

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GS E&C

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For Approval

QA/QC ENGG GSCC

QA/QC MANAGER GSCC

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GS E&C

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ISSUENCE

PREPARED By

REVIEWED By

ACCEPTED By

ACCEPTED By

REV:

DATE:

DOC.NO. OPR08-01

REV. No: 00

PAGE 1

APPROVED BY CLIENT

GULF SKY CRANES & CONT. CO. LTD INSPECTION TEST PLAN ( ITP) No:

GSCC-ZS-PV-ITP-005-2014

CLIENT : ZAMIL STEEL CO.LTD.

DATE: 29/10/2014 DRAWING No: PED-0242-05-001

P.O No: 101652 REV.0

PROJECT TITLE : RABIGH II REFINING AND PETROCHEMICAL PROJECT DESCRIPTION : PRESSURE VESSEL FABRICATION

ITE WORK PROCESESS M ACTIVITY No:

A

Pre-Inspection Meeting

1

DOCUMENTS

1.1

Weld Map, WPS, PQR, Weld Repair Procedure, Welding Control & Consumable Procedure

1.2

Welder Qualification Record Review

1.3

NDE Personnel Qualification and Procedure Review

2

Receiving Inspection

CHARECTERISTIC TO BE CHECKED

Review of Weld Map, WPS, Fabrication Drawings, & Applicable Codes & Specifications

Review of Welder Qualification Records

Review of NDE (RT, UT, MT, PT) Procedures & Codes & Spec.

EQUIPMENT NAME : BYPRO OIL DRUM REFERENCE DOCUMENTS/ ACCEPTANCE CRETERIA.

2.1

Review of MTC/ Material Specification DOC No: OPR08-01

GSCC

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Approved GSCC WPS & PQR and & Approved Procedures

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As per ASME Sec. IX

Approved 3rd Party WQT Records

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AMES Sec. V

Approved 3rd Party Procedures

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Mill Test Certificates

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As per Drawings ASME Sec. VIII Div.1

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ASME Sec. II Part A Identification Marking Heat Number against MTC / Material Specification

INSPECTION STAGES INSPECTION FORM & RECORD

Approved Fabrication Drawings, ASME Sec. IX, ASME Sec. VIII. Div 1

Visual Inspection, Dimension Checking As Per Specification Shell, Dishes, Forgings, Pipe & Fittings, Nozzles

VESEEL TAG No: P 210-D-1126

MTC & Material

Specification

Incoming Material Inspection Report, Doc. No: OPR08-40

REV.NO: 02

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Sign

GULF SKY CRANES & CONT. CO. LTD INSPECTION TEST PLAN ( ITP) No:

GSCC-ZS-PV-ITP-005-2014

CLIENT : ZAMIL STEEL CO.LTD.

DATE: 29/10/2014 DRAWING No: PED-0242-05-001

P.O No: 101652 REV.0

PROJECT TITLE : RABIGH II REFINING AND PETROCHEMICAL PROJECT DESCRIPTION : PRESSURE VESSEL FABRICATION

ITE WORK PROCESESS M ACTIVITY No:

2.2

Welding Consumables

3

Material Traceability of Pressure Parts, Attachment to Pressure Parts

4

4.1

CHARECTERISTIC TO BE CHECKED

VESEEL TAG No: P 210-D-1126

EQUIPMENT NAME : BYPRO OIL DRUM REFERENCE DOCUMENTS/ ACCEPTANCE CRETERIA.

Verification against the Requirement of the Consumable MTC

As per ASME Sec. II Part C

INSPECTION STAGES INSPECTION FORM & RECORD

GSCC

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Raw Material Inspection Report.Doc. OPR08-04

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Traceability Verification As per MTC And approved Fabrication Drawings.

Drawings, marking on Plates & Pipes ASME Sec. VIII Div.1

Approved Fabrication Drawings, Incoming Material Inspection Reports Doc.OPR08-40

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Fit-Up Alignment check, Tack Welds, Surveillance of welding parameters against the applicable WPS

Fabrication Drawings, applicable WPS and Weld Map

Inspection Report, DOC. OPR08-64

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WFirst, RRest

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PT on back gouged Surface

ASME Sec. V

3rd PARTY Procedure AIS QP-7.5.1D

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Visual Inspection of welds 100%

ASME Sec. VIII Div. 1

Inspection Report, DCO.OPR08H 07

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In-Process Inspection

Long Seam & Cir. Seam Fit-Up, Welding to the Shell to Head

Carry out MT (100%)

Carry out RT (Head to Shell Circular Seam-Full RT, Shell Long Seam-Spot RT )

DOC. No: OPR08-01

ASME Sec. V & ASME Sec VIII,Div.1

3rd PARTY, AIS QP-7.5.1C

ASME Sec. V & ASME Sec

3rd PARTY, AIS QP-7.5.1A

VIII,Div.1

REV.NO: 02

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GULF SKY CRANES & CONT. CO. LTD INSPECTION TEST PLAN ( ITP) No:

GSCC-ZS-PV-ITP-005-2014

CLIENT : ZAMIL STEEL CO.LTD.

DATE: 29/10/2014 DRAWING No: PED-0242-05-001

P.O No: 101652 REV.0

PROJECT TITLE : RABIGH II REFINING AND PETROCHEMICAL PROJECT DESCRIPTION : PRESSURE VESSEL FABRICATION

4.2

Rolled Nozzle Neck

4.3

4.4

4.5

Nozzle layout

Marking on shell and head

EQUIPMENT NAME : BYPRO OIL DRUM INSPECTION STAGES

REFERENCE DOCUMENTS/ ACCEPTANCE CRETERIA.

INSPECTION FORM & RECORD

Fit-up alignment check, Tack Welds, Surveillance of welding p a r a m e t e r s against the applicable WPS.

Fabrication Drawings, applicable WPS & ASME Sec VIII. Div.1

Inspection Reports, DOC. OPR08-64

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PT on the back gouged surfaces & 100% Visual Inspection, 100 % RT for Nozzle butt welds, 100 % MT

ASME Sec .V

3rd Party Procedure AIS QP-7.5.1A AIS-QP 7.5 1C

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Nozzle Orientation conformity and

As Per Fabrication

Inspection Reports,

Drawings.

DOC. OPR08-67

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Fit-Up Tack weld visual check, Surveillance of welding parameters against applicable WPS, weld Visual 100%

Applicable WPS/ Weld Map, Reports

Inspection Report OPR08-64 OPR08-07 H

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Verify fit-up tolerance,100 % PT & Full RT

ASME Sec .V

3rd Party Procedure AIS QP-7.5.1A AIS-QP 7.5 1D

Fit-Up Tack weld visual check, Surveillance of welding parameters against applicable WPS

Applicable WPS/ Weld Map, Reports

Inspection Report OPR08-64 OPR08-07 H

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ITE WORK PROCESESS M ACTIVITY No:

Nozzle Fabrication

VESEEL TAG No: P 210-D-1126

CHARECTERISTIC TO BE CHECKED

verification of weld edge preparation

10" above joints pipe to pipe, pipe to elbow, pipe to flange, pipe to Tee etc..

10" below joints pipe to pipe, pipe to elbow, pipe to flange, pipe to Tee etc.

Verify fit-up tolerance,100 % Weld visual & PT DOC. No:

ASME Sec .V

GSCC

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3rd Party Procedure AIS QP-7.5.1A AIS-QP 7.5 1D REV.NO: 00

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GULF SKY CRANES & CONT. CO. LTD INSPECTION TEST PLAN ( ITP) No:

GSCC-ZS-PV-ITP-005-2014

CLIENT : ZAMIL STEEL CO.LTD.

DATE: 29/10/2014 DRAWING No: PED-0242-05-001

P.O No: 101652 REV.0

PROJECT TITLE : RABIGH II REFINING AND PETROCHEMICAL PROJECT DESCRIPTION : PRESSURE VESSEL FABRICATION

Nozzle Neck to shell & head fit-up & welding

Fit-Up Tack weld visual check, Surveillance of welding parameters against applicable WPS, weld Visual 100%

Applicable WPS / Weld Main Drawings ASME Sec V

Inspection Reports Doc. OPR08-64

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WFirst, RRest

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IW

PT on back gouged Surface

ASME Sec V

3rd PARTY, AIS QP-7.5.1D

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UT on Nozzle Neck to head & shell weld

ASME Sec VIII Div-1, PED-246-UT

PED -QC-07,Rev-0

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MT on Nozzle Neck to shell and head weld

ASME Sec V

3rd PARTY, AIS QP-7.5.1C

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Inspection Report DOC. OPR08-07

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External attachment Fit-Up & Welding on the vessels including leg support and Lifting lugs MT on Leg supports to Shell Attachment welds MT on all External attachment welds & temporary support removed area & Arc strikes removed area.

4.8

All the Internal Fit-Up and Welding on the Vessel

INSPECTION STAGES INSPECTION FORM & RECORD

CHARECTERISTIC TO BE CHECKED

Welding parameters, surveillance against applicable WPS, Verification of location Inspection of weld

4.7

EQUIPMENT NAME : BYPRO OIL DRUM REFERENCE DOCUMENTS/ ACCEPTANCE CRETERIA.

ITE WORK PROCESESS M ACTIVITY No:

4.6

VESEEL TAG No: P 210-D-1126

Fit-Up Tack weld visual check, Surveillance of welding parameters against applicable WPS, weld Visual 100% Verify Fit-Up tolerance DOC .No:

Fabrication Drawings, Applicable WPS. 3rd Party MT Procedure AIS-7.5.1C

3rd PARTY, AIS QP-7.5.1C

3rd Party MT Procedure AIS-7.5.1C

3rd PARTY, AIS QP-7.5.1C

Applicable WPS/ Approved Drawings. Inspection Reports.

Inspection Report WPS, DOC. OPR08-07

REV.NO: 00

GSCC

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GULF SKY CRANES & CONT. CO. LTD INSPECTION TEST PLAN ( ITP) No:

GSCC-ZS-PV-ITP-005-2014

CLIENT : ZAMIL STEEL CO.LTD.

DATE: 29/10/2014 DRAWING No: PED-0242-05-001

P.O No: 101652 REV.0

PROJECT TITLE : RABIGH II REFINING AND PETROCHEMICAL PROJECT DESCRIPTION : PRESSURE VESSEL FABRICATION

ITE WORK PROCESESS M ACTIVITY No:

4.9

4.10

4.11

4.12

4.13

Internal Inspection of Vessel (Before closing the Head)

Final Dimension & Visual checking of Vessel

RF Pads leak Test

CHARECTERISTIC TO BE CHECKED

VESEEL TAG No: P 210-D-1126

EQUIPMENT NAME : BYPRO OIL DRUM REFERENCE DOCUMENTS/ ACCEPTANCE CRETERIA.

INSPECTION STAGES INSPECTION FORM & RECORD

ASME Sec. VIII. Div.1 Approved Drawings,

MT on Internal attachment welds

ASME Sec .V

3rd PARTY AIS QP-7.5.1C

Fabrication Drawings, Inspection Reports.

APPROVED DWG, Inspection Reports. DOC.

Fabrication Tolerance

OPR08-08

Approved Procedures QP PPT-08 Rev.0

Pneumatic Test of Pads at 5 PSIG

Certification of Equipment Applicable ASME Certification Mark in & PDR Equipment with PART STAMP

Documents Review and Equipment Release

Dossier Review (IRB)

DOC.No:

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Visual Inspection of Internal surface and verification of nozzle internal sharp corners rounding off.

Verification of dimension (Over all dimensions, Nozzles and attachments) and Final Visual Inspection

GSCC

Inspection Report DOC. OPR08-07,

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Inspection Report OPR08-12

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Drawings

Certification rub off / Photo

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ASME Sec. VIII , Div.1

Approved Formats

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REV.NO: 00

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GULF SKY CRANES & CONT. CO. LTD INSPECTION TEST PLAN ( ITP) No:

GSCC-ZS-PV-ITP-005-2014

CLIENT : ZAMIL STEEL CO.LTD.

DATE: 29/10/2014 DRAWING No: PED-0242-05-001

P.O No: 101652 REV.0

PROJECT TITLE : RABIGH II REFINING AND PETROCHEMICAL PROJECT DESCRIPTION : PRESSURE VESSEL FABRICATION

ITE WORK PROCESESS M ACTIVITY No:

LEGEND:

DOC.No:

CHARECTERISTIC TO BE CHECKED

VESEEL TAG No: P 210-D-1126

EQUIPMENT NAME : BYPRO OIL DRUM REFERENCE DOCUMENTS/ ACCEPTANCE CRETERIA.

INSPECTION STAGES INSPECTION FORM & RECORD

GSCC

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CLIENT

AI

GS E&C

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IW- Initial Witness , H- Hold Points , W- Witness Points , S- Surveillance , R- Review of Records

REV.NO: 00

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