030-ITP FOR UG GRP PIPING.pdf

Pearl GTL Project LINDE ENGINEERING

Shell Project No: HP-3000-QAT Project Document Number: T- 4.234.577

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

Unit(s):

ASU

PCWBS:

Z

Contractor Project No : 5887 Project Rev.: D

Page 2 of 16

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION H

D

10.02.09

After clarification with PMC, Issued for Review

SK

EO

AG

IFR

G

C

10.12.08

As per Site Condition, Issued for Review

SK

EO

AG

IFR

F

B

31.07.08

Issued for Company Comments

SB

EO

AG

ICC

E

B

15.07.08

Ready for Construction

KC

EO

AG

RFC

D

A

25.06.08

Issued for Company Comments

KC

EO

AG

ICC

C

O

10.06.08

Issued for Company Comments

FB

EO

AG

ICC

B

10.06.08

Issued for review

FB

EO

AG

IFR

A

09.06.08

Issued for internal review

FB

EO

AG

IIR

Date

Description

GAMA Rev. No.

Project Rev No.

Prepared Checked Approved By By By ORIGINATOR

Status

Document Title:

ITP FOR U/G GRP PIPING

LINDE ENGINEERING AG

Document No.

Contractor

Gama Qatar Co. W. L. L.

GAM

ITP

QAC

GTL

030

H

Org. Code

Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No

Project Document Number: T-4.234.577

LOC470 Vendor Code

Rev No: D

QSGTL PEARL PROJECT

Document No : GAM-ITP-QAC-GTL-030

C2 ASU Construction Works

Rev / Date

ITP FOR U/G GRP PIPING S : GAMA QATAR I: INSPECTION Item

1.0

1.1 1.2

R: DOCUMENT REVIEW

Activity

Characteristic to be Verified

C : COMPANY

S: SURVEILLANCE

Control Procedure Reference

Acceptance Criteria

V : VENDOR

H: HOLD POINT. W: Responsible Party

WITNESS

Verifying Documents

S

X

C

V

METHOD STATEMENTS / PROCEDURES Method statement for fabrication and installation of GRP PIPING

Applicable to ASU Pearl GTL

Testing of GRP piping systems

Applicable to ASU Pearl GTL

1.3 2.0

Verification of qualification of personnel

2.1

Torque Wrench

2.2

X : CONTRACTOR QC

: Rev-H / 10.02.2009

T-4.234.087

Approved RFC

Approved Documents I

R

R

R

I

R

R

R

I

H

H

H

I

R

R

R

R

T-4.234.087

Manufacturer’s recommendation

ISO 14692 Part 4 Annex D

Training by Vendor / Manufacturer

Manufacturer Certificate

Torque Value Achieved

T-4.250.955

1 Month

Calibration Certificate

Validation Sticker

T-4.234.548

1 Month

QA/QC Engineer

Calibration Certificate

I

Visual Damage

QC Inspector

GAM-QCR-QAC-GTL-079

I

R

R

R

I

S

S

S

Previous Experience

Site Engineer

Approved Documents

CONTROL OF INSPECTION ,MEASURING AND TEST EQUIPMENT

Pressure Test Gauges

2.3

Visual Inspection of GRP Pipes and components

3.0

MATERIAL

3.1

Material Receipt & Visual Inspection

As per Company Specification

3.2

Storage and Preservation

As per Manufacture recommendation

3.3 4.0

Sub-Contractor Material Approval INSPECTIONS

T-4.234.577 Rev. D

DELETED

Manufactures Data Sheets

As per Manufacturer Manufactures recommendation Data Sheets DELETED

Store In charge

As per specification

Page 4

QSGTL PEARL PROJECT

Document No : GAM-ITP-QAC-GTL-030

C2 ASU Construction Works

Rev / Date

ITP FOR U/G GRP PIPING S : GAMA QATAR I: INSPECTION Item

X : CONTRACTOR QC

R: DOCUMENT REVIEW

Activity

Characteristic to be Verified

4.1

Verification of Trench Excavation

Elevation, Orientation & Width

4.2

Laying of bedding material, prior to Installation of the GRP pipes

Bedding Granules level

4.2.1

4.3

Cleanliness before laying of pipes into the bed

Bell and Spigot a)

QC Inspector shall verify correct O Ring for the service has been selected

The surfaces to be connected, including the gasket grooves, shall be clean c) The Seal ring and groove to be checked for the correct dimension. d) Non-symmetric seals, such as lip seals, shall be checked for correct installation in the grooves e) Clean non-contaminated lubricant shall be used on both seals and spigot

Internal Cleaning As per Manufacturer recommendation’s

C : COMPANY

S: SURVEILLANCE

Control Procedure Reference

As per the drg. T-4.259.773 As per the drawing T-4.259.773 T.13.377.360 Rev E & DEP 31.40.19Gen ISO 14692-4:2002 Annex C Figure C.3

Acceptance Criteria

Survey Report

QA/QC Civil Report No foreign materials inside the pipe & Internal Cleaning before laying into trench As per Manufacturer recommendation As per Manufacturer recommendation’s

: Rev-H / 10.02.2009 V : VENDOR

H: HOLD POINT. W: Responsible Party

WITNESS S

X

C

V

Excavation Survey Report

I

S

R

S

Sand Bedding Survey Report

I

S

S

S

Site Engineer

GAM-QCR-QAC-GTL-139

I

W

W

S

Site Engineer

GAM-QCR- QAC-GTL045

QA/QC Engineer

QA/QC Engineer

Verifying Documents

I

S

S

W

b)

T-4.234.577 Rev. D

I

S

S

W

I

S

S

W

I

S

S

W

I

S

S

W

Page 5

QSGTL PEARL PROJECT

Document No : GAM-ITP-QAC-GTL-030

C2 ASU Construction Works

Rev / Date

ITP FOR U/G GRP PIPING S : GAMA QATAR I: INSPECTION Item

X : CONTRACTOR QC

R: DOCUMENT REVIEW

Activity

Characteristic to be Verified

C : COMPANY

S: SURVEILLANCE

Control Procedure Reference

V : VENDOR

H: HOLD POINT. W:

X

C

V

f) The correct tooling shall be used to enter the spigot into bell to avoid damage to the seals

I

S

S

W

g) Entry location marks on the spigot (If applicable) should be checked to ensure correct entry distance

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S

S

W

h) Pipe sections shall be aligned as straight as possible in order to retain the O-rings in their groves

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S

W

i) A feeler gauge shall be used to establish good seating of the seals

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S

S

W

j) For key lock tensile –resistance joints, clean and lubricated locking strip should be inserted in complete circumference of the locking strip groove ,and the locking strip shall have the correct cross section and length

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S

W

I

H

H

H

T-4.234.577 Rev. D

No leak

Manufacturer receipt, T.13.376.808E& DEP 31.40.10.19

As per Manufacturer recommendation

Responsible Party

WITNESS S

k) Identification and repairing of defective joints / pipes etc (if any)

Acceptance Criteria

: Rev-H / 10.02.2009

Site Engineer

Verifying Documents

GAM-QCR-QAC-GTL045,047,048

Page 6

QSGTL PEARL PROJECT

Document No : GAM-ITP-QAC-GTL-030

C2 ASU Construction Works

Rev / Date

ITP FOR U/G GRP PIPING S : GAMA QATAR I: INSPECTION Item

R: DOCUMENT REVIEW

Activity

l) Sealing Test of Joints

4.3.1

4.4

X : CONTRACTOR QC

Test Pack Preparation

Torque of the flange Bolts

C : COMPANY

S: SURVEILLANCE

Characteristic to be Verified

Control Procedure Reference

Acceptance Criteria

Leaks

T-4.240.925

No Leak

As per Specification

Bolt Tightness

T.4.234.548 & Manufacturer’s recommendation T.13.376.808E& DEP 31.40.10.19,T.13. 377.360

GRP Test Pack

: Rev-H / 10.02.2009 V : VENDOR

H: HOLD POINT. W: Responsible Party

QA/QC Engineer Site Engineer

WITNESS

Verifying Documents

GAM-QCR-QAC-GTL-045 As per specification

GAM-QCR- QAC-GTL041

S

X

I

S

I

R/A

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S

C

S

V

W

R/A

Torque Value Achieved

Site Engineer

Category ‘’A’’ Completed/ Corrected

Site Engineer

Linde Mechanical Check of test System(R 01) including punch list

I

H

H

GAM-QCR-QAC-GTL050

Site Engineer

Visual

I

S

R

S

S

Final Inspection Before Test 1. Visual Check. 2.

Flange alignment verification

3.

Permanent gaskets installation, bolts & nuts (if any)

4.5

4.6

4.

Valve installation

5.

Dimensionnel check, elevation, orientation etc.

6.

Support installation (If any)

Intermediate Back Fill

4.7

T-4.234.577 Rev. D

Installation Complete

As per Manufacturer’s recommendation & As per Company Specifications

T.13.377.421

T-4.234.069, Manufacturer’s Recipe, T13.376.808 &DEP 31.40.19

Shifted to 4.3.1

Page 7

S

QSGTL PEARL PROJECT

Document No : GAM-ITP-QAC-GTL-030

C2 ASU Construction Works

Rev / Date

ITP FOR U/G GRP PIPING S : GAMA QATAR I: INSPECTION Item

X : CONTRACTOR QC

R: DOCUMENT REVIEW

Activity

C : COMPANY

S: SURVEILLANCE

: Rev-H / 10.02.2009 V : VENDOR

H: HOLD POINT. W:

Characteristic to be Verified

Control Procedure Reference

Acceptance Criteria

No Leak

T-4.234.548 & Manufacturer’s Recipe & DEP 31.40.19/Design Code

Manufacturer’s recommendation

Site Engineer/ QA-QC Engineer

Water disposal

Manufacturer’s recommendation

Manufacturer’s recommendation

Responsible Party

WITNESS

Verifying Documents

S

X

C

V

Test Pack (MC Inspection & Test record (R02))

I

H

H

H

Site Engineer

MC Inspection & Test record (R02)

I

S

S

S

Manufacturer’s recommendation

Site Engineer

Reinstatement Check List (R03)

I

H

H

Manufacturer’s recommendation

Site Engineer

QAM-QCR-QAC-GTL-050

I

S

S

Manufacturer’s recommendation

Site Engineer

Manufacturer’s recommendation & As per Test Pack

I

W

W

4.8

4.9

Hydrostatic Pressure Testing

4.9.1

Flushing / Water disposal

4.10

Re instatement Punch Out

4.11

Final Back Fill Trench

4.12

Gross leak test for the completed subsystems (for pressure lines).

Restoration No damage of pipe & No voids at bottom of pipe No Leak

T-4.234.074 & DEP 31.40.19 Manufacturer’s recommendation & DEP 31.40.19 DEP 31.40.10.19,

4.13

Flawless Start-up Initiative (FSI) Tightness (in Valve boxes) a)

Bolt

a) Loose Bolt b) Wrong Type of Bolt c) Flange Face Condition

T.13.377.360 Rev E, DEP 70.10.70.11Gen

Full Tight without leak

Site Engineer

Joint Integrity Control Procedure T.13.377.453 , T.13.377.454 ,

I

T.13.376.815 & Flaw List

DEP 31.38.01.11-

T-4.234.577 Rev. D

Page 8

H

H

QSGTL PEARL PROJECT

Document No : GAM-ITP-QAC-GTL-030

C2 ASU Construction Works

Rev / Date

ITP FOR U/G GRP PIPING S : GAMA QATAR I: INSPECTION Item

R: DOCUMENT REVIEW

Activity

b)

X : CONTRACTOR QC

Gasket Installation

Characteristic to be Verified

a) Damaged Gasket b) Gasket Installed off centre c) Old Temporary Hydro test Gaskets still in place d) Incorrect Flange alignment in line flanges e) Debris in valve seat as a result of transport form manufacturer

C : COMPANY

S: SURVEILLANCE

Control Procedure Reference

Acceptance Criteria

Full Tight without leak

V : VENDOR

H: HOLD POINT. W: Responsible Party

DEP 31.40.10.19Gen, T.13.377.360 Rev E,

: Rev-H / 10.02.2009

Site Engineer

DEP 70.10.70.11Gen

WITNESS

Verifying Documents

Joint Integrity Control Procedure T.13.377.453 , T.13.377.454 ,

S

X

C

I

H

H

V

T.13.376.815 & Flaw List

DEP 31.38.01.11-

Flawless Start-up Initiative (FSI) – 4.14

Deleted (REF. ITEM CODE 4.2.1) Cleanliness

4.15

5.0

Closing of the pipe ends after Flushing

Video Recording Internal Inspection of the Pipes

T-4.234.577 Rev. D

Internal Cleaning

Internal Cleaning

T-4.231.172 T-13.377.561 Project Spec. Part 4, Chapter 6

No foreign materials inside the pipe after flushing

QA / QC Engineer

Visual

I

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S

No foreign materials inside the pipe after flushing

QA / QC Engineer

Recorded Video

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R

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Page 9

S

C2 ASU PEARL GTL PROJECT RASLAFFAN INDUSTRIAL CITY BOLT TIGHTENING INSPECTION REPORT

Subcontract Ref.:

Report No.:

Item Description:

Inspection Date:

Item Location / Area:

Test Code No.:

Subsystem:

ITP No.:

Ref. DWG / Docs: Used Measuring and test equipment ref. (if applicable): INSPECTIONS Item No/Spool No

Mark No./Joint No Grade

Accepted By

ORGANIZATIONS

DATE

THIRD PARTY REP. GAMA REP. LINDE REP. QSGTL OR its PMC REP.

GAM-QCR-QAC-GTL-041

Bolting

Rev. O

Size

NAME

Bolt Tightening (Torque Value)

Inspector’s Signature

SIGNATURE

QATAR - PEARL GTL PROJECT- C2 ASU

Q Q

A A

T T A A

GRP SPOOL VISUAL + NIPPLE TEST INSPECTION REPORT

R R

Report No.:

Item Description:

Inspection Date:

Item Location / Area:

Test Code No.:

Subsystem:

ITP No.: GAM-ITP-QAC-GTL-

Ref. DWG / Documents: Used Measuring and test equipment ref. (if applicable):

Line No.: Unit No:

Isometric No.: Pressure Class

Sl. Joint Spool/ item No. No No.

Dia (Inch)

Sealing Test

Joint Type Test Medium

Bonder Shop No. /Field

INSPECTION ACTIVITIES Visual Fit-up & Repair Cutting (Rep. Ref. O-Ring /Tapering Cleanliness Allignmen Defective Remarks Installation QCR of Joints t Joints FORM-

Note : DSC for lamination and adhesive joint only

ACCEPTED

ORGANIZATIONS

GAMA QATAR REP.

LINDE REP.

QS GTL or its PMC

GAM-QCR-QAC-GTL-045, Rev-A

NAME

SIGNATURE

DATE

C2 ASU PEARL GTL PROJECT RASLAFFAN INDUSTRIAL CITY BARCOL HARDNESS TESTING REPORT Subcontract Ref.:

Report No.:

Item Description:

Inspection Date:

Item Location / Area:

Test Code No.:

Subsystem:

ITP No.:

Ref. DWG / Documents: Used Measuring and test equipment ref. (if applicable): INSPECTIONS SPOOL NO

REMARKS:

JOINT NO

BASE LINE VALUE

PERCENTAGE

INSPECTOR SIGNATURE

The Actual value should not be less than 90% of the Minimum Base line value

ORGANIZATIONS

Accepted By

ACTUAL VALUE

THIRD PARTY REP. GAMA REP. LINDE REP. QSGTL OR its PMC REP.

GAM-QCR-QAC-GTL-047 Rev. O

DATE

NAME

SIGNATURE

PEARL GTL PROJECT-RLC-QATAR

Q A T A R

DAILY GRP LAMINATION FOLLOW-UP REPORT

Subcontract Ref.: Item Description: Item Location / Area: Subsystem: Ref. DWG / Documents: Used Measuring and test equipment ref. (if applicable):

Report No. Inspection Date: Test Code No.: ITP No.:

Drawing No. :

Pipe Dia. :

Spool No. : Lam. kit No. : Bond Width :

Nominal Pressure : Test Pressure : Bond Thickness : Finishing Date on :

Starting Date on :

at

hrs.

at

hrs.

Temperature: Humidity: Manufacturer Recipe Ref:

Bonder No.:

Fit Layer No. of Layers

W/R Type

Resin Type

Resin Quantity

Catalyst LPT Quantity

Resin Quantity

Catalyst LPT Quan. Delayer

Vinylester

Structure Lay up No. of Layers

W/R Type

Resin Type

Vinylester Top Tape

Internal layer Bond Widt W/R Type

Bond Thickness :

No. of Layers

Resin Type

Resin Quantity

Catalyst LPT Quantity

Vinylester Surface mat.

Accepted By

ORGANIZATIONS

DATE

THIRD PARTY REP. GAMA QATAR REP. LINDE REP. QS GTL

GAM-QCR-QAC-GTL-048, Rev-0

NAME

SIGNATURE

Q A T A R

PEARL GTL PROJECT- RLCQATAR EXCAVATION / BACKFILLING REPORT

Subcontract Ref.:

Report No.:

Item Description:

Inspection Date:

Item Location / Area:

Test Code No.:

Subsystem:

ITP No.:

Ref. DWG / Documents: Used Measuring and test equipment ref. (if applicable):

Area

:

Location

:

Description of Filling

:

a) Sand

:

b) Gravel (SC1)

:

Site Clearance

:

Excavation

:

ELEVATION AS PER DRAWING : ACTUAL ELEVATION

:

ACCEPTABLE

REMARKS:

YES

Accepted By

ORGANIZATIONS

DATE

THIRD PARTY REP. GAMA LINDE QS GTL

GAM-QCR-QAC-GTL-050 Rev. O

NAME

NO SIGNATURE

C2 ASU PEARL GTL PROJECT RAS LAFFAN INDUSTRIAL CITY

MATERIAL RECEIPT CHECK SHEET

ITEM No:

PO No:

UNIT No:

MANUFACTURER :

ITEMS TO BE CHECKED

1 Visual damage 2 Quantity 3 Test certificates 4 5 6 7 8

Date of initial inspection:

Name and signature of Inspector:

GAM-QCR-QAC-GTL-079 Rev. O

INSPECTOR INITIAL

REQ No:

REMARKS

SYSTEM CLEANLINESS ACCEPTANCE REPORT 1110 A05M

Project No

Doc.No: 0100-W-QA-1825

Isometric No: (Line No)

Page 1 of 1

GAMA

Preservation Method

Inspection result

Spool

Cleaning Method

Prefabrication

Cleanliness Class

Sheet

Piping Contractor:

Inspection method

Project No:

Piping Contractor

Date

Signature

Erection Company

Date

Signature

LINDE

Date

Signature

PMC

Name:

Name:

Name:

Signature:

Signature

Signature:

Date:

Date:

Date:

GAM-QCR-QAC-GTL-139 Rev. O

Piping Contractor-GAMA

Company-Linde

Date

Signature