QCP-Piping Prefab Erection Rev.2

JOB

UNIT

670700

000

SPC. 000-ZA-E-02631 Sh. 1 of 54

BUILDING NEW BOOSTER STATION BS-160 AT SOUTH EAST KUWAIT

Rev. 2

Document title: Quality Control Plan for Piping Prefabrication and Erection Subcontract No. Unit: P300009297 General Contract No. 37472

Doc. class.: A

KOC Doc. No. -----------------

KHARAFI NATIONAL

QUALITY CONTROL PLAN FOR PIPING PREFABRICATION AND ERECTION

2

Revised as indicated and Issued for Company Review and Approval

Farukh Butt

Fouad Khordahij

Mancini

29-03-10

1

Revised as indicated and Issued for Company Review and Approval

Farukh Butt

Fouad Khordahij

Mancini

06-02-10

0

Approved for Implementation (Ref. Letter 37472/KS/T/03639)

Farukh Butt

Fouad Khordahij

Mancini

02-11-09

C

Re-issued for Company Review and Approval (Ref. Letter 37472/KS/T/02898)

Farukh Butt

Fouad Khordahij

Mancini

13-09-09

B

Re-issued for Company Review and Approval (Ref. Letter 37472/KS/T/02239 and 02327)

Farukh Butt

Fouad Khordahij

Mancini

05-08-09

A

Issued for Company Review and Approval

Farukh Butt

Jean Yazji

Mancini

17-06-09

Prepared

Checked

Approved

Date

Rev.

Description

This document is the property of SAIPEM who will safeguard its rights according to the civil and penal provisions of the law.

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Document title: Quality Control Plan for Piping Prefabrication and Erection Subcontract No. Unit: P300009297 General Contract No. 37472

Rev. 2

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KOC Doc. No. -----------------

REVISION RECORD SHEET NOTES i)

Revisions after Rev. 1A, A & 0 are denoted by a vertical line in the left hand margin against the revised text, with the revision number displayed next to the revision line as shown on the left.

ii)

Revision nos. 1A, 2A, 3A etc. are issued for Contractor approval

iii)

Revision nos. A, B, C are issued for Company approval, and implementation after Company approval is Rev.0. Subsequent revisions are 1, 2, 3 etc.

2

No.

Date

1A

17 Mar. 2009

2A

Description of Revision

By

Rev.

App.

Issued for Contractor Review & Approval

Farukh Butt

Jean Yazji

Mancini

11 May. 2009

Reissued for Contractor Review & Approval

Farukh Butt

Jean Yazji

Mancini

A

17 June. 2009

Issued for Company Review & Approval

Farukh Butt

Jean Yazji

Mancini

B

05 Aug. 2009

Farukh Butt

Fouad Khordahij

Mancini

C

13 Aug.2009

Re-issued for Company Review & Approval (Ref. Letter 37472/KS/T/02239 and 02327 ) Re-issued for Company Review and Approval (Ref. Letter 37472/KS/T/02898)

Farukh Butt

Fouad Khordahij

Mancini

0

02 Nov.2009

Approved for Implementation (Ref. Letter 37472/KS/T/03639)

Farukh Butt

Fouad Khordahij

Mancini

1

06 Feb. 2010

Revised as indicated and Issued for Company Review and Approval

Farukh Butt

Fouad Khordahij

Mancini

2

29 Mar. 2010

Revised as indicated and Issued for Company Review and Approval

Farukh Butt

Fouad Khordahij

Mancini

This document is the property of SAIPEM who will safeguard its rights according to the civil and penal provisions of the law.

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Document title: Quality Control Plan for Piping Prefabrication and Erection Subcontract No. Unit: P300009297 General Contract No. 37472

Rev. 2

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KOC Doc. No. -----------------

CONTENTS

1.

2.

3.

4.

5.

GENERAL 1.1.

Scope and Objective

1.2.

Terms and definitions

QUALITY CONTROL PLANNING 2.1.

Information Related to this Document

2.2.

Issuing of QCP and ITPs

2.3.

Subcontractor responsibility

2.4.

Local Regulations

APPLICABLE DOCUMENTATION 3.1.

Specifications Codes and Standards

3.2.

Applicable Revision

3.3.

Construction Item definition

PIPING ERECTION 4.1.

General

4.2.

Materials Handling

4.3.

Materials Traceability

4.4.

Fit-Up of piping

4.5.

Threaded joints

4.6.

Flanged joints

4.7.

Pressure Testing

4.8.

Specific Requirements for Placing Underground RTR/Thermoplastic Material Piping in Trenches

ATTACHMENTS 5.1.

ITP LIST

5.2.

INSTALLATION FORMS LIST

5.3.

PRECOMMISSIONING FORMS LIST

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Document title: Quality Control Plan for Piping Prefabrication and Erection Subcontract No. Unit: P300009297 General Contract No. 37472

Rev. 2

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KOC Doc. No. -----------------

1

GENERAL

2

Scope and Objective

3

This document provides guidance and minimum requirements of Subcontractor for inspecting, checking and testing piping prefabrication and erection during construction of “BUILDING NEW BOOSTER STATION BS-160 AT SOUTH EAST KUWAIT”.

4

This document is additional to QAS No. 000-ZA-E-09698 (Quality Assurance Requirements for Construction Subcontractor), QAS No. 000-ZA-E-09699 (Quality Control Requirements for Contractor), (internal documents of Contractor) and shall be read together other applicable contractual documentation.

5

Terms and definitions

6

The following terms and definitions are applicable to all Contractor specifications related to quality requirements for Subcontractors. Sub Contractor Kharafi National, including its Subcontractor to whom any part of the Works has been subcontracted by Contractor/Company. Contractor

Saipem appointed by Company to perform the Works.

Company

Kuwait Oil Company that receives the services related to the Works provided by Contractor and by its Subcontractor(s).

TPI

Third Party Inspection: Any organization, authority, person or persons, to which Subcontractor has subcontracted the execution of inspection and or laboratory testing, related activities.

Works

Means the permanent new, revamped and refurbished facilities constituting the Project, including all the construction services, materials and equipment to be provided by Contractor/Company to satisfy ITP obligations pursuant to the Contract undertaken with the Company.

QMS

Quality Management System: part of the organization’s management system that focuses on achievement of results, in relation to the quality objectives, to satisfy the needs, expectations and requirements of Contractor/Company and of any other interested parties, as appropriate.

QAS

Quality Assurance Specification: Contractor document specifying the minimum requirements related to Subcontractor’s QMS and QA/QC Manual specific for the Works.

QCP

Quality Control Specification: Subcontractor plan containing all quality control requirements. This Plan complements and compiles all applicable ITP(s).

ITP

Inspection and Test Plan: Subcontractor plan of inspection and tests required by engineering and vendors documents or elsewhere specified. ITP(s) shall provide references to applicable procedures, acceptance criteria, documentation, quality records and inspection attendance to be performed, in chronological order, from initial inspection, throughout final inspections and mechanical completion. ITP(s) and relevant forms shall be issued as QCP enclosures.

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Document title: Quality Control Plan for Piping Prefabrication and Erection Subcontract No. Unit: P300009297 General Contract No. 37472

Rev. 2

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KOC Doc. No. -----------------

IN

Inspection Notification: Written notification to be issued by Subcontractor in order to allow all parties involved to perform their inspection and test witness as planned in the applicable ITP.

QA

Quality Assurance: Part of quality management focused on providing confidence that quality requirements will be fulfilled.

QC

Quality Control: Part of quality management focused on fulfilling quality requirements.

NCR

Non Conformity Report: Document recording a non-fulfilment of a requirement.

Non Conformity The non-fulfilment of specified requirements. Special Process A process, the results of which are highly dependent on the control of the process or the skill of the operator and in which the specified quality cannot be readily determined by inspection or test on the product. Calibration

Comparison of a measurement and test equipment with a reference standard or with another one provided with better tolerance in order to detect or to measure possible inaccuracies and to document or eliminate them.

7

Any other terms related to quality and not listed above shall conform to section 3 “Term and Definition” of ISO 9000:2000 “Quality Management System – Fundamentals and vocabulary”.

8

QUALITY CONTROL PLANNING

9

Information Related to this Document

10

This document includes the ITP(s) and forms, listed under paragraph 5.1 and 5.2, for performing inspection, tests to be carried out during site activities related to piping prefabrication and erection works.

11

The ITP’s are separated in two groups: 1. General ITP(s) include but are not limited to the following initial checks and

verification: This document is the property of SAIPEM who will safeguard its rights according to the civil and penal provisions of the law.

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Document title: Quality Control Plan for Piping Prefabrication and Erection Subcontract No. Unit: P300009297 General Contract No. 37472

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KOC Doc. No. -----------------

- Documentation - Personnel and equipment - Material receiving - Ambient conditions - Etc. These ITPs and relevant inspection and testing activities are coded with series TB.000X.XX. 2. Specific ITP(s) include inspection and tests which are directly related to construction

items and or part of the Works that can be identified and tracked through engineering drawings. These ITPs and relevant inspection activities are coded with series TB.010X.XX.

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Document title: Quality Control Plan for Piping Prefabrication and Erection Subcontract No. Unit: P300009297 General Contract No. 37472

Rev. 2

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KOC Doc. No. -----------------

12

Issuing of QCP and ITPs

13

Subcontractor has issue this document same as site QCP and ITP(s) using format template.

14

If additional QC Codes are required, the same shall be numbered adding an alphanumeric suffix to the preceding available QC Code. New QC Codes shall be approved by Contractor.

15

Subcontractor during the execution of the Works shall revise and update, as and when required, the QCP to incorporate any other pertinent requirements set forth in engineering specifications, standards, design codes, recommended practices, safety design, referred hereafter or included elsewhere in the contractual and vendor documents.

16

Prior to start construction work the QCP shall be submitted for review and approval.

17

Subcontractor responsibility

18

Subcontractor will prepare and update any other necessary QCP(s) and ITP(s), and quality procedures to include all inspections, examinations and tests required to verify the quality of the Works. The above documents shall be timely submitted to Contractor for review and approval in order to ensure their availability in approved status prior to starting of the piping prefabrication and erection work.

19

Subcontractor will perform and record all inspections, examinations and tests required as per contract and shall carry out all the works necessary for the preparation of inspections, examinations and tests, including adequate scaffolding for safely witnessing the inspection.

20

Subcontractor will provide, for the execution of testing, inspection and measurements all necessary equipment, tools and shall make available the applicable international Standards and Codes.

21

Subcontractor will issue inspections, examinations and tests reports immediately after the completion of each inspection activity. All reports shall be approved and signed off by Subcontractor authorized personal prior to submission to Contractor for review or approval, as appropriate.

22

Other Parties signature on inspection, examination and test reports does not release the Subcontractor from his responsibilities.

23

Local Regulations

24

Inspections and tests required by local regulations are out from the scope of this Plan. However, they shall be strictly adhered to and documented by Subcontractor. Copy of such records shall be submitted for review.

25

When local regulations are less stringent than the applicable design codes, the latter shall prevail.

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Document title: Quality Control Plan for Piping Prefabrication and Erection Subcontract No. Unit: P300009297 General Contract No. 37472

26

APPLICABLE DOCUMENTATION

27

Specifications Codes and Standards

3.1.1

Project Specifications 015-LH-1001-EF1655

-

SPC-1655-PM-4200-01

-

SPC-1655-PM-4200-02 SPC-1655-WM-01 15-WH-1002

-

CRT-1655-KOC-P001

-

KOC-P-001

-

015-WH-1001 Quality

-

Rev. 2

Doc. class.: A

KOC Doc. No. -----------------

Addendum to Specification for piping material Classes KOC specification for pressure testing piping Systems KOC Spec for piping Fabrication and Erection KOC Spec for General Welding requirements Field Welding requirements: Welding Heat Treatment and NDT of Piping Painting and Coating of metal surface – new Construction Painting and Coating of metal surface – new Construction Welding Procedure Approval & Welding Requirement

3.1.2

3.1.3

Subcontractor’s Technical Work Instructions 000-AZ-E-02580

-

Piping Erection

000-AZ-E-02588

-

Positive Material Identification Procedure (Intrex)

000-AZ-E-02590

-

Alloy Verification Procedure (HEISCO)

000-AZ-E-02577

-

Fabrication, Installation and Testing of RTRP Piping

000-AZ-E-02543

-

Procedure for Pressure Test - Piping

000-AZ-E-02576

-

Piping Fabrication

000-AZ-E-02581

-

Fabrication and Installation of Galvanized Iron-Piping

Codes and Standards Refer to the codes and standards contained in the above specification

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Document title: Quality Control Plan for Piping Prefabrication and Erection Subcontract No. Unit: P300009297 General Contract No. 37472

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KOC Doc. No. -----------------

28

Applicable Revision

29

Unless otherwise specified in contract documents, the applicable revision or edition of applicable Specifications and Standards is the last valid at the time when contract or agreement are made to enter into effective date.

30

Construction Item definition

31

Prior to start construction works the “Main Item” shall be defined including sub-items. The “Main Item” is the principal object of inspections and tests required for construction works. The “Main Item” to be related to the ITP is the “isometric” or “lines” including piping components, saddles, reinforcing plates and supports.

32

PIPING ERECTION

33

General

34

The Subcontractor shall be responsible for the receiving, identification, storing, handling, traceability and installation of all permanent piping components including fittings and valves from time of receipt at the job shop/site until final acceptance of Works, Subcontractor shall be responsible to maintain the piping material in good condition.

35

Subcontractor Superintendent, through the Craft Supervisors, shall have responsibility for the actual performance of all work directly related to the storage, segregation of different type and grade of materials, handling, (this shall include any such work performed for Subcontractors by other parties).

36

Subcontractor Superintendent shall enforce housekeeping requirements in or around the erection areas.

37

Receiving and storing piping materials shall be carried out as the relevant project documentation and as per this section.

38

Subcontractor shall keep record for control & tracing of all pipes relevant also to P.O., packing list , heat number, certificates, inspection report .

This document is the property of SAIPEM who will safeguard its rights according to the civil and penal provisions of the law.

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Document title: Quality Control Plan for Piping Prefabrication and Erection Subcontract No. Unit: P300009297 General Contract No. 37472

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KOC Doc. No. -----------------

39

Materials Handling

40

All material shall be handled with care during fabrication and installation to prevent damage. Lined and coated pipes and fittings shall be lifted with wide fabric or rubbercovered slings and padding shall be used to prevent damage to lining or coating.

41

The materials shall be handled at all times in a manner that prevents contamination, damage to the pipe-walls, bevelled ends, and to the coating (including internal coatings, if applied). Equipment & slings will be suitable for material handling, Slings shall be nylon or equivalent; steel cables shall not be used. Coated pipe shall not be rolled or dragged on the ground.

42

Internal of piping spools shall be visually inspected for cleanliness, and shall have foreign material removed from the inside, and shall have end protectors installed. After assembly and installation, the piping shall be cleaned inside to remove all loose materials.

43

Materials Traceability

44

Piping material traceability is a mandatory requirement applicable to all piping materials and components and is relevant to the identification, registration, marking of all plant lines and isometric piping materials. Standard traceability allows the identification of piping materials per:  Piping component type (pipe, elbow, flange,etc.)  Dimensions (size and thickness)  Rating (# 150; # 300 etc.) Material standard and grade (ASTM-A-106 Gr.B; ASTM-A-105/N etc.). The identification of the material from receiving, storing and throughout all construction phases is managed by means of specific piping components coding assigned by engineering to each type of component as listed in the line specification.

45

Full Traceability will be maintained the Subcontractor and shall comply with the following requirement: Transferring the material heat number on pipe segments during cutting operations, prefabrication and erection maintaining the same on all piping components with the necessary traceability marking, colour coding;  Indicating the material heat numbers and/ or traceability numbers on Traceable documents and on relevant prefabricated or erected pipe spools. Preparing the drawings with the identification and traceability summary table detailing for each isometric all pipe segments and components with the following minimum information:  drawing number showing the position of the pipe segment or components and relevant traceability number,  type, quality and size of the component/material,  material heat number,  manufacture name

This document is the property of SAIPEM who will safeguard its rights according to the civil and penal provisions of the law.

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Document title: Quality Control Plan for Piping Prefabrication and Erection Subcontract No. Unit: P300009297 General Contract No. 37472

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KOC Doc. No. -----------------

46

All the above work process shall be detailed by Subcontractor in ITP own “Piping Fabrication and Erection Procedure” and “Positive Material Identification Procedure” to be issued to Contractor for approval prior to start the work.

47

Fit-Up of piping

48

Components to be welded shall be aligned, spaced and fitted up as required by the welding specification and piping construction tolerances.

49

For socket weld connections the pipe shall be cut and inspected to ensure that the cut end of the pipe is straight to enable the specified gap between the end of the pipe and socket.

50

Threaded joints

51

Prior to starting the work, the following preliminary positive verifications shall be carried out:  availability of Subcontractor approved threaded Joints procedure;  adequacy and approval of lubricant and sealant to be used;  adequacy of pipe threading equipment and tools.

52

Subcontractor shall demonstrate to Contractor the suitability of equipment, tools and sealant for threaded joints by means of initial sample testing. Care shall be taken, not to damage the threads, during installation. The thread standard shall conform to the specified Standard. Minimum number of engaged pipe threads shall meet the requirements of the specified Standard. Unless otherwise specified the required number of exposed threads shall be from two to three.

53

For seal Welding of Threaded Joints the seal weld shall be a fillet weld going from the outer diameter of the female part, smoothly with slight concavity, to the male part covering all exposed threads without undercut, using an approved procedure. Seal welding of threaded joints is to be carried out when indicated on project documents. Seal weld will be as per ASME B31.3

54

Flanged joints

55

All type of flanged Joints shall be assembled in accordance with the applicable Piping Specification and Standard. As a minimum, bolts tightening of high pressure flanged joints rating 1500 lb and above, grinding of the inside surface of welded joints of orifice flanges and flanged connections on machinery shall be carried out under controlled condition.

56

Prior to start the work Subcontractor shall issue the installation procedure for flanged joints assembly to address as a minimum requirements and “Good Practices” for: - steel flanged bolt tightening methods; - RTR (Fibreglass) flanged tightening sequence and torque; - Gasket identification installation and verification. Flange shall not be joined without gasket, all stud & bolts shall be treated with graphitic oil before installation For underground RTR In case of specific contract requirements of SS strips the requirements will be applied.

This document is the property of SAIPEM who will safeguard its rights according to the civil and penal provisions of the law.

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Document title: Quality Control Plan for Piping Prefabrication and Erection Subcontract No. Unit: P300009297 General Contract No. 37472

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KOC Doc. No. -----------------

57

Pressure Testing

58 59

Applicable ASME B31.3, B31.4 or B31.8 will be used. Subcontractor shall make hydrostatic test diagrams and test procedures available at site prior to conducting the test. The test diagrams and procedures shall include the limits of piping (including test manifold), equipment included in each test, test pressure, test temperature, fluid and flushing requirements.

60

Pressure testing of piping shall be carried out as per project piping specification and the hydro test procedure 000-AZ-E-02543 and in accordance with the applicable code. In addition, the following requirements shall apply.

61

The test fluid shall be injected at the lowest point in the system to minimize entrapped air. All vents shall be open during filling.

62

After the test pressure is reached and before commencement of inspection of the system, the isolation valve between the temporary test manifold/piping and the piping/equipment under pressure test shall be closed and the test pump disconnected. All systems (piping and equipment) while being hydrostatic tested shall be protected from being over pressured.

63

Subcontractor shall make hydrostatic test diagrams and test procedures available at site before testing, and be available at the job sites for pressure tests. In case of test for buried System a dedicated procedure will be issued

64

For Gravity atmospheric test Subcontractor shall make dedicated procedure to describe method and acceptance.

65

All the equipments & instrumentations that could be damage by the test will be removed and reinstalled after test.

66

Specific Requirements for Placing Underground RTR/Thermoplastic Material Piping in Trenches

67

Company specification KOC-MP-011-2 will be applied for all the installation, moreover same more requirements are expressed here below in case of conflict KOC specification will prevail.

68

Small and composite spools can be pre-joined prior to lowering in the trench where there is no risk of joint failure. Pipes shall be joined sufficiently after lowering operation so that no movement of the pipe will take place at location where joints are being cured. Any vibration or movement of uncured or partially cured joints shall be avoided to minimize the risk of joint failures.

69

Applicable methods for lowering pipe into the trench shall be in accordance with pipe Manufacturer recommendations and be performed in a way not to over-stress the piping. Suitable equipment and tools for raising and lowering the pipe into the ditch shall be used.

70

For trench depth in excess of 5 feet, it shall be the Subcontractor’s responsibility to submit specific laying conditions (trench depth, handling equipment, pipe diameter, etc.) to CONTRACTOR/COMPANY for approval.

71

Bedding and backfill shall be performed as per Manufacturer recommendation. Any conflicts between project specifications and Manufacturer recommendation shall be resolved in writing by the Subcontractor through the Contractor Site Representative.

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Document title: Quality Control Plan for Piping Prefabrication and Erection Subcontract No. Unit: P300009297 General Contract No. 37472

72

The above requirements are addition.

73

ATTACHMENTS

74

ITP LIST

75

General ITP

76

77

ITP TB-0001

Document Review

ITP TB-0002

Material Receiving

Doc. class.: A

KOC Doc. No. -----------------

Specific ITP ITP TB-0101

Steel Pressure Piping Prefabrication and Erection

ITP TB-0102

Fibreglass/Plastic Pressure Piping Erection

ITP TB-0106

Piping System Precommissioning

ITP TB-0107

Atmospheric Underground Piping

INSTALLATION FORMS LIST MDT.TB.CDQ.0101

Isometric Control Sheet

MDT.TB.CDQ.0103

Check of Installed Supports and Anchor

MDT.TB.CDQ.0104

Inspection Report of flange alignment, parallelism and bolts tightening

MDT.TB.CDQ.0105

Visual Check of Orifice Flanges Report

MDT.TB.CDQ.0106

Release for Backfilling (UG Pressure Piping)

MDT.TB.CDQ.0107

Pipe Threads Checking and Wrench Tightening

MDT.TB.CDQ.0108

Release for Pressure Test

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MDT.TB.CDQ.0109

Pressure Test report

MDT.TB.CDQ.0110

RTR/Thermoplastic Joint Preparation and Assembly Report

MDT.TB.CDQ.0111

Checking of Heating Blanket Application and Curing Time

MDT.TB.CDQ.0112

Before Pressure Test- Internal Pipe Cleaning

MDT.TB.CDQ.0113

Release Report of Piping Prefabricated Spools

MDT.TB.CDQ.0117

Inspection Report of Laid

MDT.TB.CDQ.0118

Inspection Report of Pipes Watertight Test

MDT.TB.CDQ.0119

Finishing Inspection Report of Complete System Watertight Fulfilment

MDT.TB.CDQ.0120

Inspection Report for Trenches Excavation and Beddings

MDT.TB.CDQ.0121

Pre-Test Punch Listing Check List

MDT.TB.CDQ.0122

RTRP Daily Bonding Inspection Report

MDT.TB.CDQ.0123

Pipe Support Fabrication Inspection Report

MDT.TB.CDQ.0124

Final Inspection and Release Record for Pipe Support

Pipes

PRECOMMISSIONING FORMS LIST MDT.TB.CDQ.901

Pre-Commissioning Record Sheet Piping System Cleaning / Blowing / Flushing

MDT.TB.CDQ.902

Piping Items Check List - (Removal / Reinstatement)

MDT.TB.CDQ.903

Temporary Spades, Paddles & Blinds Check List – (Installation / Removal)

MDT.TB.CDQ.904

Instruments Check List - (Removal / Reinstatement)

MDT.TB.CDQ.905

System Drying and Inerting

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335226530.doc

JOB 670700

PROJECT LOCATION

QCP: 000-ZA-E-02631

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS-160 AT SOUTH EAST KUWAIT ITP No. TB-0001

DISCIPLINE

Title: DOCUMENT REVIEW QC CODE TB

TB

TB

0001

0001

0001

02

03

ITEMS

Check availability of CC approved procedure for piping internal cleaning

Reference Document

Acceptance Criteria

Quality Records/ Document

CC

Q C

SP

UPR,

Approved

000-AZ-E02543

P

R

Approved

000-AZ-E02580

P

Approved

000-AZ-E02580

Approved

CL

Notes

R

R/A

UPR- Up dated Procedure Register

R

R

R/A

P

R

R

R/A

000-AZ-E02588 000-AZ-E02590

P

R

R

R/A

Approved

000-AZ-E02577

P

W

W

W

Approved

000-AZ-E02543

P

R

R

R/A

000-AZ-E02543

Check availability of CC approved procedure for flange joint- gasket installation and flange bolt tightening

000-AZ-E02580,

Check availability of CC approved procedure for piping material traceability

000-AZ-E02580,

Involvement TP

C O

UPR

UPR

TB

0001

04

Review of approved procedure for positive material identification (PMI)

000-AZ-E02588 000-AZ-E02590, UPR

TB

TB

0001

0001

05

06

Rev. 2

Sh. 15 of 54

PIPING Description

01

UNIT 000

Check certificate of training from manufacturer for the pipe fiberglass jointing personnel.

000-AZ-E02577

Check availability of CC approved procedure for piping pressure testing: - Hydrostatic testing; - Pneumatic testing; - Leak testing; - Etc.

000-AZ-E02543

CC – Sub contractor QC – QC Sub contractor SP – Contractor Supervision

UPR

UPR

ORGANIZATION CODE CO –Contractor Commissioning TP – Laboratory / Third Party CL – Company

P – Perform/Submit S – Surveillance R – Review

INVOLVEMENT CODE W – Witness H – Hold Point R/A – Review/Approval

JOB 670700

PROJECT LOCATION

QCP: 000-ZA-E-02631

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS-160 AT SOUTH EAST KUWAIT ITP No. TB-0002

DISCIPLINE

Title: MATERIAL RECEIVING QC CODE TB

0002

Piping bulk material receiving at warehouse

Reference Document

Packing list 000-AZ-E-02013 000-AZ-E-02572

TB

TB

0002

0002

02

04

Rev. 2

Sh. 16 of 54

ITEMS

PIPING Description

01

UNIT 000

Warehoused material identification and traceability (Identification marks, Tags, colour coding etc.) -PMI (if required) (See Notes)

Acceptance Criteria

Mill Test Certificates, Purchase Order IFC Drawings

000-AZ-E-02013 000-AZ-E-02014

000-AZ-E-02572

000-AZ-E-02572

Quality Records/ Document OSD Report MAGA Print-out “RICEMATE” “STNNCNF” Warehouse Log book () Warehouse Material Maps PMI certification

Involvement CC

P

Q C

H

SP

W

TP

C O

CL

Notes

W

000-AZ-E-02013 - Material Management Storage and Preservation Procedure 000-AZ-E-02572- Handling, Unload and storage of Project materials

-PMI shall be carried out in accordance to Project/Contract specification. 000-AZ-E-02014 – PMI Procedure

P

H

S

S

P

W

S

S

Piping Materials protection and preservation 000-AZ-E-02013

CC – Sub contractor QC – QC Sub contractor SP – Contractor Supervision

000-AZ-E-02013

ORGANIZATION CODE CO –Contractor Commissioning TP – Laboratory / Third Party CL – Company

Warehouse Log book ()

P – Perform/Submit S – Surveillance R – Review

INVOLVEMENT CODE W – Witness H – Hold Point R/A – Review/Approval

JOB 670700

PROJECT LOCATION

QCP: 000-ZA-E-02631

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS-160 AT SOUTH EAST KUWAIT ITP No. TB-0101

QC CODE TB 0101

TB 0101

TB 0101

01a

01b

02

Sh. 17 of 54

DISCIPLINE

Title: STEEL PRESSURE PIPING PREFABRICATION AND ERECTION

(only for underground Piping) Check coordinates and elevation of trench excavation and bedding compaction.  (See Notes) Piping Material Heat Number Traceability

Reference Document

ITEMS

Acceptance Criteria

Quality Records/ Document

Involvement Notes CC

Q C

SP

TP

CO

CL

R

Document review and material receiving applicable inspection shall be completed as per ITP No. TB-0001 and ITP No. TB-0002

S

 Refer ITP No. CV-0201 in QCP No. 000-ZA-E02612.(QCP for General Civil Works)

AFC Drawings, Updated Drawing Register

AFC Drawings

MDT.TB.CDQ.0101

P

R

R

AFC Piping Drawings

AFC Piping Drawings

Piping arrangement DWGS

P

H

W

Latest Revision

Latest Revision

MDT.TB.CDQ.0120

Material Test Certificates

Weld Summary List

P

W

S

000-AZ-E-2576 000-AZ-E-2580 SPC-1655-PM4200-02

ISO-Weld Map

S

Material Test Certificates

CC – Sub contractor QC – QC Sub contractor SP – Contractor Supervision 335226530.doc

Rev. 2

PIPING

Description Pre-installation inspection:  (See Notes) - Verification of isometric, piping arrangement dwg, components and spools - Preparation of isometric control sheets.

UNIT 000

ORGANIZATION CODE CO –Contractor Commissioning TP – Laboratory / Third Party CL – Company

P – Perform/Submit S – Surveillance R – Review

INVOLVEMENT CODE W – Witness H – Hold Point R/A – Review/Approval

JOB 670700

PROJECT LOCATION

QCP: 000-ZA-E-02631

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS-160 AT SOUTH EAST KUWAIT ITP No. TB-0101

QC CODE TB 0101

03

Sh. 18 of 54

DISCIPLINE

Title: STEEL PRESSURE PIPING PREFABRICATION AND ERECTION

Rev. 2

ITEMS

PIPING Reference Document

Acceptance Criteria

Description Inspection of orifice flanges :  (See Notes) - Visual Inspection of Internal weld profile; - Dimensional checks; - Inspection of orifice flanges (orientation).

UNIT 000

AFC Drawings, 000-AZ-E-2576, SPC-1655-PM4200-02

AFC Drawings, SPC-1655-PM4200-02 Clause 4.5, 4.6

Quality Records/ Document

MDT.TB.CDQ.0105

Involvement Notes CC

Q C

SP

TP

CO

W

CL

P

H

H

W

Dimensional checks

P

H

W

S

Welding, NDE (PMI), PWHT (if required)  (See Notes) Check of identification marking of spools

P

H

W

S

P

H

W

For inspection of flow orifice plate, refer to ITP No.SM-0101 in QCP No.000-ZA-E-02651 “Instrumentation and Automation system”

W

TB AFC Drawings,

2

TB 0101 04A

Release of Pipe Supports - Dimensional checks - Welding, NDE, PWHT (if required)  (See Notes) CC – Sub contractor QC – QC Sub contractor SP – Contractor Supervision

335226530.doc

000-AZ-E-2576,

000-AZ-E-2576,

SPC-1655-PM4200-02

SPC-1655-PM4200-02

ORGANIZATION CODE CO –Contractor Commissioning TP – Laboratory / Third Party CL – Company

MDT.TB.CDQ.0123 MDT.TB.CDQ.0124

P – Perform/Submit S – Surveillance R – Review

 P

R

S

INVOLVEMENT CODE W – Witness H – Hold Point R/A – Review/Approval

PMI if required shall be carried out as per ITP No. WL- 0101 in 000-ZA-E02623. All Welding and NDE

JOB 670700

PROJECT LOCATION

QCP: 000-ZA-E-02631

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS-160 AT SOUTH EAST KUWAIT ITP No. TB-0101

QC CODE TB 0101

TB 0101

TB 0101

TB 0101

TB 0101

05

06

07

08

09

Sh. 19 of 54

DISCIPLINE

Title: STEEL PRESSURE PIPING PREFABRICATION AND ERECTION

Pipe supports and pipe anchor: positions according to drawings

Final mechanical inspection of installed piping release for pressure testing:  (See Notes) -Clearance of punch items preventing pressure test -Final inspection of piping joints:  (See Pre-test internal cleaning and pipe circuit preparation

CC – Sub contractor QC – QC Sub contractor SP – Contractor Supervision

Rev. 2

ITEMS

PIPING Reference Document

Acceptance Criteria

Description Inspection of piping flanges alignment, parallelism (pipe to pipe, pipe to equipment and machinery) and bolts tightening For threaded joint check the minimum number of engaged pipe threads and maximum exposed pipe threads

UNIT 000

000-AZ-E-2580 SPC-1655-PM4200-02 000-AZ-E-2581 SPC-1655-PM4200-02

SPC-1655-PM4200-02 Clause 4.12, 4.20 SPC-1655-PM4200-02 Clause 4.15

AFC Drawing, 000-AZ-E-2580, SPC-1655-PM4200-02

AFC Drawing SPC-1655-PM4200-02 Clause 4.7

AFC Drawings, 000-AZ-E-2543 SPC-1655-PM4200-01 000-AZ-E-2543, SPC-1655-PM4200-01

Quality Records/ Document

MDT.TB.CDQ.0104

MDT.TB.CDQ.0107

Notes CC

Q C

SP

TP

CO

CL

P

H

W

S

P

W

S

S

P

H

W

MDT.TB.CDQ.0103

AFC Drawings, SPC-1655-PM4200-01 Clause 4.1

MDT.TB.CDQ.0108 , 108A, Welding Summary List (MDT.WL.CDQ.

SPC-1655-PM4200-01 Clause 4.1

MDT.TB.CDQ.0112

ORGANIZATION CODE CO –Contractor Commissioning TP – Laboratory / Third Party CL – Company

Involvement

W

P

H

H

H

P

W

S

S

P – Perform/Submit S – Surveillance R – Review

INVOLVEMENT CODE W – Witness H – Hold Point R/A – Review/Approval

 Piping test-pack preparation (TP- Folder).  For welding, PWHT and NDE works, refer to ITP NO. WL-0101 in QCP No.

JOB 670700

PROJECT LOCATION

QCP: 000-ZA-E-02631

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS-160 AT SOUTH EAST KUWAIT ITP No. TB-0101

QC CODE TB 0101

10

Sh. 20 of 54

DISCIPLINE

Title: STEEL PRESSURE PIPING PREFABRICATION AND ERECTION

UNIT 000

Rev. 2

ITEMS

PIPING Reference Document

Acceptance Criteria

Description

Quality Records/ Document

Involvement Notes CC

Q C

SP

P

H

H

TP

CO

CL

Piping pressure testing 000-AZ-E-2543 SPC-1655-PM4200-01

TB 0101

11

SPC-1655-PM4200-02 clause 4.2

MDT.TB.CDQ.0109

H

Piping Lay-up

(follow ITP TB-0106 Precommissioning activities)

N/A

N/A

NA

R

R

 See Notes

TB010112(Underground Piping)  See NotesAFC DrawingAFC DrawingMDT.TB.CDQ.0106PHHW Refer ITP No.CV-0201. in QCP n.000-ZA-E-02612 for general civil works.

CC – Sub contractor QC – QC Sub contractor SP – Contractor Supervision 335226530.doc

ORGANIZATION CODE CO –Contractor Commissioning TP – Laboratory / Third Party CL – Company

P – Perform/Submit S – Surveillance R – Review

INVOLVEMENT CODE W – Witness H – Hold Point R/A – Review/Approval

 For painting, coating and insulation works refer to QCP - 000-ZA-E-02633 for Painting Work; - 000-ZA-E-02634 for Insulation Work; - 000-ZA-E-02635 for

JOB 670700

PROJECT LOCATION

QCP: 000-ZA-E-02631

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS-160 AT SOUTH EAST KUWAIT ITP No. TB-0102

TB

0102

PIPING Acceptance Criteria

Quality Records/ Document

CC

Q C

SP

Before commencement the Project works review and approval of following documents:

AFC Drawing

AFC Drawing

P

H

A

BPS

BPS

Bonding Procedure Specification (BPS),

-Bonding Procedure Specification  See Notes

Bonder’s Qualification Certificate

Bonder’s Qualification Certificate

Bonder’s Qualification Certificate,

Description 01

ITEMS

Reference Document

QC CODE

-Bonder’s Qualification  See Notes

Rev. 2

Sh. 21 of 54

DISCIPLINE

Title: FIBERGLASS/PLASTIC PRESSURE PIPING ERECTION

UNIT 000

ASME B 31.3

ASME B 31.3

Involvement TP

CO

CL W/A

Notes  Refer 000-AZ-E-02577 (Procedure for Fabrication and Erection of RTRP piping) for 1. Bonding Procedure Specification (BPS),

Bonder’s Register

2. Bonder’s Qualification Certificate, 3. Bonder’s Register

TB

TB

0102

0102

01a

01b

Pre-installation inspection:  See Notes - Verification of isometric, piping arrangement dwg, components and spools; - Preparation of isometric control sheets. (Underground Piping) Check coordinate and elevation of trench excavation and bedding compaction.

AFC Drawing, Updated Drawing Register

Latest AFC Drawing

MDT.TB.CDQ.0101

P

R

R

R

AFC Piping Drawings

AFC Piping Drawings

Piping arrangement DWGS

P

H

W

W

Latest Revision

Latest Revision

MDT.TB.CDQ.0120

 See Notes

CC – Sub contractor QC – QC Sub contractor SP – Contractor Supervision

ORGANIZATION CODE CO –Contractor Commissioning TP – Laboratory / Third Party CL – Company

P – Perform/Submit S – Surveillance R – Review

INVOLVEMENT CODE W – Witness H – Hold Point R/A – Review/Approval

Document review and material receiving applicable inspection shall be completed as per ITP No. TB-0001 and ITP No. TB-0002

 Refer ITP No. CV-0201 in QCP No. 000-ZA-E-02612. (QCP for General Civil Works)

JOB 670700

PROJECT LOCATION

QCP: 000-ZA-E-02631

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS-160 AT SOUTH EAST KUWAIT ITP No. TB-0102

QC CODE TB

TB

TB

TB

0102

0102

0102

0102

Description 02

03

04

05

Check joint and assembly preparation: a) Squareness of cut spigot end b) Insert depth c) Nose thk. d) Spigot diameter e) Adhesive application Check heating blanket application and curing time.

Final mechanical inspection of installed piping:  See Notes - Pre-test punch listing - Release for pressure testing Pre-test internal cleaning and pipe circuit preparation

CC – Sub contractor QC – QC Sub contractor SP – Contractor Supervision

Rev. 2

Sh. 22 of 54

DISCIPLINE

Title: FIBERGLASS/PLASTIC PRESSURE PIPING ERECTION

UNIT 000

ITEMS

PIPING Reference Document

Acceptance Criteria

Quality Records/ Document

CC

Q C

SP

000-AZ-E-2577

000-AZ-E-2577

MDT.TB.CDQ.0110

P

W

S

S

KOC-MP-011-2

BPS

MDT.TB.CDQ.012 2

KOC-MP-011-2

000-AZ-E-2577

P

W

W

S

BPS

BPS

MDT.TB.CDQ.0111 MDT.TB.CDQ.0122

MDT.TB.CDQ.0108, MDT.TB.CDQ.0121

P

H

H

H

MDT.TB.CDQ.0112

P

W

S

S

BPS

Involvement TP

CO

CL

Notes

000-AZ-E-2577

AFC Drawing,

AFC Drawing,

000-AZ-E-2577

KOC-MP-011-2

KOC-MP-011-2

Clause 11

000-AZ-E-2577 KOC-MP-011-2

KOC-MP-011-2

ORGANIZATION CODE CO –Contractor Commissioning TP – Laboratory / Third Party CL – Company

P – Perform/Submit S – Surveillance R – Review

INVOLVEMENT CODE W – Witness H – Hold Point R/A – Review/Approval

 Piping test-pack preparation (TP- Folder).

JOB 670700

PROJECT LOCATION

QCP: 000-ZA-E-02631

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS-160 AT SOUTH EAST KUWAIT ITP No. TB-0102

QC CODE TB

TB

0102

0102

Description 06

07

Piping pressure testing

(Underground Piping) Check of trenching and Release for backfilling  See Notes

CC – Sub contractor QC – QC Sub contractor SP – Contractor Supervision

Rev. 2

Sh. 23 of 54

DISCIPLINE

Title: FIBERGLASS/PLASTIC PRESSURE PIPING ERECTION

UNIT 000

ITEMS

PIPING Reference Document

Acceptance Criteria

Quality Records/ Document

Involvement CC

Q C

SP

TP

CO

CL

Line list,

Line List

000-AZ-E-2577

MDT.TB.CDQ.0 109

P

H

H

W

KOC-MP-011-2

KOC-MP-011-2 Clause 14.0

AFC Drawing Latest Revision

AFC Drawing Latest Revision

MDT.TB.CDQ.0 106

P

H

H

H

ORGANIZATION CODE CO –Contractor Commissioning TP – Laboratory / Third Party CL – Company

P – Perform/Submit S – Surveillance R – Review

INVOLVEMENT CODE W – Witness H – Hold Point R/A – Review/Approval

Notes

 Refer ITP No. CV-0201 in QCP No. 000-ZA-E02612.(QCP for General Civil Works)

JOB 670700

PROJECT LOCATION

QCP: 000-ZA-E-02631

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS-160 AT SOUTH EAST KUWAIT ITP No. TB-0106

DISCIPLINE

Title: PIPING SYSTEM PRECOMMISSIONING QC CODE TB

TB

TB

TB

TB

TB

0106

0106

0106

0106

0106

0106

01

02

03

04

05

06

Description Preparation of piping system Mechanical Completion

Pre-Commissioning Record Sheet Piping System Cleaning / Blowing / Flushing

Piping Items Check List - (Removal & Reinstatement)

Temporary Spades, Paddles & Blinds Check List - (Installation)- (Removal)

Instruments Check List - (Removal) (Reinstatement)

System Drying and Inerting

CC – Sub contractor QC – QC Sub contractor SP – Contractor Supervision

UNIT 000

Rev. 2

Sh. 24 of 54

ITEMS

PIPING Reference Document

Acceptance Criteria

Quality Records/ Document

000-AZ-E-02543,

SPC-1655-PM4200-01 clause 4.15, 4.16

SPC-1655-PM4200-01 000-AZ-E-02543, SPC-1655-PM4200-01

SPC-1655PM-4200-01 Clause 4.15

AFC Drawing, 000-AZ-E-02543 SPC-1655-PM4200-01

SPC-1655PM-4200-01

AFC Drawing, 000-AZ-E-02543 SPC-1655-PM4200-01

SPC-1655PM-4200-01

AFC Drawing, 000-AZ-E-02543 SPC-1655-PM4200-01

SPC-1655PM-4200-01

000-AZ-E-02543 SPC-1655-PM4200-01

SPC-1655PM-4200-01 Clause 4.15

Involvement CC

Q C

SP

TP

C O

TEST PACK Folder

P

R

R

R

MDT.TB.CDQ.901

P

H

H

W

MDT.TB.CDQ.902

P

H

H

W

MDT.TB.CDQ.903

P

H

H

W

MDT.TB.CDQ.904

P

H

H

W

MDT.TB.CDQ.905

P

H

H

H

Notes

CL

Clause 4.16

Clause 4.16 (If applicable)

Clause 4.16

ORGANIZATION CODE CO –Contractor Commissioning TP – Laboratory / Third Party CL – Company

P – Perform/Submit S – Surveillance R – Review

(If required by Project Specification)

INVOLVEMENT CODE W – Witness H – Hold Point R/A – Review/Approval

JOB 670700

PROJECT LOCATION

QCP: 000-ZA-E-02631

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS-160 AT SOUTH EAST KUWAIT

ITP No. TB-0107

QC CODE TB 0107

01

Sh. 25 of 54

DISCIPLINE

Title: ATMOSPHERIC UNDERGROUND PIPING Description Check atmospheric underground piping installation before backfilling

Rev. 2

ITEMS

PIPING Reference Document AFC Drawing 000-AZ-E-02543, SPC-1655-PM4200-01

TB 0107

02

Gravity testing of the pipe as required by the testing procedure Release for Backfilling

000-AZ-E-02543, SPC-1655-PM4200-01

TB 0107

03

Check the integrity of the complete system (pipes and PITP, manholes) watertight fulfilment.

000-AZ-E-02543, SPC-1655-PM4200-01

CC – Sub contractor QC – QC Sub contractor SP – Contractor Supervision

UNIT 000

Acceptance Criteria

Quality Records/ Document

CC

QC

SP

MDT.TB.CDQ.0117

P

H

W

W

No Leaks detected MDT.TB.CDQ.0118

P

H

W

W

No Leaks detected MDT.TB.CDQ.0119

P

H

H

W

AFC Drawing Latest revision

ORGANIZATION CODE CO –Contractor Commissioning TP – Laboratory / Third Party CL – Company

Involvement

P – Perform/Submit S – Surveillance R – Review

TP

CO

CL

INVOLVEMENT CODE W – Witness H – Hold Point R/A – Review/Approval

Notes

PLANT LOCATION

JOB

UNIT

670700

000

QC CODE

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

REPORT No DATE:

ISOMETRIC CONTROL SHEET PAGE

LINE NUMBER

ISO/SK No.

SPOOL No.

JOINT TYPE

MATERIAL TYPE AND GRADE

NOTES

OF

BUTT BRANCH JOINT WELD WELD No.



REINFO FILLED ORIFICE RCED WELD FLANGE PAD





























































































































































INSPECTION NOTIFICATION REFERENCE

IN No. KHARAFI NATIONAL

SAIPEM

KOC

NAME DESIGNATION SIGNATURE Date

Form code: MDT.TB.CDQ.0101

335226530.doc

Page 26 of

54

PLANT LOCATION

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

JOB

UNIT

670700

000

QC CODE

REPORT No DATE:

CHECK OF INSTALLED SUPPORTS AND ANCHOR Test Pack No:

PAGE

LINE NUMBER

NOTES=

C= CONFORMING NC= NOT CONFORMING KHARAFI NATIONAL

CORRECT NUMBER AND POSITION OF SUPPORTS AND ANCHOR ACCORDING TO DRAWINGS

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

OF NOTES

INSPECTION NOTIFICATION REFERENCE (TO DRW, SPECIFICATION)

SAIPEM

IN No. KOC

NAME DESIGNATION SIGNATURE Date Form code: MDT.TB.CDQ.0103

335226530.doc

Page 27 of

54

PLANT LOCATION

JOB

UNIT

670700

000

QC CODE

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

REPORT No

BS 160 - AT SOUTH EAST KUWAIT

DATE:

INSPECTION REPORT OF FLANGE ALIGNMENT, PARALLELISM AND BOLTS TIGHTENING JOINT REF.No. (see note 1)

Test Pack No:

PIPING ISOMETRIC REF.DWG.No. (see note 1)

Joint no. :

Line number:

ISO/DWG :

Joint no. :

Line number:

ISO/DWG :

Joint no. :

Line number:

ISO/DWG :

Joint no. :

Line number:

ISO/DWG :

CHECKS CHECKS OF CORRECT MATERIAL

C

NC 

Flange

Check correct installation for : Size (inch), Type, Rating, Material

Gasket

Check correct installation for : Size (inch), Type, number for Ring Gasket) , Material (Outer Guide Ring - Inner Guide Ring -Ring Joint Basket – Others…..) C  NC 

Bolts & Nuts

C

Check correct installation for : Size (inch), Type, Material, Quantity

YES 

Lubricant:

NC 

NO 

CHECKS BEFORE BOLTS TIGHTENING PARALLELISM CHECK ALIGNMENT CHECK

C



REMOVAL OF TEMPORARY GASKETS AND INST. OF PERMANENT FINAL GASKET

NC 

C 

NC 

BOLTS TIGHTENING By Torque

:

Bolt tensioning method :

 

Torque value

Torque/Tensioning equipment No: RESULTS:

ACCEPTABLE

Calibration due :



NOT ACCEPTABLE

NOTES Notes: 1-Subcontractor shall identify on piping isometric dwgs. the joint reference number using an alfa

numeric code.

KHARAFI NATIONAL

:



INSPECTION NOTIFICATION REFERENCE

IN No.

SAIPEM

KOC

NAME DESIGNATION SIGNATURE Date Form code: MDT.TB.CDQ.0104

JOB

335226530.doc

UNIT

Page 28 of

54

670700 PLANT LOCATION

000

QC CODE

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

REPORT No DATE:

VISUAL CHECKS OF ORIFICE FLANGES Test Pack No:

PAGE

PIPING LINE NUMBER

NOTES:

ORIFICE FLANGE No.

C= CONFORMING NC= NOT CONFORMING KHARAFI NATIONAL

INTERNAL GRINDING OF WELD ROOT

ORIFICE FLANGE ORIENTATION PRESSURE HOLES

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

OF NOTE / REMARKS

INSPECTION NOTIFICATION REFERENCE (TO DRW, SPECIFICATION)

SAIPEM

IN No. KOC

NAME DESIGNATION SIGNATURE Date Form code: MDT.TB.CDQ.0105

335226530.doc

Page 29 of

54

PLANT LOCATION

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

335226530.doc

JOB

UNIT

670700

000

QC CODE

REPORT No DATE:

Page 30 of

54

KHARAFI NATIONAL NAME

SAIPEM

KOC

RELEASE FOR BACKFILLING (U/G PRESSURE PIPING)

DESIGNATION

Test Pack No:

PAGE

SIGNATURE Date

PIPING LINE NUMBER

DRAWING NUMBER

CHECK THE CORRECT INSTALLATION OF PIPING IN TRENCHES RELEASE FOR BACKFILLING

YES / NO

OF

REMARKS



YES 

NO 

YES 

NO 

YES 

NO 

YES 

NO 

YES 

NO 

YES 

NO 

YES 

NO 

YES 

NO 

YES 

NO 

YES 

NO  INSPECTION NOTIFICATION REFERENCE

NOTES

IN No.

Form code: MDT.TB.CDQ.0106

335226530.doc

Page 31 of

54

PLANT LOCATION

JOB

UNIT

670700

000

QC CODE

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

REPORT No DATE:

PIPE THREADS CHECKING AND WRENCH TIGHTENING Procedure :

Test Pack No:

PAGE

OF

VISUAL CHECK OF THE THREADS

PIPING LINE NUMBER

C  NC

NOTES:

C= CONFORMING NC= NOT CONFORMING KHARAFI NATIONAL

NOTES

WRENCH TIGHTENING ENGAGED AND EXPOSED CHECK THREADS

C  NC

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC 

C 

NC  INSPECTION NOTIFICATION REFERENCE

(TO DRW, SPECIFICATION)

SAIPEM

IN No. KOC

NAME DESIGNATION SIGNATURE Date Form code: MDT.TB.CDQ.0107

335226530.doc

Page 32 of

54

PLANT LOCATION

JOB

UNIT

670700

000

QC CODE

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

REPORT No DATE:

RELEASE FOR PRESSURE TEST TEST PACK NUMBER:

PIPING LINE NUMBER

Clearance of Punch Items preventing pressure test (1)-(2)

Cleaning execution and line ready for pressure test (3)

Temporary installation (4)

Release for pressure Test

NOTES

 NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES

Notes:

1) 2) 3) 4)

This Form shall be used in conjunction with the applicable Pre-Test Punch Listing Checklist. MDT.TB.CDQ.0121 Indicate on NOTE “No Punch items. “If there are no punch list to be recorded. For pre-test cleaning report see MDT.TB.CDQ.0112 For Temporary installation use MDT.TB.CDQ.0102 TEMPORARY SPADES, PADDLES & BLINDS – (INSTALLATION)

REMARKS

INSPECTION NOTIFICATION REFERENCE

IN No. KHARAFI NATIONAL

SAIPEM

KOC

NAME DESIGNATION SIGNATURE Date Form code: MDT.TB.CDQ.0108

335226530.doc

Page 33 of

54

PLANT LOCATION

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

335226530.doc

JOB

UNIT

670700

000

QC CODE

REPORT No DATE:

Page 34 of

54

KHARAFI NATIONAL

SAIPEM

NAME

KOC

PRESSURE TEST REPORT

TEST PACK NUMBER: DESIGNATION LINE NUMBER : SIGNATURE

LINE NUMBER :

LINE Date NUMBER :

LINE NUMBER :

LINE NUMBER :

LINE NUMBER :

LINE NUMBER :

LINE NUMBER :

LINE NUMBER :

LINE NUMBER : PAGE

OF

TEST PROCEDURE No.: Pressure Test Check List Y

N

N/A

Y

1- Discs and flappers removed from check valves

6- Temperature equilibrium established between test fluid and system

2- Vents and drains installed

7- Lab. analysis of water chemistry made

3- Bleed valve installed

8- Safety precautions enforced for air/gas tests

N

N/A

4- Press. Temp. Recorder installed 5- Flushing procedure reviewed and approved

Test Pressure_(BAR)

______________

Type of Test Fluid

______________

Duration of Test

Test Results -

______________

Acceptable

P.G-1 No:

Calib.Due:

P.G-2 No:

Calib.Due:

P.G-3 No:

Calib.Due:

PSV No:

Calib.Due:

Pressure/Temp.Recorder No:

Calib.Due:

Not Acceptable





NOTES

INSPECTION NOTIFICATION REFERENCE

IN No. Form code: MDT.TB.CDQ.0109

PLANT LOCATION

JOB

UNIT

670700

000

QC CODE

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

REPORT No DATE:

RTR/THERMOPLASTIC JOINT PREPARATION AND ASSEMBLY REPORT

Line No.

Joint No.

Size cm inch

 

Joint preparation

 

Pass

 335226530.doc

 

Fail



Adhesive application

 

Pass



 

Fail



Release for Heating Blanket Curing Yes 



 





Not

Page 35 of

54





















































































































































































NOTES

INSPECTION NOTIFICATION REFERENCE

IN No. KHARAFI NATIONAL

SAIPEM

KOC

NAME DESIGNATION SIGNATURE Date Form code: MDT.TB.CDQ.0110

335226530.doc

Page 36 of

54

PLANT LOCATION

JOB

UNIT

670700

000

QC CODE

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

REPORT No

BS 160 - AT SOUTH EAST KUWAIT

DATE:

CHECKING OF HEATING BLANKET APPLICATION AND CURING TIME

Procedure:

Test Pack No:

JOINT NO.

LINE NUMBER

PAGE

- Check size - Check proper installation of heating blanket - Check pipe ends closure

Check voltage

Check adhesive bonding curing time

OF

Release for Pressure Test

C 

NC 

C 

NC 

C

NC 













 

































































































































































































NOTES

Yes

Not 



INSPECTION NOTIFICATION REFERENCE

IN No. KHARAFI NATIONAL

SAIPEM

KOC

NAME DESIGNATION SIGNATURE Date Form code: MDT.TB.CDQ.0111

335226530.doc

Page 37 of

54

PLANT LOCATION

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

JOB

UNIT

670700

000

QC CODE

REPORT No DATE:

BEFORE PRESSURE TEST - INTERNAL PIPE CLEANING TEST PACK. No:

PAGE

LINE No.

Cleaning execution for line ready for pressure test

 C  C  C  C  C  C  C  C  C  C  C  C  C  C  C 

C

OF

NOTES

 NC  NC  NC  NC  NC  NC  NC  NC  NC  NC  NC  NC  NC  NC  NC 

NC

NOTES

INSPECTION NOTIFICATION REFERENCE

IN No. KHARAFI NATIONAL

SAIPEM

KOC

NAME DESIGNATION SIGNATURE Date Form code : MDT.TB.CDQ.0112

335226530.doc

Page 38 of

54

PLANT LOCATION

JOB

UNIT

670700

000

QC CODE

SOUTH EAST KUWAIT PROJECT TITLE

BUILDING NEW BOOSTER STATION BS-160

REPORT No DATE:

RELEASE REPORT OF PIPING PREFABRICATED SPOOLS PAGE SL. No.

Isometric Drg. No.

335226530.doc

Line No

Rev

Spoo l

Piping Class

Matl. Check

Fit Up & Welding

PWHT + Hardness

NDT

Visual Check

OF

Dimens Welded ional Pipe Check Support

Paint Syste m

Page 39 of

54

Re ma rks

IN No. KHARAFI NATIONAL

SAIPEM

KOC

NAME SIGNATURE DESIGNATION DATE Form code: MDT.TB.CDQ.0113

335226530.doc

Page 40 of

54

PLANT LOCATION

JOB

UNIT

670700

000

QC CODE

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

REPORT No

BS 160 - AT SOUTH EAST KUWAIT

DATE:

INSPECTION REPORT OF LAID PIPES Test Pack No:

PAGE REFERENCE DRAWING

Tag or line number

Number

OF

LAID PIPES

Rev.

-MATERIALS (DIAMETERS DIMENSIONS) -GRADIENTS -LEVELS -POSITIONS

RESULTS

FROM PIT/MANHOLE/ CATCH BASIN

TO PIT/MANHOLE/ CATCH BASIN

C NC C NC C NC C NC C NC C NC C NC C NC C NC C NC C NC

C NC C NC C NC C NC C NC C NC C NC C NC C NC C NC C NC NOTES:

C= CONFORMING NC= NOT CONFORMING

(TO DRW, SPECIFICATION)

CONFORMIN G/ NOT CONFORMIN G

INSPECTION NOTIFICATION REFERENCE

IN No. KHARAFI NATIONAL

SAIPEM

KOC

NAME DESIGNATION SIGNATURE DATE Form code: MDT.TB.CDQ.0117

335226530.doc

Page 41 of

54

PLANT LOCATION

JOB

UNIT

670700

000

QC CODE

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

REPORT No

BS 160 - AT SOUTH EAST KUWAIT

DATE:

INSPECTION REPORT OF PIPES WATERTIGHT TEST Test Pack No:

PAGE

PIPE Drawing No / line number

FROM

TO

Internal PITP / PITP / DiameterØ MANHOLES MANHOLES

NOTES

RESULTS Duration Time (Minutes)

OF

RELEASE FOR BACKFILLING

PASS

FAIL

YES

NOT

N/A















































































































INSPECTION NOTIFICATION REFERENCE

IN No. KHARAFI NATIONAL

SAIPEM

KOC

NAME DESIGNATION SIGNATURE Date Form code: MDT.TB.CDQ.0118

335226530.doc

Page 42 of

54

PLANT LOCATION

UNIT

670700

000

QC CODE

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

JOB

REPORT No DATE:

FINISHING INSPECTION REPORT OF COMPLETE SYSTEM WATERTIGHT FULFILMENT TEST PACK No:

PAGE

Line Number

NOTES:

C= CONFORMING NC= NOT CONFORMING

Drawing number

(TO DRW, SPECIFICATION)

PITP, MANHOLES INSTALLED STEPS, FRAMES, COVER SLAB, GRATING & ERMETIC COVER

OF

PITP, MANHOLES INTERNAL CLEANING

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

C  NC 

INSPECTION NOTIFICATION REFERENCE

IN No. KHARAFI NATIONAL

SAIPEM

KOC

NAME DESIGNATION SIGNATURE Date Form code: MDT.TB.CDQ.0119

JOB 335226530.doc

UNIT

Page 43 of

54

670700 PLANT LOCATION

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

335226530.doc

000

QC CODE

REPORT No DATE:

Page 44 of

54

KHARAFI NATIONAL

SAIPEM

KOC

INSPECTION REPORT FOR TRENCHES EXCAVATION AND BEDDING

NAME DESIGNATION

REFERENCE

SIGNATURE Date

PAGE

Line No.

Drawing No.

CONTROLS TRENCH BEDDING COORDINATES COMPACTION ELEVATIONS



C

NOTES: = CONFORMING SPECIFICATION)



OF

RESULTS PASS

FAIL





C  NC 

C NC NA





C  NC 

C NC NA





C  NC 

C NC NA





C  NC 

C NC NA





C  NC 

C NC NA





C  NC 

C NC NA





C  NC 

C NC NA





C  NC 

C NC NA





C  NC 

C NC NA





C  NC 

C NC NA





C  NC 

C NC NA





NC= NOT CONFORMING NA=NOT APPLICABLE (TO DRW/

INSPECTION NOTIFICATION REFERENCE

IN No.

Compaction test certificate No: Form code: MDT.TB.CDQ.0120

PLANT LOCATION

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

JOB

UNIT

670700

000

QC CODE

REPORT No DATE:

PRE-COMMISSIONING RECORD SHEET PIPING SYSTEM CLEANING /BLOWING /FLUSHING Area: System No.:

Location: Sub system No.:

Test Pack No:

Service: Cleaning Medium: 335226530.doc

Page 45 of

54

Pressure Max.: METHOD USED:

P&ID No.

Line No.

FROM

BLOWING / FLUSHING & CLEANING SATISFACTORY EXECUTED

TO

C / NC/ NA

DATE



C NC NA C NC NA C NC NA C NC NA C NC NA C NC NA C NC NA C NC NA C NC NA Comments: Blowing / Flushing / Cleaning has been satisfactorily performed in accordance with PROCEDURE: Cleaning Observations:

C

NC= NOT CONFORMING NA=NOT APPLICABLE (TO DRW/

NOTES= = CONFORMING SPECIFICATION)

KHARAFI NATIONAL

INSPECTION NOTIFICATION REFERENCE

IN No.

SAIPEM

KOC

NAME DESIGNATION SIGNATURE Date Form code: MDT.TB.CDQ.901

PLANT LOCATION

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

JOB

UNIT

670700

000

QC CODE

REPORT No DATE:

PIPING ITEMS CHECK LIST - (REMOVAL & REINSTATEMENT) Test Pack No: SYSTEM No. PIPING ITEM

335226530.doc

SUB SYSTEM No. LOCATION LINE / EQUIPMENT No.

P & ID No.

REMOVAL DATE

REINSTATEMENT DATE

Page 46 of

54

NOTES=

C= CONFORMING NC= NOT CONFORMING

INSPECTION NOTIFICATION REFERENCE (TO DRW, SPECIFICATION)

KHARAFI NATIONAL

IN No.

SAIPEM

KOC

NAME DESIGNATION SIGNATURE Date Form code : MDT.TB.CDQ.902

PLANT LOCATION

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

JOB

UNIT

670700

000

QC CODE

REPORT No DATE:

TEMPORARY SPADES, PADDLES & BLINDS CHECKLIST – (INSTALLATION & REMOVAL) Test Pack. No: SYSTEM No. BLIND No.

335226530.doc

SUB SYSTEM No. LOCATION LINE / EQUIPMENT No.

P & ID No.

INSTALLATION DATE

REMOVAL DATE

Page 47 of

54

NOTES=

C= CONFORMING NC= NOT CONFORMING

INSPECTION NOTIFICATION REFERENCE (TO DRW, SPECIFICATION)

KHARAFI NATIONAL

IN No.

SAIPEM

KOC

NAME DESIGNATION SIGNATURE Date Form code : MDT.TB.CDQ.903

PLANT LOCATION

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

JOB

UNIT

670700

000

QC CODE

REPORT No DATE:

INSTRUMENTS CHECK LIST - (REMOVAL & REINSTATEMENT) Test Pack. No: SYSTEM No. INSTRUMENT TAG No.

335226530.doc

SUB SYSTEM No. LOCATION LINE / EQUIPMENT No.

P & ID No.

REMOVAL DATE

REINSTATEMENT DATE

Page 48 of

54

NOTES

INSPECTION NOTIFICATION REFERENCE

IN No. KHARAFI NATIONAL

SAIPEM

KOC

NAME DESIGNATION SIGNATURE Date Form code : MDT.TB.CDQ.904

335226530.doc

Page 49 of

54

PLANT LOCATION

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

BS 160 - AT SOUTH EAST KUWAIT

JOB

UNIT

670700

000

QC CODE

REPORT No DATE:

SYSTEM DRYING AND INERTING WE CERTIFY THAT SYSTEM No.: .......................................and SUBSYSTEM No.: ....................................... HAVE BEEN SAMPLED AND TESTED AS FOLLOWS: REQUIRED VALUE: ....................................... MEASURED VALUE: ....................................... DEW POINT: ______________________________________________________________________________ OXYGEN: _________________________________________________________________________________ SAMPLE POINTS

RESULT :

C 

NC 

Instrument Tag No. Calibration due date.

NOTES=

C= CONFORMING NC= NOT CONFORMING KHARAFI NATIONAL

INSPECTION NOTIFICATION REFERENCE (TO DRW / SPECIFICATION)

SAIPEM

IN No. KOC

NAME DESIGNATION SIGNATURE Date Form code : MDT.TB.CDQ.905

335226530.doc

Page 50 of

54

PLANT LOCATION

JOB

UNIT

670700

000

QC CODE

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION

REPORT No

BS 160 - AT SOUTH EAST KUWAIT

DATE:

FINAL INSPECTION AND RELEASE RECORD FOR PIPE SUPPORT DRAWING / DOCUMENT NUMBER: Sl.No

Item Number/ Sub assembly Number

REV.: Type of item

Qty

Matl. Check

Weld Visual

Final Dimen sion

Trail Assy.

SB & Painting

NDT

NOTES=

Galvan izing

Markin g& Taging

Rema rks

INSPECTION NOTIFICATION REFERENCE

IN No. SUB CONTRACTOR

KHARAFI NATIONAL

SAIPEM

KOC

NAME DESIGNATION SIGNATURE Date Form code: MDT.TB.CDQ.0124

335226530.doc

Page 51 of

54

PLANT LOCATION

JOB

UNIT

670700

000

QCP CODE

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS 160 - AT SOUTH EAST KUWAIT

REPORT NO

TEST PACK. No:

PRE-TEST PUNCH LISTING CHECKLIST SL.NO.

ITEM NO.

DESCRIPTION

Form code : MDT.TB.CDQ.0121

ACTION BY

NOTE: A - To be done prior to test C - During Pre-commissioning.

CATEGORY

COMPLETION DATE

Signature & Date

RESULT KN

S.p.A

KOC

B - To be done after test.

RTRP DAILY BONDING INSPECTION REPORT (Adhesive joints) Sl.No.

335226530.doc

ISO No.

Rev. No.

Piping Class

Joint no

Joint Type

Size (Inch)

Thicknes s (Sch/mm)

Bonder No

BPS No

Fit up Insp.

Curing

Final Insp.

Page 52 of 54

Adhesive Type used

Remarks

PLANT LOCATION

UNIT

670700

000

QCP CODE

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS 160 - AT SOUTH EAST KUWAIT

KHARAFI NATIONAL

JOB

REPORT NO

KOC

SAIPEM

NAME DESIGNATION SIGNATURE DATE Form Code: MDT.TB.CDQ.0122

PIPE SUPPORT FABRICATION INSPECTION REPORT Sl.No.

SUPPORT NO / DRAWING NO.

MARK / PART NO.

TYPE OF ITEM

MATERIAL

SUB CONTRACTOR

QTY

FIT UP ACCEPTANCE

DIM. AS PER DRG.

KHARAFI NATIONAL

DIM OBSERVED

WPS NO

DATE OF WELDING

WELDER NO

WELD VISUAL

KOC

SAIPEM

NAME DESIGNATION SIGNATURE 335226530.doc

NDT REPORT (IF APPLICABLE)

Page 53 of 54

REMARKS

PLANT LOCATION

SOUTH EAST KUWAIT PROJECT TITLE BUILDING NEW BOOSTER STATION BS 160 - AT SOUTH EAST KUWAIT

JOB

UNIT

670700

000

QCP CODE REPORT NO

DATE Form Code: MDT.TB.CDQ.0123 Refer ITP-RV-0101 in QCP 000-ZA-E-02635 for Lining and Coating Works.

Latest revision Latest revision - Check coating and holiday testing before back-filling -Check of trenching and Release for backfilling

335226530.doc

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