030-itp for ug grp piping.pdf

Pearl GTL Project

LINDE ENGINEERING

Shell Project No: HP-3000-QAT Contractor Project No : 5887

Project Document Number: T- 4.234.577 Project Rev.: D Page 2 of 16

Purchase Order Number:

2MH127

Tag/Item Number(s): N/A

Unit(s): ASU

PCWBS: Z

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

GAMA Rev.

Project Rev

Date Description Prepared

By Checked

By

Approved By

Status

No. No. ORIGINATOR

LINDE ENGINEERING AG

Document Title:

ITP FOR U/G GRP PIPING

Contractor

Gama Qatar Co. W. L. L.

Document No.

LOC470 GAM ITP QAC GTL 030 H

Org.

Code

Doc.

Type

Disc. Code

Geogr. Area

Seq.

No

Rev. No

Vendor Code

Project Document Number: T-4.234.577 Rev No: D

QSGTL PEARL PROJECT Document No : GAM-ITP-QAC-GTL-030

C2 ASU Construction Works

ITP FOR U/G GRP PIPING Rev / Date : Rev-H / 10.02.2009

S : GAMA QATAR X : CONTRACTOR QC C : COMPANY V : VENDOR

I: INSPECTION R: DOCUMENT REVIEW S: SURVEILLANCE H: HOLD POINT. W: WITNESS

Item Activity Characteristic to be

Verified Control Procedure

Reference Acceptance Criteria

Responsible Party

Verifying Documents S X C V

T-4.234.577 Rev. D Page 4

1.0 METHOD STATEMENTS / PROCEDURES

1.1

Method statement for fabrication and installation of GRP PIPING

Applicable to ASU Pearl GTL

T-4.234.087 Approved RFC

Site Engineer

Approved Documents

I

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1.2 Testing of GRP piping systems

Applicable to ASU Pearl GTL

T-4.234.087

Manufacturers recommendation

Approved Documents

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1.3 Verification of qualification of personnel Previous Experience

ISO 14692 Part 4 Annex D

Training by Vendor / Manufacturer

Manufacturer Certificate

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H

H

2.0 CONTROL OF INSPECTION ,MEASURING AND TEST EQUIPMENT

2.1

Torque Wrench

Torque Value Achieved

T-4.250.955

1 Month

QA/QC Engineer

Calibration Certificate

I R R

2.2 Pressure Test Gauges

Validation Sticker T-4.234.548 1 Month Calibration Certificate I R R

2.3 Visual Inspection of GRP Pipes and components

DELETED

3.0 MATERIAL

3.1

Material Receipt & Visual Inspection

As per Company Specification

Manufactures Data Sheets

Visual Damage QC Inspector GAM-QCR-QAC-GTL-079 I R

R

R

3.2

Storage and Preservation

As per Manufacture recommendation

Manufactures Data Sheets

As per Manufacturer recommendation

Store In charge

As per specification

I S S S

3.3 Sub-Contractor Material Approval DELETED

4.0 INSPECTIONS








Reference Acceptance Criteria Responsible Party Verifying Documents S X C V

T-4.234.577 Rev. D Page 5

4.1 Verification of Trench Excavation Elevation, Orientation & Width

As per the drg. T-4.259.773

Survey Report

QA/QC Engineer

Excavation Survey Report I S R S

4.2

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

Bedding Granules level

As per the drawing

T-4.259.773 QA/QC Civil Report

QA/QC Engineer

Sand Bedding Survey

Report

I S S S

4.2.1

Cleanliness before laying of pipes into the

bed

Internal Cleaning

T.13.377.360 Rev E

& DEP 31.40.19-Gen

No foreign materials inside the pipe & Internal Cleaning before laying into trench

Site Engineer GAM-QCR-QAC-GTL-139 I W W S

4.3

Bell and Spigot a) QC Inspector shall verify correct O

Ring for the service has been selected

As per Manufacturer recommendations

ISO 14692-4:2002 Annex C Figure

C.3


As per Manufacturer recommendations

Site Engineer

GAM-QCR- QAC-GTL-

045

I

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S

W

b) The surfaces to be connected, including the gasket grooves, shall be clean

I S S W

c) The Seal ring and groove to be checked for the correct dimension.

I S S W

d) Non-symmetric seals, such as lip seals, shall be checked for correct installation in the grooves

I S S W

e) Clean non-contaminated lubricant shall be used on both seals and spigot

I S S W









T-4.234.577 Rev. D Page 6

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

I S S W

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

I S S W

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

I 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

I S S W

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

No leak

Manufacturer receipt,

T.13.376.808E& DEP 31.40.10.19


Site Engineer

GAM-QCR-QAC-GTL-

045,047,048

I

H

H

H









T-4.234.577 Rev. D Page 7

l) Sealing Test of Joints Leaks T-4.240.925 No Leak QA/QC Engineer

GAM-QCR-QAC-GTL-045

I S S W

4.3.1

Test Pack Preparation

As per Specification T.4.234.548 & Manufacturers

recommendation

GRP Test Pack

Site Engineer As per

specification I R/A R/A

4.4

Torque of the flange Bolts

Bolt Tightness

T.13.376.808E&

DEP 31.40.10.19,T.13.

377.360

Torque Value Achieved

Site Engineer

GAM-QCR- QAC-GTL- 041

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4.5

Final Inspection Before Test

1. Visual Check.

2. Flange alignment verification

3. Permanent gaskets installation, bolts & nuts (if any)

4. Valve installation

5. Dimensionnel check, elevation, orientation etc.

6. Support installation (If any)

Installation Complete T.13.377.421 Category A

Completed/ Corrected Site Engineer

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

I H H S

4.6 Intermediate Back Fill

As per Manufacturers recommendation & As

per Company Specifications

T-4.234.069, Manufacturers

Recipe, T13.376.808

&DEP 31.40.19

GAM-QCR-QAC-GTL-050

Site Engineer Visual I S R

4.7 Shifted to 4.3.1









T-4.234.577 Rev. D Page 8

4.8

4.9

Hydrostatic Pressure Testing

No Leak

T-4.234.548 & Manufacturers Recipe & DEP

31.40.19/Design Code


Site Engineer/ QA-QC

Engineer

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

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H

H

4.9.1 Flushing / Water disposal Water disposal Manufacturers

recommendation Manufacturers

recommendation Site Engineer

MC Inspection & Test record (R02)

I S S S

4.10 Re instatement Punch Out Restoration

T-4.234.074 & DEP 31.40.19


Site Engineer Reinstatement Check List

(R03) I H H

4.11 Final Back Fill Trench No damage of pipe & No voids at bottom of pipe


Site Engineer QAM-QCR-QAC-GTL-050 I S S

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

No Leak Manufacturers

recommendation & DEP 31.40.19


Site Engineer Manufacturers

recommendation & As per Test Pack

I W W

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

DEP 31.40.10.19,

T.13.377.360 Rev E,

DEP 70.10.70.11- Gen

DEP 31.38.01.11-

Full Tight without leak Site Engineer

Joint Integrity Control Procedure T.13.377.453 ,

T.13.377.454 ,

T.13.376.815 & Flaw List

I H H









T-4.234.577 Rev. D Page 9

b) Gasket Installation

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

DEP 31.40.10.19-Gen,

T.13.377.360 Rev E,

DEP 70.10.70.11- Gen

DEP 31.38.01.11-

Full Tight without leak Site Engineer

Joint Integrity Control Procedure T.13.377.453 ,

T.13.377.454 ,

T.13.376.815 & Flaw List

I H H

4.14 Flawless Start-up Initiative (FSI)

Cleanliness Deleted (REF. ITEM CODE 4.2.1)

4.15

Closing of the pipe ends after Flushing

Internal Cleaning

T-4.231.172

No foreign materials inside the pipe after flushing

QA / QC Engineer

Visual I S S S

5.0

Video Recording Internal Inspection of the

Pipes

Internal Cleaning

T-13.377.561 Project Spec. Part

4, Chapter 6

No foreign materials inside the pipe after flushing

QA / QC Engineer

Recorded Video I R R

GAM-QCR-QAC-GTL-041 Rev. O

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 Bolting Bolt Tightening (Torque Value)

Inspectors Signature Grade Size

ORGANIZATIONS DATE NAME SIGNATURE

Accepte

d B

y THIRD PARTY REP.

GAMA REP.

LINDE REP.

QSGTL OR its PMC REP.

Sealing Test

Test Medium

Visual (Rep. Ref.

QCR FORM-

Cutting /Tapering of Joints

CleanlinessFit-up &

Allignment

O-Ring Installation

Repair Defective

JointsRemarks

Inspection Date:

Test Code No.:

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

QATAR - PEARL GTL PROJECT- C2 ASU

GAMA QATAR REP.

LINDE REP.

DATESIGNATURE

Isometric No.:

Used Measuring and test equipment ref. (if applicable): Line No.:

Dia (Inch)

Pressure ClassUnit No:

QS GTL or its PMC

Joint No.

Note : DSC for lamination and adhesive joint only

Shop /Field

Sl. No Spool/ item No.

NAMEORGANIZATIONS

A

C

C

E

P

T

E

D

GRP SPOOL VISUAL + NIPPLE TEST INSPECTION REPORTReport No.:

Joint Type

INSPECTION ACTIVITIES

Bonder No.

Item Location / Area:

Ref. DWG / Documents: Subsystem:

Item Description:

QQQ AAA TTT AAA RRR

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



RASLAFFAN INDUSTRIAL CITY

BARCOL HARDNESS TESTING REPORT



Item Location / Area: Test Code No.:

Subsystem: ITP No.:

Ref. DWG / Documents:


INSPECTIONS

SPOOL NO JOINT NO BASE LINE VALUE ACTUAL VALUE PERCENTAGE INSPECTOR SIGNATURE

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


Accepte

d B

y THIRD PARTY REP.

GAMA REP.

LINDE REP.

QSGTL OR its PMC REP.

Subcontract Ref.: Report No.Item Description: Inspection Date: Item Location / Area: Test Code No.: Subsystem: ITP No.: Ref. DWG / Documents:

Drawing No. : Pipe Dia. :Spool No. : Nominal Pressure :

Lam. kit No. : Test Pressure :Bond Width : Bond Thickness :

Starting Date on : at hrs. Finishing Date on :Temperature:

Humidity:Bonder No.:

Fit LayerW/R Type Resin Quantity

W/R Type Resin Quantity Delayer

Top Tape

Bond Widt Bond Thickness :W/R Type Resin Quantity

Surface mat.

ORGANIZATIONS DATE

No. of Layers Resin Type

GAMA QATAR REP.

NAME

PEARL GTL PROJECT-RLC-QATAR

DAILY GRP LAMINATION FOLLOW-UP REPORT

Catalyst LPT Quantity


No. of Layers

at hrs.

Manufacturer Recipe Ref:

Acc

epte

d B

y

LINDE REP.

QS GTL

THIRD PARTY REP.SIGNATURE

Resin Type

Vinylester

Catalyst LPT Quan.

Vinylester

Catalyst LPT Quantity

Structure Lay up

Internal layer

Vinylester

No. of Layers Resin Type

QQQ AAA TTT AAA RRR

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


PEARL GTL PROJECT- RLC- QATAR

EXCAVATION / BACKFILLING REPORT



Item Location / Area: Test Code No.:

Subsystem: ITP No.:

Ref. DWG / Documents:


Area :

Location :

Description of Filling :

a) Sand :

b) Gravel (SC1) :

Site Clearance : Excavation : ELEVATION AS PER DRAWING : ACTUAL ELEVATION :

REMARKS:

ACCEPTABLE

YES NO


Accepte

d B

y THIRD PARTY

REP.

GAMA

LINDE

QS GTL

QQQ AAA TTT AAA RRR


RAS LAFFAN INDUSTRIAL CITY


MATERIAL RECEIPT CHECK SHEET

ITEM No: PO No: REQ No:

UNIT No: MANUFACTURER :

ITEMS TO BE CHECKED INSPECTOR

INITIAL REMARKS

1 Visual damage

2 Quantity

3 Test certificates

4

5

6

7

8

Date of initial inspection:

Name and signature of Inspector:

Project No: Project No

Piping

Contractor:Page 1 of 1

Date Signature Date Signature Date Signature Date Signature

GAMA LINDE PMC

Company-LindePiping Contractor-GAMA

Prefabrication Erection

Inspection

meth

od

Cle

anlin

ess C

lass

1110 A05MIsometric No:

(Line No)

Inspection

result

Pre

serv

ation

Meth

od

Piping Contractor Company

Sheet

Cle

anin

g

Meth

od

Spool

SYSTEM CLEANLINESS ACCEPTANCE REPORT

Doc.No: 0100-W-QA-1825

Date: Date: Date:

Name: Name: Name:

Signature: Signature Signature:


030-itp for ug grp piping.pdf

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