84501-9200-9p-006_r2_inspecti... for equipment & material

8/11/2019 84501-9200-9P-006_R2_Inspecti... for Equipment & Material

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TABLE OF CONTENTS

1. INTRODUCTION ................................................................................................................4

2. SCOPE .................................................................................................................................4

3. PURPOSE............................................................................................................................4

4. DEFINITIONS ......................................................................................................................4

5. RESPONSIBILITIES..........................................................................................................6

6. APPLICATION....................................................................................................................7

7. PROCEDURE FOR PROCUREMENT............................................................................8

8. PROCEDURE SITE FABRICATION/INSTALLATION ................................................9

APPENDIX 1 .....................................................................................................................10

APPENDIX 2 .....................................................................................................................12

APPENDIX 3 .....................................................................................................................13

APPENDIX 4 .....................................................................................................................21

APPENDIX 5 .....................................................................................................................22

APPENDIX 6 .....................................................................................................................26

APPENDIX 7 .....................................................................................................................29

APPENDIX 8 .....................................................................................................................30

APPENDIX 9 .....................................................................................................................31

APPENDIX 10 ...................................................................................................................33


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1. INTRODUCTION

This procedure, in addition to Project Procedure 84501-9200-9P-005, (Equipment

Criticality Rating),shall be used to establish project quality and certification andprogram requirements

2. SCOPE

This procedure is restricted to Contractors responsible for engineering anddesign, procurement and construction activities.

3. PURPOSE

The purpose of this procedure is to provide guidance in the determination ofinspection requirements for inclusion in the following documents produced by the

Contractor:

Purchasing Inspection Specifications and Plans

Site Fabrication, Erection/Installation Specifications

Site Inspection and Testing Plan

4. DEFINITION

For the purpose of this procedure, the following definitions apply:

Shall - Denotes a mandatory action

Should - Denotes a strongly recommended action

Contractor - Each organization that carries out all or part of the detailed

engineering and design and procurement of project equipment and materials.

Owner ConocoPhillips Indonesia Inc. Ltd

Project

Quality Plan - A document produced by the Supplier and Contractor

summarizing the specific activities relevant to a Suppliers and Contractors scope

of work. The document shall reference those activities pertinent to the purchaseorder scope and identify procedures appropriate to the management and controlof those activities.

Procurement Inspection Plan - A document produced by the Contractor

outlining the overall inspection requirements pertinent to the procurement of


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equipment and materials. The plan shall ensure appropriate reference to orincorporate Belanak Project inspection requirements.

Purchase Order Supplier Quality Control/Inspection Plan - A document

defining the requirements for the specific inspections to be performed duringmanufacture, and test.

Site Inspection and Test Plan - A document produced by the Contractordefining specific inspection and test activities relevant to site fabrication,

installation and test.

Positive Material Identification (PMI) - The ability to trace material to a Material

Test Report (MTR).

Alloy Verification (AV) - Physical verification of material composition using

material analyzers. It is used to supplement PMI in order to verify a Material Test

Report.

Material Test Report (MTR) - A document issued and authenticated by the

material manufacturer defining the chemical composition and mechanical

properties of a material.

Material Traceability - Ability to trace material to a material trac eability report

during any stage of procurement, manufacture, storage or installation.

Certificate of Conformance (COC) A document issued by a relevant

organization certifying that the products supplied conform in every respect to thepurchase specifications.

Inspection Certificate - A document certifying the satisfactory completion of a

stage inspection, final inspection or test. The document is authenticated by the

purchaser's appointed inspection authority and, where required by the designcode, also s igned by an independent inspection authority.

Concession Request - A formal document raised by a Supplier or Contractorrequesting the purchaser's permission to deviate from a purchase specification.

Positive Material Identification (PMI) Program - A document produced by the

Contractor defining the extent of PMI to be performed on specific materials inorder to enable verification and traceability of material to MTR's during any stage

of supply, storage, manufacture or final installation

Project Specifications - The project engineering standards those are developed

for a Specific Project incorporating requirements for specific inspections and teststo be performed in the procurement, fabrication, installation and commissioning ofequipment, systems and materials.


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Specification Deviation Request - A formal document issued by the Contractor

to request permission to deviate from a specification or Project inspection

requirement.

5. RESPONSIBILITIES

5.1 Contractor

5.1.1 The Contractor is responsible for maintaining a documented system to ensurethat required inspection activities are planned, performed, witnessed and verified

and to provide adequate assurance that all equipment, materials fabrication,installation and tests fully comply with the requirements of this procedure andproject specification and design code requirements.

5.1.2 The system shall provide an auditable trail verifying that inspection and

certification requirements satisfy quality and safety standards indicative ofequipment or system criticality as determined b y the Contractor.

5.1.3 Other responsibilities shall include the following:-

Preparation of the overall Procurement Inspection Plan for approval by Company.

Documenting the inspection practices to be considered in association withprocurement of equipment and materials. The Plan and associated Contractor'sprocedures shall clearly define responsibilities within the Contractors organization

for specifying and approving inspection plans and performing inspectionactivities.

- approval of agreed Supplier or Inspection Plans prior to manufacture,fabrication, installation and test.

- performing necessary inspection and verification activities to ensureequipment, materials and installation conform in every respect with relevantapproved Project specifications and design codes.

- the review of Inspection Requirements to ensure the necessaryrequirements are incorporated in the final inspection plans.

- issue of Deviation Requests for approval by the Project Team where

deviations from Project Inspection requirements are requested.

- ensuring that inspection requirements are cost effective and fully comply

with relevant Project design codes.

5.2 Specific Project Development

5.2.1 The Contractors Engineering Manager shall be responsible for the maintenance,revision, implementation and update of this procedure.


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5.2.2 The Specific Project Team shall be responsible for providing guidance in theinterpretation of inspection and certification requirements to Contractors and

undertaking technical assessments and audits to ensure compliance withrequirements.

5.2.3 The Contractors engineering function shall be responsible for approving

deviations to Project Inspection Plans and communicating such concessions tothe Company for approval

5.2.4 When a deviation is deemed to be of a general nature and affects all Contractors,this shall be notified accordingly to the Company the Project team shall beresponsible for ensuring that inspection requirements, particularly on systems or

equipment interfacing with other packages, are consistent.

5.3 Quality Assurance

5.3.1 The responsibilities defined in this section apply to both Company Project Teamand Contractors.

5.3.2 Quality Assurance shall be responsible for ensuring that systems and programs

employed by the Contractor's engineering, procurement, and constructionorganizations demonstrate that quality objectives and Project requirements, asdefined in the contract document and described in this procedure, are being

achieved.

5.3.3 Contractors Quality Assurance shall perform and document assessment, andaudits relevant to engineering and design, procurement and constructionactivities to provide assurance that the Project Quality Assurance Program andcontract requirements are being implemented by all organizations contracted to

supply products or services to the Project.

5.4 Safety

5.4.1 As a function of the Project Safety Reviews, shall ensure that in review andimplementation of the Contractors systems for control of design, procurement,and construction activities that quality systems and inspection requirements are

consistent, documented, and provide confidence in the design and operationalsafety of the facilities.

6. APPLICATION

6.1 This procedure is for INTERNAL project use by Contractors, and shall not beissued to Suppliers or Sub-Contractors.

6.2 This procedure shall be used by all Contractors following the establishment ofcriticality ratings as a guidance document in the determination of Inspection


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requirements pertaining to, Material Certification, Material Traceability, PositiveMaterial Identification requirements.

6.3 The Inspection requirements detailed in Appendices 3-10 defines the basis forthe inspection activities to be incorporated in supplier and site inspection plans.They are NOT an instruction to Contractors to perform an inspection task.

6.4 The determination of Purchaser, Supplier and Site Inspection involvement is theresponsibility of each Contractor and will demonstrate to the Company that

adequate inspection tasks are being performed by the Contractor to provideassurance of the integrity of equipment and the completed facilities.

6.5 Site inspection activities will be documented and agreed in appropriate Inspection

Plans and indicate the level of Inspection involvement performed by thecompany, Contractor.

6.6 Certification shall be produced to certify satisfactory acceptance of productsduring all stages of manufacture, fabrication, installation and testing.

6.7 Certification requirements shall be defined by the Contractor and shall satisfy the

requirements of the Contract document.

6.8 It shall be the Contractor's responsibility to ensure that requirements of anyIndependent Inspection Authority, Company Project and applicable design codes

are defined in the appropriate Purchase Orders.

6.9 Requirements for Site Inspection and Testing are described in more detail inContractors Procedures.

7. PROCUREMENT PROCEDURE

7.1 Following award of Criticality Rating and determination of Quality Program

requirements for an item of equipment (reference Project Procedures 84501-9200-9P-005), the Contractor shall use this procedure as a basis for advising the

supplier of the Inspection and Certification requirements associated with thepurchase order.

7.2 Appendices 2-10 shall be used to assist in preparing the appropriate

documentation to advise the Contractors Supplier of the required inspection,material certification, Material traceability and positive material identification

requirements.

7.3 Depending on the equipment or material, the final clarification and agreement ofinspection and certification requirements with the supplier; the levels of purchaserand any Independent Inspection Authority involvement will be determined by the

C d i i h C S li d i


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Contractor and prior agreement with Company or at Supplier pre-productionmeeting or by return of an agreed QC Inspection Plan.

7.4 The originator of the material requisition or equivalent document shall determinethe extent of inspection in accordance with the requirements of 84501-9200-9P-

005 Equipment Criticality Rating to be imposed on supplier of bulk materials orstandard "off the shelf" items. Requirements for such suppliers to submit detailed

Quality Assurance Plans will be determined by the Contractor but such suppliersshould have demonstrated an ability to comply with appropriate project qualityrequirements and be included on the Company Approved Manufacturers List.

84501-9400-9W-001

8. SITE FABRICATION AND INSTALLATION PROCEDURES

8.1 The Contractor shall reference Appendices 2-10 to assist in the determination ofSite Inspection, Testing and Certification requirements for Project Site Fabricationand Installation Specifications.

8.2 The Site Fabrication and Installation Specifications shall form the basis againstwhich Site QC and Inspection Plans are developed for each Sub-Contractor. TheSite Inspection, Test and Certification Requirements describe the requirements,

procedures, documentation and certification requirements to be utilized to verifythe acceptance of the prescribed site inspection activities.

8.3 Completed system certification packages are coming together with SuppliersCertification in Fabrication Dossiers to form System Handover Packages.

8.4 The System Handover Packages are subsequently referenced in the appropriate

completion certificates prepared by the Contractor for Project Company

acceptance.

APPENDIX 1


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APPENDIX 1

GENERAL NOTES FOR DETERMINING INSPECTION

AND CERTIFICATION REQUIREMENTS

1. It is the Contractors ultimate responsibility to ensure adequate levels of

inspection and test are performed and that certification and traceability provideadequate verification to certify products and systems have been manufactured,installed and tested to the satisfaction of the Company. The Company shall

perform such inspections and audits as desired to monitor activities of Contractor,Suppliers

2. Appendices 3 through 8 define the basis for the determination of Inspection

Requirements with respect to the categories listed.

3. For equipment, Criticality Rating 1 or Criticality Rating 2, these requirements shallbe mandatory as relevant to the type of equipment being considered and shall beincorporated in appropriate manufacturing or fabrication inspection plans.

4. These requirements do NOT preclude the Contractor from incorporating

additional requirements where considered necessary to provide assurance thatlevels of equipment integrity have been achieved.

5. The difference between levels of inspection for Criticality Rating 1 and CriticalityRating 2 items are determined by the Contractor. These levels shall clearlydemonstrate that the percentage of inspection, non-destructive testing, leak andpressure testing performed reflect the significance of the item being considered.

6. Detailed requirements where listed on the attached inspection plans for CriticalityRating 1 and Criticality Rating 2 equipment, supplement requirements outlined in

the present specification's. All present specification requirements for Inspection,

Testing, and Certification shall be complied with where referenced in Appendices2 through 10.

7. Facility to deviate from Project specifications and minimum inspection andcertification requirements as referenced herein shall be permitted where cost

effectiveness can be demonstrated without loss or risk to equipment or systemintegrity. Contractor's deviations to inspection requirements on Criticality Rating 1

and Criticality Rating 2 equipment will be by exception only and must be fully

supported.

8. For the purpose of satisfying the requirements of this procedure the Contractorsresponsible for ensuring that requirements for deliverables, approvals, inspection,documentation, traceability and certification, comply with those sections of the

contract document pertinent to the engineering procurement and


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contract document pertinent to the engineering, procurement andconstruction activities that may not be specifically stated in this document.

9. It shall be deemed by the Company that the Contractor has considered andincorporated all relevant inspection, test and certification requirements asrequired by this and referenced documents contained herein and in all purchase

orders issued either by Contractor or by organizations acting on his behalf. TheContractor shall also ensure that orders placed by suppliers comply with the

primary requirements.

10. The Contractors system shall ensure that ALL concessions deviating from ProjectSpecifications are documented and controlled.

11. Where necessary or considered appropriate by Company the requirements of thisprocedure and shall also apply to modifications, refurbishment or tie-ins toexisting equipment.

12. Requirements for Material Traceability, Material Test Reports (MTR's), PositiveMaterial Identification (PMI), and Alloy Verification (AV) apply to all engineering

disciplines and should be read in conjunction with the relevant sections ofAppendices 2-7

APPENDIX 2


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APPENDIX 2

MINIMUM INSPECTION REQUIREMENTS

CIVIL, ARCHITECTURAL, STRUCTURAL, HVAC

1. Minimum inspection requirements for this category shall comply with the relevantProject specifications; Project approved standards and design codes as stated inthe Contract document. These may be supplemented by Contractors established

codes, standards, and practices where approved by Company

NOTE: Refer to Appendices 8-10 for Material Traceability, Certification andPositive Material Identification requirements.

APPENDIX 3


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APPENDIX 3


VESSELS/EXCHANGERS/TANKAGE

GENERAL NOTES:

1. The supplementary inspection requirements as defined in this Appendix only

apply to equipment with Criticality Rating 1 and Criticality Rating 2. Indistinguishing the requirements for levels of inspection between the two groups,

refer to General Notes Appendix 1, Paragraphs 1. and 5.

2. The requirements of this Appendix cover the minimum engineering qualitycontrol/inspection requirements for vessels, tankage and heat exchangers

whether individual or part of a package unit and supplement Projectspecifications and Design Code Requirements.

3. Where necessary, the requirements of this Appendix shall apply both to newitems and to modifications or refurbishment to existing equipment.

4. Requirements for site erected tanks or fabricated equipment shall comply with all

relevant inspection requirements and supplemented by activities specific to thetype of equipment

5. As a minimum, inspection requirements for Criticality Rating 3 equipment shall

comply with Project specifications and Project Approved design codes.Deviations are subject to Company approval and should be sought where costeffectiveness and proven established practices can be justified.

6. Above equipment groups classified as Criticality Rating 4 shall satisfy theContractors purchasing specification requirements as defined by the Contractor.

Standard equipment or off the shelf items, which are tested and certified asconforming to the product purchase specification would be acceptable.


INSPECTION ACTIVITY

REF. DESCRIPTION OF INSPECTION ACTIVITY

1. Pre-production visit to Supplier's works to monitor the Contractors adherence the

following:

- Supplier has relevant Standards and Specifications.

- Final drawings approved before manufacture commences.

- Suppliers sub-orders have been placed and copies forwarded to


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Suppliers sub orders have been placed and copies forwarded toPurchaser.

- Quality Control/Stage Inspection Plan agreed.

- Schedule of Welding Procedures available and approved beforeproduction commences.

COMMENTS:

- Record Specification and drawing numbers and status.

- Copies of sub-orders where indicated in Quality Program andPurchase Order to Contractor.

- Review to include suppliers Quality Control Plans where indicated

in Quality Program.

2. Following materials inspected and positively identified against material testcertificates:

- Plates, pressings, tubes, forging, castings and joint materials necessaryfor pressure containment.

- Materials forming internals welded to pressure containment parts,

- Materials forming external appendices, e.g., compensating pads, saddles,

doubling plates where welded directly to pressure containing parts.- Alloy verification of above by portable material analyzer as per Contractors

PMI positive material identification program.

3. Check material control implemented at following stages and that identificationand traceability are maintained:

- Stores inward (include free issue material)

- During storage.- Fabrication through to final acceptance

- Control of weld consumables.

4. Undertake full dimensional checks on:

- Receipt of materials

- Following set up of strakes/shell sections

- On completion of welding of strakes

- Prior to heat treatment, if applicable

COMMENTS:


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- Dimensional check shall ensure manway/nozzle/ flange

orientations, hold-down orientations are in accordance with AFCdrawings, actual dimensions where different are noted on As Builtdrawings.

- On columns, checks to include: (a) Spacing and level of traysupports. (b) Distance between downcomer and tray levels. (c)

Weir heights.

5. Witness welding procedure qualifications and welder qualifications (to include allMechanical Tests/NDT and test plates as required.

N.B. Existing qualifications may be acceptable if they are current and valid inaccordance with code requirements. Review/approve WPS/PQR.

6. Inspect welding set ups of longitudinal and circumferential seams.

7. Check welding being performed in accordance with procedure and inspect:

- Root pass

- Filler runs

- Final after capping run

- Grinding back to sound metal where second side weld required.

COMMENTS:

- Check to include:

- Application of preheat and inter-pass temperature

- Correct type and size of electrode or wire for root and capping runs

Each weld to carry welder's identification (method of identification to be agreed

with Purchaser for alloy, austenitic and low temperature steel plus non-ferrousmaterial).

8. Inspect during fabrication and check shape and workmanship of dished headmanufacture as 5. through 7. above. Note minimum thickness at knuckle radius.

9. Inspect branch connections before welding. Particularly for excessive root gap,

misalignment with hole penetration in plate/tube; surface condition of weld

preparation. Note: Flame cut holes to have all heat affected areas removed bygrinding.

10. Inspection of completed branch attachment welds and flange/neck welds. Checkno flange face distortion or damage to joining faces. Ensure that where

compensating pads are fitted, API tapped vent holes are provided (provision for


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vent holes in slip-on flanges where specified).

11. Inspection of completed external attachment welds. Ensure API tapped ventholes are provided on saddles/ doubling plates which cross main longitudinal orcircumferential shell welds.

N.B. Where vessel to be insulated, all tapped holes to be fitted with extension

tube extending beyond insulation prior to shipment from works.

12. Check and approve NDT operator qualification meets NDT criteria. WhereContractor has own NDT facility, check competence of operator and assessfacilities/ equipment.

13. Check and approve NDT procedures:

- Dye penetrant

- Magnetic particle

- Ultrasonic

- Radiographic

14. Witness following NDT:

Dye Penetrant:

- Root run (including second side if applicable)

- Completed weld

- After heat treatment

- Review all reports

Magnetic Particle:

- Root run (including second side if applicable)

- Completed weld

- After heat treatment

- Review all reports

Ultrasonic Examination:

- Review examination report

Radiography:

- Interpret radiographs

- Review report


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COMMENTS:


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- MT of all seam/nozzle/ branch and internal attachment welds in

ferrous materials.

- Review all required radiographs.

- All seams covered by compensating pads on doubling plates to be

radiographed prior to their attachment.

15. Visual examination; all external and internal attachment welds to the pressure

shell complete/ acceptable; (before stress relieving if applicable).

16. Review Heat Treatment Procedures.

17. Witness soapy water/air test on compensating and doubling plates (before stressrelieving where applicable). 10% witnessing as a minimum requirement andreview test reports.

18. Check suitability and calibration records of thermal measurement equipment and

positioning of temperature probes.

19. Review Heat Treatment Record chart for compliance with ASME Code and P.O.

specifications.

20. Witness hydrotest. During test check for any undue deflections, pressure

drops/variations, water temperature and chloride content.

21. Verify nameplate detail correct and stamped with relevant Inspection Authoritystamp when required. Ensure correct weight indicated and verified.

22. Witness vessel draining; ensuring adequate venting and vessel fully drained priorto shipment.

23. Final external, internal inspection and dimensional check. Before final close

check that all relevant bolts and gaskets are in place and that vessel internals aresupported and protected to avoid damage in transit, e.g., dip pipes. All internal

bolts are tightened and locked. All external openings are protected and sealed.

24. Inspect painting system or other protection specified. Ensure preparation,application, thickness and paint specification in accordance with specified

requirements.

25. Inspect insulation, ensure where vent holes have been provided in vesselexternal attachments that vent pipes are fitted. Check vapour barrier, insulationand cladding grade, thickness. All seams or apertures in cladding sealed withmastic.

26. Review, approve and countersign Manufacturing Data Books and FabricationData Dossiers


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Data Dossiers.

27. Inspect shipment preparation, packing, opening protection, dry-out, purging andmarking.

28. Additional minimum requirements for site erected tankage only.

- Vacuum box test floor - MT/DP floor to shell welds internal/external

- Air on water roof test.

Additional Requirements for Heat Exchangers

29. Tube end weld procedure approved and in accordance with Contractorsspecification (if applicable).

30. Tube roll expansion procedure approved and in accordance with Contractorsspecification.

31. Inspect weld procedure qualification test blocks for tube end welding process andapprove mechanical testing and NDT results. (to include any shift test block

requirements where specified)

32. Review and approve results of ultrasonic examination of tube-sheet before drillingand following explosive cladding where applicable.

33. Inspect tube-sheets following machining and check ligament size, weldpreparations and detail of rolling grooves in accordance with appropriate TEMA

classification. Tube holes to be checked for ovality, diameter, tolerance andsurface finish.

NOTE: Check minimum of 10%

34. Inspect bellows assembly following welding of;

- Root pass

- Final capping run

- Second side where applicable

35. Witness dye penetrant/MT examination of bellows assembly finished weld.

36. Review NDT reports, DP, MT, radiographic, other, bellows assembly.

- Interpret radiographs

37. Check and inspect test rings/glands available for leak and hydrostatic testingwhere applicable; i e ; "U" tube and floating head exchangers (will be supplied as


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where applicable; i.e.; U tube and floating head exchangers (will be supplied as

specified in Purchase Order).

38. Material inspected and positively identified against material certificate.

39. Examine assembly of tubes, baffles, tie rods, spacers. Note provision of sliding

strips on floating head and 'U' tube exchangers. Check tolerances before tube

end welding or expansion is performed; baffle clearance correct, tube/tube holeclearances in baffles correct; tube/tube-sheet is fully de-greased prior to welding.

40. Where measured tube expansion is specified check tube ends for scoring ordamage after expansion.

NOTE: Examine a minimum of 50%

41. Inspect during tube expanding or tube end welding for compliance with

procedure.

NOTE: Examine as necessary to determine compliance.

42. Witness dye penetrant examination of tube end welds.

- Final

NOTE: Examine 100%

43. Witness leak test of tube end welds (before and after post weld tube expansion if

called for) before hydrotest. Assess results of test and if leaks exceed 1% of thetube welds per tube-sheet refer to Contractor for full investigation.

44. Check gasket material and installation is correct prior to assembly for test. Alsoconduct following test if bundle removed. In such cases, new gaskets to be fitted.

45. Witness shell side hydrostatic test (tube sheets exposed).

46. Witness tube side hydrostatic tests including channels and covers.

47. Ensure all exchanger test rings/glands, etc. as specified on purchase order are

available for shipment with exchanger. Test rings should be those incorporatedin final hydrostatic test.

48. Witness tubing bundle insertion to assure no undue strain is imposed.

APPENDIX 4


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PIPING

1. Minimum inspection requirements for piping systems incorporating all pipe,valves, flanges, fittings etc. shall be in accordance with ANSI B31.3

supplemented by any additional requirements defined in Company specifications.

2. All piping system specifications shall be reviewed by Company to ensure

consistency in application of inspection and certification requirements withrespect to piping classes, components, material and duty. This requirement isparticularly important on piping systems interfacing with other Contractors where

consistency of requirements is essential both on safety grounds and also tofacilitate system handover.

3. Procurement specifications for bulks shall, as a minimum, comply with therequirements of the Contract documents.

4. Procurement specifications for valves shall comply with Project approved codes

and standards and should be consistent with respect to Contractors pipingclasses, duty and materials of construction.

5. Requirements for supplementary inspection and certification as referenced in

applicable codes and standards shall be determined by the Contractor.

NOTE: Refer to Appendices 8-10 for Material Traceability and Certificationand Positive Material Identification requirements.

APPENDIX 5


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MACHINERY

1. The supplementary inspection requirements as defined in this Appendix onlyapply to machinery in Criticality Rating 1 and Criticality Rating 2. In distinguishing

the requirement for levels of inspection between the two classifications, refer tothe General Notes, Appendix 1 Notes 1. and 5.

2. The requirements of this Appendix cover the minimum engineering QC/Inspection requirements for machinery whether individual or part of a packageunit.

3. As a minimum, all Criticality Rating 3 machinery shall comply Project

specifications Deviations are subject to Company approval and should be soughtwhere cost effectiveness and proven established practice can be justified.

4. Machinery classified as Criticality Rating 4 shall satisfy the Contractorsprocurement specification requirements. Standard equipment or off the shelf

items as determined by the Contractor, which have been tested and certified asconforming with the product purchasing specification would be acceptable.

NOTE: Refer to Appendices 8-10 for Material Traceability, Certification and

Positive Material Identification requirements.

INSPECTION ACTIVITY

5. Pre-production visit to Supplier's works to check the following:

- Supplier has and understands all relevant standards and specifications.

- Drawings approved before manufacture commences.

- Any special manufacturing process as defined by the Contractors orsuppliers specification or standards are approved.

- Sub orders have been placed and contain relevant specifications,standards, and drawings as appropriate.

- Manufacturing quality control plan approved before manufacture

commences

- Documentation, certification, mechanical data and fabrication data dossier

requirements defined.

COMMENTS:

- Check and record all document/drawing numbers and revision

status.

- Special manufacturing procedures should typically include:

Welding procedures


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- Welding procedures

- NDT procedures

- Heat treatment procedures

- Hard facing/coating procedures

- Forming procedures unique to manufacturing process.

- Function and Performance Test procedures.

6. Inspect material and verify compliance with certification, design and specificationrequirements for:

- Chemical analysis and physical properties

- Material tests

- Heat treatment

- NDT examinations

- Alloy verification (portable material analyzer)

7. Check that material control implemented at following stages and that

identification and traceability are maintained:

- Stores inward

- During storage

- During manufacture through to final acceptance

- Control of welding consumables

8. Check material in accordance with Purchaser's specification; i.e.; ASTM, API;schedule/rating, welded or screwed connections.

9. Witness welding procedure qualification (to include all mechanical tests, NDT andtest plates as required by code).

Review/approve WPS weld procedure specification and WPQR weld

procedure qualification record

N.B. existing weld procedures may be acceptable if they are current and valid asdetermined by applicable code.

10. Verify welder qualifications current and applicable to approved procedure.

11. Dimensional check of:

- Major static/rotating components

- Bearing/sleeve/thrust/seal sizes; clearances

Nozzle elevation/orientations


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- Nozzle elevation/orientations

- Bed-plate/hold down bolt hole location

12. Verify NDT operators' qualifications are current and applicable to NDT scope.Where supplier has own NDT facility, assess suitability and operator

competence.

13. Witness following NDT activities of castings or welded fabricated components:

- Dye penetrant

- Magnetic particle

- Ultrasonic (Review reports only)

- Radiography (Interpret radiographs and review reports, only)

COMMENTS:

- Machined components only; extent of NDT examination to be in

accordance with procurement specification and as agreed onSuppliers manufacturing quality plan.

- NDT requirements for ancillary equipment and pipe work to be inaccordance with this section of the procedure.

14. Check surface finish in accordance with specification requirements on criticalcomponents, i.e.; bearings, journals, thrust collars, and fitted bonnets.

15. Witness balancing of rotating element:

- Couplings

- Impellers

- Gearwheels

- Rotor and rotor assembly

16. Witness over-speed checks on rotating components:

- Impellers

17. Where applicable, check heat treatment procedure approved; verify calibrationand location of temperature probes correct. (stress relieving of fabricated

components)

18. Where applicable, check heat treatment record chart, verify treatment controlledwithin parameters.

19. Hydrostatic test of machine casing, to include where applicable, all ancillary pipework and equipment.


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20. Mechanical running test of machine and auxiliaries when specified.

21. Performance test, when specified on equipment data sheet.

22. Strip test - bearing and seal examination.

23. String test (complete unit test) when specified on equipment data sheet.

24. Witness and verify noise level measurement complies with contractor's

specification.

25. Witness and verify vibration levels within limits as defined in Contractorsspecification.

26. Final inspection and cleanliness check prior to shipment. Ensure all machinesurfaces protected, openings sealed, paint coatings applied where specified; allnameplates fitted and correctly labelled (including ancillary components). Ensureany temporary transportation restraints, supports secure and clearly identified.

27. Review and approve Mechanical Data and Fabrication dossiers, Operating and

Maintenance Manuals, Spares Schedules.

28. NPSH test to API and ANSI standard, as required.

29. Operational tests of lube oil console, including cleanliness test. (API) standard

minimum supplemented by Contractor's standard.)

30. Final dimensional check for field corrections in relation to anchor bolt holes,grade, etc are per approved outline drawing.

31. Electrical function test to NEMA and order specifications.

32. Witness gas leak test when specified. (API standard)

APPENDIX 6



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ELECTRICAL

1. The supplementary inspection requirements as defined in this Appendix onlyapply to electrical equipment such as motors, transformers, variable speed drives

and switch gear in Criticality Rating 1 and Criticality Rating 2. In distinguishing therequirements for levels of inspection between the two classifications, refer to the

General Notes, Appendix 1 notes 1. and 5.

2. The requirements of this section cover the minimum engineering qualitycontrol/inspection requirements for classes of electrical equipment as defined in

1.0 above and whether individual or part of a package unit.

3. As a minimum, inspection requirements for all Criticality Rating 3 electricalequipment shall comply with appropriate IEEE Institute of Electrical andElectronic Engineers inc. regulations, Contractor's specifications and Deviationsare subject to Company approval. Company approval should also be sought

where cost effectiveness and proven established practice can be justified.

4. Electrical equipment classified as Criticality Rating 4 shall satisfy the Contractorsprocurement specification requirements. Standard proprietary equipment or off

the shelf items as determined by the Contractor, and which has been tested and

certified as conforming with the product purchasing specification would beacceptable.

5. For major electrical machines, refer also to Appendix 5, Machinery inspectionRequirements.

NOTE: Refer to Appendices 8 and 9 for Material Traceability andCertification Requirements.

INSPECTION ACTIVITY

6. Pre-production visit to Supplier's works to check the following:

- Supplier has and understands all relevant standards and specifications.

- Drawings approved before manufacture commences when required in thepurchase order.

- Any special manufacturing process as defined or supplier's specification orstandards are approved.

- Sub orders have been placed and contain relevant specifications,standards, and drawings as appropriate.

- Manufacturing quality control plan approved before manufacturecommences (including those of sub suppliers).


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- Documentation, certification, data dossier and QC dossier requirementsdefined.

COMMENTS:

- Check and record all document/drawing numbers and revision

status.

7. Audit/examine material and verify compliance with material certification, design,specification and IEEE regulations as defined in the Contractors specification.Review manufacturers test certificate.

8. Where specified, check that material control is implemented and thatidentification and traceability are maintained throughout manufacture and final

acceptance.

9. Pre-assembly components inspection, ensure all components which make up acomplete item/system are inspected and checked to ensure:

- Traceability maintained

- Rating in accordance with specifications

- Components are free from injurious defects.

10. Where specified in Contractors specification or IEEE regulations ensure allpressure containment components are hydrostatically tested.

- Review certificate of test only.

COMMENTS:

Where ancillary items or pipe work are used to provide cooling, etc., theseshall be subjected to hydrostatic test

- Associated motor oil coolers, etc.

- Electrical items such as oil reservoirs on transformers.

11. Initial assembly and function test (including all calibration checks, tests as definedin the Contractors specifications, engineering standards and IEEE regulations

referred to therein).

12. Final acceptance test.

13. Review and approve Mechanical Data and Fabrication dossiers, Operating andMaintenance Manuals and Spares Schedules.


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APPENDIX 7



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INSTRUMENTATION

1. The minimum inspection requirements for standard instruments shall comply withrelevant Company specifications and Contractors procedures and standards.

2. Instrument "specials" i.e. items which are not normal supply, or are unique to theprocess design requirements shall be identified on a specific list copied to the

Company. Such instrumentation particularly where manufacturing processedinvolve specialized techniques, i.e. specialized castings, welding, NDT or heattreatment, adequate levels of inspection and test in the purchase order

specifications.


APPENDIX 8

MATERIAL TRACEABILITY REQUIREMENTS


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Q

To be read in conjunction with Appendices 9 and 10. Refer to the Contract document fordefinition of Material Traceability.

1. Material traceability is the ability to trace to Material Test Reports (MTR's) at any

stage from purchase to installation.

2. The scope of Material Traceability required is outlined in Appendices 9 & 10.

3. Marking of materials shall as a minimum comply with relevant US codes andstandards and be transferred to off cuts where appropriate to maintain requiredlevels of traceability.

4. Individual Contractors shall be responsible for implementing their own systems to

achieve required levels of material traceability. The system shall demonstrate thatmaterial control, segregation, marking and traceability is planned anddocumented to provide the necessary level of assurance to the Company thatinstalled materials of construction are certified and fully comply with the

applicable code and specification requirements.

5. Where Material Test Reports are required, heat numbers will be traceable to theindividual material component.

6. Where Material Test Reports are not required, marking shall be in accordancewith relevant Codes and Standards.

7. The Contractors system for Material Traceability during site fabrication shallfacilitate compliance with requirements of the Contract document with respect tosystem acceptance certification.

8. Material color coding requirements shall comply with Project specificationsrequirements.

APPENDIX 9

MATERIAL TEST REPORT REQUIREMENTS


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To be read in conjunction with Appendices 8 and 10. Refer to the Contract document fordefinition of Material Test Reports (MTR's).

1. General Notes:

Section A: For ANSI/ASME P1 Material Grades

I. MTR's will only be required if specifically requested in Contractors

specifications. Approved design codes or purchase orders. Typically thefollowing examples would be advised:

- carbon steel vessels where metallurgy is critical i.e. lowtemperature equipment.

- boiler code piping; SA 106

- materials are required to satisfy NACE standards in H2S or othersimilar duties where composition and metallurgy of finishedcondition is critical.

- materials restricted to maximum carbon content below standard.

II. Contractor will be clearly defined in the appropriate design and purchase

documents.

III. For vessels fabricated in accordance with ASME rules, the AuthorizedInspection may require MTR's for other specific cases in which case theywill be provided.

IV. Other standard carbon steel products will require a certificate ofconformance issued by the organization qualified to certify that products

comply with specified requirements.

Section B: For ANSI/ASME materials higher than P1

V. MTR's shall be required for all materials higher than P1, i.e. alloy steels,stainless steel grades, etc.

VI. Exceptions to the above may be referred to the Project Specialist where

use of the material is not relevant to process design conditions or for

safety reasons but constitutes Contractors or manufacturers normalstandard i.e. instrumentation components. Such concessions shall bedocumented in accordance with the Company specifications.

Section C: Form of Certificates

VII. Standard Material Test Report/Material Certificates satisfying the


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applicable Code requirements are acceptable. The Europeanrequirements for type A, B, or C material certificates shall not bemandatory.

VIII. The form of the certificate shall contain a record of chemical composition,

supplied condition and physical properties, including the results of anyspecific tests required by the purchase order or specification; i.e. hardnessvalues, Charpy impact test results etc.

IX. Such MTR's shall be furnished and authenticated by the material

manufacturers and traceable to individual components. Copies of originalMTR's are acceptable.

Section D: Civil

X. As a minimum, the Contractor shall provide MTR's for structuralassemblies employing critical materials of construction. The scope shall be

determined by the Contractor but should typically include for:

- primary structural steel

- lifting devices, runway beams, gantries, cranes, etc.

- equipment anchor bolts where critical to security of the item.

Section E: Electrical

XI. As a minimum, the Contractors system shall ensure certification isavailable for electrical equipment consistent with an item's electrical ratingand classification in compliance with hazardous zone ratings. Certification

is to be verified during installation and site acceptance.

Section F: Bolting

XII. `The Contractors system for the inspection and verification that boltingmaterials comply with specified requirements shall ensure incorrect orrogue bolting materials are rejected at the suppliers or prior to receipt in

module yard or site stores.

APPENDIX 10

POSITIVE MATERIAL IDENTIFICATION REQUIREMENTS


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To be read in conjunction with Appendices 8 and 9 for definition of Positive MaterialIdentification (PMI) and Alloy Verification (AV).

1. Attention is drawn to the need for each Contractor to read and familiarize itself

with the Contract Document.

2. Alloy materials shall as a minimum comply with the Project requirements for PMI,

which includes the requirements of MTR's, marking, traceability and AV.

3. Specific traceability to as built drawings will not be required by the Company aspart of the final handover documentation; refer to Project Procedure 84501-9200-

9L-002

4. The Contractors PMI program shall demonstrate that the system for tracingmaterial to MTR's provides for simple traceability during purchasing, storescontrol, fabrication and installation. The following sections provide guidance tothe Contractor for the determination of PMI requirements, but does not relieve the

contractor from its obligation to include any additional materials in the PMIprogramme where it considers this to be justified or necessary.

5. Components subject to PMI:

5.1 Vessels and Piping Systems

All pressure retaining parts. PMI for internals as determined by the Contractorand defined in procurement documentation.

5.2 Machinery:

Pressure containing casing. PMI of ancillary components and internals as

determined by the Contractor and defined in procurement documentation.

5.3 Instruments:

As determined by the Contractor.

5.4 Bolting:

As determined by the Contractor, but as a minimum:

- to include sampling check of all bulk alloy steel stud bolts included in theASTM A-193 classification.

- alloy bolts critical to and used in equipment subject to PMI.

5.5 Welding:

As determined by the Contractor but as a minimum PMI of sample deposit of

finished weld


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finished weld.

84501-9200-9p-006_r2_inspecti... for equipment & material

Documents