STACK TRAVELLER INSPECTION &TEST PLAN FOR MAIN STEELDOC NR. : 36009-912-03-013QUALITY CONTROL PLANARAB STEEL FABRICATION CO.REV : 0QUALITY CONTROL DEPT.DATE : 10/05/2008PROJECT : SIDI KRIR / ELATF POWER STATIONPROJECT NO : 36009ITEM : STRUCTURAL STEELCLINET : NEM HENGELOInspected By1-FABR.(ASF QC)2- NEM (NEM supervision)3- NEM client4- OWNERReference CodesAWS D1.1- 2004 (STEEL)ASME II -PART C- 2004AWS D1.6 - 1999 (STAINLESS STEEL)EN10204 - 2004NEM SPECSEN10025ASME B30.20 (LIFTING STRUCTURE)Applicable ProceduresVISUAL TEST PROCEDURE (ASF-VT)RADIOGRAPHIC TEST PROCEDURE (ASF-RT)BENDING /FORMING PROCEDURE(ASF-BF)MAGNETIC TEST PROCEDURE (ASF-MT)LIQUID PENETRANT TEST PROCEDURE (ASF-PT)ELECTRODE HANDLING PROCEDURE(ASF-EHP)ULTRASONIC TEST PROCEDURE (ASF-UT)PAINTTING PROCEDURE(ASF-PP)MATERIAL RECIVING PROCEDURE(ASF- MRP)Identefication Of Inspection PointsHP : Hold PointDR : Dimentional ReportMT : Magnetic TestPT : Penetrant TestWP : Witness PointVR : Visual ReportHT : Hydro TestNDT :NonDestructive TestingRI :Random inspectionMIR:Material Inspection ReportVT : Visual TestingPO : Purchase OrderRD : Review DocumentBVR :Becking/Holding Verification ReportRT : Radiographic TestPWHT : Post Weld Heat TreatmentRemarksREV.NO.PREPARED BYREVIEWED BYAPPROVED BY0Eng :AMR ZIDANEng :Hossam MoustafaEng :SIGN :SIGN :SIGN :DATE : 10/05/2008DATE :DATE :DATE :CLIENT : NEM HENGELOPREPARED BY:Eng/ AMR ZIDANDATE : 10/05/2008STRUCTURE CODE : AWS D1.1REVIEWED BYEng/ Hossam MoustafaREV NO :0ITEM : STRUCTURAL STEELAPPROVED BY:No.DESCRIPTIONProcedureAcceptance criteriaVerifying document1234RemarksINSP. POINTSSIG.DATEINSP. POINTSSIG.DATEINSP. POINTSSIG.DATEINSP. POINTSSIG.DATEPre-inspection meetingPIM agendaMINUTES OF MEETINGHPHPHPHPEngineering & Materials Review And Pre-commencement approval1Review of TravellerNEM SPECSSIGNATURE ON TRAVELLERHPRDHPHP2preparation of WPS & Supporting PQR & weld typicalAWS D1.1AWS D1.1SEC.4NEM APPROVD WPS& PQR & weld typicalHPRDHP/RDHP/RD3Review / Approval OF procedures (Material&NDT&Conservation&fabrication& painting&Repiar procedure)NEM APPROVED PROSEDUREHPRDHPHP4Welders Qualification Incl. Identification on welds (Welders list)AWS D1.1SEC.4VALID CERTIFICATESHPRI5Nondestructive testing personal qualificationSNT-TC-1ALEVEL II OPERATORVALID CERTIFICATESHPRDRDRD6Check completeness order documentationPURCHASING REQUISITIONCOMPLETEPO. ACCEPTANCE FORMHPRDHPHP7Material Certification ReviewASF-MRP4EN10204&MATERIAL SPECS3.1&2.2 CERTIFICATES&MIRHPRDRDRD8Re-stamping of cut certified materialsNEM APPROVEDUNIQUE NUMBER WHICH REFER TO CERTIFICATE/ HEAT NO.INDELIABLE MARKHPRI9Storage &handelling of materials and/or welding consumableASF-EHPASME II -C / SUPLLIERS STDBVRHPRIfabrication sequencesICutting & drilling of hot rolled beams10DT/VTASF-DT/ASF-VTAPPLICABLE DWG.&NEM SPECSSIGNATURE ON TRAVELLERHPWPRIRIIICutting Webs & flanges for B.U.S11DT/VTASF-DT/ASF-VT/ASF-BF5APPLICABLE DWG.&NEM SPECSSIGNATURE ON TRAVELLERHPWPRIRIIVWELDING ALL B.U.S PLATES (PREHEAT ACCORDING TO WPS BEFOR TACK WELDING AND WELDING)13weldingreviewed wps,swelding according to nem reviewed wps,sreviewed wps,sHPWPRIRIINTER PASS TEMERATURE WILL BE CHECKED14DT/VTASF-DT/ASF-VTAPPLICABLE DWG.&NEM SPECSSIGNATURE ON TRAVELLERHPWPRIRI15All butt joint in plate sections of main columns are 100%UT and butt jointes for top and bottom girders shall be 100% RT OR UTASF- RT & ASF-UTAWS D1.1 -PART 6CRT & UT REPORTHPRDRDRDIIIFit up of B.U.S16DT/VTASF-DT/ASF-VTAPPLICABLE DWG.&NEM SPECSDRHPWPRIRIIVWELDING ALL B.U.S (PREHEAT ACCORDING TO WPS BEFOR TACK WELDING AND WELDING)17weldingreviewed wps,swelding according to nem reviewed wps,sreviewed wps,sHPWPRIRIINTER PASS TEMERATURE WILL BE CHECKED18DT/VTASF-DT/ASF-VTAPPLICABLE DWG.&NEM SPECSSIGNATURE ON TRAVELLERHPWPRIRI19All Fillet joints shall be 10% PT or MTASF -PT OR ASF- MTAWS D1.1 -PART 6CPT OR MT REPORTHPRIRDRDVFIT UP FOR COLUMNS BASE PLATE, STIFFNER &ATTACHMENT20DT/VTASF-DT/ASF-VT5APPLICABLE DWG.&NEM SPECSDRHPWPRIRIVICOLUMNS BASE PLATE, STIFFNER &ATTACHMENT WELDING 9 , 1021weldingreviewed wps,swelding according to nem reviewed wps,sreviewed wps,sHPWPRIRIINTER PASS TEMERATURE WILL BE CHECKED22DT/VTASF-DT/ASF-VTAPPLICABLE DWG.&NEM SPECSVRHPWPRIRI23All Fillet joints shall be 10% PT or MTASF -PT OR ASF- MTAWS D1.1 -PART 6CPT OR MT REPORTHPRIRDRD24all full penetration joints 100%UTASF- UTAWS D1.1 -PART 6CUT REPORTHPRDRDRDVIICutting of welded plate girders25DT/VTASF-DT/ASF-VTAPPLICABLE DWG.&NEM SPECSSIGNATURE ON TRAVELLERHPWPRIRIVIIIfit-up of welded plate girders26DT/VTASF-DT/ASF-VTAPPLICABLE DWG.&NEM SPECSSIGNATURE ON TRAVELLERHPWPRIRIIXwelding of welded plate girders 6 , 9 , 1027weldingreviewed wps,swelding according to nem reviewed wps,sreviewed wps,sHPWPRIRIINTER PASS TEMERATURE WILL BE CHECKED28DT/VTASF-DT/ASF-VTAPPLICABLE DWG.&NEM SPECSSIGNATURE ON TRAVELLERHPWPRIRI29All Fillet joints shall be 10% PT or MTASF -PT OR ASF- MTAWS D1.1 -PART 6CPT OR MT REPORTHPRIRDRD30butt joint in top and bottom girders are 100% RT OR UTASF- RT & ASF-UTAWS D1.1 -PART 6CRT & UT REPORTHPRDRDRD31full penetration K- joints shall have UT -examinationASF- UTAWS D1.1 -PART 6CUT REPORTHPRDRDRDXtrial fit up of first goal post 7(TRIAL FIT OF FIRST GOAL POST AND A SECAND TRIAL FIT OF A PORTAL SHALL BE POINTED OUT BY NEM QC)32DT/VTASF-DT/ASF-VTAPPLICABLE DWG.&NEM SPECSDRHPHPHPHPXISurface Treatment33Surface preparation prior to painting or coatingNEM ACCEPTANCE&ASF-PPNEM SPECS(ikz09 205-10&21003-784-01)PAINTING REPORTHPRI34Surface protection for steel(Dry film thickness of painting)NEM SPECS (225999-784-01)&ASF-PPNEM SPECS(ikz09 205-10&21003-784-01)PAINTING REPORTHPRD/RIRDRDXIIBacking & Final inspection and documentation35Final visual and inspection of packing and shipping condition +shipping releaseNEM ACCEPTANCE(IKZ09-713-10)NEM ACCEPTANCEPACKING LISTHPWPHPHP36Document Review & Certificate of conformityNEM ACCEPTANCENEM ACCEPTANCETRAVELLAR& CERTIFICATEHPRDHPHP37NEM QC WRITTEN RELEASE NOTENEM ACCEPTANCENEM ACCEPTANCETRAVELLAR& CERTIFICATEHPHPHPHPREMARKES1-DURING INITIAL 10%EXAMINATION,ANY WELDS ARE REGECTED,ADDITIONAL 20%OF PRODUCTION SHALL BE EXAMINED,IF THIS REVEALS AN ADDITIONAL DEFECT THEN REMAINDER OF(WELDER,S)DAY-PRODUCTION SHALL BE 100%EXAMINED.FIRST SUBSEQUENT(WELDER,S)BATCH SHALL BE 20%EXAMINED.2-REPAIRS SHALL REEXAMINED BY THE SAME TECHNIQUE THAT REVEALED THE INITIAL DEFECT.3-LIFTING AND HANGING LUG WELD SHALL BE 100%MT.4-MATERIAL CERTIFICATES SHALL BE BUNDLED AND ACCOMPANIED BY A SUMMARIZING COVER SHEET,BEARING REFERANCE BETWEEN REQUISITION ITEM NUMBER AND HEAT / CERTIFICATE NUMBER .5-TWO SHOP-WELDED SPLICE ARE ALLOWED IN MAIN COLUMN6-FOR THICKNESS GREATER THAN 8 mm,RT MAY BE REPLACED BY UT AFTER BUYER PRIOR CONSENT7-IF THE TRIAL FIT FOR ONE PORTAL IS FOUND SUCCEFULL NO OTHER TRIAL FITS ARE REQUIRED,IF MAJER REPAIRS ARE REQUIRED THE TRIAL FIT IS REJECTED.AFTER REPAIRS A RE-TRIAL FIT FOR THE FIRST PORTAL IS REQUIRED AND A SECOND TRIAL FIT FOR THE OTHER SHALL BE DONE ,AND SO ON ,THE RE-TRIAL WILL NOT BE REIMBURSED BY NEM8-ASF WILL SUBMITE THERE PROCEDURE FOR UT ,BASED ON DIGITAL READ OUT9-WELD CROSSING AND T CROSSING WELDS 10% RT and All butt joint in main columns shall be 100% UT10-AFTER REMOVALE OF TEMPORARY WELDED ATTACHMENTS , THE AFFECTED AREA 100% MT.

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