s pm g000 1520 0013 4 inspection record book

JGC Job Code 0-5361-20-0000Doc. No. S-PM-G000-1520-0013

ARAMCO OVERSEAS COMPANY B.V. & SUMITOMO CHEMICAL CO., LTD.

Project Management Services for

Rabigh Phase II Petrochemical Project

REV DATE REASON FOR ISSUE PREPD CHKD APRD3 01-Nov-10 FOR ITB Y.KURIBAYASHI Y.ENOKI T.KIYAMA4 5-AUG-11 FOR ITB M. RAHMAN Y. OGAWA T. KIYAMA

Approved for Aramco Overseas Company B.V. Approved for Sumitomo Chemical Co., Ltd.

Signature / Date Name Signature / Date Name

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GENERAL REQUIREMENTSFOR

INSPECTION RECORD BOOK

Document Issue Purpose

: For Approval : For Information : For Design : For ITB : For Internal

Project Management Services forRabigh Phase II Petrochemical Project JGC Job Code: 0-5361-20-0000General Requirements for Inspection Record Book Doc. No.: S-PM-G000-1520-0013 < 4 >

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REVISION RECORD

Revision Section Description

4 6.1 3)Measurement system has been changed from SI Unit to MKS Unit to avoid discrepancy with requirement of S-PM-G000-1222-0001 Rev.10 (Basic Engineering Design Data (BEDD))


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1 SCOPE........................................................................................................................................................ 4

2 DEFINITION ................................................................................................................................................ 4

3 APPLICABLE DRAWINGS, SPECIFICATIONS, AND CODES AND STANDARDS .................................... 4

4 ORDER OF PRECEDENCE OF DOCUMENTS ........................................................................................... 4

5 DEVIATIONS AND CLARIFICATIONS........................................................................................................ 4

6 CONTENTS AND DATA/RECORDS TO BE INCLUDED............................................................................. 4

7 UNIT OF COMPILATION............................................................................................................................. 5

8 MANNER OF COMPILATION...................................................................................................................... 5

9 SUBMISSION OF INSPECTION RECORD BOOK....................................................................................... 5

10 LIST OF IRB TABLE CONTENTS............................................................................................................ 6

TABLE-1 IRB CONTENTS FOR STEEL STRUCTURE / PLATFORM AND LADDERS...................................... 7TABLE-2 IRB CONTENTS FOR PRESSURE VESSEL OR HEAT EXCHANGER .............................................. 8

TABLE-3 IRB CONTENTS FOR AIR FIN COOLER............................................................................................ 9

TABLE-4 IRB CONTENTS FOR FIRED HEATER ............................................................................................ 11

TABLE-5 IRB CONTENTS FOR BOILER......................................................................................................... 13

TABLE-6 IRB CONTENTS FOR PUMP............................................................................................................ 15

TABLE-7 IRB CONTENTS FOR COMPRESSOR............................................................................................. 17

TABLE-8 IRB CONTENTS FOR PIPING / FITTINGS ....................................................................................... 20

TABLE-9 IRB CONTENTS FOR VALVE / INSTRUMENTS VALVE.................................................................. 21

TABLE-10 IRB CONTENTS FOR INSTRUMENT ............................................................................................. 22

TABLE-11 IRB CONTENTS FOR PROCESS CONTROL SYSTEMS ............................................................... 23

TABLE-12 IRB CONTENTS FOR PANEL / SUBSTATION............................................................................... 24TABLE-13 IRB CONTENTS FOR UPS & DC SYSTEM .................................................................................... 25

TABLE-14 IRB CONTENTS FOR CABLE / WIRES.......................................................................................... 26

TABLE-15 IRB CONTENTS FOR TRANSFORMER......................................................................................... 27

TABLE-16 IRB CONTENTS FOR SWITCHGEAR ............................................................................................ 28

TABLE-17 IRB CONTENTS FOR TELECOMMUNICATION EQUIPMENT ....................................................... 29

TABLE-18 IRB CONTENTS FOR PACKAGE UNIT.......................................................................................... 30


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1 SCOPE1.1 This document specifies the preparation and compilation requirements of Inspection Record Book

(IRB) for Vendor shop fabricated equipment and materials.

1.2 The purpose of this procedure is to maintain the uniformity and consistency of the IRB preparation and compilation by all parties and personnel involved.

2 DEFINITIONCOMPANY: Aramco Overseas Company B.V. and Sumitomo Chemical Co. Ltd.

3 APPLICABLE DRAWINGS, SPECIFICATIONS, AND CODES AND STANDARDSFollowing document shall be referred to together with this specification:

1) S-PM-G000-1140-0503 : Procedure for Project Record Books

2) S-PM-G000-1520-0001 : Shop Inspection Requirements including Inspection Levels

3) S-PM-G000-1520-0003 : General Specification for Non Destructive Examination

4) S-PM-G000-1520-0005 : Non Conformity Control Procedure

5) S-PM-G000-1520-0009 : General Requirements for Material Certificate and Traceability

6) S-PM-G000-1520-0010 : Welding Requirements for Pressure Vessels

7) S-PM-G000-1131-0007 : Waiving and Clarification procedure

4 ORDER OF PRECEDENCE OF DOCUMENTSThe order of precedence shall be:

- This specification- Project drawings and specifications- Applicable Saudi Aramco Standards- Applicable International Codes and Standards

5 DEVIATIONS AND CLARIFICATIONSAny deviations or clarifications from this specification require COMPANY approval under the Waiving and Clarification Procedure (S-PM-G000-1131-0007).

6 CONTENTS AND DATA/RECORDS TO BE INCLUDED

6.1 General

Data/record/certificates indicated in Inspection and Testing Plan are the minimum requirements to be included in IRB and in general, Table-1 to Table-18 to be referred as applicable:

1) Each page shall be given a page number, such as A1, B1, B2, etc, and page number should be placed at the top right corner of each sheet.

2) COMPANY P.O. No. shall be indicated beside the Purcasers P.O. No. on each sheet / record / certificate, wherever the Purchasers P.O. No. is shown (Hand-writing is acceptable).


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3) All certificates, charts, records, etc. shall be in the English language or translation using the MKS system of measurement.

4) IRB contents shall be approved by COMPANY before formal IRB submission.

6.2 Quality

All certificates, documents and reports contained in the Inspection Record Book shall be readily reproducible.

All certificates must remain unaltered as issued at source. Altered certificates will be cause for rejection of certificates and associated equipment/materials.

7 UNIT OF COMPILATION

7.1 Equipment which has Equipment Item Number

IRB shall be compiled per equipment item number. For equipment that is identical, they may be compiled in one book.

.7.2 Bulk Materials

IRB shall be compiled for each shipment per P.O. Number. In case of blanket orders, IRB shall be compiled per each suffix P.O. Number.

7.3 Package Units

IRB shall be compiled per unit item number. Sections of each equipment item and materials, which comprise the unit, shall be separated by section dividers.

7.4 Structural Steel

IRB shall be compiled for each structure I.D. number. The common records/certificates can be compiled in a separate volume, in which case, a sheet, which refers to the common IRB volume, shall be inserted.

8 MANNER OF COMPILATION

Data/records or certificates shall be collected, filed and accumulated in each stage of fabrication/inspection. The progressively filed data/records/certificates shall be available for review by Purchasers and COMPANYs Inspector at any time of their visit to shop. When each data/records or certificates are reviewed by Purchasers inspector, he will imprint his stamp on the cover sheet or front sheet of each data/records or certificates.

9 SUBMISSION OF INSPECTION RECORD BOOK

For each shipment, Inspection Record Book shall be submitted to Purchaser as one of Vendor Documents. The reports incorporated in the Inspection Record Book shall be in English or both English and Native Language. The Inspection Record Book shall be reviewed and endorsed (signed) by Purchasers inspector on the cover sheet before submitting to Purchaser as formal documents.


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10 LIST OF IRB TABLE CONTENTS

z Table-1 : Steel Structure / Platform and Ladders

z Table-2 : Pressure Vessel or Heat Exchanger

z Table-3 : Air Fin Cooler

z Table-4 : Fired Heater

z Table-5 : Boiler

z Table-6 : Pump

z Table-7 : Compressor

z Table-8 : Piping / Fittings

z Table-9 : Valve / Instruments Valve

z Table-10 : Instrument

z Table-11 : Panel / Substation

z Table-12 : Process Control Systems

z Table-13 : UPS & DC System

z Table-14 : Cable / Wires

z Table-15 : Transformer

z Table-16 : Switchgear

z Table-17: Telecommunication Equipment

z Table-18 : Package Unit


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Table-1 IRB Contents for Steel Structure / Platform and Ladders

Sec-1 Steel Structure / Platform and Ladders

Para Description

- IRB Index

A Inspection release certificate (IRC) signed by COMPANYs inspector.

B Non-Conformity reports (NCR) with disposition reports including repair or rework records, if any.

C M.O.M of pre-inspection meeting, (if applicable.)

D Deviation & confirmation sheet approved by COMPANY, if any.

E Completed Inspection Test Plan (ITP)

F AS Built Drawings

G Welding Procedure Specification (WPS) and Procedure Qualification Records (PQR) including Weld Map

H Welders/Welding Operators Qualification List

I Summary of Material Certificates

J Material Certificates.

K Non-Destructive Examination Reports

L Visual & Dimension Inspection Report

M Report on Repairs (if applicable)

N Painting/Coating Report

O Other Records if required by Requisition and Specification


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Table-2 IRB Contents for Pressure Vessel or Heat Exchanger

Sec-1 Pressure Vessels or Heat Exchanger

Para Description

- IRB Index






F As Built Drawing

G Certificates issued by Authorized Agencies, Certificate of Compliance for Fabricated Item. (including ASME STAMP)

H Welding Procedure Specification (WPS) and Procedure Qualification Records (PQR) including Weld Map

I Welders/Welding Operators Qualification Certificate List

J Summary of Material Certificates

K Material Certificates and / or Material Test reports

L Non-Destructive Examination Reports

M PMI Test Reports/Chemical Check Reports/Ferrite Measurement Reports /Production Impact Test, Hardness Test, etc. (if applicable)

N Tube Bending / Expansion Inspection Reports (if applicable)

O Heat Treatment / PWHT Records including Chart (if applicable)

P Hydrostatic Test/Leak Test Reports Chloride Test of Water for Stainless Steel Items

Q Visual & Dimension Inspection Report

R Report on Repairs (if applicable)

S Name Plate Rubbing/Photograph

T Painting/Coating Report

U Flange Face Inspection Report with Photo

V Rust Prevention Report

W Other Report if required by Requisition and Specification


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Table-3 IRB Contents for Air Fin Cooler

Sec-1 Air Fin Cooler

Para Description

- IRB Index






F As Built Drawing








N Tube bending / Expansion Inspection Report

O Tube bundle Inspection Report

P Heat Treatment / PWHT Records including Chart (if applicable)

Q Hydrostatic Test/Leak Test Reports

R Visual & Dimension Inspection Report

S Assembly Report and Shop Run Test Reports, 1 per Train (if applicable)

T Report on Repairs (if applicable)

U Name Plate Rubbing/Photograph

V Painting/Coating Report

X Flange Face Inspection Report with Photo

Y Rust Prevention Report

Z Other Report if required by Requisition and Specification

Sec-2 Mechanical Component items (Fan / Blade etc)

Para Description

A Summary of Material Certificates

Project Management Services forProject Management Services forRabigh Phase II Petrochemical Project JGC Job Code: 0-5361-20-0000General Requirements for Inspection Record Book Doc. No.: S-PM-G000-1520-0013 < 4 >

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B Material Certificates and / or Material Test reports

C Non-Destructive Examination Reports

D Balance Inspection Report

E Visual & Dimension Inspection Report

F Report on Repairs (if applicable)

G Other Report if required by Requisition and Specification

Sec-3 Driver Unit (Motor )

Para Description

A Motor Material Test Report

B Motor Test Report

C Other Report if required by Requisition and Specification


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Table-4 IRB Contents for Fired Heater

Sec-1 Fired Heater

Para Description

- IRB Index






F As Built Drawing








N Finned Tube Inspection Report

O Hydrostatic Test/Leak Test Reports

P Visual & Dimension Inspection Report

Q FAT Test Report or Performance Test Report







Sec-2 Refractory / Insulation including Refractory Anchor

Para Description


B Refractory Material Inspection Report such as Material Certificates and Pre Qualification Batch Test


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C Refractory Lining Inspection Report such as Production Test, Hammering Test

D Other Report if required by Requisition and Specification

Sec-3 Burner

Para Description

A AS Built Drawings for Duct / Stack

B Summary of Material Certificates including Anchor

C Material Certificates and / or Material Test reports

D PMI Test Reports, Hardness Test, etc. (if applicable)

E Hydrostatic Test Reports

F Visual & Dimension Inspection Record



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Table-5 IRB Contents for Boiler

Sec-1 Common for Boiler Package

Para Description

- IRB Index






F AS Built Drawings







M PMI Test Reports, Hardness Test, etc. (if applicable)

N Heat Treatment/PWHT Records including Chart (if applicable)

O Hydrostatic Test Reports including piping and tubing

P Visual & Dimension Inspection Record

Q Report on Repairs (if applicable)

R Name Plate Rubbing/Photograph

S Painting/Coating Records

T Rust Prevention Report

U Other Report if required by Requisition and Specification

Sec-2 Duct / Stack

Para Description


B Welding Procedure Specification (WPS) and Procedure Qualification Records (PQR) including Weld Map

C Welders/Welding Operators Qualification Certificate List

D Summary of Material Certificates including Anchor

E Material Certificates and / or Material Test reports


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F Non-Destructive Examination Reports

G Smoke / Soap Test Report (if applicable)

H Visual & Dimension Inspection Record

I Report on Repairs (if applicable)

J Painting/Coating Records

K Other Report if required by Requisition and Specification

Sec-3 Burner

Para Description


B Summary of Material Certificates including Anchor

C Material Certificates and / or Material Test reports

D PMI Test Reports, Hardness Test, etc. (if applicable)

E Hydrostatic Test Reports



Sec-4 Refractory / Insulation including Refractory Anchor

Para Description


B Refractory Material Inspection Report such as Material Certificates and Pre Qualification Batch Test

C Refractory Lining Inspection Report such as Production Test, Hammering Test

D Other Report if required by Requisition and Specification

Sec-5 Electrical Panel (if applicable)

Para Description

A Summary of Material Certificates including Anchor

B Material Certificates and / or Material Test reports

C Functional / Operational / Performance Test Report

D FAT Report

E Visual & Dimension Inspection Record

F Other Report if required by Requisition and Specification

Sec-6 Miscellaneous

Para Description

A Certificate List


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Table-6 IRB Contents for Pump

Sec-1 Common for Pump Unit

Para Description

- IRB Index






F AS Built Drawings

G Certificates issued by Authorized Agencies, Certificate of Compliance for Fabricated Item. (including ASME STAMP), if any






M PMI Test Reports / Production Impact Test, Hardness Test, etc. (if applicable)


O Hydrostatic Test Reports

P Performance Test Report

Q Mechanical Running Test Report

R Rotor Balance Test Report

S Visual & Dimension Inspection Record

T Report on Repairs, including Casing Repair (if applicable)

U Name Plate Rubbing/Photograph

V Painting/Coating Records

W Rust Prevention Report

X Other Report if required by Requisition and Specification

Sec-2 Driver Unit (Motor )

Para Description


B Motor Test Report


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Sec-3 Accessory Unit (Lube Oil system etc)

Para Description


B Material Test Certificate

C NDE Test Reports (if applicable)

D Hydrostatic Pressure Test

E Function Test Report


G Motor Test Report / Certificate

H Painting Report (if applicable)

I Other Report if required by Requisition and Specification

Sec-4 Miscellaneous

Para Description

A Certificate List

B Piping Material Test Certificates


D Instruments Material Test Certificates

E Other Report if required by Requisition and Specification


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Table-7 IRB Contents for Compressor

Sec-1 Common for Compressor Unit

Para Description

- IRB Index






F As Built Drawing







M PMI Test Reports / Production Impact Test, Hardness Test, etc. (if applicable)


O Rotor Low Speed / High Speed Balance Test Report

P Over Speed Test / Run Out Test Report

Q Clearance Report

R Magnetism Measurement Report

S FAT Test reports / Certificate / Electrical or Instrument Equipment/Parts Inspection Report (if applicable)

T Mechanical Running Test Report (if applicable)

U Performance Test Report (if applicable)

V Hydrostatic Test Reports

W Visual & Dimension Inspection Report

X Report on Repairs (if applicable)

Y Name Plate Rubbing/Photograph

Z Painting/Coating Report

AA Flange Face Inspection Report with Photo

AB Rust Prevention Report


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AC Other Report if required by Requisition and Specification

Sec-2 Gear Unit

Para Description

A As Built Drawing



D Summary of Material Certificates



G PMI Test Reports / Production Impact Test, Hardness Test, etc. (if applicable)

H Rotor Balance Test Report

I Tooth Contact Check Report

J Mechanical Running Test Report

K Visual & Dimension Inspection Report

L Painting/Coating Report

M Flange Face Inspection Report with Photo

N Other Report if required by Requisition and Specification

Sec-3 Driver Unit ( if applied Driver by Electrical Motor )

Para Description


B Motor Test Report


Sec-3 Driver Unit (if applied Driver by Steam Turbine )

Para Description

A As Built Drawing



D Summary of Material Certificates



G PMI Test Reports / Production Impact Test, Hardness Test, etc. (if applicable)

H Hydrostatic Test Reports

I Rotor Balancing Test Report

J Run out Measurement Report


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K Mechanical Running Test Report

L Performance Test Report (if applicable)

M Visual & Dimension Inspection Report

N Painting/Coating Report

O Flange Face Inspection Report with Photo

P Other Report if required by Requisition and Specification

Sec-4 Accessory Unit (Lube Oil system , Dry Gas Systems etc)

Para Description


B Material Test Certificate

C NDE Test Reports (if applicable)

D Hydrostatic Pressure Test

E Function Test Report


G Motor Test Report / Certificate

H Painting Report (if applicable)


Sec-5 Miscellaneous Item

Para Description

A Certificate List






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Table-8 IRB Contents for Piping / Fittings

Sec-1 Piping / Fittings

Para Description

- IRB Index


B Non-conformity reports (NCR) with disposition reports including repair or rework records, if any.




F Welding Procedure Specification (WPS) and Procedure Qualification Records (PQR) including Weld Map , (if applicable)

G Welders/Welding Operators Qualification List, (if applicable)

H Summary of Material Certificates

I Material Certificates.

J Non-Destructive Examination Reports

K PMI Test Report, ( if applicable)

L Hydrostatic Test/Leak Test Reports Steel Items


N Report on Repairs (if applicable)

O Painting/Coating Report

P Other Records if required by Requisition and Specification


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Table-9 IRB Contents for Valve / Instruments Valve

Sec-1 Valve including instruments Valve

Para Description

- IRB Index








H Summary of Material Certificates,


J Non-Destructive Examination Reports

K Hydrostatic Test/Leak Test Reports

L PMI Test Report / Hardness Test , (if applicable)


N Function Test , (if applicable)

O Motor Test Report / certificate, (if applicable)

P Report on Repairs (if applicable)

Q Painting/Coating Report

R Other Records if required by Requisition and Specification


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Table-10 IRB Contents for Instrument

Sec-1 Instrument

Para Description

- IRB Index








H Summary of Material Certificates


J Non-Destructive Examination Reports (if applicable)

K PMI Test Report, ( if applicable)

L Performance Test Report (if applicable)

M Loop Check Report (if applicable)

N Calibration Test Report (if applicable)

O Hydrostatic Test/Leak Test Reports Steel Items

P Visual & Dimension Inspection Report

Q Report on Repairs (if applicable)

R Painting/Coating Report

S Other Records if required by Requisition and Specification


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Table-11 IRB Contents for Process Control Systems

Sec-1 Process Control Systems

Para Description

- IRB Index






F AS Built Drawings / Schematic Drawings

G Summary of Material Certificates

H Material Certificates

I PMI Test Reports (if applicable)

J Visual & Dimension Inspection Record

K Hardware Test Report

L Software Test Report

M Calibration Report

N FAT Report (including performance, wiring connection check and functional tests)

O I-FAT Report

P Report on Repairs (if applicable)

Q Painting/Coating Records

R Other Report if required by Requisition and Specification


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Table-12 IRB Contents for Panel / Substation

Sec-1 Panel / Substation

Para Description

- IRB Index






F Summary of Material Certificates,

G Material Certificates.

H Terminal Tightness Check Report (if applicable)

I FAT Report

J Visual & Dimension Inspection Report

K Report on Repairs (if applicable)

L Painting/Coating Report

M Other Records if required by Requisition and Specification


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Table-13 IRB Contents for UPS & DC System

Sec-1 UPS & DC System

Para Description

- IRB Index






F FAT Report

G Static Switch full load, No-Break, Change-Over Report

H Shut down of AC and DC Supplies Report

I Battery Cell Discharge Test

J Visual and Dimensional Test Report

K Report on Repairs (if applicable)

L Other Report if required by Requisition and Specification


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Table-14 IRB Contents for Cable / Wires

Sec-1 Cable / Wires

Para Description

- IRB Index






F FAT Report

G Shield Continuity Report

H Report on Repairs (if applicable)



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Table-15 IRB Contents for Transformer

Sec-1 Transformer

Para Description

- IRB Index






F Routine Test Report

G FAT Report

H Report on Repairs (if applicable)



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Table-16 IRB Contents for Switchgear

Sec-1 Switchgear

Para Description

- IRB Index






F FAT Report

L Primary and Secondary Injection Test Report

M Mechanical Operation Check Report

N Pull-in/Drop-out Voltage Test Report

O Heat Soak Test Reports

P Type Test Report

Q Visual and Dimensional Test Report


S Other Report if required by Requisition and Specification


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Table-17 IRB Contents for Telecommunication Equipment

Sec-1 Tele communication Equipment

Para Description

- IRB Index






F FAT Report

G Type Test Report

H Visual and Dimensional Test Report

I Report on Repairs (if applicable)

J Other Report if required by Requisition and Specification


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Table-18 IRB Contents for Package Unit

Sec-1 Package Unit

Para Description

- IRB Index






F As Built Drawing








N Heat Treatment / PWHT Records including Chart (if applicable)

O FAT Report

P Hydrostatic Test/Leak Test Reports

Q Visual & Dimension Inspection Report







Sec-2 Steel Structure (if applicable)

Para Description

A Welding Procedure Specification (WPS) and Procedure Qualification Records (PQR) including Weld Map

B Welders/Welding Operators Qualification List

C Summary of Material Certificates


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D Material Certificates.

E Non-Destructive Examination Reports

F Visual & Dimension Inspection Report

G Report on Repairs (if applicable)

H Painting/Coating Report

I Other Records if required by Requisition and Specification

Sec-3 Local Panel

Para Description

F Summary of Material Certificates,

G Material Certificates.

H Insulation Resistance Check Report

I Wiring Continuity Check Report

J Grounding Connection Check Report

K Functional / Operational / Performance Test Report

L FAT Report


N Report on Repairs (if applicable)

O Painting/Coating Report

P Other Records if required by Requisition and Specification

Sec-4 Miscellaneous

Para Description

A Certificate List





F Motor Material Test Report

G Motor Test Report

H Other Report if required by Requisition and Specification