(732-ITP-20 (V-6903) 42000-SNG-69-42000P-MS-5733-502-0000-06

PETROLEUM DEVELOPMENT

OMAN L.L.C. (PDO) Contractor Job No. : 20036 Unit No

Vendor Doc. No. : 732/QAP/20 Rev. 06

Project Title: SAIH NIHAYDA CONDENSATE STABILIZATION PLANT (SNCP) Doc..Category : Q3

Sheet No 1 of 8

PDO Contract No. C311194

Document Title: INSPECTION & TEST PLAN (QAP) FOR V 6903

(LP Inlet Condensate Flash Vessel) PDO Doc. No.

Rev. 06 SNG-69-42000P-MS-5733-502-0000

Project No. 20036 Unit Description:

INSPECTION & TEST PLAN (QAP) FOR V 6903 (LP Inlet Condensate Flash Vessel)

MR No. :- 20036-0100-M31-MR-42000 REV. 02 PURCHASE ORDER No. :- 4580041305 TAG No. : V 6903 POS. : 00050 PR ITEM No. :- 00051 VESSEL CATEGORY:- GENERAL SERVICE PRESSURE VESSEL NACE MR-01-75

06 26/05/2014 REVISED TO INCORPORATE PDO COMMENTS S. Naik P.V.Ghanekar 05 14/04/2014 REVISED TO INCORPORATE PDO COMMENTS S. Naik P.V.Ghanekar 04 17/07/2013 ISSUE FOR APPROVAL S. Naik P.V.Ghanekar 03 10/06/2013 ISSUE FOR APPROVAL S. Naik P.V.Ghanekar 02 08/04/2013 REVISED TO INCORPORATE ABB COMMENTS S. Naik P.V.Ghanekar 01 14/01/2013 ISSUE FOR APPROVAL S. Naik P.V.Ghanekar

Rev Date Description Prepared Checked Approved

Contractor Details (Headquarters and Offices): ABB SpA - Process Automation Division via Luciano Lama 33 20099 Sesto S.Giovanni (MI) - Italy

Document property of ABB SpA: its reproduction, circulation and use without prior consent is forbidden

17/06/2014

Company comments on Rev. 05 shall be considered.

732/QAP/20 Page 2 of 8 ....

CLIENT QAP No. : 732/QAP/20 Rev. 06P.O. No. DATE : 19/05/2014EQUPT. No. CODE OF CONSTRUCTION : ASME SEC VIII DIV 1 ED 2010 ADDENDA 2011PROJECT NAME : SAIH NIHAYDA CONDENSATE STABILIZATION PLANT (SNCP) DRG. No. : 732-E-20CONTRACTOR JOB No. INSPECTION : AI (LR Insurance, Inc.)

SPECIFICATIONS FOR PRESSURE VESSELS

:SP 2069 Rev. 0, SP 2051 Rev. 2, DEP 31.10.00.10 Sep. 2011,

SP 2041 Rev. 2, DEP 30.10.60.18 May 2004& NACE MR 0175.

SP 1176 Rev. 2, DEP 30.10.02.17 Feb. 2011

GR A.I. ABB PDO1.0

1.1 Drawing, DesignCalculations Review of DocumentsASME Sec. VIII Div. 1

/ 20036-0100-M31-MR-42000ASME Sec. VIII Div. 1

/ 20036-0100-M31-MR-42000

Approved Drawing, Design

CalculationsH R RA RA

1.2 Quality Assurance Plan,IRR Approval Review of documentsASME Sec. VIII Div. 1/ Approved Drawing

/ 20036-0100-M31-MR-42000

ASME Sec. VIII Div. 1/ Approved Drawing

/ 20036-0100-M31-MR-42000QAP H H RA RA

1.3

Procedures - NDE, Heat Treatment, Hydrotest,

Hardness, PMI, Painting, Packing transport &

preservation procedures

Documented ProcedureASME Sec. VIII Div. 1 / Approved Drawing

/ 20036-0100-M31-MR-42000

ASME Sec. VIII Div. 1/ Approved Drawing

/ 20036-0100-M31-MR-42000

Procedure Documents H R RA RA

1.4 Pre inspection meetingReviewing & understanding of

technical requirements and Approval of MTC.

Purchase order / 20036-0100-M31-MR-42000

Purchase order / 20036-0100-M31-MR-42000

Minutes ofmeeting H ---- H H

2.0

Material after receipt (For Pressure Parts)

Plates, Pipes

H H RA RA

Forging, fittings, Fastners, gaskets etc. H R RA RA

SP 1246 Part 1,2,3,4 Rev. 2 & Part 5 Rev. 3, DEP 31.22.20.31- Gen. Feb. 2011,

SL.NO

G.R.ENGINEERING PRIVATE LTD. -TARAPUR

INSPECTION & TEST PLAN (QAP) FOR V 6903

: ABB S.p.A - Italy.: 4580041305 DTD 02-12-2012.: V 6903.

: 20036

TYPE OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORMS FORMAT OF RECORDScope of Inspection

REMARKS

DOCUMENTS

MATERIAL INSPECTION

STAGE / ACTIVITY

2.1

Review of manufacturer's test certificates, Identification co-realting heat number, Visual

damages & Dimesional inspection, Transfer of identity & physical

verification.

ASME Sec. -II A/BData sheet /

Approved Drawing / TDC / SP 2069, DEP 31.22.20.31

& NACE MR-01-75

ASME Sec. -II A/BData sheet /

Approved Drawing

Material Test Certificates, Identification

reports

1) ALL CS materials shall be killed or semi killed & Carbon content shal be 0.23% max. 2) Mateial for shell & head shall be supplied in normalised condition. Chemical composition : Carbon (c) = 0.20 % (Max) for plate, 0.25 % for forgings, 0.23% for seamless pipe, Sulfur (s) = 0.003 % (Max) Vanadium (V) + Niobium (NB) = 0.03 (Max) Carbon Equivalent (CE) = 0.43% (t 50mm) 4) Forged products above 50 mm thick shall be 100 % ultrasonically examined

Form No. GR 11 Rev. 02 FOR DETAILED NON DESTRUCTIVE EXAMINATION REQUIREMENTS REFER ANNEXURE "A"

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REMARKSSTAGE / ACTIVITY

2.2Non Pressure Parts (including internals,

supports etc.)

Review of Material Test Certificates

ASME Sec.-II A, Approved Drawing,

SP 2069, DEP 31.22.20.31

ASME Sec. -II A, Approved Drawing

Material Test Certificates H --- R R

3.0

3.1 Shop Weld & Test Plan WPS,PQR,WPQ & Consumable, NDT Plan

ASME Sec. IX / Approved Drawing /

DEP 30.10.60.18 & 31.22.20.31 ASME Sec. IX Weld Plan H R RA RA

3.2 PQR Welding parameters ASME Sec. IX /

Approved Drawing / DEP 31.10.60.18

ASME Sec. IX /Approved Drawing WPS/ PQR H R RA RA

3.3 WPQ Qualification requirementsASME Sec. IX /

Approved Drawing / DEP 31.10.60.18

ASME Sec. IX /Approved Drawing WPQ H R RA RA

3.4 Welding Consumable Chemical & mechanical properties ASME Sec. II part C /DEP 31.10.60.18 ASME Sec. II part CBatch Test Certificate R R R R

4.0

Visual & Dimensional inspection including profile check & minimum

thickness mesurementH W W

Dye Penetrant Test (to detect cracks inside & outside

knuckle surface area) H R W

Normalising of dished ends. Heat Treatment Chart H R R

Simulation Test Coupon of normalised dished end.

Inspection Report H W H W Test Coupon for physical test

RT - Full for weld seams in dished ends. RT Report H R R

RT films review.

WELDING INSPECTION WPS & PQR

Inspection of Formed Components

4.1Inspection of Formed

Components (Dished ends)

ASME Sec. VIII Div. 1 / Approved Drawing / SP 2069

Appendix 8,SP 1176, DEP 31.22.20.31 CL 4.10,

SNG-69-42000P-MS-6038-517-0000,

SNG-69-42000P-MS-6038-539-0000,

SNG-69-42000P-MS-6026-525-0000,

SNG-69-42000P-MS-6038-536-0000

ASME Sec. VIII Div. 1 / Approved Drawing

Inspection report


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5.0Visual & dimensional inspection,

weld edge, root - gap, offset, alignment & cleanliness etc. for

long seams of shell, dished end & nozzles

H H 10%W5% W

Visual & dimensional inspection, weld edge, root - gap, offset,

alignment & cleanliness etc. for circular seam, neck to flange,

nozzles on shell/head

H W 10%W5% W

PT of weld edges to detect linear discontinuties.

ASME Sec. VIII Div. 1/Approved Drawing /

SNG-69-42000P-MS-6038-539-0000

ASME Sec. VIII Div. 1 Inspection Report H R10%W

5% W

5.2 Intermediate Inspection of weldsVisual / Interpass temperature / PT

insp. after backchip

ASME Sec. VIII Div. 1 & Sec. IX / Approved Drawing

/ SNG-69-42000P-MS-6038-517-0000 /SNG-69-42000P-

MS-6038-539-0000

ASME Sec. VIII Div. 1 & Sec. IX

Inspection Report H R S S

Visual inspection for reinforcement, undercuts,

surface defects etc.

ASME Sec. VIII Div. 1 & Sec. V / Approved Drawing / SNG-69-42000P-MS-6038-517-0000

ASME Sec. VIII Div. 1 & Sec. V / Approved Drawing

Inspection Report H W W W

Welder Identification stamp on completed weld (Die stamp)

Dye Penetrant Test

ASME Sec. VIII Div. 1 /Approved Drawing

/ SNG-69-42000P-MS-6038-539-0000

ASME Sec. VIII Div. 1 Inspection Report H R S SPT shall also be carried out for the tack

welds(after removal & ground flush) utilized to aid construction.

Radiography Test

ASME Sec. VIII Div. 1 /Data sheet / Approved Drawing/

SNG-69-42000P-MS-6038-536-0000

ASME Sec. VIII Div. 1 RT Report H R RA RA Review of Radiography films

Inspection during fabrication


/ SNG-69-42000P-MS-6038-517-0000


Inspection Report

5.3 Inspection of completed welds

5.1

Weld edge perparation & setup of pressure parts

(Long seam, circular seam, nozzle neck to flange, nozzle on

shell/head)


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Visual / Dimensional Inspection H R R R

PT for fillet welds of lifting lugs and other

pressure bearing weldsH R R R

Final visual & dimensional Inspection

ASME Sec. VIII Div 1 / Approved Drawing / SNG-69-42000P-MS-

6038-517-0000

ASME Sec. VIII Div 1 / Approved Drawing

Inspection Report H W H H

MT of finish welds

ASME Sec. VIII Div. 1 & Sec. V , DEP 31.22.20.31 /

Approved Drawing / SNG-69-42000P-MS-

6038-540-0000

ASME Sec. VIII Div. 1 Inspection Report H R S S

RT of finish welds

ASME Sec. VIII Div. 1/Data sheet /

Approved Drawing /SNG-69-42000P-MS-

6038-536-0000

ASME Sec. VIII Div. 1 Inspection Report H R RA

Mechanized UT of branch weld

ASME Sec. VIII Div. 1 /Data sheet /


6038-525-0000

ASME Sec. VIII Div. 1 Inspection Report H R W W

5.6 Post Weld Heat Treatment of equipment Review of

Heat Treatment Cycle

ASME Sec. VIII Div. 1/Approved Drawing

/ SNG-69-42000P-MS-6026-519-0000


Heat Treatment Chart H R RA R

PWHT of equipment Soaking Temperature :- 61010C.

Inspection of the equipment before PWHT 5.5

5.4

Fitment & Welding

of Internal & External attachments etc.


/ SNG-69-42000P-MS-6038-517-0000,

SNG-69-42000P-MS-6038-539-0000


Inspection Report


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RT of Pressure part bult welds

ASME Sec. VIII Div. 1/Data sheet / Approved Drawing

/SNG-69-42000P-MS-6038-536-0000


MT of Pressure part welds


/SNG-69-42000P-MS-6038-540-0000


Mechanized UT of branch weld

ASME Sec. VIII Div. 1 /Data sheet /


6038-525-0000

ASME Sec. VIII Div. 1 Inspection Report H R W W

Hardness test of welds, HAZ

ASME Sec. VIII Div. 1 / Approved Drawing / SP 2069

Appendex-8, DEP 31.22.20.31 CL 6.2 / SNG-69-42000P-MS-

6061-526-0000


Hardness test report H R W W

248 HV10 maximum for ferritic metals in process services, including H2 and sour service

conditions.

6.0

6.1Final Visual &

Dimensional Inspection(Internal & External)

Dimensions, completeness of the assembly, as built thickness

measurement

ASME Sec. VIII Div. 1 & Sec. V /Approved Drawing

/ DEP 30.22.20.31, SNG-69-42000P-MS-6038-554-0000

ASME Sec. VIII Div. 1 & Sec. V /Approved Drawing

Inspection Report H H H H

6.2 Positive Material Identification PMI examination of alloy materials

ASME Sec. II A / DEP 31.10.00.10 & SP 2069,

SNG-69-42000P-MS-6180-523-0000

ASME Sec. II A PMI Report H R W W

6.3 Pneumatic test of Nozzle RF pads Leak check

ASME Sec. VIII Div. 1 & Sec. V / Approved Drawing / DEP

30.22.20.31 CL 6.9, SNG-69-42000P-MS-6180-520-0000

ASME Sec. VIII Div. 1 & Sec. V / Approved Drawing Test Report H R RW

10%W

NDE after PWHT5.7

FINAL INSPECTION


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6.4 Trial assembly of supplied Internals Trial fitting of internals P.O. /

Internals supplier Drawings P.O. /

Internals supplier Drawings Inspection

Report H W W

6.5 Interior & exteriorcleaning

All completed equipment shall be cleaned internally and externally to

remove scale, weld spatter,dirt, and foreign material.

Approved Drawing / DEP 31.22.20.31 Approved Drawing

Inspection Report H R R

6.6 Hydrostatic Testing (Horizontal) Leak check /

Pressure drop


/ DEP 30.22.20.31 CL 6.9, SP 2069 / SP 2051CL 6.4.4,

SNG-69-42000P-MS-6180-520-0000


Inspection Report H H H H

6.7 Drying of equipment CleanlinessApproved Drawing

/ DEP 30.22.20.31 CL 6.9, SP 2069 CL 6.2

Approved Drawing Inspection Report H ----

6.8 External & Internal Surface preparation Visual Inspection for

worksmanship, profile check H ----

6.9 Painting(Internal & External)Visual inspection for workmanship,

DFT checking, Adhesion H ---- W W

Painting shall be checked for surface chloride contaimination , Holiday / pinhole, Adhesion test

& DFT test.Criteria of Acceptability as per specification SP-

1246 Part-1 Table B1

7.0 Inspection of Mandatory & Commissioning spares Verification of spares20036-0100-M31-MR-42000 /

Approved Drawing / P.O.20036-0100-M31-MR-42000 /

Approved Drawing / P.O. Spares List H ---- H

7.1Verification of Name plateand authorise for ASME

certification markName plate review Approved Drawing Approved Drawing Inspection Report H H H

Approved Drawing / Data Sheet

/SP -1246, (PCS-1/9) / SNG-69-42000P-MS-

6180-521-0000

Approved Drawing / Data Sheet

/SP -1246, (PCS-1/9)

Inspection Report


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7.2 Attachment of Stamped name plate on the equipmentName plate attachment

confirmation Approved Drawing Approved DrawingRub off

/ Photo copy of Name Plate

H W

7.3 Inspection Release Note / Despatch ClearanceVerification of documents & issue

of IRN 20036-0100-M31-MR-42000 /

Approved Drawing / P.O.20036-0100-M31-MR-42000 /

Approved Drawing / P.O. IRN R --- H R

7.4 Signing of Manufacturer's Data Report (MDR) Review of MDRASME Sec. VIII Div. 1 /

Approved DrawingASME Sec. VIII Div. 1

/Approved Drawing MDR H H H R

7.5 Check of packing & packing listVisual Inspection

/ Varification P.O.

/ 20036-0100-M31-MR-42000 P.O.

/ 20036-0100-M31-MR-42000 Packing list H --- W

7.6 Manufacturing Record Book(MRB) Review of MRB P.O.

/ 20036-0100-M31-MR-42000 P.O.

/ 20036-0100-M31-MR-42000 MRB H ---- H R

Legends :

S. NAIK P. V. GHANEKARQA Engineer QA Manager Authorised Inspector

H- Hold ( Do not proceed without approval), W- Witness(Give due notice, work may proceed after schedule date), R- Document Review,RA- Approval of Documents RW-Random Witness, S- Survellance, NDE- Non Destructive Examination, PT - Dye Penetrant Test, RT - Radiographic Examination, UT - Ultrasonic Test, P.O.- Purchase Order, CS - Carbon steel, PMI - Positive Material Identification, TDC - Technical Delivery Condition, HAZ - Heat Affected Zone


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