09 - Static Equipment Procurement

ITB FOR PROJECT NAME PART II PROJECT SPECIFICATIONS

SECTION 4 ‐ PROJECT EXECUTION INSTRUCTIONS 4.7 QUALITY ASSURANCE & QUALITY CONTROL

4.7.2 INSPECTION & TESTING

Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 1 of 84

IX STATIC EQUIPMENT – Procurement Stage

INSPECTION AND TEST PLAN (ITP) FOR LOW ALLOY AND CLAD PRESSURE VESSEL

(Tower, Vessel and Heat Exchanger)

Print Name

Signature Name of Company Doc No:

EPM‐ITP‐QP‐001 Prepared By: (1)

Approved By: (2) Revision 0

SABIC App: Stage Procurement Discipline: Static Equipment PROJECT: Date:

Location: (3) Item Name (3): Tag No (3): Page:

Sr. No

Inspection Activity Characteristic Verified (4) Reference Document (5)

Acceptance Criteria (6)

Verifying Document (7)

Inspection Responsibility

Vendor

EPC

SABIC

Remarks

1 Raw Material Inspection

a) Mechanical Test (including. bond shear test for cladding and impact test if specified)

Tensile strength, impact, bend and bonding shear strength properties.

SESQ01-F35, SES Q01-S01 SES Q01-T02, ASME II

SES Q01- S01 clause 6 Conform to ASME II, SA-263, SA-264 and SA-265, and minimum bond shear test of 140 MPa.

Material Test Certificate I R R

b) Non

Destructive Examination (if specified)




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 2 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

i. Ultrasonic examination for plate and forging

Subsurface discontinuities.

SES Q01 S01 SESQ01-F35, Project Specification for NDT

SES Q01 S01 Clause 8.2.3 SES Q01 F35 Clause 6 Material Specification

NDT Report I R R

ii. Liquid Penetrant Examination for forging

Surface discontinuities

SES Q01 T01, Project Specification for NDT

SES Q01 T01 clause 6.3.4 NDT Report I R R

iii. Ultrasonic

examination for cladding

Lack of Bonding

SES Q01 S01 SESQ01-F35, SES Q01 T01 Project Specification for NDT

SES Q01 S01 Clause 8.2.3 SES Q01 F35 Clause 6 SES Q01 T01 clause 6.3.2

NDT Report I R R

2

Material Certification (pressure parts and stress members)

Material used to be identified and certified

SESQ01-F35, SESQ01-F08, SES Q01-S01’ SES Q02-F01

Material per the required specification

Material Certificate R R R

3

Material Identification for Alloy

Verification of Alloy Material SES Q01-T07

Percentages of alloying elements within tolerances

PMI Report I W2 R

4

Ultrasonic Examination for Claddings (after forming)

Lack of bonding

SES Q01 S01 SESQ01-F35, SES Q01 T01 Project Specification for NDT


NDT Report I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 3 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

5

Welding Procedure Specification Approval

Essential, nonessential, and supplementary essential variables in accordance to PQR

SES W11-F01 ASME IX

WPS approved As per SES W11-F01/ASME Section IX requirements

WPS /PQR Register I W1* R

6 Welder/ Welding Operator approval

Welder ability to deposit sound weld metal and welding operators ability to operate the welding equipment

ASME IX SES W11-F01

Welders and Operator Approved As per SES W11-F01/ ASME Section IX requirements

Welder and Welding Operator Qualification Test

I W1* R

NOTE: * Previous records may be reviewed.

7

Weld Joint Fit-up Edge Preparation (including clad stripping)

Root gap, land zone including angle, weld face cleanliness, material specification, alignment and fit-up dimensions. Copper sulfate test after clad stripping.

SES Q01- F01 SES Q01- F08 SES Q01-F35 Relevant WPS Vendor drawings

As per WPS, Drawings, Clad materials completely removed

Weld Map Report/ Reference Welding Inspection Checklist

I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 4 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

8

Magnetic Particle Examination or Liquid Penetrant Examination a) Edge to be welded (if specified) b) Attachment welds c) Deposited Welds for cladding d) knuckle area of formed heads.


SES Q01 S01 SES Q01 T01 Project Specification for NDT

SES Q01 S01 Clause 8.2.4, 8.2.5 & 8.2.6 SES Q01 T01 clause 6.3.3 & 6.3.4

NDT Report I W2 R

9 Inspection During Welding

Interpass temperature, interpass cleaning and other essential non-essential parameters and weave width. Visual and LPT after back gouging prior to second side welding.

SES Q01- F01 SES Q01-T01 WPS

As per WPS SES Q01-T01 clause 6.3.4

Welding Inspection Checklist NDT Report

I R R

10 Visual Examination of Completed Welds

Surface defects, weld size and profile/appearance. Identification of weld and welders.

SES Q01-T01 SES Q01-S01 ASME Sec VIII Div. 1 & 2

SES Q01-T01 ASME Sec VIII div 1 clause UW 33 & 35 or Div 2 clause 7.5.2

Welding Inspection Checklist

I R R

11 PMI on Weld Overlay

Verification of Alloy Material

SES Q01-T07

Percentages of basic alloying elements within tolerances

PMI Report I W2 R

12 Reinforcing Pad Test Leaks around the pad SES Q01-S01 SES Q02-T02 No leaks around the pad Leak test

Report I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 5 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

13 Post Weld Heating, if required As per WPS SES Q01-F01

WPS Relevant WPS As per WPS I R R

14 Ultrasonic Examination of Welds before PWHT and / or Hydro test

Surface and subsurface discontinuities

SES Q01-S01 ASME Sec VIII Div. 1 & 2

ASME Sec VIII Div. 1 Appendix 12, ASME Sec VIII Div. 2 Article 9-3

NDT Report I R R

15

Radiographic Examination (checking of radiographic film)

Surface and internal discontinuities.

SES Q01-S01 ASME Sec VIII Div. 1 & 2

ASME div . 1 Clause UW 51/52 or div 2 Clause 7.5.3 as applicable

NDT report , I R R

16

Post Weld Heat Treatment

Heating temperature, soaking time and cooling rate

SES Q01-S01, ASME VIII Div. 1 and 2

Heating /cooling rate and soaking time as per the requirements

PWHT Chart I R R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 6 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

17

Ultrasonic Examination of Cladding after PWHT

Lack of bonding

SES Q01 S01 SES Q01-F35, SES Q01 T01 Project Specification for NDT


NDT Report I W2 R

18 Magnetic Particle Examination after PWHT

a) Pressure retaining welds

Surface and near surface discontinuities

SES Q01-T01 SES Q01-S01, ASME VIII Div.1 and 2 Project Specification for NDT ,

SES Q01 S01 Clause 8.2.4, 8.2.5 SES Q01 T01 clause 6.3.3

NDT Report

I

W2

R

b) Vessel to support welds

c) Non-pressure attachment welds

d) Removal of temporary attachment areas, thermocouple and arc strike ground areas




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 7 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

19

Liquid Penetrant Examination after PWHT (Deposit Welded for Cladding, pressure retaining and attachment welds, removal of temporary attachment areas and arc strike ground areas)


SES Q01-T01 SES Q01-S01, ASME VIII Div.1 and 2 Project Specification for NDT ,

SES Q01 S01 Clause 8.2.6, SES Q01 T01 clause 6.3.4

NDT Report I W2 R

20 Tube Bending Inspection

Visible laminations, Scale, Scratches, flattening and crack

SES Q02-F01

Crack not permissible other defects within specification

Inspection Report I W2 R

21 PWHT of Tubes After Bending- if specified

Heating /cooling Rate and soaking time. Temp Range & Duration

SES Q02-F01, Project Specification for PWHT

Correctly performed and temperature readings conform to the requirements.

PWHT Chart and report I W2 R

22 Tube to Tube sheet Joint Inspection

Cleanliness, tube expansion, welding defects and tightness check

SES Q02-F01, SES Q02-E01, SES Q02-T01,

Clean, wall thinning within the range, free of welding defect and passed tube leak or tightness check


23 Hardness Test Hardness of the weld and heat affected zone

SES Q01-F01, SES Q02-T01, SES Q01-S01

Below the maximum allowable limit as specified in reference project specification

Hardness Test Report I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 8 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

24

Final Visual and Dimensional Inspection (incl. stacking of multiple shell arrangement and bundle inspection)

Visual defects, general surface condition / appearance, alignment and main dimensions

SES Q01-F28 Vendor Drawings

As per drawing and relevant project specification

Inspection Report I H H

25 Hydrostatic Test (and Chloride Check, if required)

Water quality, Equipment Calibration, Test Pressure and Duration

SES Q01-T01 SES Q01-T02 SES Q01-S01 ASMEVIII Div. 1 & 2.

Chloride content within the specified limit as per the specification. No Leaks. Test Pressure Maintained

Pressure Test Report I H W1

26

Ultrasonic and Magnetic Particle Examination after Hydro Test (if specified)

Internal and Surface discontinuities

SES Q01-T01 SES Q01-S01, ASME VIII Div.1 and 2 Project Specification for NDT

SES Q01 S01 Clause 8.2.3 SES Q01 F35 Clause 6 SES Q01 T01 clause 6.3.2 SES Q01 S01 Clause 8.2.4, SES Q01 T01 clause 6.3.3

NDT Report I W1 R

27 Internal Installation Check (if any)

Installation of all internal components/accessories and tightening of fasteners.

Vendor Drawings, SES Q01-T72, SES Q01-F72

Conform to vendor drawings and specified bolt torque

Inspection Report I W1 W2

28 Rust Prevention Check and Painting Inspection

Surface preparation, DFT, surface defect, rust prevention and equipment preservation

SES Z01-G07, SES T01-S01 Project Procedure for Equipment / Material Preservation

Surface profile/condition. DFT within the lower and upper limits and free from surface irregularities. Equipment properly dry and securely preserved

Painting and preservation reports

I W1 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 9 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

29 Shipping Preparation Inspection

Certified records, release note, proper packaging, nameplate data, orientation/spare parts markings, preservation, loading and shipping instructions.

SES Q01-S01, SES Q02-F01, SES Z01-G07

Fulfilled all requirements

Equipment Dossier, Packing Lists, Packing Inspection Reports. Inspection Release Note.

I W1 W2

Legend

(1) ‘Prepared by’ should be the name, signature and Company’s name for the Vendor’s/Sub Contractor’s representative. (2) ‘Approved by’ should be the name, signature and Company’s name for the Contractor’s representative. (3) ‘Location’, ‘Item Name’ and ‘Tag Number’ shall be used if applicable. (4) ‘Characteristics Verified’ are the parameters checked during the inspection activity. (5) ‘Reference Document’ is the Project Specification / Code / Standard / Drawing, Procedure etc on the basis of which inspection shall be conducted. (6) ‘Acceptance Criteria’ is the tolerance, reading, value or an outcome derived from reference documents. (7) “Verifying Document’ is the record generated during inspection & Testing using approved forms / checklists. (8) “Inspection Responsibility’ is the role of Vendor / Sub Contractor , Contractor and SABIC for each inspection step. Inspection responsibility shall be ‘I’ for Inspection, ‘R’ for review, ‘S’ for Surveillance,

“W1’ for 100% Witness, ‘W2’ for random witness and ‘H’ for hold. For the explanation of these inspection responsibilities refer to the ‘definitions’ part of PEI section 4.7.1 (9) Rust prevention coating should protect the material from corrosion and shall be easily removed in the field. Austenitic stainless steel materials shall not be coated but shall be protected from ferritic

contamination, chloride attack and galvanic corrosion.




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 10 of 84

INSPECTION AND TEST PLAN (ITP) FOR HIGH ALLOY PRESSURE VESSEL

(Tower, Vessel and Heat Exchanger)

Print Name






Sr. No





Vendor

Contr

SABIC

Remarks

1 Raw Material Inspection

1. Mechanical

Test (impact test if specified)

Tensile, compression, impact, weldability, fatigue and bend strength properties.

Purchase Specification

Material as per project specification and by approved vendors

Material Test Certificate R R R

2. Non Destructive

Examination (if specified)

a) Ultrasonic Examination of Plate and Forging

Lamination and other Internal discontinuities.

SES Q01 S01 Project Specification for NDT

SES Q01 S01 Clause 8.2.3

NDT Report I R R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 11 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

b) Liquid Penetrant Examination of Forging


SES Q01 T01, Project Specification for NDT

SES Q01 T01 clause 6.3.4 NDT Report I R R

2 Material Certification (pressure parts and stress members)

Material used to be identified and certified

SES Q01-S01, SES Q02-F01

Material per the required specification Material Certificate R R R

3 Material Identification for Alloy

Verification of basic alloy element

SES Q01-T07

SES Q01-T07 Clause 8

PMI Report, I W2 R

4


Essential, nonessential, andsupplementary essential variables in accordance to PQR

SES W11-F01 ASME IX

WPS approved As per SES W11-F01/ASME Section IX requirements


5 Welder/ Welding Operator approval


ASME IX SES W11-F01

Welders and Operator Approved As per SES W11-F01/ ASME Section IX requirements


I W1* R


6 Weld Joint Fit-up and Edge Preparation

Root gap, land zone including angle, weld face cleanliness, alignment, material specification and fit-up dimensions.

SES Q01- F01 Relevant WPS Vendor drawings

As per WPS, Drawings,

Weld Map Report/ Reference Welding Inspection Checklist

I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 12 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

7

Liquid Penetrant Examination a) Edge to be welded (if specified) b) Attachment welds c) knuckle area of formed heads.


SES Q01 S01 SES Q01 T01 Project Specification for NDT

SES Q01 S01 Clause 8.2.6 SES Q01 T01 clause 6.3.4

NDT Report I W2 R

8 Inspection During Welding

Interpass temperature, interpass, cleaning and other essential non-essential parameters and weave width. Visual, LPT after back gouging prior to second side welding.

SES Q01- F01 SES Q01-T01 WPS

As per WPS SES Q01-T01 clause 6.3.4

Welding Inspection Checklist NDT Report

I R R

9 Visual Examination of Completed Welds

Surface defects, weld size and profile/appearance. Identification of weld and welders,

SES Q01-T01 SES Q01-S01 ASME Sec VIII Div. 1 & 2


Welding Inspection Checklist I R R

10 PMI on Pressure Retaining Welds


SES Q01-T07

Percentages of basic alloying elements within tolerances

PMI Report I W2 R

11 Ferrite Content Check (when required)

Ferrite number SES Q01-F01

Ferrite number within the minimum and maximum range of relevant specification

Inspection Report I R R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 13 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

12 Reinforcing Pad Test Leaks around the pad SES Q01-S01 SES Q02-T02

No leaks around the pad Leak test Report I W2 R

13

Radiographic Examination (checking of radiographic film)


SES Q01-S01, ASME Sec VIII Div. 1 & 2

ASME div . 1 Clause UW 51/52 or div 2 Clause 7.5.3 as applicable

NDT report , I R R

14

Post Weld Heat Treatment - if Required

Heating temperature, soaking time and cooling rate

SES Q01-S01, ASME VIII Div. 1 and 2

Heating /cooling rate and soaking time as per the requirements

PWHT Chart and report I R R

15 Hardness Test Hardness of the weld and heat affected zone

SES Q01-F01, SES Q02-T01, SES Q01-S01

Below the maximum allowable limit as specified in reference project specification

Hardness Test Report I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 14 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

16

Liquid Penetrant Examination after PWHT (Pressure retaining and attachment welds, removal of temporary attachment areas and arc strike ground areas)



SES Q01 S01 Clause 8.2.6, SES Q01 T01 clause 6.3.4

NDT Report I W2 R

17 Tube Bending Inspection

Visible laminations, scale, scratches, flattening and crack

SES Q02-F01 Crack not permissible other defects within specification


18 PWHT of Tubes After Bending - if specified


SES Q02-F01, Project Specification for PWHT

Correctly performed and temperature readings conform to the requirements.


19 Tube to Tube sheet Joint Inspection

Cleanliness, tube expansion, welding defects and tightness check

SES Q02-F01, SES Q02-E01, SES Q02-T01

Clean, wall thinning within the range, free of welding defect and passed tube leak or


20

Final Visual and Dimensional Inspection (incl. stacking of multiple shell arrangement and bundle inspection)

Visual defects, general surface condition / appearance, alignment and main dimensions

SES Q01-F28 Vendor Drawings

As per drawing and relevant project specification

Inspection Report

I H H




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 15 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

21

Hydrostatic Test (and Chloride Check)

Water quality, Equipment Calibration, Test Pressure and Duration

SES Q01-T01 SES Q01-T02 SES Q01-S01 ASMEVIII Div. 1 & 2.

Chloride content within the specified limit as per the specification. No Leaks. Test Pressure Maintained

Pressure Test Report

I H W1

22

Ultrasonic and Liquid Penetrant Examination after Hydro. Test (if specified)

Internal and surface discontinuities


SES Q01-S01 clause 8.2.3 SES Q01-T01 clause 6.3.2 SES Q01-S01 clause 8.2.6, SES Q01-T01 clause 6.3.4

NDT Report

I W1 R

23

Visual Check after Pickling (when required)

Check for stains, inorganic contaminants, rust or scale.

Approved pickling and passivation procedure

Free of surface contaminants

Inspection Report

I W1 W2

24

Internal Installation Check (if any)

Installation of all internal components/accessories and tightening of fasteners.

Vendor Drawings, SES Q01-T72, SES Q01-F72

Conform to vendor drawings and specified bolt torque

Inspection Report

I W1 W2

25

Rust Prevention Check and Painting Inspection

Surface preparation, DFT, surface defect, rust prevention and equipment preservation

SES Z01-G07, SES T01-S01 Project Procedure for Equipment / Material Preservation

Surface profile / condition. DFT within the lower and upper limits and free from surface irregularities. Equipment properly dry and securely preserved

Painting and preservation reports

I W1 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 16 of 84

Sr. No





Vendor

EPC

SABIC

Remarks

26

Shipping Preparation Inspection

Certified records, release note, proper packaging, nameplate data, orientation/spare parts markings, preservation, loading and shipping instructions.

SES Q01-S01, SES Z01-G07


Equipment Dossier, Packing Lists, Packing Inspection Reports. Inspection Release Note.

I W1 W2

Legend

1) ‘Prepared by’ should be the name, signature and Company’s name for the Vendor’s/Sub Contractor’s representative. (2) ‘Approved by’ should be the name, signature and Company’s name for the Contractor’s representative. (3) ‘Location’, ‘Item Name’ and ‘Tag Number’ shall be used if applicable. (4) ‘Characteristics Verified’ are the parameters checked during the inspection activity. (5) ‘Reference Document’ is the Project Specification / Code / Standard / Drawing, Procedure etc on the basis of which inspection shall be conducted. (6) ‘Acceptance Criteria’ is the tolerance, reading, value or an outcome derived from reference documents. (7) “Verifying Document’ is the record generated during inspection & Testing using approved forms / checklists. All forms and checklists shall be attached to the ITP and submitted to the Company during the

approval Stage. (8) “Inspection Responsibility’ is the role of Vendor / Sub Contractor , Contractor and Company for each inspection step. Inspection responsibility shall be ‘I’ for Inspection, ‘R’ for review, ‘S’ for Surveillance,

“W1’ for 100% Witness, ‘W2’ for random witness and ‘H’ for hold. For the explanation of these inspection responsibilities refer to the ‘definitions’ part of PEI section 4.7.1




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 17 of 84

INSPECTION AND TEST PLAN (ITP) FOR CARBON STEEL PRESSURE VESSEL (Tower, Vessel and Heat Exchanger)

Print Name






Sr. No





Vendor

Contr

SABIC

Remarks

1 Material Certificates

Size, heat number Material specification mechanical properties and chemical composition etc

ASME Sec II Part A or B as applicable Purchase order specification

ASME Sec II Part A or B as applicable and certified by 3rd party

Certified mill test report

R R R

2 Welding Procedure Qualification Test

Essential, nonessential, andsupplementary essential variables

ASME IX, SES W11-F01

WPS and PQR Approved As per SES W11-F01


3




Welders and Operator Approved as per SES W11-F01/ASME Sec IX As per SES W11-F01

Approved Welder list

I W1* R

NOTE: * If WPS already exist, records may be reviewed.

4

Edge Preparation and Fit-up inspection Weld Joint Fit-up

Root gap, land zone including angle, material, LPT/MPT of weld face Preheat, Dimensions,

Drawings SES Q01-F28

As per drawings and project specification,

Fit-up Report

I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 18 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

Inspection during welding

Interpass temperature, interpass cleaning and other essential non-essential parameters, weave width, Visual, LPT/MPT of back gauging

SES Q01- F01 Q01 T01 WPS



5

Visual Inspection of completed Welds

Weld profile and welding discontinuities, Identification of weld and welders

SES Q01-S01 SES Q01-T01 SES Q02-F01 ASME Sec VIII


Welding Inspection Checklist Visual Inspection Report

I S S

6

Magnetic Particle Examination or Liquid Penetrant Examination

a) Knuckle area of formed heads b) Back gouging and/or grinding (if any) c) Pressure retaining and attachment welds d) Tube to tubesheet weld joints e) temporary attachment removal areas and arc strike ground areas


Manufacturer Approved PT/MT Procedure

Free from unacceptable discontinuities NDT Report I

W2

R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 19 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

7 Reinforcing Pad Leak Test

Leaks around the pad SES Q01-S01 SES Q02-T02

No leaks Leak test Report I W1 W2

8

Radiographic Examination ( Before and after PWHT)


SES Q01-S01 SESQ01-T01 Manufacturer Approved RT Procedure

SES Q01-S01 clause 8.2.2 SESQ01-T01clause 6.3.1

RT report

I R R

9 Post Weld Heat Treatment (when required)


SESW12-F04 SES Q01-S01 Project Specification for PWHT

SESW12-F04

PWHT Chart and report

I R R

10

Ultrasonic Examination of pressure retaining welds (before and after PWHT or Hydro test)

Detecting surface and internal discontinuities

SES Q01-T01 Manufacturer Approved UT Procedure

SES Q01-T01 clause 6.3.2 UT Report

I R/W2 R

11

Hardness Test

Hardness of the weld and heat affected zone

SES Q01-F01/ S01, SES Q02-F01 Project Specification

Hardness result within the specification

.Hardness Test Report

I W1 R

12

Magnetic Particle / Liquid Penetrant Examination after PWHT

Surface and near surface discontinuities in pressure and non pressure retaining welds arc strike ground areas (including temporary attachment removal area)

SES Q01-T01 Manufacturer Approved MT/PT Procedure

SES Q01-T01 clause 6.3.3/6.3.4 Free from unacceptable discontinuities

NDT Report

I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 20 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

15

Tube bending inspection

Visible laminations, scale, scratches, flattening and crack

SES Q02-F01 SES Q02- T01

Crack not permissible other defects within specification, SES Q02- T01


14 PWHT of tubes after bending (if specified)


SES Q02-F01 Project Specification for PWHT

SES Q02-F01 clause 6.6

PWHT Chart and report

I W2 R

Legend

(1) ‘Prepared by’ should be the name, signature and Company’s name for the Vendor’s/Sub Contractor’s representative. (2) ‘Approved by’ should be the name, signature and Company’s name for the Contractor’s representative. (3) ‘Location’, ‘Item Name’ and ‘Tag Number’ shall be used if applicable. (4) ‘Characteristics Verified’ are the parameters checked during the inspection activity. (5) ‘Reference Document’ is the Project Specification / Code / Standard / Drawing, Procedure etc on the basis of which inspection shall be conducted. (6) ‘Acceptance Criteria’ is the tolerance, reading, value or an outcome derived from reference documents. (7) “Verifying Document’ is the record generated during inspection & Testing using approved forms / checklists. (8) “Inspection Responsibility’ is the role of Vendor / Sub Contractor , Contractor and SABIC for each inspection step. Inspection responsibility shall be ‘I’ for Inspection, ‘R’ for review, ‘S’ for Surveillance, “W1’ for 100% Witness, ‘W2’ for random witness and ‘H’ for hold. For the explanation of these inspection responsibilities refer to the ‘definitions’ part of PEI section 4.7.1 (9) Rust prevention coating should protect the material from corrosion and shall be easily removed in the field.




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 21 of 84

INSPECTION AND TEST PLAN (ITP) FOR TRAYS FOR COLUMNS

Print Name






Sr. No





Vendor

Contr

SABIC

Remarks

1

Material Certificate

Quantity, size, heat number,material specification, mechanical properties and chemical composition etc

SES Q01-F72 Purchase order specification

Material as per project specification and by approve vendors. SES Q01-F72

Mill Test Certificates, Material Test Report

R R R

2

Material Identification

Percentage of basic alloying elements

SES Q01-T07 SES Q01-T07 clause 8 Material Certificate and detailed alloy verification map

I R R

3

Visual and Dimensional Inspection* (incl. trial assembly)

General surface condition, thickness, schedule for nozzle and fitting, markings, main dimensions, etc.

, SES Q01-T72

Clean, smooth and free from imperfections . Compliance with the applicable drawings and project specifications

Inspection Report

I W1 W1

4 Leak testing

Leak Testing criteria according to the type of tray.

SES Q01-F72, SES Q01-T72

Leakage rate as per the specification

Leak Test Report I W1 W1

NOTE: * One tray of each diameter and of each specific type shall be pre‐assembled on a solid flat level at shop.




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 22 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

7 Tray Marking Inspection

Each tray part shall be piece-marked, Tray deck sections marked with the tray number

SESQ01-F72, SES Q01-T72

Clear and traceable Inspection Report

I W1 R

Indelible non-lead paint or an approved dye shall be used for marking

8

Rust Prevention Check and Painting Inspection

Protection from rust and damage

SES Z01-G07, SESQ01-F72 Project Procedure for Equipment / Material Preservation

Protected with Rust inhibitor but shall be easily removable at site.

Painting and Preservation report

I W2 R


Packaging, preservation, marking, loading and shipping instructions , Tray parts and tray hardware for different tray designs shall not be intermixed

SES Q01-F72 SES Z01-G07

Securely packed and preserved. Materials for different columns shall not be mixed

Packing Lists, Packing Inspection Reports. I W1 W2

Legend

(1) ‘Prepared by’ should be the name, signature and Company’s name for the Vendor’s/Sub Contractor’s representative. (2) ‘Approved by’ should be the name, signature and Company’s name for the Contractor’s representative. (3) ‘Location’, ‘Item Name’ and ‘Tag Number’ shall be used if applicable. (4) ‘Characteristics Verified’ are the parameters checked during the inspection activity. (5) ‘Reference Document’ is the Project Specification / Code / Standard / Drawing, Procedure etc on the basis of which inspection shall be conducted. (6) ‘Acceptance Criteria’ is the tolerance, reading, value or an outcome derived from reference documents. (7) “Verifying Document’ is the record generated during inspection & Testing using approved forms / checklists. (8) “Inspection Responsibility’ is the role of Vendor / Sub Contractor , Contractor and SABIC for each inspection step. Inspection responsibility shall be ‘I’ for Inspection, ‘R’ for review, ‘S’ for Surveillance, “W1’ for 100% Witness, ‘W2’ for random witness and ‘H’ for hold. For the explanation of these inspection responsibilities refer to the ‘definitions’ part of PEI section 4.7.1 (9) Rust prevention coating should protect the material from corrosion and shall be easily removed in the field. Austenitic stainless steel materials shall not be coated but shall be protected from ferritic contamination, chloride attack and galvanic corrosion




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 23 of 84

INSPECTION AND TEST PLAN (ITP) FOR

AIR COOLED HEAT EXCHANGERS

Print Name






Sr. No





Vendor

Contr

SABIC

Remarks

1 Tube Bundle Assembly

1.1

Material Certificate (pressure parts)

Size, heat number material specification, nominal composition and grade, class, or type designation.

SESQ02-F02, ASME II’ Purchase order specification

Material as per specification and by approve vendors

Mill Test Certificates, Manufacturer's Test Reports

R R R

1.2

Material identification for alloy

Verification of basic alloying elements

SESQ01-T07,

SESQ01-T07 clause 8 Material as per the acceptance criteria defined in applicable specification

PMI Report

I W2 R

1.3 Welding Procedure Qualification Test (WPS/PQR)

Essential, nonessential, andsupplementary essential variables

SES W11-F01 ASME IX

WPS/PQR approved as per SES W11-F01/ASME Sec IX


1.4



ASME IX SES W11-F01

Welders and Operator Approved as per SES W11-F01/ASME Sec IX

WQT, Welder Register, Welder ID Card

I W1* R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 24 of 84

Sr. No





Vendor

Contr

SABIC

Remarks


1.5

Edge preparation and Fit-up Inspection

Root gap, land zone including angle, material specification, fit up Dimension, alignment

Relevant WPS, Drawings, API 661

As per WPS, drawing and project specification


I W1 R

1.6 Inspection during welding

Interpass temperature, interpass cleaning and other essential non-essential parameters, weave width, Visual, LPT/MPT of back gauging




I W1 R

1.7 Visual Inspection of Completed Welds

Weld profile and surface discontinuities Surface defects, weld profile. Identification of weld and welders,

SES Q02-F02, Drawings

Clean and Free from weld surface discontinuities and sharp edges. SES Q01-T01 ASME Sec VIII div 1 clause UW 33 & 35 or Div


I S S

1.8

Magnetic Particle Examination or Liquid Penetrant Examination a. Edge for corner joint as per UG-93 (d) (3) b. Edge to be welded (if specified c. Back gouging and/or grinding (if any) d. Pressure Retaining welds including tube

Surface discontinuities Manufacturer approved MT / PT procedure

ASME Sec VIII div 1 mandatory Appendix 6/ ASME Sec VIII Div 2 clause 7.5.3 as applicable

NDT Report I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 25 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

to tube sheet weld joints.

1.9

Radiographic examination (Before & after PWHT)

Detect surface and internal discontinuities

ASME Sec V & VIII div 1 or 2 Manufacturer approved RT procedure

ASME Sec VIII div 1 clause UW 51 or 52 as applicable/ ASME Sec VIII Div 2 clause 7.5.3

Radiographic Test Report I R R

1.10

Post weld heat treatment (when required)


SES Q02-F02 Project Specification for PWHT

Heating /cooling, Soaking time as per requirements..


1.11 Hardness Test

Brinell hardness of the weld and heat affected zone SES Q02-F02 Hardness within the

specification .Hardness Test Report I W1 R

1.12 Tube to Tube sheet Joint Inspection

Fixation, cleanliness, welding defects and tightness check

SES Q02-F02, API 661

Clean, free of welding defect and passed tube leak or tightness check


1.13

Final Visual and dimensional inspection

General surface condition, weld appearance and main dimensions.

SES Q02-F02 API 661

As per drawing and project specification

Visual and Dimensional Report

I W1 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 26 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

1.14

Magnetic particle examination or liquid penetrant examination after PWHT (pressure retaining welds, thermocouple removal areas, removal of temporary attachment areas and arc strike ground areas)

Surface discontinuities Manufacturer Approved PT / MT Procedure

No relevant indications NDT Report I W2 R

1.15 Hydrostatic test (and Chloride Check, if required)

Equipment Calibration, Test Pressure and Duration

. SESQ02-F02 ASME VIII

No Leaks. Test Pressure Maintained

Pressure Test Report I W1 W1

2 Structural Component Refer to ITP for Structure

3 Electrical Components Refer to ITP for Electrical

4 Assembly and Run-in Test (each fan-driver combination)

Overall Performance, Vibration test, Noise test and Fan tip clearance

SES Q02-F02 API 661 As per specification

Inspection and Test Report

I W1 W2

5 Painting Inspection Drying out and Rust prevention

Surface preparation, DFT, surface defect, rust prevention and equipment preservation.

SES T01-S01 SES Z01-G07

Surface profile and DFT within lower and upper limits given in relevant specification. Free from surface irregularities. Equipment preserved (refer Note 9)


I W1 W1




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 27 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

6


Certified records, packaging, nameplate data and spare parts markings, preservation, loading and shipping instructions

SES Q02-F02 SES Z01-G07 Fulfilled all requirements

Equipment Dossier, Packing Lists, Packing Inspection Reports

I W1 W2

Legend





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 28 of 84

INSPECTION AND TEST PLAN (ITP) FOR MATERIAL AND SHOP FABRICATION STAGE OF

ATMOSPHERIC STORAGE TANKS

Print Name






Sr. No





Vendor

Contr

SABIC

Remarks


Size, heat number material specification, grade, class, type designation , chemical analysis and thickness.

SES Q03-T06, Purchase specification

Material as per documentation and by approve vendors

Mill Test Certificates, Manufacturer's Test Reports

R R R

2 Material Identification Verification of Alloy Material

SES Q01-T07

SES Q01-T07 clause 8 Percentages of alloying element within tolerances

PMI reports I W2 R

3 Welding Procedure Qualification Test (WPS/PQR)

Essential, nonessential, and supplementary essential variables


API 650 Sec. 7 SES W11-F01

WPS /PQR Log I W1* R

4

Welder’s and Welding Operator’s Performance Qualification Test



API 650 Sec. 7 SES W11-F01 Welder

Register I W1* R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 29 of 84

Sr. No





Vendor

Contr

SABIC

Remarks


5 Welding Control Welding materials, welding specification, procedure and welder performance

SESQ03-T06 WPS

New materials and strictly control. As per relevant WPS

Batch certificate, Surveillance log sheet

I W2 / S R /S

6

Shell/Bottom/Roof Plates , Nozzles and Man ways Fabrication Edge a) Preparation and Fit-up Inspection,

Root gap, land zone, alignment, radius of shell plate. Material specification, type, thickness, rating etc.

Relevant WPS Drawing As per WPS and Drawing

Fit-up Inspection Report

I W2 R

7 Shell Plate Assembly

Peaking, banding, staggering of vertical joints, diameter, circumference and visual inspection of weld

Drawing, API620

Compliance to Drawing and project specification

Inspection Report

I W2 R

a) Bottom/ Roof

Plate assembly

Verify actual diameter, orientation of weld seam, bolt center distance and visual inspection of weld

I W2 R

b) Nozzle/

Manway on Shell and roof

Orientation, elevation, levelness, projection and straddle of flange bolt holes and visual inspection of welds

I W2 R

c) Structural Attachment

Location,elevation and visual inspection of welds I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 30 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

8 Inspection during welding

Interpass temperature, interpass cleaning and other essential non-essential parameters, weave width, Visual, LPT/MPT of back

i

API 650 Sec 5WPS

API 650 Sec 5 WPS

Welding Inspection Checklist EPM-QF-06-A006

9 Platform and Ladder fabrication and assembly

Main dimensions, general surface condition and quality of galvanized items.

Drawings, SES Q03-S20

Compliance to Drawing and project specification


10 Radiographic Examination as per API 650


Manufacturer approved RT procedure

API 650 Section 6.1 RT Report I R R

11 Liquid Penetrant Examination or Magnetic Particle Examination

Surface and near surface discontinuities in welds arc strike ground areas (including temporary attachment removal area)

Manufacturer Approved MT/PT Procedure

API 620

NDT Report

I W2 R

Surface and near surface discontinuities in pressure and non pressure retaining welds arc strike

12 Pneumatic Test of Reinforcing pad

Leaks around the pad both inside and outside of the shell

API 620 No Leaks Pneumatic Test Report I W1 R

13 Vacuum Box Test Leak tightness of the bottom plate welds API 620 API Section 6.6

Vacuum box Test Report I W2 R

14 Oil Leak test of shell to bottom weld joints

Leak tightness of initial weld pass on inside shell API 620 No leak thru weld seams Oil Leak test

report I W2 R

15 Final Visual and Dimensional Inspection

General surface condition and weld appearance. Plumbness, roundness and main dimensions.

Drawings, API 620

Compliance to relevant drawings and specification





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 31 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

16 Hydrostatic Test

Equipment Calibration, Pressure, duration, Leak tightness, strength and deformation.

Drawings, Approved Hydrotest Procedure API 620

No leak or apparent deformation

Hydrostatic test report I W1 W1

17 Leak Test above liquid Level ( if applicable) Vacuum test or solution test API 620 No leak

Vacuum Box / Pneumatic Test Report

I W1 R


Surface preparation and Condition of Painting. Rust prevention, internal cleanliness and equipment preservation

SES T01-S01 SES Z01-G07,

Surface profile and DFT within lower and upper limits. Free from surface irregularities. Equipment adequately clean and securely preserved(refer Note 9)


I W1 R


Certified records, packaging, nameplate data, marking of orientation. Preservation, loading and shipping instructions

SES Z01-G07

Fulfilled the requirements of relevant project specification

Equipment Dossier, Packing Lists, Packing Inspection Reports.

I W1 W2

Legend

(1) ‘Prepared by’ should be the name, signature and Company’s name for the Vendor’s/Sub Contractor’s representative. (2) ‘Approved by’ should be the name, signature and Company’s name for the Contractor’s representative. (3) ‘Location’, ‘Item Name’ and ‘Tag Number’ shall be used if applicable. (4) ‘Characteristics Verified’ are the parameters checked during the inspection activity. (5) ‘Reference Document’ is the Project Specification / Code / Standard / Drawing, Procedure etc on the basis of which inspection shall be conducted. (6) ‘Acceptance Criteria’ is the tolerance, reading, value or an outcome derived from reference documents. (7) “Verifying Document’ is the record generated during inspection & Testing using approved forms / checklists. (8) “Inspection Responsibility’ is the role of Vendor / Sub Contractor , Contractor and SABIC for each inspection step. Inspection responsibility shall be ‘I’ for Inspection, ‘R’ for review, ‘S’ for Surveillance, “W1’ for 100% Witness, ‘W2’ for random witness and ‘H’ for hold. For the explanation of these inspection responsibilities refer to the ‘definitions’ part of PEI section 4.7.1




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 32 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

(9) Rust prevention coating should protect the material from corrosion and shall be easily removed in the field. Austenitic stainless steel materials shall not be coated but shall be protected from ferritic contamination, chloride attack and galvanic corrosion




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 33 of 84

INSPECTION AND TEST PLAN (ITP) FOR MATERIAL AND PRE-FABRICATION STAGE OF

CRYOGENIC STORAGE TANKS

Print Name






Sr. No





Vendor

Contr

SABIC

Remarks


Material specification mechanical properties including impact testing and chemical composition etc.

API 650 Purchase Specification

API 650 Section 2 Material as per specification and by approve vendors

Mill Certificates, Manufacturer's Test Reports

W2 W2 R

2 Material Identification


SES Q01-T07

Material as per the acceptance criteria defined in applicable specification

PMI Report I W2 R

3



SES W11-F01 ASME IX API 650 Section 7

SES W11-F01 ASME IX API 620 Clause 6.7


4 Welder and Welding Operator Qualification Test


SES W11-F01 ASME IX API 650 Section 7

SES W11-F01 ASME IX API 620 clause 6.8


I W1* R





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 34 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

5 Inner Tank & Outer Tank

1. Material identification Material used to be certified

SESQ01-T07 SESQ03-T06

SESQ01-T07 clause 8

Material Certificate and detailed alloy

I W2 R

2. Edge

preparation inspection

Root gap, land zone including angle

Weld joint design as per Drawing

Weld joint design as per Drawing

Weld Map Report/ Reference

I W2 R

3. Inspection during welding

Interpass temperature, interpass cleaning and other essential non-essential parameters,

API 650 WPS

API 650 WPS

Weld Inspection Report

4. Back chip inspection

Soundness of weld metal prior to back welding

Dye Penetration Testing Procedure

Free from defect PT report I W2 R

5. Visual inspection of completed welds

Surface defects, weld profile. Identification of weld and welders,

API 650 API 650

Weld Inspection Report of weld and welders

6. Dimensional check and visual inspection

a) Shell plate

Verify peaking, banding diameter, circumference and visual inspection of weld

Drawing API 650

Within Tolerance as per API 650 5





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 35 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

b) Shell stiffener Numbers and location Relevant Calculation and Drawing

As per Calculation and Drawing

Inspection Report

I W2 R

c) Suspended deck w/framing

Minimum thickness, number and design

Relevant Calculation and Drawing


Inspection Report

I W2 R

d) Nozzle, manhole

Orientation, elevation, levelness projection and stradleness of flange bolt holes ,and visual inspection of welds

Drawing APl 650

Within Tolerance as per API 650


e) Anchor strap Diameter and Thickness Relevant Calculation and Drawing


Inspection Report

I W2 R

6 Radiographic Examination

Surface and internal discontinuities

API 650 ASME V API 650 Section 6 NDT Report I R R

7

Liquid Penetrant Examination or Magnetic Particle Examination

Surface discontinuities API 650 ASME V API 650 Section 6 NDT Report I W1 R

8 Pneumatic Test of Reinforcing Plate Reinforcement pad test API 650 Leakage around

reinforcement No Leaks I W1 R

9 Post Weld Heat Treatment (if necessary)

Heating /cooling Rate. Temp Range & Duration

SES W12-F04, WPS API 650 Sec 3.7

SES W12-F04, WPS API 650 Sec 3.7





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 36 of 84

Sr. No





Vendor

Contr

SABIC

Remarks




Surface profile and DFT within lower and upper limits. Free from surface irregularities. Equipment adequately clean and securely preserved


I W2 R



SES Z01-G07


Equipment Dossier, Packing Lists, Packing Inspection

I W1 W2

Legend





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 37 of 84

INSPECTION AND TEST PLAN (ITP) FOR SHOP FABRICATION STAGES OF PRESSURE

STORAGE AND SPHERICAL TANKS

Print Name






Sr. No





Vendor

Contr

SABIC

Remarks


Material specification mechanical properties and chemical composition etc.

SESQ01-F35 SES Q01-F05 SESQ01-F08 SESQ01-T07

Material as per specification and by approve vendors


R R R

2 Material Identification


SES Q01-T07

SES Q01-T07 clause 8 PMI Report I W2 R

3 Ultrasonic Examination Surface and subsurface discontinuities

SES Q01-T01 Manufacturer approved UT/MT

d

SES Q01- T01 clause 6.3.2 & Clause 6.3.3/6.3.4 UT Report I W1 R

4


Essential, nonessential, andsupplementary essential variables in accordance to PQR

SES W11-F01 ASME IX

WPS approved as per SES W11-F01 ASME IX





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 38 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

5 Welder and Welding Operator Qualification Test


SES W11-F01 ASME IX

Welders and Operator Approved as per SES W11-F01 ASME IX


I W1* R


6 Edge Preparation Inspection

Root gap, land zone including angle Relevant WPS As per WPS

Weld Map Report/ Reference

I W2 R

7 Back Chip Inspection Soundness of weld metal prior to back welding

Dye Penetration Testing Procedure

Free from defect PT report I W2 R

8

Post Weld Heat Treatment (if necessary)


SES P13-C02, SES W12-F04 Relevant WPS, ASME

SES Q03- F09 PWHT Chart and report I W2 R

9 Dimensional Check and Visual Inspection

Visual inspection, minimum plate thickness, schedule for nozzle and fitting, markings, main dimensions,Edge preparation, Rolling, Joint alignment etc

SES Q01-T02 SESQ01-T06 SESQ01-F28 SESZ01-G04

As drawing and SES Q03 – F09

Traveler, drawing I W1 R

10 Pneumatic Test of Reinforcing Plate Reinforcement pad test API 650 Free from leakage around

reinforcement No Leaks I W1 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 39 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

11 Radiographic Examination

Detect surface and internal discontinuities ASME V SES Q03- F09 NDT Report I R R

12

Liquid Penetrant Examination and/or Magnetic Particle Examination

Surface discontinuities ASME V SES Q03- F09 NDT Report I W2 R






I W2 R



SES Z01-G07



I W1 R

Legend





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 40 of 84

INSPECTION AND TEST PLAN (ITP) FOR FIRED HEATERS (Incl. thermal reactor and incinerator for sulfur unit and spent caustic

incinerator)

Print Name






Sr. No

Inspection Activity Characteristic Verified (4)

Reference Document (5)




Vendor

Contr

SABIC

Remarks

1 Pyrolysis Furnaces

Tube material, chemical analysis, mechanical tests , WPS and NDE inspection

SES Q04-S01, API 560, Relevant ASME Standard

Material as per specification. Manufacturing report I R R

Weld Joint Fit-up

Edge Preparation including back chipping , preheat

WPS, drawing API 560 Welding Fit up report I R R

Visual inspection of completed welds

Surface defects, weld profile. Identification of weld and welders

API 560, Pressure Design code

API 560 clause17, Pressure Design code

Welding inspection Report I R R

Positive Material Identification Chemical composition

API 560, SES Q01 – T07

API 560 clause 17.5.4, SES Q01 – T07 clause 8

PMI report

I R R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 41 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

2 Tube Coils

a) Material Certification

Material specification mechanical properties and chemical composition etc.

API 560 SES Q04- S01

SES Q04- S01 API 560


I R R

b) Liquid penetrant examination Surface discontinuities API 560

API 560 clause 17 NDT Report I R R

c) Dimensional Check

and Visual Inspection

Main dimensions, welds and surface cleanliness, weld appearance and etc.

Manufacturer’s Drawings, SES Q04-X01

As per drawing SES Q04-X01 Inspection Report I R R

d) Radiographic examination


API 560


e) Hydrostatic test Equipment Calibration ,Test Pressure and Duration

API 560

API 560 clause 17No Leaks. Test Pressure Maintained

Pressure Test Report I W2 R

f) Pneumatic test Equipment Calibration ,Test Pressure and Duration

API 560

API 560 clause 17No Leaks. Test Pressure Maintained

Pneumatic Test Report I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 42 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

g) Radiographic examination


API 560 ASME V


3 Headers Bend and Collector

a) Material Certificate Casting-quality factors ISO 15649

Headers shall be of metallurgy equivalent to the tubes.


I R R

b) Mechanical Test

Determining the tensileproperties.

SES Q01-T02 SES Q01-T07 ASME V ASME VIl

Mechanical test successful

Manufacturer's Test Reports I R R

c) Liquid penetrant examination Surface discontinuities ASME V As per

specification NDT Report I W1 R

d) Visual examination


API 560 As per drawing and API 560 clause 17


e) Radiographic examination


API 560 ASME V API 560 clause 17 NDT Report I R R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 43 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

f) Hydrostatic test Equipment Calibration ,Test Pressure and Duration

API 560 Relevant ASME Codes

No Leaks. Test Pressure Maintained API 560 clause 17


4 Piping, terminals and manifolds

a) Material Certificate Heat number material specification and grade, class, or type designation.

SESQ01-T07 API 560 ISO 13704

Materials as per specifications

Mill Certificates, Manufacturer's Test Reports I R R

b) Liquid penetrant examination

Surface discontinuities ASME V No recordable indications

NDT Report

I W1 R

c) )Visual examination


SES Q01-F28/ SES Q06-S01/ Drawings

As per drawing and no relevant indications

Inspection Report

I W1 R



ASME V No recordable indications

NDT Report I R R

5 Tube supports




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 44 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

a)Material Certificate

Heat number, material specification and grade, class, or type designation

API 560

For exposed radiant and shield-section tube supports, the material shall be 25Cr-12Ni or higher alloy.


I R R

b)Liquid penetrant examination Surface discontinuities ASME V No recordable

indications NDT Report I R R

c) Visual examination






Surface and internal discontinuities ASME V No recordable


6 Fabricated Straight Tube

a) Visual inspection (weld portion)



As per drawing and no relevant defect

Inspection Report

I W1 W2




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 45 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

b) Liquid penetrant

examination (weld portion)

Surface discontinuities ASME V No recordable indications NDT Report I W1 R

c) Radiographic examination (weld portion)


ASME V

No recordable indications

NDT Report I R R

d) Hydrostatic test Equipment Calibration, Test Pressure and Duration

Approved Hydrotest Procedure


Pressure Test Report M W1 W2

6 Radiant Coil Assembly (Semi-assembled)

a) Visual inspection (weld portion, Spot Inspection after installation)



As per drawing and no relevant defects


b) Liquid penetrant examination

Detect surface discontinuities ASME V No recordable

indications NDT Report I W1 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 46 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

c) Radiographic examination

Detect surface and internal discontinuities A SME V No recordable


d) Hydrostatic test Equipment Calibration, Test Pressure and Duration




7

Radiant Coil Assembly (Completed)

a) Visual inspection



As per drawing and no relevant defects


b) Liquid penetrant


Surface discontinuities ASME V No recordable indications NDT Report I W1 R

c) Radiographic







Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 47 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

d) Pneumatic test Test Pressure and Duration

Approved Test Procedure



7

Convection Coil (Boiler Feed Water and Steam Superheater coils) and Transfer Line

a) Material certificates

Quantity, size, heat number , material specification and grade, class, or type designation.

SESQ01-T07

Material as documentation and by approve vendors


R R R

b) Material identification for alloy

Material used to be certified SESQ01-T07 Per the

specification

Material Certificate and detailed alloy verification map

I W2 W2

c) Visual inspection and dimensional inspection

Visual inspection, minimum plate thickness, schedule for nozzle and fitting, markings, main dimensions, Edge preparation, R lli


As drawing and specification Inspection report I W1 W2

d) Magnetic particle or dye penetrant test Surface discontinuities

ASME V No recordable indications

NDT Report I W2 W2




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 48 of 84

Sr. No





Vendor

Contr

SABIC

Remarks




f) Post weld heat treatment (when required)


SES P13-C02, SES W12-F04 Relevant WPS, ASME B31.3 Project Specification for PWHT

Correctly performed and temperature readings conform to the requirements requirements..

PWHT Chart and report I R* R*

g) Hardness test Brinnell hardness of the weld and heat affected zone

ASTM E 10. SES Q01-F01 Project Speciification

Hardness within specification .Hardness Test Report I W2 R

h) Hydrostatic test Test Pressure and Duration




I W1 W1




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 49 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

8 Convection Coil (LTC and HTC coils)



SESQ01-T07 Material as documentation and by approve vendors

Mill Certificates, Manufacturer's Test Reports R R R

b) Material

identification for alloy

Material used to be identified and certified SESQ01-T07 Conform to

specification

Material Certificate and detailed alloy verification map

I W2 W2

c) Visual inspection

and dimensional inspection

Visual inspection, minimum plate thickness, schedule fornozzle and fitting, markings, main dimensions, Ed ti


As drawing and specification Inspection report I W1 W1

d) Magnetic particle or dye penetrant test

Detect surface discontinuities ASME V No recordable

indications NDT Report I W2 W2




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 50 of 84

Sr. No





Vendor

Contr

SABIC

Remarks


Detect surface and internal discontinuities ASME V No recordable


f) Post weld heat

treatment (when required)


SES P13-C02, SES W12-F04 Relevant WPS, ASME

Correctly performed and temperature readings conform to the requirements requirements..

PWHT Chart and report I R* R*

g) Hardness test Brinnell hardness of the weld and heat affected zone

ASTM E 10. SES Q01-F01

Hardness within specification .Hardness Test Report I W2 R

h) Hydrostatic test Equipment Calibration ,Test Pressure and Duration

Relevant ASME Codes



* Review of temperature chart

9 Burners

a) Visual and dimensional inspection

Main dimensions, surface cleanliness, appearance and etc.

Drawings As per drawing and no relevant indications

Inspection Report I W R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 51 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

b) Material certificates


SESQ01-T07



R R R

10 Casting (Tube support)



Material Specification SES Q04-S01 API 560

Material as per Specification by approve vendors


I R R

b) Visual and dimensional inspection

Visual inspection, minimum plate thickness, schedule for nozzle and fitting, markings, main dimensions, Edge preparation, Rolling, Joint alignment etc

Drawing SESZ01-G04

As drawing and specification

Traveler, drawing I W2 R

c) Dye Penetrant / MPT Test Surface discontinuities API 560 ;

ASME V

API 560clause 17. 3

NDT Report I W2 R



API 560 ASME V

API 560clause 17.

NDT Report I R R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 52 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

11 Refractory

Material

Selection of refractory and materials

API 560

a) fireclay brick, ASTM C 27; b) insulating firebrick, ASTM C 155;

Mill Certificates, Manufacturer's Test Reports I R R

Installation

a) Surface preparation Cleanliness of steel surfaces

API 650 Project Specification

Steel surfaces cleaned no dirt, grease, paint, loose scale or other foreign materials.


b) Check of attachment

and dimension for refractory anchor

Type and thickness, API 650

Project Specification

As per Project Specification, Code and Standard


c) Visual inspection No defects such as crack, void, cavity and gap

API 650 Project Specification

As per Project Specification, Code and Standard





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 53 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

13 Spent Caustic Incinerator

( SES Q 05‐ S02 )

13.1 Furnace, quench

tank, scrubber and cooler


Quantity, size, heat number , material specification and grade, class, or type designation

Material Specification

Material as specification and by approve vendors


R R R

b) Welding Procedure Specification Approval


SES W11-F01 ASME IX

WPS approved as per SES W11-F01 ASME IX


c) Welder and Welding

Operator Qualification Test

Welder ability to deposit sound weld metal and welding operators ability to operate the welding

SES W11-F01 ASME IX

Welders and Operator Approved


I W1* R

Note: *Previous records may be reviewed.

d) Material identification


SES Q01-T07

SES Q01-T07Clause 8

Alloy testing reports, I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 54 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

e) Edge preparation inspection

Root gap, land zone including angle

Relevant WPS, Drawing

As per WPS, Drawing

Weld Map Report/ Reference I W2 R

f) Visual Inspection of

Completed Welds

Weld profile and welding discontinuities, Identification of weld

SES Q05-S02 API 560

SES Q05-S02 API 560

Welding Inspection report dentification of weld and welders

g) Dimensional and visual inspection

Visual inspection, minimum plate thickness, schedule for nozzle and fitting,



Traveler, drawing

I W1 W1

h) Dye penetrant or

magnetic particle examination

Detect surface discontinuities

ASME V SES Q05-S02 API 560

NDT Report

I W1 W1

i) Pneumatic leak test Equipment Calibration ,Test Pressure and Duration

Relevant ASME Codes



I W1 W1

j) Hydrostatic test

Equipment Calibration ,Test Pressure and Duration

Relevant ASME Codes



I W1 W1

13.2 Burner




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 55 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

a) Material certificates Heat number, material specification and grade, class, or type designation.

API 560

The materials used shall be chosen for strength, as well as temperature- and corrosion-resistance, for the anticipated service conditions.vendors


R R R

b) Dimensional and visual inspection


API 560 Project Specification and Drawings



c) Capacity check Heat release

API 560 Project Specification and Drawings

As per Specification, Code and Standard


13.3. Casting (Tube support and press. parts)



SESQ01-T07 Material as documentation and by approve vendors


R R R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 56 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

b) Visual and dimensional inspection

Surface defect and main dimensions,

SES Q01-T02 SESQ01-T06SESQ01-F28SESZ01-G04



c) Dye penetrant test (press. parts) Surface discontinuities ASME V

No recordable indications As per Material / Welding specification

NDT Report I W2 R

d) Radiographic

examination (press. Parts)

Surface and internal discontinuities ASME V

No recordable indications As per Material / Welding specification

NDT Report I R R

13.4 Refractory (shop installed)

Refer to Refractory ITP




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 57 of 84

Sr. No





Vendor

Contr

SABIC

Remarks






I W2 R



SES Z01-G07



I W1 W2

Legend





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 58 of 84

INSPECTION AND TEST PLAN (ITP) FOR

STEAM BOILERS & AUXILIARIES

Print Name

Signature Name of Company Doc No: EPM‐ITP‐QP‐010

Prepared By: (1)


SABIC App: Stage Procurement Disciplin Static Equipment PROJECT: Date:

Location Item Name (3): Tag No (3): Page:

Sr. No





Vendor

Contr

SABIC

Remarks

1 Materials

a) Material

Certificate

Material specification, classification, grade, rating type, marking etc.

SES Q06-S01 ASME1 ASME SA192 Relevant material specification

Material as per specification and by approved vendors. Electric resistance welded tubes shall be ASME SA178 Grade A or SA226


R R R

b) Material identification Verification of alloy material SES Q01-T07 SES Q01-T07 clause 8 Material

Certificate I R R

c) Welding Procedure Specification Approval


SES W11-F01 ASME IX

WPS approved in accordance with SES W11-F01 ASME IX


d) Welder and Welding Operator Qualification Test


SES W11-F01 ASME IX

Welders and Operator Approved in accordance with SES W11-F01 ASME IX


I W1* R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 59 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

Note : * Previous record may be reviewed.

3

Steam and Water Drums

Merge components having similar inspection

a) Edge

preparation and fit-up

Root gap, land zone including angle, staggering of long seam, circumference, ovality and etc.

Drawings, WPS As per Drawings Inspection Report I W2 R

b) Back chipping inspection

Depth of gouged groove and surface discontinuities

Drawings/ manufacturer PT procedure

As per Drawing and no defect

PT Report I W2 R

c) Visual Inspection of Completed Welds


As per relevant ASME code

SES Q06-S01 As per relevant ASME code

Welding Inspection report dentification



Manufacturer RT Procedure as per ASME Sec V

SES Q06-S01 RT Report I R R

e) Post weld heat treatment

Heating/Cooling rate, Holding time and temperature range.

ASME Sec. I

PWHT variables within the range as per SES Q06-S01 / As per relevant ASME code





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 60 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

f) Mechanical

test of welded joint

Hardness SES Q01-F01 Not exceed the maximum hardness limit

Hardness Report I R R

g) Hydrostatic test Test Pressure and Duration SES Q06-S01

SES Q06-S01

Pressure Test Report I H H

h) Dimensional check and Visual inspection


SES Q01-F28/ SES Q06-S01/ SES Q01-D15 Drawings

SES Q06-S01


i) Magnetic particle examination

Detect surface and near surface discontinuities

ASME V and Manufacturer MT procedure

SES Q06-S01

MT Report

I W2 R

4

Boiler Tube

a) Visual inspection and dimension check








Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 61 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

b) Magnetic

particle examination



SES Q06-S01 MT Report I R R



ASME V and Manufacturer RT Procedure


d) Penetrant test for welding of tube attachments to tube.

Surface discontinuities ASME V and Manufacturer PT Procedure

SES Q06-S01 PT Report I W1 R

5 Furnace Wall Tube (Panel)

a) Dimensional



Drawings, SES Q01-F28, SES Q06-S01

SES Q06-S01


b) Penetrant test to weld parts between tubes and tube attachments

Surface discontinuities ASME V and Manufacturer PT Procedure

SES Q06-S01 PT Report I W1 R

6 Furnace Wall Header




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 62 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

a) Edge preparation and Fit-up for butt welded joints

Root gap, land zone including angle, alignment and etc.

Drawings and Relevant WPS As per Drawings and WPS Inspection

Report I W2 R

b) Visual Inspection

of Completed Welds



Welding Inspection Report

c) Postweld heat

treatment (if required)


ASME Sec. I As per relevant ASME code

SES Q06-S01


d) Dimension and

Visual Inspection (after PWHT)


SES Q01-F28/ SES Q06-S01

As per drawing and no relevant i defect




ASME V and manufacturer RT procedure


7 Saturated Steam Connecting Pipe

a) Edge Preparation & Fit up (visual Inspection)


Drawings and Relevant WPS As per drawing and WPS Inspection

Report I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 63 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

b) Visual Inspection of completed welds





I W2 R

c) Magnetic

Particle Examination

Surface and subsurface discontinuities


SES Q06-S01 MT Report I W R

d) Radiographic Examination




e) Dimension &

Visual Examination


Drawings, SES Q01-F28/ SES Q06-S01



8 Superheater header



Drawings and Relevant WPS As per drawing and WPS Inspection

Report I W2 R

b) Visual Inspection of completed welds








Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 64 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

c) Magnetic



ASME V, SES Q06-S01 and Manufacturer MT procedure


MT Report I W1 R



ASME V, and manufacturer RT procedure


RT Report I R R

e) Post Weld Heat Treatment

Heating/Cooling rate, Holding time and temperature.

ASME Sec. I

PWHT variables within the range.


f) Dimension & Visual Inspection (after PWHT)

All main dimensions, surface condition

Drawings/ SES Q01-F28/ SES Q06-S01

As per drawing and significant deformation


9 Superheater tube

a) Dimensional









Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 65 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

b) Penetrant Test of welding on Tubes to Tube attachments


ASME V ; relevant ASME code and Manufacturer PT

SES Q06-S01 As per relevant ASME code PT Report I W R



ASME V , and manufacturer RT procedure


RT Report I R R

10 Desuperheater

a) Edge

preparation and fit-up (Visual Inspection)


Drawings As per drawing Inspection report I W2 R

b) Visual Inspection of Completed welds


SES Q06 – S01 Relevant ASME code


Inspection report l W1 R

c) Magnetic

Particle examination



SES Q06-S01 As per relevant ASME code N l t i di ti

MT Report I W1 R




SES Q06-S01 As per relevant ASME code SES Q06- X03

RT Report I R R



ASME Sec. I As per relevant ASME code SES Q06- X03





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 66 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

f) Dimension & Visual Inspection (after PWHT)

Overall length, straightness, surface condition and etc.

Drawings/ SES-Q01-F28/ SES- Q06-S01

As per drawing and no significant deformation

Inspection report

I W1 R

11 Economizer header

a) Edge Preparation and Fit-up (Visual Inspection)

Root gap, land zone including angle, alignment etc. Drawings As per

Drawings Inspection report I W2 R

b) Visual Inspection of Completed welds


SES Q06-S01 relevant ASME code

SES Q06-S01 relevant ASME code

Weld Inspection report l W1 R

c) Magnetic





MT Report I W1 R

d) Radiographic examination Welding defect and discontinuities

ASME V and Manufacturer RT Procedure


RT Report I R R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 67 of 84

Sr. No





Vendor

Contr

SABIC

Remarks


Heating/Cooling rate, Holding time and temperature range. ASME Sec. I



f) Dimensional &

Visual Inspection





12 Economizer Tube

Dimensional & Visual Inspection

Overall length, Straightness, surface condition etc.

Drawings As per drawings

Inspection report

I W2 R

1 3 Boiler External Piping


Root gap, land zone including angle, alignment etc.

Drawings and relevant WPS

As per drawings and WPS

Inspection report

I W2 R

b) Visual Inspection of Completed Welds


relevant ASME code

relevant ASME code

Weld Inspection report




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 68 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

c) Radiographic examination Welding defect and discontinuities

ASME V Manufacturer RT Procedure


RT Report R R R

d) Magnetic


Detect surface and near surface discontinuities


SES Q06-S01 As per relevant ASME code N l t

MT Report I W1 R


Heating/Cooling rate, holding time and temperature range. ASME B31.1



f) Dimensional & Visual Inspection (after PWHT)

All main dimensions, straightness, surface condition etc.

Drawings, Relevant project specification

Dimensions with in tolerance and no surface irregularities


14 Assembled boiler

a) Hydrostatic test Equipment Calibration, Test Pressure and Duration ASME Sec. I


Pressure Test Report I H H

b) Pneumatic leak

test for welded wall enclosure

Equipment Calibration, Test Pressure and Duration ASME Sec. I


Pneumatic Test Report I W1 W1




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 69 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

c) Visual Inspection (Including internal inspection of furnace)

All main dimensions, location of nozzles and other attachments. Position of supporting, hanging, fixing devices. Condition of nozzle ends, fin tubes, etc.


As per drawings and project specifications


d) Structural steel

(incl. grating and ladder)

Refer to ITP for Structural Steel

e) Burners and

Burner Management

Visual and Dimension check

Burners, pilots, igniters, burner piping, valves, fittings, supports, and combustion control

SES Q06-S01Drawing



f) Forced draft fan

Material Certificate Material specification and grade, class, or type designation.

SESQ01-F35SES Q01-F05SESQ01-F08SESQ01-T07



R R R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 70 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

Visual and dimension check

All main dimensions including Type, Speed SES G11-S02

Centrifugal type, constant speed


g) Rotor Assembly Balancing API 673

Statically and dynamically balanced


h) Vibration Monitoring

Probe, signal conditioners, monitors and interconnecting wiring

SES G19-S01.

As per specificatin

Inspection Report

I W1 W1

i) Ducts (Air and gas) and stack To check with Construction ITP

j) Safety Valve Refer to Instrumentation ITP

15 Chemical Storage Tank

a) Hydrostatic Test Equipment Calibration, Test Pressure and Duration

ASMEVIII


Pressure Test Report I H R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 71 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

b) Dimensional & visual inspection



Inspection Report

I W1 R

16 Chemical feeder and Sampling cooler

a) Dimensional & visual inspection

Main dimensions, surface cleanliness, appearance and t

Drawings As per drawing and

l t


b) Hydrostatic test of pump


ASMEVIII



I R R

17 Deareator Refer to ITP for Carbon Steel and pressure Vessel

18 Soot blower




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 72 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

Material Certificate


SESQ01-F35 SES Q01-F05 SESQ01-F08 SESQ01-T07



R R R

Hydrostatic test


ASMEVIII



R R R

Dimension check and visual inspection



Inspection Report

I W2 R

19 Soot blower control panel Refer to ITP for Control System

20 Flash tank and Blow tank

Refer to ITP for Carbon Steel and pressure Vessel




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 73 of 84

Sr. No





Vendor

Contr

SABIC

Remarks




Surface profile and DFT within lower and upper limits. Free from surface


I W2 R

22



SES Z01-G07


Equipment Dossier, Packing Lists, Packing Inspection

I W1 W2

Legend





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 74 of 84

INSPECTION AND TEST PLAN (ITP) FOR INSTRUMENT AIR DRYER

Print Name






Sr. No





Vendor

Contr

SABIC

Remarks

1 Material certificate (Pressure parts)

Quantity, size, heat number ,material specification and grade, class, or type designation.

SES Q01-F35SES Q01-F05SESQ01-F08SESQ01-T07



R R R

2 Hydrostatic Test


SES Q01-T01 SES Q01-F07SES Q01-T02ASMEVIII



3 Operation test including sequence test Functional and operational Project

Specification Fulfill the specification Inspection records I W1 W1

4 Dimensional and visual inspection

Visual inspection, minimum plate thickness, schedule fornozzle and fitting, markings, main dimensions, Edge preparation, Rolling, Joint alignment etc


As per drawing and specification

Traveler, drawing I W1 W1




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 75 of 84

Sr. No





Vendor

Contr

SABIC

Remarks




Surface profile and DFT within lower and upper limits. Free from

f

Painting and Preservation report I W2 R



SES Z01-G07



I W1 W2

Legend





Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 76 of 84

INSPECTION AND TEST PLAN (ITP) FOR FLARE STACK

Print Name






Sr. No





Vendor

Contr

SABIC

Remarks

1 Flare tip and molecular seal


SESQ01-F35SES Q01-F05SESQ01-F08SESQ01-T07SES Q05-X01



I R R

b) Visual and dimensional


Drawings



2 Pilot burner and pilot mixer


SESQ01-F35SES Q01-F05SESQ01-F08SESQ01-T07SES Q05-X01



I R R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 77 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

b) Visual and dimensional


API 560, Project Specification and Drawings



3 Ignition panel

Visual and dimensional



Inspection Report

I R R

Ignition test I W1 R




Surface profile and DFT within lower and upper limits. Free from surface


I W2 R

5



SES Z01-G07



I W1 W2

Note : ITPs for hoists if any, structural steel, piping, drums, electrical & instrumentation shall be prepared separately.

Legend

(1) ‘Prepared by’ should be the name, signature and Company’s name for the Vendor’s/Sub Contractor’s representative. (2) ‘Approved by’ should be the name, signature and Company’s name for the Contractor’s representative. (3) ‘Location’, ‘Item Name’ and ‘Tag Number’ shall be used if applicable.




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 78 of 84

(4) ‘Characteristics Verified’ are the parameters checked during the inspection activity (5) ‘Reference Document’ is the Project Specification / Code / Standard / Drawing, Procedure etc on the basis of which inspection shall be conducted. (6) ‘Acceptance Criteria’ is the tolerance, reading, value or an outcome derived from reference documents. (7) “Verifying Document’ is the record generated during inspection & Testing using approved forms / checklists. (8) “Inspection Responsibility’ is the role of Vendor / Sub Contractor , Contractor and SABIC for each inspection step. Inspection responsibility shall be ‘I’ for Inspection, ‘R’ for review, ‘S’ for Surveillance, “W1’ for 100% Witness, ‘W2’ for random witness and ‘H’ for hold. For the explanation of these inspection responsibilities refer to the ‘definitions’ part of PEI section 4.7.1 (9) Rust prevention coating should protect the material from corrosion and shall be easily removed in the field. Austenitic stainless steel materials shall not be coated but shall be protected from ferritic contamination, chloride attack and galvanic corrosion




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 79 of 84

INSPECTION AND TEST PLAN (ITP) FOR WATER AND WASTE WATER TREATING

Print Name






Sr. No





Vendor

Contr

SABIC

Remarks

1 *Equipment and Materials as Noted Below

Note: * Vessel, Drum, Heat Exchanger, Rotating Machineries, Electrolytic Chlorinate, Structural Steel, Cooling Tower, Ejector, Piping Material.

a) Material certificate

(for applicable pressure vessel)

Quantity, size, heat number , material specification and grade, class, or type

SESQ01-F35SES Q01-F05SESQ01-F08SESQ01 T07

Material as documentation and by approve


R R R

b) Hydrostatic test

‐ Vessel, drum Equipment Calibration, Test Pressure and Duration

SES Q01-T01 SES Q01-F07SES Q01-T02

No Leaks. Test Pressure


‐ Prefabricated pipe


SES Q01-T01 SES Q01-F07SES Q01-T02ASMEVIII



I R R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 80 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

c) Dimensional and visual inspection

Visual inspection, minimum plate thickness, schedule for nozzle and fitting, markings, main dimensions, Edge preparation, Rolling, Joint alignment etc



Traveler, drawing

I W1 R

d) Running test for rotating machineries Refer to ITP for Rotating Machineries

2 Lining Work Pin hole test, Thickness Project Specification

As per Project Specification


3 Instruments Refer to ITP for “Instruments & Materials”

4 Electric Motor (Below 150KW) Refer to ITP for “Electric Motor (below 150KW).

5 Rust prevention check and painting inspection

Condition of Painting, Rust prevention and equipment preservation

SES Z01-G07, Project Procedure for Equipment / Material Preservation

Equipment preserved


I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 81 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

6 Shipping preparation inspection

Certified records,,proper packaging, preservation, loading and shipping instructions

SES Q01-F07 SESQ01-G01.SESQ01-T06 SES Q01-D20


Packing Lists, Packing Inspection Reports

I W1 W2

Legend

(1) ‘Prepared by’ should be the name, signature and Company’s name for the Vendor’s/Sub Contractor’s representative. (2) ‘Approved by’ should be the name, signature and Company’s name for the Contractor’s representative. (3) ‘Location’, ‘Item Name’ and ‘Tag Number’ shall be used if applicable. (4) ‘Characteristics Verified’ are the parameters checked during the inspection activity. (5) ‘Reference Document’ is the Project Specification / Code / Standard / Drawing, Procedure etc on the basis of which inspection shall be conducted. (6) ‘Acceptance Criteria’ is the tolerance, reading, value or an outcome derived from reference documents. (7) “Verifying Document’ is the record generated during inspection & Testing using approved forms / checklists. (8) “Inspection Responsibility’ is the role of Vendor / Sub Contractor , Contractor and SABIC for each inspection step. Inspection responsibility shall be ‘I’ for Inspection, ‘R’ for review, ‘S’ for Surveillance, “W1’ for 100% Witness, ‘W2’ for random witness and ‘H’ for hold. For the explanation of these inspection responsibilities refer to the ‘definitions’ part of PEI section 4.7.1 (9) Rust prevention coating should protect the material from corrosion and shall be easily removed in the field. Austenitic stainless steel materials shall not be coated but shall be protected from ferritic contamination, chloride attack and galvanic corrosion.




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 5 of 84

INSPECTION AND TEST PLAN (ITP) FOR EQUIPMENT FOR API SEPARATOR

Print Name






Sr. No





Vendor

Contr

SABIC

Remarks

1 Dimensional and visual inspection

Visual inspection, minimum plate thickness, schedule for nozzle and fitting, markings, main dimensions,



Inspection report I W1 W1

2 Operation test Functional check

Project Specification, Code and Standard

As per specification

Inspection report I W1 W1




Surface profile and DFT within lower and upper limits. Free from surface irregularities.


I W2 R




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 6 of 84

Sr. No





Vendor

Contr

SABIC

Remarks

4



SES Z01-G07



I W1 R

Legend

(1) ‘Prepared by’ should be the name, signature and Company’s name for the Vendor’s/Sub Contractor’s representative. (2) ‘Approved by’ should be the name, signature and Company’s name for the Contractor’s representative. (3) ‘Location’, ‘Item Name’ and ‘Tag Number’ shall be used if applicable. (4) ‘Characteristics Verified’ are the parameters checked during the inspection activity. (5) ‘Reference Document’ is the Project Specification / Code / Standard / Drawing, Procedure etc on the basis of which inspection shall be conducted. (6) ‘Acceptance Criteria’ is the tolerance, reading, value or an outcome derived from reference documents. (7) “Verifying Document’ is the record generated during inspection & Testing using approved forms / checklists. (8) “Inspection Responsibility’ is the role of Vendor / Sub Contractor , Contractor and SABIC for each inspection step. Inspection responsibility shall be ‘I’ for Inspection, ‘R’ for review, ‘S’ for Surveillance,

“W1’ for 100% Witness, ‘W2’ for random witness and ‘H’ for hold. For the explanation of these inspection responsibilities refer to the ‘definitions’ part of PEI section 4.7.1 (9) Rust prevention coating should protect the material from corrosion and shall be easily removed in the field. Austenitic stainless steel materials shall not be coated but shall be protected from ferritic

contamination, chloride attack and galvanic corrosion




Sub Sec. 4.7.2

Rev. No.

Rev. Date Mar 2010

Page 5 of 84

Documents

09 - Static Equipment Procurement