(732-ITP-40 (V-6905) 42000-SNG-69-42000P-MS-5733-504-0000-06

PETROLEUM DEVELOPMENT

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

Vendor Doc. No. : 732/QAP/40 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 6905

(Off Spec Condensate Degassing Boot) PDO Doc. No.

Rev. 06 SNG-69-42000P-MS-5733-504-0000

Project No. 20036 Unit Description:

INSPECTION & TEST PLAN (QAP) FOR V 6905 (Off Spec Condensate Degassing Boot)

MR No. :- 20036-0100-M31-MR-42000 REV. 02 PURCHASE ORDER No. :- 4580041305 TAG No. : V 6905 POS.: 00090 PR ITEM No. :- 00091 VESSEL CATEGORY:- GENERAL SERVICE PRESSURE VESSEL NACE MR-01-75 & SOUR SERVICE.

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 response sheet shall be considered

732/QAP/40 Page 2 of 8....

CLIENT QAP No. :732/QAP/40 Rev. 06P.O. No. DATE : 16/05/2014EQUPT. No. CODE OF CONSTRUCTION : ASME SEC VIII DIV 1 ED 2010 ADDENDA 2011

DRG. No. : 732-E-40CONTRACTOR 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 , Design Calculations Review of Documents ASME 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 PlanIRR 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


/ 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

2.1 Foundation Template InspectionVisual & dimensional inspection, checking of match markings

Approved drawing Approved drawing Inspection Report H ---- R

3.0

Material after receipt (For Pressure Parts)

Plates, Pipes

H H RA RA

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

G.R.ENGINEERING PRIVATE LTD. -TARAPUR

INSPECTION & TEST PLAN (QAP) FOR V 6905

: ABB S.p.A - Italy.: 4580041305 DTD 02-12-2012.: V 6905.

PROJECT NAME :SAIH NIHAYDA CONDENSATE STABILIZATION PLANT (SNCP): 20036

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

SL.NO STAGE / ACTIVITY TYPE OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORMS

FORMAT OF RECORD

Scope of InspectionREMARKS

DOCUMENTS

Foundation Template Inspection

MATERIAL INSPECTION

3.1

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, SP 2041, 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 shall 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) 3) 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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SP 1176 Rev. 2, DEP 30.10.02.17 Feb. 2011

GR A.I. ABB PDO







FORMAT OF RECORD


3.2Non 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

4.0

4.1 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

4.2 PQR Welding parameters ASME Sec. IX

/ Approved drawing / DEP 30.10.60.18

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

4.3 WPQ Qualification requirementsASME Sec. IX

/ Approved drawing / DEP 30.10.60.18

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

4.4 Welding Consumable Chemical & mechanical properties ASME Sec. II part C/ DEP 30.10.60.18 ASME Sec. II part C

Batch Test Certificate R R R R

5.0

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

5.1Inspection 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


Inspection report


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SP 1176 Rev. 2, DEP 30.10.02.17 Feb. 2011

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FORMAT OF RECORD


6.0

Visual & 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

6.2 Intermediate Inspection of welds Visual / 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


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 of completed welds 6.3

Inspection during fabrication

6.1

Weld edge perparation & setup of pressure parts

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

shell/head)


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


Inspection Report


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SP 1176 Rev. 2, DEP 30.10.02.17 Feb. 2011

GR A.I. ABB PDO







FORMAT OF RECORD


6.4 Skirt to Head fit up & welding Visual & dimensional

ASME Sec. VIII Div. 1/Approved Drawing /

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

ASME Sec. VIII Div. 1/Approved Drawing

Inspection Report H R R Skirt to head weld shall be PT examined.

Visual / Dimensional Inspection H R R R

PT for fillet welds of lifting lugs and other pressure bearing welds, vessel to skirt joint.

H 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

6.6

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

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

6038-539-0000


Inspection of the equipment before PWHT

Inspection Report6.5

Fitment & Welding of Internal & External attachments

etc.


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SP 1176 Rev. 2, DEP 30.10.02.17 Feb. 2011

GR A.I. ABB PDO







FORMAT OF RECORD


6.7 Post Weld Heat Treatment of equipment Review of

Heat Treatment Cycle


/ SNG-69-42000P-MS-6180-519-0000


Heat Treatment Chart H R RA R

PWHT of equipment Soaking Temperature :- 61010C.

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 / DEP

31.22.20.31 CL 6.2, SP 2069 Appendix-8, 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.

7.0

7.1Final Visual &

Dimensional Inspection(Internal & External)

Dimensions, completeness of the assembly, as built thickness measurement

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

/ DEP 31.22.20.31, SNG-69-42000P-MS-6038-554-0000

ASME Sec. VIII Div. 1 /Approved Drawing

Inspection Report H H H H

7.2 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

6.8

FINAL INSPECTION

NDE after PWHT


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SP 1176 Rev. 2, DEP 30.10.02.17 Feb. 2011

GR A.I. ABB PDO







FORMAT OF RECORD


7.3 Pneumatic test of Nozzle RF pads Leak check

ASME Sec. VIII Div. 1/Sec VApproved Drawing / DEP

31.22.20.31 CL 6.9, SP 2051 & SNG-69-42000P-MS-6180-520-0000

ASME Sec. VIII Div. 1/Sec VApproved Drawing Test Report H R RW

10%W

7.4 Trial assembly of supplied Internals

Trial fitting of internals P.O. / Internals supplier Drawings P.O. /

Internals supplier Drawings Inspection

Report H W W

7.5 Interior & exterior cleaning

All completed equipment shall be cleaned internally and externally to remove scale, weld spatter,dirtand foreign material.

Approved Drawing / DEP 31.22.20.31 Approved Drawing

Inspection Report H R R

7.6 Hydrostatic Testing (Horizontal)Leak check

/ Pressure drop

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

31.22.20.31, SP 2069, SP 2051 & SNG-69-42000P-MS-

6180-520-0000


Inspection Report H H H H

7.7 Drying of equipment Cleanliness Approved Drawing /DEP 31.22.20.31 & SP 2069 Approved DrawingInspection

Report H ----

7.8 External & Internal Surface preparation Visual Inspection for

worksmanship, profile check H ----

7.9 Painting(Internal & External)

Visual inspection for workmanship,

DFT checking, AdhesionH ---- 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

8.0 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

Approved Drawing / Data Sheet

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

6180-520-0000

Approved Drawing / Data Sheet

SP -1246 (PCS-1/9)

Inspection Report


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SP 1176 Rev. 2, DEP 30.10.02.17 Feb. 2011

GR A.I. ABB PDO







FORMAT OF RECORD


8.1Verification of Name plate and authorise

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

8.2Attachment of Stamped

name plate on the equipment

Name plate attachment confirmation Approved Drawing Approved Drawing

Rub off / Photo copy of name

plateH W

8.3 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

8.4Signing of Manufacturer's

Data Report (MDR)

Review of MDR ASME Sec. VIII Div. 1 /Approved DrawingASME Sec. VIII Div. 1 /

Approved Drawing MDR H H H R

8.5 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

8.6 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
