(732-ITP-90 (V-6901) 42000-SNG-69-42000P-MS-5733-551-0000-06

PETROLEUM DEVELOPMENT

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

Vendor Doc. No. : 732/QAP/90 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 6901

(Kauther Slug Catcher)

PDO Doc. No.: Rev. 06

SNG-69-42000P-MS-5733-551-0000

Project No. 20036 Unit Description:

INSPECTION & TEST PLAN (QAP) FOR V 6901 (Kauther Slug Catcher)

MR NO. :- 20036-0100-M31-MR-42000 REV. 02 PURCHASE ORDER NO. :- 4580041305 TAG No. : V 6901 POS. : 00010 ITEM NO. :- 00011. VESSEL CATEGORY:- ENGINEERED PRESSURE VESSEL NACE MR-01-75 & SOUR SERVICE

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

732/QAP/90 Page 2 of 8...

CLIENT : ABB S.p.A - Italy. QAP No. : 732/QAP/90 Rev. 6P.O. No. : 4580041305/01 DTD 14-03-2013. DATE : 19/05/2014EQUPT. No. : V 6901. CODE OF CONSTRUCTION : ASME SEC. VIII DIV 2 ED 2010 ADDENDA 2011PROJECT NAME : SAIH NIHAYDA CONDENSATE STABILIZATION PLANT (SNCP) DRG. No. : 732-E-90CONTRACTOR JOB No. : 20036 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 PDO

1.0

1.1 Drawing , Design Calculations Review of Documents ASME Sec. VIII Div. 2/ 20036-0100-M31-MR-42000ASME Sec. VIII Div. 2

/ 20036-0100-M31-MR-42000

Approved Drawing, Design

CalculationsH R RA RA

1.2 Quality Assurance Plan, IRR Approval Review of documentsASME Sec. VIII Div. 2/ Approved Drawing

/ 20036-0100-M31-MR-42000

ASME Sec. VIII Div. 2/ 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. 2 /

/ Approved Drawing/ 20036-0100-M31-MR-42000

ASME Sec. VIII Div. 2 / / Approved Drawing

/ 20036-0100-M31-MR-42000

Procedure Documents H R RA RA

1.4 Pre inspection meetingReviewing & understanding of

technical requirements and Approval of MTC.

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

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

Minutes ofmeeting H ---- H H

2.0

Material after receipt (For Pressure Parts)

Plates, Pipes

H H RA RA

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

Scope of InspectionREMARKS

DOCUMENTS

SL.NO STAGE / ACTIVITY TYPE OF CHECK REFERENCE DOCUMENT

ASME Sec.-II A/B / Data sheet / Approved

Drawing

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

ASME Sec.-II A/B / Data sheet / Approved

Drawing / TDC / SP 2069, SP 2041, DEP 31.22.20.31 & NACE-MR-01-75.

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) Sulfur (s) = 0.003 % (Max) for plate, 0.01% for seamless product, 0.025% for forging, Vanadium (V) + Niobium (NB) = 0.03 (Max) Carbon Equivalent (CE) = 0.43% (t 50mm) & 0.45 % (50mm < t 200mm) 3) Clad plate material shall be ultrasonically tested at the mill in accordance with ASME SA-578.4) Forged products above 50 mm thick shall be 100 % ultrasonically examined

ACCEPTANCE NORMS FORMAT OF RECORD

G.R.ENGINEERING PRIVATE LTD. -TARAPUR

INSPECTION & TEST PLAN (QAP) FOR V 6901

MATERIAL INSPECTION

2.1

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

damages & Dimesional inspection, Transfer of identity &

physical verification.

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

732/QAP/90 Page 3 of 8...





SP 1176 Rev. 2, DEP 30.10.02.17 Feb. 2011,

GR A.I. ABB PDO

Scope of InspectionREMARKSSL.NO STAGE / ACTIVITY TYPE OF CHECK REFERENCE DOCUMENT





2.2Non Pressure Parts (including internals,

supports etc.)

Review of Material Test Certificates

ASME Sec.-II A, Approved Drawing,

SP 2069, DEP 31.22.20.31

ASME Sec.-II A, Approved Drawing

Material Test Certificates H --- R R

3.0

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

ASME Sec. IX / Approved Drawing / DEP 30.10.60.18 &

31.22.20.31

ASME Sec. IX Weld Plan H R RA RA

3.2 PQR Welding parameters ASME Sec. IX

/ Approved Drawing / DEP 30.10.60.18

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

3.3 WPQ Qualification requirementsASME Sec. IX

/ Approved Drawing / DEP 30.10.60.18

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

3.4 Welding Consumable Chemical & mechanical properties ASME Sec. II Part C

/ DEP 30.10.60.18 ASME Sec. II Part CBatch Test Certificate R R R R

4.0

Visual & Dimensional inspection including profile check &

minimum thickness mesurementH W W

Dye Penetrant Test (to detect cracks inside &

outside knuckle surface area) H R W

Normalising of dished ends. Heat Treatment Chart H R R

Simulation Test Coupon of normalised dished end.

Inspection Report H W H W Test Coupon for physical test

UT to check lack of bond after forming 100 % surface area UT report H ---- W

UT shall be carried out in accordance with specification ASME SA-578 level 1

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

RT films review.

WELDING INSPECTION WPS & PQR

Inspection report

Inspection of Formed Components

Inspection of Formed Components

(Dished ends)


/ SP 2069 Appendix 8, SP 1176, DEP 31.22.20.31

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

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

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

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

ASME Sec. VIII Div. 2/ Approved Drawing4.1


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SP 1176 Rev. 2, DEP 30.10.02.17 Feb. 2011,

GR A.I. ABB PDO






5.0

Visual & dimensional inspection, weld edge,cut back, root - gap, offset, alignment & cleanliness

etc. for long seams of shell, dished end & nozzles

H H 10%W5 %W

Visual & dimensional inspection, weld edge, cut back, 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. 2 /Approved Drawing /

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

ASME Sec. VIII Div. 2 Inspection Report H R10%W

5 %W

5.2 Intermediate Inspection of welds Visual / Interpass temperature / PT insp. after backchip

ASME Sec. VIII Div. 2 & Sec. IX / Approved Drawing

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

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

ASME Sec. VIII Div. 2 & Sec. IX

Inspection Report H R S S

Visual inspection for reinforcement, undercuts, surface

defects etc.

ASME Sec. VIII Div. 2 & 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)

MT of welds

ASME Sec. VIII Div. 2/Approved Drawing

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

ASME Sec. VIII Div. 2 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. 2/Data sheet /

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

6038-536-0000

ASME Sec. VIII Div. 2 RT Report H R RA RA Review of Radiography films

5.3Base Metal Welding

(Inspection of completed CS weld)

Inspection during fabrication

5.1

ASME Sec. VIII Div. 2 / Approved Drawing

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

Weld edge perparation & setup of pressure parts

( Long seam, circular seam, nozzle neck

to flange, nozzle on shell/head)


Inspection Report


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SP 1176 Rev. 2, DEP 30.10.02.17 Feb. 2011,

GR A.I. ABB PDO






Visual inspection for reinforcement, undercuts, surface

defects etc.

ASME Sec. VIII Div. 2/ SNG-69-42000P-MS-

6038-517-0000


Inspection Report H W W W

PT of final layer


/ DEP 31.22.20.31 CL 6.5 /SNG-69-42000P-MS-

6038-539-0000

ASME Sec. VIII Div. 2, Appendix 8

Inspection Report H R W W

Chemical analysis of weld overlay

ASME Sec. VIII Div. 2 /Approved Drawing

/ ASME Sec. II C / SP 2069ASME Sec. II C Inspection Report H R RA RA

Chemical analysis of one seam from each shell course and one seam from each head.

Alloy elements to be checked as per ASME II Sec. C

Visual / Dimensional Inspection H R R R

PT for fillet welds of lifting lugs and other

pressure bearing weldsH R R R

Final visual & dimensional Inspection

ASME Sec. VIII Div. 2 / Approved Drawing / SNG-69-42000P-MS-

6038-517-0000


Inspection Report H W H H

MT of finish welds

ASME Sec. VIII Div. 2 & Sec. V , DEP 31.22.20.31 /

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

6038-540-0000

ASME Sec. VIII Div. 2 Inspection Report H R S S

RT of finish welds



6038-536-0000

ASME Sec. VIII Div. 2 Inspection Report H R RA

Mechanized UT of Category A, B (above 50mm thk) & D welds

ASME Sec. VIII Div. 2 /Data sheet /


6038-525-0000

ASME Sec. VIII Div. 2 Inspection Report H R W W

5.5 Fitment & Welding of Internal & External attachments etc.


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

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


5.4Overlay welding

(Clad restoration)

Inspection Report

5.6 Inspection of the equipment before PWHT


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SP 1176 Rev. 2, DEP 30.10.02.17 Feb. 2011,

GR A.I. ABB PDO






5.7 Inspection of the equipment before PWHT PMI examination of

alloy materials & welds

ASME Sec. II- B/C, / DEP 31.10.00.10, SP 2069,

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

ASME Sec. II- B/C PMI Report H R W W

5.8 Post Weld Heat Treatment of equipment Review of Heat Treatment Cycle


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


Heat Treatment Chart H R RA R

PWHT of equipment Soaking Temperature :- 61010C.

Soaking Time :- 135 minutes minimum.

100 % PT of weld overlay machine surface


/ DEP 31.22.20.31 CL 6.5 /SNG-69-42000P-MS-

6038-539-0000

ASME Sec. VIII Div. 2, Appendix 8

Inspection Report H R W W

RT of Pressure part butt welds for thk below 50mm



6038-536-0000


MT of Pressure part welds

ASME Sec. VIII Div. 2/Approved Drawing

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


Mechanized UT of Category A, B (above 50mm thk) & D welds

ASME Sec. VIII Div. 2 /Data sheet /


6038-525-0000

ASME Sec. VIII Div. 2 Inspection Report H R W W

Hardness test of welds, HAZ

ASME Sec. VIII Div. 2 / Approved Drawing /

SP 2069 Appendix-8, DEP 31.22.20.31 CL 6.2, SNG-69-42000P-MS-6061-526-0000


Hardness test report H R W W

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

service conditions.

5.9 NDE after PWHT


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SP 1176 Rev. 2, DEP 30.10.02.17 Feb. 2011,

GR A.I. ABB PDO






6.0

6.1Final Visual & Dimensional

Inspection(Internal & External)

Dimensions, completeness of the assembly, as built thickness measurement


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


Inspection Report H H H H

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

Internals supplier Drawings P.O. /

Internals supplier Drawings Inspection

Report H W W

6.3 Interior & exterior cleaning

All completed equipment shall be cleaned internally and externally to remove scale, weld spatter,dirt,

and foreign material.

Approved Drawing / DEP 30.22.20.31 Approved Drawing

Inspection Report H R R

6.4 Hydrostatic Testing (Horizontal) Leak check

/ Pressure drop


/ DEP 31.22.20.31 CL 6.9, SP 2069 CL 6.2,

SP 2051 CL 6.4.4,SNG-69-42000P-MS-

6180-520-0000


Inspection Report H H H H

6.5 Drying of equipment CleanlinessApproved Drawing

/ DEP 31.22.20.31 CL 6.9, SP 2069 CL 6.2.

Approved Drawing Inspection Report H ----

6.6 External Surface preparation Visual Inspection for worksmanship, profile check H ----

6.7 PaintingVisual inspection for

workmanship, DFT checking, Adhesion

H ---- W W

Painting shall be checked for surface chloride contaimination , Holiday / pinhole, Adhesion test & DFT test.Criteria

of Acceptability as per specification SP-1246

Part-1 Table B1

7.0 Inspection of Mandatory & Commissioning spares Verification of spares20036-0100-M31-MR-42000 / Approved Drawing / P.O.

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

FINAL INSPECTION

Approved Drawing / Data Sheet /

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

6180-521-0000

Approved Drawing / Data Sheet /

SP -1246 (PCS-1)

Inspection Report


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SP 1176 Rev. 2, DEP 30.10.02.17 Feb. 2011,

GR A.I. ABB PDO






7.1Verification of Name plateand authorise for ASME

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

7.2Attachment of Stamped

name plate on the equipment

Name plate attachment confirmation Approved Drawing Approved Drawing

Rub off / Photo copy

of name plateH W

7.3 Inspection Release Note / Despatch ClearanceVerification of documents & issue

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

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

7.4 Signing of Manufacturer's Data Report (MDR) Review of MDRASME Sec. VIII Div. 2 / Approved Drawing

ASME Sec. VIII Div. 2 / Approved Drawing MDR H H H R

7.5 Check of packing & packing listVisual inspection /

Varification P.O. /

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

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

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

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

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

Legends :

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

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