ITP Piping-PMLSB Fire Water

INSPECTION AND TEST PLAN - PIPING WORK
CUSTOMER : OPTIMAL CONTROLLED COPY NO

PROJECT : 10" TAILGAS LINE
BY : DIALOG HOLDINGS SDN BHD
ITEM PROCESS QC SPEC /

NO DESCRIPTION ACTIVITY ACCEPTANCE CRITERIA
1 Material Control
1.1 Receipt Inspection - Check material against purchasing docs Project Proc. DH/KCTF/QC/MC.02
- Check Material Certificates DIN 50049.3.1.B
- Visual Inspection of material to ensure Relevant ASTM spec. for pipe and fittings.
conformity to relevant specification
1.2 Storage of Material - Ensure all material adequately protected N/A
1.3 Handling of materials - Ensure all material carefully handled N/A
1.4 Rectification of Nonconforming Items - Determine disposition of nonconforming Control Procedure DHSB/CP/4.14
material and follow-up corrective action
2 Welding Procedures
2.1 Qualification of WPS - Submit WPS for Approval ASME 9
3 Welder Qualification
3.1 Qualification of Welders - Perform Welder Qualification Test ASME 9
- Visual Inspection ASME 9
- Non-destructive Testing ASME 9
- Issue ID Tag N/A
1 of 22

4 Piping Fabrication
4.1 Marking / cutting / edge prep. - Visual Inspection AFC Isometric drawing /
ASME B31.3 Fig. 328.4.4
4.2 Fit-up - Fit-up Inspection WPS / ASME B31.3 Fig. 328.4.5
- Check location of branch connections AFC Isometric drawing
- Check weldolet / elbolet penetrations Cut holes must be at 90º and dressed
4.3 Tacking - Visual Inspection WPS

- Check correct consumeable WPS
4.4 Hi-Low transitions - Check with welding gauge ASME B31.3 Fig 324.8 / WPS
5 Production welding
5.1 Welding Execution - Amps, weave width WPS
6 Control of Welding Consumables
2 of 22

6.1 Receipt - Check manufacturer's certificate Project Proc. DH/KCTF/QC/MC.01
6.2 Storage - Ensure stored dry and sealed Project Proc. DH/KCTF/QC/MC.01
6.3 Baking - Bake and hold electrodes in Project Proc. DH/KCTF/QC/MC.01

accordance with manufacturer's rec.
6.4 Issuing - Record weight and type of electrodes Project Proc. DH/KCTF/QC/MC.01
issued
7 Inspection of Completed Welding

7.1 Visual - Visual Inspection ASME B31.3 - 1996
7.2 Dimensional - Dimensional Inspection AFC Isometric drawing
8 Non destructive testing

8.1 Radiography - Request RT % marked on AFC Isometric drawing
- Interpret radiographs ASME B31.3 Table 341.3.2.a and 354.3.2b
3 of 22

8.2 Magnetic Particle Examination - Evaluate Weld Quality ASME B31.3 Table 341.3.2.a and 354.3.2b
9 Welding Repairs
- Review NDT report ASME B31.3 para 328.6
- Perform repair WPS
10 Hydrostatic testing
10.1 Prior to Hydrotest - Prepare Hydrotest Packages Project Procedure DH/KCTF/QC/MW.13 (a, b)
- Review NDT and Inspection Docs N/A
- Perform Line Walk and check against ISO N/A
10.2 Hydrotest Equipment - Check rating of temporary blinds Same pressure rating as permanet material
- Check calibration of gauges and recorder Project Procedure DH/KCTF/QC/MW.13 (a, b)
10.3 During Testing - Check test pressure Apply pressure as required by P&ID Dwg
- Hold for 1 hour Project Procedure DH/KCTF/QC/MW.13 (a, b)
- Visual Inspection for leaks Project Procedure DH/KCTF/QC/MW.13 (a, b)
10.4 Reinstatement - Check that gaskets are replaced Isometric Dwg and P&ID
- Check condition of bolting Bolting is to be in new condition
- Check in-line instument etc are replaced Isometric Dwg and P&ID
4 of 22

11 Flushing / drying - Visual Inspection Piping is to be air dried and free from water
( on specific lines only )
12 Documentation - Review all Quality Records and compile N/A

QC Catalogue.
Prepared By : Tim Swift
Approved By : Chan Fok Kyong
5 of 22
WORK DOC. NO. : DH/TAILGAS/QC/MW.02 REV : 0
OLLED COPY NO. : ABBREVIATIONS
M = MONITOR W = WITNESS
R = REVIEW AP = APPROVAL
RD = RANDOM H = HOLD
VERIFYING RESPONSIBILITY INSP. STATUS REMARK
RECORD
DHSB OPTIMAL DHSB OPTIMAL
Delivery Note N/A QC Inspector W M Acceptance of material to be stamped

Material Receiving Inspection Report QC Inspector W M on Delivery Note.
Material Receiving Inspection Report QC Inspector W M
N/A Supervisor Mat. Controller W M
Supplier Corrective Action Request QA/QC Mngr - M Identify Nonconforming Material by

segregation or colour coding.
Welding Procedure Specification QC Mngr. QC Mngr. W AP

Procedure Qualification Record (PQR)
Welder Qualification Test Record QC Inspector QC Inspector W AP

RT Report QC Inspector QC Inspector W AP
ID Tag QC Inspector QC Inspector W AP
6 of 22
RECORD
N/A Supervisor QC Inspector w M
N/A QC Inspector QC Inspector W M

As Built Dwg QC Inspector QC Inspector W M
N/A QC Inspector QC Inspector M M

N/A QC Inspector QC Inspector M M Fitter to check all transitions.
N/A Welder / QC Inspector M M

QC Inspector
QC Inspector
7 of 22
RECORD
Retain all manufacturer's certificates Storeman QC Inspector W M
N/A Storeman QC Inspector W M
Baking Log Storeman QC Inspector W M
Consumable Issue Register Storeman QC Inspector W M
Visual Inspection Report QC Inspector / QC Inspector W M

Supervisor
As Built Drawing Supervisor / QC Inspector W M
QC Inspector
NDT Request QC Inspector QC Inspector W M

RT Report - QC Inspector - M Interpretation by NDT Company
8 of 22
RECORD
MT Report QC Inspector QC Inspector W M
RT Report QC Inspector QC Inspector W M Re-number weld as repair (eg R1, R2)

Visual Inspection Report QC Inspector QC Inspector W RD Repeat Inspection as above.
Test Packages QC Inspector QC Inspector W AP

Test Packages QC Inspector QC Inspector W H
Punchlists QC Inspector QC Inspector W AP
Hydrotest Checklist Supervisor QC Inspector W M

Calibration Certificates QC Inspector QC Inspector W R
Hydrotest Report QC Inspector QC Inspector W W

Reinstatement Report QC Inspector QC Inspector W M

9 of 22
RECORD
Flushing / Drying Report Supervisor QC Inspector W W Only required where indicated on dwg.
QC Catalogue QC Inspector QC Inspector W H
10 of 22
INSPECTION AND TEST PLAN - PIPING WORK (SHOP)
CLIENT : PC METHANOL SDN. BHD PLANT 1 CONTROLLED COPY
PROJECT : TO SUPPLY & CONSTRUCT FIREWATER SYSTEM
BY : WELFIELD SERVICES SDN BHD
ITEM
PROCESS DESCRIPTION QC ACTIVITY SPECIFICATION / ACCEPTANCE CRITERIA
NO
1 Drawing Control
1.1 Marking of weld nos on Isometric dwgs - Prepare AFC N/A
1.2 Workshop Receipt of Dwgs from PCMSB - Review against Drawing Masterlist N/A
2 Material Control
2.1 Receipt Inspection - Check material against purchasing docs
- Check Material Certificates DIN 50049.3.1.B
- Visual Inspection of material to ensure Relevant ASTM spec. for pipe and fittings.
conformity to relevant specification
2.2 Storage of Material - Ensure all material adequately protected N/A
2.3 Handling of materials - Ensure all material carefully handled N/A
2.4 Rectification of Nonconforming items - Determine disposition of nonconforming
material and follow-up corrective action
3 Welding Procedures
3.1 Qualification of WPS - Submit WPS for Approval ASME -IX
4 Welder Qualification
4.1 Qualification of Welders - Perform Welder Qualification Test ASME -IX
11 of 22
ITEM
NO
- Visual Inspection ASME -IX

- Non-destructive Testing ASME -IX
- Issue welder certificates ASME -IX
5 Piping Fabrication
5.1 Marking / cutting / edge prep. - Visual Inspection AFC Isometric drawing /
ASME B31.3 Fig. 328.4.4
5.2 Fit-up - Fit-up Inspection WPS / ASME B31.3 Fig. 328.4.5
- Check location of branch connections AFC Isometric drawing
- Check weldolet / elbolet penetrations Cut holes must be at 90º and dressed
5.3 Tacking - Visual Inspection WPS

5.4 Hi-Low transitions - Check with welding gauge ASME B31.3 Fig 324.8 / WPS
6 Production welding
6.1 Welding Execution - Amps, weave width WPS
12 of 22
ITEM
NO
13 of 22
ITEM
NO
7 Control of Welding Consumables

7.1 Receipt - Check manufacturer's certificate
7.2 Storage - Ensure stored dry and sealed
7.3 Baking/Holding - Bake and hold electrodes in

accordance with manufacturer's rec.
7.4 Issuing - Record weight and type of electrodes

issued
8 Inspection of Completed Welding

8.1 Visual - Visual Inspection ASME B31.3
8.2 Dimensional - Dimensional Inspection AFC Isometric drawing
9 Non destructive testing

9.1 Radiography N/A N/A
9.2 Dye-Penetration Testing - Evaluate Weld Quality ASME B31.3
9.3 Magnetic Particle Examination N/A ASME B31.3
14 of 22
ITEM
NO
10 Welding Repairs
- Review NDT report ASME B31.3
- Perform repair WPS
11 Hydrostatic testing
11.1 Prior to Hydrotest - Prepare Hydrotest Packages
- Review NDT and Inspection Report N/A
- Perform Line Walk and check against ISO N/A
11.2 Hydrotest Equipment - Check rating of temporary blinds Same pressure rating as permanet material
- Check calibration of pressure gauges
and recorder
11.3 During Testing - Check test pressure Apply pressure as required by P&ID Dwg
- Hold for 1 hour
- Visual Inspection of leaks
11.4 Reinstatement - Check that gaskets are replaced Isometric Dwg and P&ID
- Check condition of bolting Bolting is to be in new condition
- Check in-line instument etc are replaced Isometric Dwg and P&ID
15 of 22
ITEM
NO
12 Flushing / drying - Visual Inspection Piping is to be air dried and free from water
( on specific lines only )
13 Documentation - Review all Quality Records and compile N/A

QC Catalogue.
Prepared By : Approved By:
Name : Name :
Date : Date :
Signature : Signature :
16 of 22
DOC. NO. : WSSB/PML/ITP/01/2012 REV : 0
ROLLED COPY NO. : ABBREVIATIONS
RESPONSIBILITY INSP. STATUS REMARK
VERIFYING RECORD
WSSB PCMSB WSSB PCMSB
Approved Isometrics Dwgs QC Inspector QC Inspector R/AP R/AP

Transmittals Supervisor QC Dept. R R
Delivery Note Mat. Controller QC Inspector W M Acceptance of material to be stamped

Material Receiving Inspection Report Mat. Controller QC Inspector W M on Delivery Note.
Material Receiving Inspection Report Mat. Controller QC Inspector W M

Supplier Corrective Action Request QA/QC Mngr./ - W M Identify Nonconforming Material by
QC Inspector segregation or colour coding.
Welding Procedure Specification QC Mngr. QC Mngr. W AP

Procedure Qualification Record (PQR)
Welder Qualification Test Record QC Inspector QC Inspector W W
17 of 22
VERIFYING RECORD

RT Report QC Inspector QC Inspector W AP
Welder Certificates QC Inspector QC Inspector W AP
N/A Supervisor QC Inspector W M

As Built Dwg QC Inspector QC Inspector W M

N/A QC Inspector QC Inspector M M Fitter to check all transitions.

QC Inspector
18 of 22
VERIFYING RECORD
QC Inspector
19 of 22
VERIFYING RECORD
Retain all manufacturer's certificates Storeman QC Inspector W M
N/A Storeman QC Inspector W M
Baking Log Storeman QC Inspector W M
Consumable Issue Register Storeman QC Inspector W M
Visual Inspection Report QC Inspector QC Inspector W RD

As Built Drawing QC Inspector QC Inspector W RD
N/A
DPT Report QC Inspector QC Inspector W W Interpretation by NDT Company
MT Report QC Inspector QC Inspector W W
20 of 22
VERIFYING RECORD
NDT Report QC Inspector QC Inspector W M Re-number weld as repair (eg R1, R2)
Visual Inspection Report QC Inspector QC Inspector W RD Repeat Inspection as above.
Test Packages QC Inspector QC Inspector R/AP R

N/A QC Inspector QC Inspector R/AP R
Punchlists QC Inspector QC Inspector W W
Hydrotest Checklist Supervisor QC Inspector W M

Calibration Certificates QC Inspector QC Inspector R R


21 of 22
VERIFYING RECORD
Flushing / Drying Report Supervisor QC Inspector W W Only required where indicated on dwg.
QC Document QC Inspector QC Inspector R/AP H
Appraised By (PCMSB):
Name :
Date :
Signature :
22 of 22

ITP Piping-PMLSB Fire Water

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INSPECTION AND TEST PLAN - PIPING WORK

CUSTOMER : OPTIMAL CONTROLLED COPY NO

ITEM PROCESS QC SPEC /

1.3 Handling of materials - Ensure all material carefully handled N/A

ITEM PROCESS QC SPEC /

4.3 Tacking - Visual Inspection WPS

- Check correct consumeable WPS

6 Control of Welding Consumables

ITEM PROCESS QC SPEC /

6.1 Receipt - Check manufacturer's certificate Project Proc. DH/KCTF/QC/MC.01

6.3 Baking - Bake and hold electrodes in Project Proc. DH/KCTF/QC/MC.01

7 Inspection of Completed Welding

7.2 Dimensional - Dimensional Inspection AFC Isometric drawing

8 Non destructive testing

ITEM PROCESS QC SPEC /

ITEM PROCESS QC SPEC /

12 Documentation - Review all Quality Records and compile N/A

Prepared By : Tim Swift

Approved By : Chan Fok Kyong

Delivery Note N/A QC Inspector W M Acceptance of material to be stamped

N/A Supervisor Mat. Controller W M

N/A Supervisor Mat. Controller W M

Supplier Corrective Action Request QA/QC Mngr - M Identify Nonconforming Material by

Welding Procedure Specification QC Mngr. QC Mngr. W AP

Welder Qualification Test Record QC Inspector QC Inspector W AP

N/A Supervisor QC Inspector w M

N/A QC Inspector QC Inspector W M

N/A QC Inspector QC Inspector M M

N/A QC Inspector QC Inspector M M Fitter to check all transitions.

N/A Welder / QC Inspector M M

N/A Storeman QC Inspector W M

Baking Log Storeman QC Inspector W M

Consumable Issue Register Storeman QC Inspector W M

Visual Inspection Report QC Inspector / QC Inspector W M

NDT Request QC Inspector QC Inspector W M

RT Report QC Inspector QC Inspector W M Re-number weld as repair (eg R1, R2)

Test Packages QC Inspector QC Inspector W AP

Hydrotest Checklist Supervisor QC Inspector W M

Hydrotest Report QC Inspector QC Inspector W W

Reinstatement Report QC Inspector QC Inspector W M

QC Catalogue QC Inspector QC Inspector W H

- Visual Inspection ASME -IX

5.3 Tacking - Visual Inspection WPS

- Check correct consumeable WPS

7 Control of Welding Consumables

7.2 Storage - Ensure stored dry and sealed

7.3 Baking/Holding - Bake and hold electrodes in

7.4 Issuing - Record weight and type of electrodes

8 Inspection of Completed Welding

9 Non destructive testing

13 Documentation - Review all Quality Records and compile N/A

Prepared By : Approved By:

Approved Isometrics Dwgs QC Inspector QC Inspector R/AP R/AP

Delivery Note Mat. Controller QC Inspector W M Acceptance of material to be stamped

N/A Supervisor Mat. Controller W M

Welding Procedure Specification QC Mngr. QC Mngr. W AP

Welder Qualification Test Record QC Inspector QC Inspector W W

Welder Qualification Test Record QC Inspector QC Inspector W AP

N/A Supervisor QC Inspector W M

N/A QC Inspector QC Inspector W M

N/A QC Inspector QC Inspector M M

N/A QC Inspector QC Inspector M M Fitter to check all transitions.

N/A Welder / QC Inspector M M