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Duqm Refinery Project

EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

CONTENTS

1.0 PURPOSE ........................................................................................ 3

2.0 SCOPE ............................................................................................ 3

3.0 DEFINITIONS / ABBREVIATIONS .............................................................. 3

4.0 REFERENCES .................................................................................... 3

5.0 RESPONSIBILITY & AUTHORITY .............................................................. 4

6.0 DESCRIPTION of activities .................................................................... 4

6.1 General Requirements ................................................................................................. 4


6.2 Calibration of Inspection, Measuring and Test Equipment......................................... 5
6.3 Control of Inspection, Measuring and Test Equipment .............................................. 6
6.4 Extent of Re-inspection, Re-examination or Re-Test ................................................. 8

7.0 RECORDS ........................................................................................ 9

8.0 APPENDICES..................................................................................... 9

8.1 Equipment Calibration Table .................................................................................... 10


8.2 Validation-Calibration of Welding Machines ........................................................... 13
8.3 Calibration Record of Welding Machines ................................................................. 14
8.4 Sample IM&TE Register ........................................................................................... 14

Notes:
This document shall be applied to Construction/Inspection & Test activities carried at Duqm
Refinery EPC Package 2 – Utilities and Off Site, Project sites.

This document is based on widely used international codes, standards and a good engineering
practice that is applied in Oil & Gas Projects and is intended to highlight the minimum tests and
inspections that ensure quality requirements are fulfilled within the scope of the document.

This document is generated to provide guidelines to PSJV Project teams including their sub-
contractors during preparation of project specific QCPs and shall be customized to meet specific
requirements based on applicable project specifications and/or other statutory and regulatory
requirements. It may also be utilized at bidding/proposals stage.

In case of any conflict between this document and the Project specification, drawings and
applicable codes, the project specification shall take precedence over this QCP.

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Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

1.0 PURPOSE
1.1 The purpose of this procedure is to ensure that all inspection measuring and test
equipment used during construction is checked at regular intervals and is functioning
correctly for the activity to be performed and documented. This procedure is issued to
cover the requirements of clause 7.1.5 of the ISO 9001:2015.

2.0 SCOPE
2.1 This Quality Control Procedure defines the Quality Control activities and the system to
be applied for controlling IM&TE used by PSJV and their Subcontractor(s) personnel at
Project site.

2.2 This document identifies all IM&TE that is subject to control and all applicable
information regarding calibration or functional tests, calibration methods and
intervals.

3.0 DEFINITIONS / ABBREVIATIONS


Company : Duqm Refinery & Petrochemical Industries LLC
Contractor : Joint venture of Petrofac International LTD &
SAMSUNG ENGINEERING CO.LTD
Subcontractor : All companies, firms and partnerships to whom
any part of the Work has been subcontracted by
Contractor
Project : Duqm refinery Project
ITP : Inspection & Test Plan
QC : Quality Control
QCI : Quality Control Inspector
QCE : Quality Control Engineer
SQM : Site Quality Manager
IM & TE : Inspection, Measuring and Test Equipment
RFI : Inspection Request
PPE : Personnel protective equipment
HSSE : Health safety security environment
SHALL : Indicates a requirement
SHOULD : Indicates a recommendation

4.0 REFERENCES
DRP001-OUF-PRO-Q-000-516 : QCP- Quality Observation, Daily Surveillance
& Quality Walkthrough at Site

DRP001-OUF-PRO-Q-000-514 : QCP-Closed loop RFI & Inspection Control


Procedure
DRP001-OUF-PRO-L-000-010 : Punch Control Procedure

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Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

DRP001-OUF-GMD-Q-000-500 : Project Quality Plan


DRP001-OUF-GMD-Q-000-503 : Nonconformance control procedure
DRP001-OUF-GMD-Q-000-502 : Quality Key Performance Indicators

: Vendor Quality and Environmental


DRP001-OUF-PRO-Q-000-003
Requirements
DRP001-OUF-PRO-Q-000-501 : Project Quality Audit Procedure
DRP001-OUF-PRO-Q-000-508 : Inspection Coordination Procedure with
Supplier
DRP001-OUF-PRO-Q-000-511 : Material Identification & Traceability Procedure
DRP001-OUF-PRO-Q-000-513 : Right First Time (RFT) Procedure
DRP001-OUF-SPE-Q-000-507 : QA/QC Implementation During Construction
DRP001-OUF-PRO-L-000-003 : Construction Quality Plan
All Contractor & Sub-contractor : Quality Control Procedure as applicable
documents
All Contractor & Sub-contractor : Inspection & Test Plan as applicable
documents
All Contractor & Sub-contractor : Inspection & Test Record as applicable
documents

5.0 RESPONSIBILITY & AUTHORITY


5.1 It is the responsibility of the individual department user to control the calibration of
IM & TE. It is the responsibility of all persons using IM & TE and QC Inspectors in the
field to ensure that all IM & TE is suitably identified with the calibration status in
accordance with this procedure.

5.2 PSJV QC Document Controller shall be responsible for maintaining IM&TE register and
related records. He shall distribute an updated list to all concerned on a weekly
basis.

5.3 SQM shall ensure that requirements of this procedure is implemented and strictly
followed at site during construction phase of the Project.

6.0 DESCRIPTION OF ACTIVITIES

6.1 General Requirements


6.1.1 Subcontractor shall select the appropriate inspection, measuring and test equipment
that are capable of the necessary accuracy and precision required for accomplishing
the function of determining conformance to specified requirements.
6.1.2 By thirty (30) days before starting the first inspection, examination or test,
Subcontractor shall register equipment selected in the registration list, and submit
the list together with calibration records traceable to internationally or nationally
recognized measurement standards, and / or the manufacturer's certificates to PSJV
for acceptance. Subcontractor shall separately list following items in the registration
list:
(a) Equipment to be calibrated at prescribed intervals against certified equipment

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Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

(b) Equipment to be calibrated or adjusted prior to use


(c) Equipment to be only registered
6.1.3 Subcontractor shall ensure that all equipment registered with PSJV QC are identified
with a label directly affixed on them with their registration number and expiration
period.
6.1.4 For equipment to be calibrated or adjusted prior to use, PSJV QCI will witness
calibration or adjustment performed by Subcontractor, where required.
6.1.5 When the effectiveness of any equipment is suspected during witness inspection,
examination or test, PSJV QC shall immediately request Subcontractor to replace
such equipment with properly calibrated equipment at any time.
6.1.6 All IM&TE shall be mechanically and electrically in good condition. All equipment
shall be kept in the separate location which these can be easily accessible and shall
be logged for outgoing and incoming by sub-contractor QC Document controller
6.1.7 All IM&TE shall have a valid calibration certificate and sticker indicating the
calibration date and next due.
6.1.8 All IM&TE shall be handled by competent technicians.
6.1.9 Manufacturer’s instruction manual shall be available at site for ready reference.
6.1.10All IM&TE shall be periodically calibrated/validated based on this procedure and
applicable Project specification.
6.1.11Original Calibration records of IM&TE belongs to Subcontractor shall be maintained by
each Subcontractor QC.
6.1.12Original Calibration records of IM&TE supplied by PSJV, shall be maintained by PSJV
QC Document Controller, he shall also maintain copy of calibration records received
from Subcontractor(s).
6.2 Calibration of Inspection, Measuring and Test Equipment
6.2.1 PSJV and Subcontractor(s) shall have a calibration program which assures that all
applicable IM & TE are maintained within rated accuracy for each test instrument
calibrated.

6.2.2 The firm providing calibration service shall maintain up to date calibration
instructions and procedures for each IM&TE calibrated.

6.2.3 The accuracy shall be directly traceable to the International or National


measurement standards, where no such standards exists, the basis used for
calibration or verification shall be recorded.

6.2.4 IM&TE shall be calibrated in accordance with the frequency as mentioned in


Appendix-8.1

6.2.5 Dated calibration labels shall be visible on IM&TE.

6.2.6 Records which shows date and results of IM&TE calibrated or tested must be kept up
to date.

6.2.7 Calibrating standard shall be of better accuracy than that of the IM&TE tested.

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Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

6.2.8 Calibration shall be against a certified reference standard or device whose accuracy
is:

a) Traceable to national or international standards.

b) Obtained from an independent reproducible standard derived from accepted


values of natural physical constants.

c) Otherwise verifiable to an accuracy tolerance smaller than one-half of the


smallest measurement increment on the device to be calibrated.

6.2.9 The basis used for calibration or verification shall be recorded.

6.2.10 In-house calibration of IM & TE shall be performed against certified reference


standards. The certified reference standards shall be kept under lock, under the
control of the Calibration Shop. Original calibration records for on-site and off-site
calibrations shall be held by the relevant departments and a copy forwarded to QC
department.

6.2.11 Calibration/Test records shall include the following minimum requirements:

a) PSJV Project Number


b) Description of equipment tested
c) Description of Tests
d) Test data
e) Analysis and recommendations
f) Identification of the testing organization
g) Equipment identification
h) Details of master equipment used for calibration
i) Humidity, temperature, and other conditions that may affect the results of the
tests and /or calibrations
j) Date of inspections, tests, maintenance, and/or calibrations
k) Indication of desired results when calibrations are to be performed
l) Tolerance
m) Indication of as found and as left results, as applicable
n) Actual deviation/Error
o) Sufficient space to allow all results and comments to be indicated
6.3 Control of Inspection, Measuring and Test Equipment
6.3.1 IM & TE, whether newly purchased or received from within PSJV group, will be
checked for availability of the Calibration Certificate/Certificate of Compliance
and/or previous Calibration Records prior to use in the field, for verification and
registration purposes. The absence of certification will result in the quarantine of the
equipment until certification is supplied or the equipment re-calibrated and IM & TE
registered.

6.3.2 No item of IM & TE will be issued for use at site prior to registration in the IM&TE
register and the assignment of a unique identification number by PSJV QC.

6.3.3 As individual items of IM & TE are received, along with the required certification,
each department user shall maintain a list of IM&TE available with them and submit
original Calibration certificates to Subcontractor QC department.

6.3.4 Prior to submitting calibration records to PSJV QC, Subcontractor QC shall verify
validity of calibration certificate and physical condition of IM&TE.

6.3.5 All inspection, measuring and test equipment used for the inspection or acceptance
of construction work shall be assigned, and permanently identified with an individual

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Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

serial number. These serial numbers shall be placed on the equipment by such
appropriate means as to produce durable identifications. Inspection, measuring and
test equipment with missing or illegible identification serial number shall be re-
calibrated before use.

6.3.6 Identification number shall be as follows:

Project No: Subcontractor’s Sequential


Discipline Code
Name Number

01- Civil 001 to 999

02- Mechanical 001 to 999

03- Equipment 001 to 999

Painting/Coating/Fire
04- 001 to 999
Proofing

05- PWHT 001 to 999


JIXXX XXX
06- E&I 001 to 999

07- Hydro Test/Piping 001 to 999

08- Welding 001 to 999

09- Surveying 001 to 999

10- NDT 001 to 999

All PSJV equipment shall be prefixed with “PSJV”

Example of unique identification number for IM&TE: GTP-01-001 (Civil IM&TE belongs
to Subcontractor, GTP).

6.3.7 After verification of IM&TE and Calibration record by PSJV QCE/QCI, PSJV QC
Document Controller shall:

a) Register and archive the Calibration Certificate/Certificate of Compliance and the


calibration records (if applicable) for reference.

b) Affix valid unique identification sticker (see below for sample) on IM & TE and
state re-calibration due date on the sticker.

Reg. No: JIXXX-SAMPLE-01-001

Cal. Date: Cal. Due Date: Sign by PSJV QCI:

6.3.8 IM&TE register shall record following information, where applicable:


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Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

a) Subcontractor Name

b) Registration Number

c) Equipment Name

d) Equipment Type/Model Number

e) Equipment Serial Number

f) Manufacturer’s Name

g) Calibration Frequency

h) Date calibrated

i) Calibration expiry date

j) Calibration method

k) Equipment Location

6.3.9 Departments using measuring and test equipment are responsible for monitoring
calibration due dates and submitting instruments and devices for calibration on time.
Subcontractor and PSJV QCD shall monitor relevant Departments of IM & TE, which
must be removed from use due to expired calibration period.

6.3.10 Inspectors and testing personnel will not accept measurement values obtained on
measuring and test equipment that have exceeded calibration due dates.

6.3.11 Calibration intervals shall not be longer than as specified in the respective equipment
Calibration Table (see Appendix-8.1) for each item of inspection, measuring and test
equipment. However specific requirements for each IM&TE shall be specified by PSJV
SQM by considering the nature of measurement, frequency of use, suitability,
accuracy, previous experience, and manufacturer’s recommendations.

6.3.12 Issuance, return and maintenance of the inspection, measuring and test equipment
shall be controlled by each Department user by means of logging-in/-out.

6.3.13 The QCD will confirm and monitor the calibration status of equipment during in-
process examination. Each time after the equipment recalibration, the certificates
and register to be updated
6.4 Extent of Re-inspection, Re-examination or Re-Test
6.4.1 When deficiencies are found in equipment covered by this procedure, the deficient
equipment will be immediately tagged as such (“NOT TO BE USED”) and segregated
from the construction work to prevent inadvertent further use of the equipment until
repaired and/or re-calibrated.

6.4.2 When any registered equipment is found to be out of calibration at the re-
calibration, Subcontractor shall immediately submit the evaluation reports of the
validity and acceptability of the previous inspection, examination or test results
conducted using defective equipment, and the extent of re-inspection, re-
examination, or re-test to PSJV SQM.

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Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

6.4.3 To the extent possible, previous inspection measurements made with the deficient
equipment shall be re-checked with calibrated equipment to verify accuracy of
previous measurement.

7.0 RECORDS
Nil

8.0 APPENDICES
Appendix-8.1: Equipment Calibration Table
Appendix-8.2: Validation-Calibration of Welding Machines
Appendix-8.3: Calibration Record of Welding Machines
Appendix-8.4: Sample IM&TE Register

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Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

8.1 Equipment Calibration Table


APPENDIX-8.1
EQUIPMENT CALIBRATION TABLE
CIVIL IM&TE
EQUIPMENT CALIBRATION REQUIRED CALIBRATION PERIOD (MONTHLY)
/FUNCTIONAL TEST
Test Sieves CAL 12
L.A. Apparatus (CBR Test) CAL 12
Weighing scales (Mechanical) CAL 12
Weighing scales (Electronic) CAL 12
Ovens/Dryers CAL 12
Density Meters (sand cone) F.T. prior to use
Density Meters (nuclear) F.T. prior to use
CAL (by Certified Agency) 12
Flakiness & Elongation test Sieves CAL 12
Proctor Measuring Apparatus (Mould) CAL 12
Plasticity Index Test Apparatus (Atterberg) CAL 12
Aggregates Density Mould CAL 12
Sand Density Mould CAL 12
Speedy Meter Moisture Pressure Tester F.T. prior to use
Apparatus
Slump Cone F.T. prior to use
Concrete Cubes Mould F.T. prior to use
Concrete Cubes Compression Testing CAL. 12
Apparatus
Air Content Testing Apparatus CAL 12
Concrete Schmidt Test Hammer (Rebound CAL 12
Hammer)
Timers CAL 12
Volumetric Glassware F.T. prior to use**
Batching Plant –(Concrete) F.T. prior to use
CAL (by Certified Agency) 12
**once only, after purchase prior to initial use

SURVEYING IM&TE

EQUIPMENT CALIBRATION REQUIRED CALIBRATION PERIOD (MONTHLY)


/FUNCTIONAL TEST
Automatic Level CAL 12
Electronic Digital Theodolite CAL 12
Total Station CAL 12
Electronic Distomat (EDM) CAL 12
Measuring Tape Replace, if any damage Prior to use
Spirit Level Replace, if any damage Check Spirit bubble vertically,
prior to use.

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Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

MECHANICAL IM&TE

EQUIPMENT CALIBRATION REQUIRED CALIBRATION PERIOD (MONTHLY)


/FUNCTIONAL TEST
Ultrasonic Thickness Gauge F.T./CAL prior to use. Note 1
Ultrasonic Set F.T./CAL see note.1
MPI Magnet Check CAL 12
Holiday Detector F.T. 12
Densitometer (for radiographic film F.T. prior to use
interpretation
Radiation Survey Meter CAL 6
Personal Dosimeter CAL 12
Clamp-on Meter CAL 12
Welding Gauge (Cambridge type) NOT REQUIRED NOT REQUIRED
Welding Machines CAL see Appendix-8.2
Welding Rod Ovens F.T. see note.2
Welding Rod Quivers F.T see note.2
Thermocouple for PWHT NOT REQUIRED NOT REQUIRED
Thermocouple Recorder for PWHT CAL 3
High/Low Gauge NOT REQUIRED NOT REQUIRED
Digital Thermometer CAL 12
Dry Film Thickness CAL 12
Wet Film Thickness NOT REQUIRED NOT REQUIRED
Hygro-Thermometer F.T. prior to use
Magnetic Steel Temp. Gauge NOT REQUIRED NOT REQUIRED
Surface Profile Gauge F.T. prior to use
DP/RH% Calculator F.T. prior to use
Surface Profile Comparator NOT REQUIRED NOT REQUIRED
Pressure Gauge CAL once a month
Dead Weight Tester CAL 24
(Budenberg)
Digital Pressure Gauge CAL 12
Dial Gauge CAL 12
Torque Meter F.T prior to use (note 3)
Hardness Tester (except Telebrinnel Bar F.T 12
type
Micrometers CAL 12
Vernier Caliper CAL 12
Slip Gauges CAL 12
Combination Set/Squares F.T. prior to use
Tapes/Rules NOT REQUIRED Prior to use
Purge Monitor CAL 12
Note.1: Ultrasonic sets are calibrated prior to use for testing purposes, but they require
electrical tests 12 monthly to an applicable national standard.

Note.2: Torque meters will be tested prior to use against a "Master". The "Master" will be
calibrated every 12 months by an external laboratory. The “Master” will be purchased with a
valid calibration certificate.

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Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

ELECTRICAL/INSTRUMENTATION IM&TE
EQUIPMENT CALIBRATION REQUIRED CALIBRATION PERIOD
/FUNCTIONAL TEST (MONTHLY)
Loop Tester CAL 12

Insulation Tester CAL 12

Meg Ohm Tester CAL 12

Digital Voltmeter CAL 12

Thermocouple Potentio Meter CAL 12

D.C. Power Supply CAL 12

Secondary Injection Set CAL 12

Digital Ground Resistance Tester CAL 12

Digital Calibrator CAL 12

Precision Pneumatic Calibrator CAL 12

Digital Pressure Calibrator CAL 12

Clamp-on Meter CAL 12

Current Injection Filter Unit CAL 12

Current Generator CAL 12

V/A Calibrator CAL 12

Precision Simulator CAL 12

Digital Manometer CAL 12

Decade Resistance Box CAL 12

Diaphragm Test Gauge CAL 12

Compound Test Gauge CAL 12

Fluidized Bath with Digital Temperature CAL 12


Controller
DC HV Test Set CAL 12

AC HV Test Set CAL 12

Primary Injection Set CAL 12

Lux Meter CAL 12

Analog Insulation Tester CAL 12

Digital Multi meter CAL 12

High Voltage Insulation Tester CAL 12

Cable Locator CAL 12

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Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

PAINTING-IM&TE

EQUIPMENT CALIBRATION REQUIRED CALIBRATION PERIOD


/FUNCTIONAL TEST (MONTHLY)
Coating Thickness Standard F.T Prior to use
Holiday Detector or Pin Hole Detector CAL 12
Dial Gauge F.T 12
Digital Thermometer CAL 12
Measured Foils CAL 60
Temperature Gauge CAL 12
Whirling Hygrometer or Sling F.T Prior to use
Hygrometer
Adhesion Tester CAL 12
Dolly Pull off CAL 12
Pressure Gauge CAL 12

8.2 Validation-Calibration of Welding Machines


APPENDIX-8.2

VALIDATION – CALIBRATION OF WELDING MACHINES

This validation – calibration scheme shall be used in the absence of any specific manufacturer’s
instructions.

Code of Practice for Validation of Arc Welding equipment: BS EN 50504

Grade: 1

Validation Accuracy Values:

For SMAW, GTAW, SAW, MAG/FCAW Current Accuracy + 10%

For SMAW, GTAW, SAW Voltage Accuracy + 5%

For MAG/FCAW Voltage Accuracy + 10%

For SAW, MAG/FCAW Wire Feed Accuracy + 2.5%

Instrumentation Accuracy

Electrical instruments must have accuracies at least 10 times higher than the ones indicated for
validation.

Measuring instrumentation to be used

Ammeter, Voltmeter, Stopwatch, Rule.

Variables to be measured and be validated/calibrated.

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Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

1) OCV [open circuit voltage]


2) For SMAW, GTAW, MAG take measurements for every 50 Amps starting from 50A up
to 250A and validate amps and volts.
3) For SAW take measurements for every 100 Amps starting from 100 A up to 700 A
and validate amps and volts.
4) For SAW and MAG validate repeatability of wire feed(WF) as above

Frequency of validation

Once every six months and after repairs

Records of validation / calibration for each welding machine must be kept indicating
Manufacturer, Type and Serial Number

Suggested calibration form, Appendix-8.3

General Note: The maintenance of the accuracy and the consistency of the performance of the
welding equipment is a key component in the final quality of the weld. Based on the above the use
of meters and measuring equipment on welding machines that are required to produce welds of
high integrities and reliability is strongly recommended.

8.3 Calibration Record of Welding Machines

8.4 Sample IM&TE Register

Page 14 of 15
Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
Project No. JI 2037 / SO 0267

Page 15 of 15

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