KBR

INSPECTION TEST PLAN FOR LINE PIPE

NO. INSPECTION ACTIVITY Level 1 Level 2 Level 3

Selected Level of Inspection >
1 PRE-INSPECTION MEETING H H H

2 DOCUMENTATION REVIEW
Vendor Quality Plan (To be submitted prior to Pre-Inspection Meeting) R R R
Manufacturing Schedule R R R
Manufacturing Procedure Specification R R R
Material Substitution Requests R R R
Chemical Composition of Steel R R R
Chemical & Physical Properties of Welding Material R R R
Material Test Reports R R R
NDE Procedures R R R
NDE Personnel Qualifications R R R
Welding Procedures (WPS's & PQR's) R R R
Welder Performance Qualifications R R R
Weldability Data R R R
Acceptance Test Procedure R R R
Heat Treatment Procedure R R R
Traceability Procedure R R R
Marking / Identification Procedure R R R
Hydrostatic Test Procedure R R R
Packing, Shipping, Handling & Storage Procedure R R R
Manufacturer's Data Report

3 STEEL PRODUCING (MELTING & CONTINUOUS CASTING)

Verify Electric Furnace or Basic Oxygen Furnace Steel Producing Method W SW/R R
Verify Killed / Deoxidized Practice (Si and/or Al Content) W SW/R R
Verify Fine Grain Practice (ASTM No. 8 or Finer) W SW/R R
Verify Vacuum Degassed or Argon Stirred (Thickness Above 19mm) W SW/R R
Verify Calcium Treatment (Sulfide-Inclusion Shape Control) W R R
Verify Continuous Casting Slab Production W SW/R R
Verify Hot Scarfing of Slabs (To Reveal Sub-Surface Defects) W SW/R R
Verify Chemical Analysis W R R

4 PLATE PRODUCTION
Rolling of Slabs into Plate W SW/R N/A
Heat Treatment of Plate (If Applicable) W SW/R R
Shearing / Machining Edges of Plate W SW/R N/A
Ultrasonic Examination of Sheared Edges W SW/R R
Ultrasonic Examination of Entire Plate W SW/R R

Note: H = Hold Point

W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable
 KBR

INSPECTION TEST PLAN FOR LINE PIPE

NO. INSPECTION ACTIVITY Level 1 Level 2 Level 3

Selected Level of Inspection >
5 PIPE MANUFACTURE
Verify Production Specification Level as PSL-2 (API 5L) W/R SW/R R
Verify Welding Process as DSAW W SW/R R
Verify Fused Flux for SAW W SW/R R
Verify Acceptable Mositure Control of SAW Flux W SW/R R
Verify Correct Welding Consumables W SW/R R
Monitor Production Forming & Fit-Up SW SW/R N/A
Monitor Production Welding SW SW N/A
Monitor Cold Expansion SW SW/R N/A
Monitor End Preparation SW SW N/A

6 MANUFACTURING PROCEDURE QUALIFICATION TEST

Testing as Required by API-5L (PSL-2) H H W
Radiographic Examination of Welded Seam H H W
Wet Magnetic Particle Examination of Welded Seam H H W
All Weld Metal Tensile Tests H H W
Impact Testing of Base Material (5 Sets) H H W
Impact Testing of Weld Deposit & HAZ (5 Sets) H H W
Impact Testing of Weld Deposit & HAZ (Tranisition Curves) H H W
Hardness Testing of Weld Deposit & HAZ H H W

7 INITIAL TESTING
Chemical Analysis W/R SW/R SW/R
Carbon Equivalent W/R SW/R SW/R
Tensile Tests (Base Material) W/R SW/R SW/R
Tensile Tests (Weld Deposit) W/R SW/R SW/R
Flattening Tests W/R SW/R SW/R
Manipulation Test For SWA Weld Deposits W/R SW/R SW/R
Impact Tests (Base Material) W/R SW/R SW/R
Impact Tests (weld Deposit) W/R SW/R SW/R
Drop Weight Tear Test W/R SW/R SW/R

8 PRODUCTION TESTING
Chemical Analysis W/R SW/R R
Tensile Test (Base Material & Weld Deposit) W/R SW/R R
Flattening Test W/R SW/R R
Guided Bend Test W/R SW/R R
Hardness Test W/R SW/R R
Impact Test (Base Material) W/R SW/R R
Drop Weight Tear Test W/R SW/R R
Macro Etch to Verify Out-of-Line Weld Bead W/R SW/R R

Note: H = Hold Point

W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable
 KBR

INSPECTION TEST PLAN FOR LINE PIPE

NO. INSPECTION ACTIVITY Level 1 Level 2 Level 3

Selected Level of Inspection >
9 INSPECTION OF PIPE ( * 5%-10% Random Inspection)
Traceability W SW/R SW/R
Outside / Inside Diameter W SW/R SW/R
Out-of-Roundness W SW/R SW/R
Wall Thickness W SW/R SW/R
Weight W R R
Length W SW/R SW/R
Straightness W SW/R SW/R
Dents W SW/R SW/R
Offset of Plates Edges W SW/R SW/R
Out-of-Line Weld Bead (Etch & Inspect Weld Zone of 3 Pipes Per Shift) W SW/R SW/R
Height of Weld Reinforcement W SW/R SW/R
Hard Spots W SW/R SW/R
Cracks & Leaks W SW/R SW/R
Laminations W SW/R SW/R
Arc Burns W SW/R SW/R
Undersut W SW/R SW/R
Sharp-Edged Imperfections W SW/R SW/R
Magnetism W SW/R SW/R
Pipe Ends / Bevel Preparation W SW/R SW/R

10 FABRICATION OF JOINTERS
Fit-Up of Pipe Sections W SW N/A
Monitor Production Welding SW SW N/A
Visual & Dimensional Inspection W SW SW/R
Radiographic Examination (Review All Radiographs) R R R

11 PRESSURE TESTING
Calibration of Test Gauge R R R
Calibration of Pressure Chart R R R
Hydrostatic Test W SW/R SW/R

12 NONDESTRUCTIVE EXAMINATION (After Completion of Expansion & Hydro

Ultrasonic Examination of Reference Standard / Pipe W SW/R R
Ultrasonic Examination of Weld Seam W SW/R SW/R
Ultrasonic Examination of Pipe Ends W SW/R SW/R
Wet Fluorescent Magnetic Particle Examinationof Pipe Ends & Weld End Bevel W SW/R SW/R
Radiographic Examination of Repair Welds & Weld Start / Stop Areas R R R

Note: H = Hold Point

W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable
 KBR

INSPECTION TEST PLAN FOR LINE PIPE

NO. INSPECTION ACTIVITY Level 1 Level 2 Level 3

Selected Level of Inspection >
13 MARKING, TAGGING & SHIPPING INSPECTION ( * 5%-10% Random Sampli
Cleaning, Dry Out & Surface Preparation W SW SW
Preservation, Marking, Bar Coding & Tagging W SW/R SW/R
Round-Up Spiders / Bracing W SW SW
End Shipping Protection W SW SW
Quantitative Check W SW SW
Shipping Preparation & Protection W SW SW

14 COMMENTS
* If discrepancies are detected during random sampling, additional inspection
shall be conducted to verify compliance.
If a discrepancy exists between this document and the applicable purchase
order, the information listed on the purchase order shall take precedent.

Note: H = Hold Point

W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable
 KBR

INSPECTION TEST PLAN FOR LINE PIPE

Level 4

N/A

R
R
R
R
R
R
R
N/A
N/A
R
R
N/A
R
R
R
R
R
R

R
R
R
R
R
R
R
R

N/A
R
N/A
R
R

Note: H = Hold Point

W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable
 KBR

INSPECTION TEST PLAN FOR LINE PIPE

Level 4

R
R
R
R
R
N/A
N/A
N/A
N/A

R
R
R
R
R
R
R
R

R
R
R
R
R
R
R
R
R

R
R
R
R
R
R
R
R

Note: H = Hold Point

W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable
 KBR

INSPECTION TEST PLAN FOR LINE PIPE

Level 4

SW/R
SW/R
SW/R
SW/R
SW/R
SW/R
SW/R
SW/R
SW/R
SW/R
SW/R
SW/R
SW/R
SW/R
SW/R
SW/R
SW/R
SW/R
SW/R

N/A
N/A
SW/R
R

R
R
R

R
R
R
R
R

Note: H = Hold Point

W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable
 KBR

INSPECTION TEST PLAN FOR LINE PIPE

Level 4

SW
SW
SW
SW
SW
SW

Note: H = Hold Point

W = Witness Point
SW = Spot Witness
R = Review
N/A = Not Applicable