Inspection Test Plan

SAUDI ARAMCO
THERMAX LIMITED WELDING PROCEDURE SPECIFICATIONS

BOILER & HEATER GROUP
INSPECTION & TEST PLAN (QA PLAN) FOR CONTROL NO. : ITP/ERPLN /P01
SAUDI ARAMCO
REVISION NO.: 0
WELDING PROCEDURE SPECIFIC
BOILER DRUMS DATE : 28-05-2011
PAGE : 1
1.0 JOB SPECIFIC DATA : -
CUSTOMER :
SAUDI ARAMCO
WELDING PROCEDURE SPECIFICATIONS
CONSULTANT : - PROJECT NO:
INSP. AGENCY: DESIGN CODE :
2.0 QUALITY STAGES & INSPECTION :
SR. INSPECTION STAGES ACCEPTANCE * INSP. BY

NO. STANDARD
CHARACTERISTICS METHOD EXTENT TL CLI
1 MATERIAL IDENTIFICATION H H
Review & Verification of Material Test Certs. & Drawing Review 100% Drawing, ASME Sec-II
Correlation of MTC with Material Visual 100% Mill Test

Certificate
Dimensional Inspection Measurement 5% Drawing/ Mill Test

Certificate
Identification-Boiler/Heat/Plate/ Part/Shell No.& Mat.Specs. Visual 100% Identification

Punching
IA Stamp Transfer Verify 100% Stamp Transfer
Verify UT Testing for Plate & Nozzle Forgings in MTC Review 100% Material Spec.
HOT ROLLED DRUM:Simulated Heat Treatment & PWHT test coupon Review 1 Sample HT Cycle & Material
/Heat Specs./Code
Identification & Dimensional Inspection of Dished Ends Measurement 100% Drawing
Document review for Dished Ends & Manhole Rims Review 100% Drawing & Code
Identification & Dimensional Inspection of Manhole Rims Measurement 100% Drawing
2 SETUP OF L-SEAMS OF SHELL ALONGWITH TEST COUPON H H
Production Test Coupon with L-Seam Verify One PTC / IBR-1950

Heat/Drum
Intermediate SR (if D/T<20 for CS & <18 for AS) Review of 100% IBR-1950/HT
HT chart Procedure
Ovality, (Inside dia. Min & Max.) Measurement 100% 1% of Nominal ID or

5mm max.
*INSP.BY -THERMAX LI IBR -IBR CLI -CLIENT/TPI
Session : tccom9420m040 INSPECTION & TEST PLAN (QA PLAN) Contd...

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO
CHARACTERISTICS METHOD EXTENT TL IBR CLIWELDING PROCEDURE SPECIFICATIONS
Shell length, Outside circumference Measurement 100% Drawing
Profile D/4 100% Drawing, IBR 1950

Template
Weld Preparation Template 100% Drawing
Offset / Mismatch Measurement 100% 10%of Nominal plate

thickness or 3mm max
Flaw detection on weld edges PT/MT 100% Free from

Lamination, Crack &
Liner Indications
Tack Weld Soundness PT 100% Procedure PT(Refer

Note No.3)
Shell identification/IA Stamp Visual 100% Drawing, IA Stamp
3 L-SEAM WELDING H R
Backgauging after 1st side welding PT/MT 100% Procedure PT/MT
Inspection after both side welding Visual 100% Procedure VT
Weld reinforcement - Flush ground from Outside Visual 100% IBR-1950
Inspection after Re-rolling of shell:
Profile D/4 100% Within 0.3% of ID

Tempelate
Ovality Measurement 100% 1%of ID or 5mm Max.
Welder/Welding Operator ID Visual 100% Qualified welder

list/IBR Certificate
Weld soundness RT & MT 100% Procedure RT, MT
NDE for CS Drum thk. >&= 100 mm & AS Drum thk. >&=50mm UT 100% Procedure UT
4 PWHT & TESTING OF PTC H H
Heat-Treatment Cycle Review 100% IBR-1950
Heat-Treatment Compliance to Code Review of 100% IBR-1950

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO. STANDARD
SAUDI ARAMCO
HT chart
Mech. Properties of PTC Mechanical One PTC / Material

Testing Heat /Dru Specifications
5 C-SEAM SETUP H H
Orientation Visual 100% Drawing
Total length Measurement 100% Drawing
Alignment of shell courses Visual & 100% 1mm/mtr, 5mm max.

Measureme
Weld preparation Template 100% Drawing
Alignment / Root offset. Measurement 100% 10% of Nominal plate

thickness + 1mm or
4mm max.
Flaw detection on weld edges. PT/MT 100% Free from

Lamination, Crack &
Liner Indications

Note No.3)
IF WELD PROCESS & HT IS DIFFERENT THAN L-SEAM WELDING :
Production Test Coupon with C-seam Verify One PTC / IBR-1950

Heat/Drum
6 C-SEAM WELDING H R
Weld reinforcement -Flush ground from outside Visual 100% IBR-1950
Welder/Welding Operator ID Verify 100% Qualified welder

list / IBR Certifica
te
*INSP.BY /TPI

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

NO. STANDARD
SAUDI ARAMCO
7 BUTT WELD SETUPS FOR NOZZLES/STUBS H H
Alignment Measurement 10% Drawing
Setup Dimensions Measurement 10% Drawing
Tackweld Soundness by PT PT 100% Procedure PT(Refer

Note No.3)
8 WELDING OF BUTT WELDS OF NOZZLES/STUBS H R
Weld Soundness RT 100% Procedure RT
9 NOZZLES,STUBS,MH RIM & OTHER OPENINGS ON SHELL/D'END H -
MARKING ON SHELL :
Four Quadrant distribution & Punching Combination 100% Within 2 mm

set, W.L
Drum Centreline punching Measurement 100% Equidistant within 1

mm
-No. & size of holes Count & 100% Drawing

Visual
-Distance from reference, Tangential Distance Measurement 100% Drawing
-Orientation Visual 100% Drawing
MARKING ON D'END :
-Four Quadrant distribution & Punching Measurement 100% Within 2 mm
- No. & size of holes Count & 100% Drawing

Visual
- Distance from reference, Tangential Distance Measurement 100% Drawing
- Orientation Visual 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5

NO. STANDARD
SAUDI ARAMCO
10 INSPECTION OF OPENINGS H -
1) Opening on shell
Number of holes count 100% Drawing
Distance from reference Measurement 100% Drawing
Size of holes Measurement 100% Drawing
Visual Inspection Visual 100% No surface

defects(Refer Note N
o.3)
- Nozzle Openings >&=10NPS PT/MT 100% Procedure PT/MT
2) Opening on D'end
Number of holes Count 100% Drawing
Orientation. Visual 100% Drawing
Size of holes Measurement 100% Drawing
Visual Inspection Visual 100% No surface

defects(Refer Note N
o.3)
Flaw detection on M/H Opening PT/MT 100% Procedure PT/MT
11 SETUP OF NOZZLES,STUBS,MH RIM & OTHER BRANCH CONNECTIONS ON SHELL/D'END H H
SETUP OF MH RIM WITH D'END
-Projection from shell Measurement 100% Drawing
-Alignment & Squareness. Measurement 100% Within 1 Degree/ 3mm

max.
-Weld preparation. Template 100% Drawing
-Tackweld soundness. PT 100% Procedure PT(Refer

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 6

NO. STANDARD
SAUDI ARAMCO
Note No.3)
SETUP OF NOZZLES WITH D'END
- Identification & Orientation. Visual 100% Drawing
- Alignment & Squareness. Measurement 100% Within 1 Degree/ 3mm

max.
- CTC distance/Projection Measurement 100% Drawing
- Weld preparation Template 100% Drawing
- Tackweld soundness PT 100% Procedure PT(Refer

Note No.3)
SETUP OF NOZZLES WITH SHELL:
-Identification & Orientaion Visual 100% Drawing
-Alignment & Squareness Measurement 100% Within 1 Degree/ 3mm

max.
-CTC distance/Projection Measurement 100% Drawing
-Weld preparation Template 100% Drawing
-Tackweld soundness PT 100% Procedure PT(Refer

Note No.3)
12 WELDING OF NOZZLES,STUBS,MH RIM & OTHER BRANCH CONNECTIONS ON SHELL/D'END H R
I) WELDING OF MANHOLE RIM WITH D'END
-Backgauging after 1st side welding PT 100% Procedure PT
-Weld visual Inspection Visual 100% Procedure VT(Refer

Note No.3)
-Weld size Measurement 100% Drawing
-Weld soundness UT & MT 100% Procedure UT, MT
-Welder ID. Verify 100% Qualified welder

list

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 7

NO. STANDARD
SAUDI ARAMCO
II) WELDING OF NOZZLES WITH D'END
- Weld visual inspection Visual 100% Procedure VT(Refer

Note No.3)
- Weld size Measurement 100% Drawing
- Welder ID. Verify 100% Qualified welder

list
- MT of all Nozzle Welds MT 100% Procedure MT
Full penetration welds >=10 NPS or above 25 thk UT/RT 100% Procedure UT/RT
Full penetration set through nozzle welds UT/RT 100% Procedure UT/RT
III) WELDING OF NOZZLES WITH SHELL:
-Weld Visual inspection Visual 100% Procedure VT(Refer

Note No.3)
-Weld Size Measurement 100% Drawing
-Welder ID Verify 100% Qualified welder

list
-Full penetration Nozzle welds>=10NPS & Safety valve nozzle UT/RT 100% Procedure UT/RT
& Full penetration Nozzle welds> 25mm thick UT/RT 100% Procedure UT/RT
-Full penetration set through nozzle welds UT/RT 100% Procedure UT
-MT of All Nozzle welds MT 100% Procedure MT
13 IDENTIFICATION AND DIMENSIONS OF MANHOLE COVER PLATE & PLACING INSIDE THE DRUM H R
Identification Visual 100% Drawing
Dimensions Measurement 100% Drawing
14 SETUP OF DISHED END TO SHELL H H
Orientation & Alignment of shells Visual & 100% Drawing

Measureme
Weld preparation Template 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 8

NO. STANDARD
SAUDI ARAMCO
Alignment / Root offset Measurement 100% 10% of Nominal plate

thickness + 1mm or
4mm max.
Flaw detection on weld edges PT/MT 100% Free from

Lamination, Crack &
Liner Indications

Note No.3)
Performance Qualification for Welding Operator Verify 100% Qualified welder

list
15 WELDING OF DISHED END TO SHELL H R
Weld reinforcement- Flush ground from outside Measurement 100% Drawing, IBR-1950
Welding Operator ID Visual 100% Qualified welder

list
16 CLEARANCE FOR PWHT H H
Compliance of all Welding,including Ext./Inetrnal attachment Verify 100% Drawing
Overall Major Dimensions Measurement 100% Drawing
NDE Clearance Verify 100% NDT Reports
Nozzle Butt Welds RT 100% Procedure RT
Lifting Lug UT 100% Procedure UT
**NDE of all accessible Pressure Retaining Welds MT 100% Procedure MT
**If not covered earlier

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 9

NO. STANDARD
SAUDI ARAMCO
All attachment Welds MT/PT 100% Procedure MT/PT
Removal of all temporory attachment Welds MT/PT 100% Procedure MT/PT
Traceability of weld joints Review 100% Completed weldmap
17 PWHT H R
Heat-Treatment Cycle Review 100% Heat Treatment

Procedure
Heat-Treatment Compliance to Code Review of 100% Heat Treatment

HT chart Procedure
18 INSPECTION & NDE AFTER PWHT H R
Major Dimensions Measurement 100% Drawing
Flange facing Visual 100% Drawing
LSeam, CSeam, Nozzle Welds PT/MT 10% Procedure PT/MT
All T-joints PT/MT 100% Procedure PT/MT
MT of MH rim to D'end welds, accessible area MT 100% Procedure MT
Safety valve nozzle welds MT 100% Procedure MT
Nozzle Welds >=10NPS or above 25thk MT 100% Procedure MT
NDE for CS Plate thk >&= 100mm & AS Plate thk. >&=50mm **
**UT/RT of Shell seams (L & C Seams) UT/RT 100% Procedure UT/RT
**All accesible pressure retaining welds(LS,CS,Nozzle Welds) PT/MT 100% Procedure PT/MT
19 HYDROSTATIC TEST H H
Hydro Test Verify 100% Drawing, Hydrostatic

test Procedure
Recording Deformation : Measurement Every Shell No Permenant

Deformation
Outside Circumference at 0 Kg/SqCm

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 10

NO. STANDARD
SAUDI ARAMCO
Outside Circumference at MAWP
Outside Circumference at HTP
Outside Circumference at 0 Kg/SqCm
Pressure test result Record 100% Satisfactory
IA Stamp/Code punching on satisfactory Pressure test Visual / 100% IBR-1950, Legible

Rub-off Stamping & Rub-off
20 DRAINING & DRYING AFTER HYDRO TEST H -
Draining, Drying & Cleaning Visual 100% Inside surface shall

be Dry & Clean
21 MARKING FOR DRILLING H -
Orientation of rows Measurement 100% Drawing
No.of rows count 100% Drawing
No.of Openings/Holes per row Count 100% Drawing
Pitch Measurement 100% Drawing
Hole size Visual 100% Drawing
22 DRILLING INSPECTION H -
Orientation of rows Visual 100% Drawing
No.of rows count 100% Drawing
No.of Holes per row Count 100% Drawing
Distances from refernce lines Measurement 100% Drawing
Linear Ligament (minimum) Measurement 100% Drawing
Circumferencial Ligament (minimum) Measurement 100% Drawing
Hole Diameter Plug gauge 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 11

NO. STANDARD
SAUDI ARAMCO
Groove dimensions Measurement 100% Drawing
Surface Finish of Drilled Holes Visual 10% 125 to 250 RMS
Quadrant Line Punching for Reference Measurement 100% Drawing
NDE on Holes coming on shell welds ** PT/MT 100% Procedure PT/MT
** Note :Both side flush grinding to be done before NDT
23 FINAL INSPECTION H H
Fitment of Drum Internals Verify 100% Drawing
Attachments of all non pr.parts internal/exteral Visual 100% Drawing
Compliance to Drg for Scope Verify 100% Drawing BOM
Traceability of weld joints Review 100% Completed Weldmap
Centreline punching Visual 100% Drawing
Code Compliance Certificati 100% Compillation of

on / Docum stage IR's & MTC's,
Code
24 PAINTING INSPECTION H -
Surface Preparation Visual 100% Drawing, Painting

Specs.
Paint Shade, Make, Batch No. Visual 100% Drawing, Painting

Specs.
Visual Inspection after painting Visual 100% Complete coverage of

area, No rundowns,
Peel-offs, Cracks
Paint-Dry Film Thickness (DFT) Measurement Random Drawing, Painting

Specs.
Application of rust prevention oil on inside surface Visual 100% Drawing/Specs.
Capping / Blanking of all Openings Visual 100% All Openings Shall

be Covered /Capped

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 12

NO. STANDARD
SAUDI ARAMCO
Marking of C/L punching Visual 100% All drum centreline

marked
25 INSPECTION RELEASE NOTE H -
Final Document Review Review 100% Drawing, Compilation

of document
Inspection Release Note Issuance of

IRN
3.0 NOTES :
1) Following documents, as applicable are to be reviewed during inspection.
1. WPS,PQR,WPQ and Welding Technology sheet(WTS)

2. Material Test Certificates
3. Manufacturing Records
4. All the required Inspection Records.
Following Documents shall be referred for this QAP (As Applicable) :
1) NDE Procedures
+---+-----------+-------------------------------------------+
|Sr.|Control No.|Procedure Description |
+---+-----------+-------------------------------------------+
|1) |RT12 |Radiographic Examination of Welded Joints |
+---+-----------+-------------------------------------------+
|2) |PT1 |Liquid Penetrant Examination |
+---+-----------+-------------------------------------------+
|3) |MT3 |Magnetic Particle Examination |
+---+-----------+-------------------------------------------+
|4) |UT2 |Ultrasonic Examination Of Butt Welds |
+---+-----------+-------------------------------------------+
|5) |UT4 |Straight Beam Ultrasonic Examination of |
| | |Rolled Steel Plates |
+---+-----------+-------------------------------------------+
2) RECORD NOT REQUIRED TO GENERATE FOR VISUAL INSPECTION AND

TACK WELD SOUNDNESS AS MENTIONED IN THIS ITP.

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 13
4.0 INSPECTION POINTS

INSPECTION POINTS ARE INDICATED BY :
R Record Review Point RECORD REVIEW POINT is a recording operation in the operation / production
cycle marked by the AI/Customer/TPI. Record of inspection is maintained
and will be made available to AI/Customer/TPI for review during next
HOLD/WITNESS stage Inspection,as applicable.
W Witness Point WITNESS POINT is defined as a notification operation in operation / production

cycle marked by the AI/Customer/TPI to excercise their option to witness
and verify a specific operation. Further processing shall proceed where the
AI/Customer/TPI do not validate their option. The notification shall be
documented in a manner acceptable to AI/Customer/TPI, as applicable.
H Hold Point HOLD POINT is defined as a verification of the operation by the requesting
authority AI,Customer/TPI.Further processing is prohibited until acceptance
of the operation & documentation is completed by the requesting authority.
- - Inspection option will not be exercised
5.0 RECORD OF REVISIONS :
REV NO. DATE CHANGES
PREPARED BY CHECKED BY APPROVED BY ACCEPTED BY CLIENT/CONSULTANT/TPI
*INSP.BY TL -THERMAX LI IBR -IBR CLI -CLIENT/TPI
Session : tccom9420m040 INSPECTION & TEST PLAN (QA PLAN)

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
DISHED ENDS FOR BOILER DRUM DATE : 15-09-2011
PAGE : 1
CUSTOMER :

NO. STANDARD
Material Test Certificates Review 100% Drawing, ASME Sec-II

Certificate
Dimensional Inspection Measurement 5% Drawing/Mill Test

Certificate
Identification & Stamp Transfer Visual 100% Identification

Punching & Stamp Tra
nsfer
UT of Plates UT 100% ASTM A578 Level B
2 INSPECTION OF DISHED ENDS AFTER FORMING H R
Surface Finish Visual 100% Spinning/Die Marks

to be ground smooth
Inspection of template on layout Measurement 100% Proper matching
Inside Circumference Measurement 100% Drawing
Inside Circumference-For a Pair of Dished End Measurement 100% Within +/- 5mm
Ovality Measurement 100% 1% of ID or 5mm max.
Thinning Measurement 5Spots Min. Drawing, IBR-1950
Profile-Increase in Depth, Decrease in Depth Template 100% Drawing, IBR-1950
Height Measurement 100% Drawing
Knuckle Radius Template 100% Decrease not

Permissible

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO
Straight Face(Lesser of Inside & Outside readings) Measurement 100% Drawing
PT from Inside,Outside on Knuckle Portion & On Edge PT 100% Procedure PT
Heat-Treatment (As Applicable) Review of 100% Drawing, IBR-1950

HT chart
Lamination Check UT 100% No Laminations

/Procedure UT
Identification & Stamping on D/E Visual 100% Legible

of document
Inspection Release Note Issuance of 100%

IRN
3.0 NOTES :

1) NDE Procedures
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3
+---+-----------+-------------------------------------------+
SAUDI ARAMCO
+---+-----------+-------------------------------------------+ WELDING PROCEDURE SPECIFICATIONS




SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
MEMBRANE PANELS DATE : 15-09-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO

NO. STANDARD
Material Test Certificates Review 100% Drawing, Material

Spec.

Certificate

Certificate
Identification Visual 100% Punching/Stencilling
2 PREPRODUCTION SAMPLE OF SWAGED TUBE ENDS H R
Surface Defects PT 100% Procedure PT
Normalising of swage tube ends Review of 100% HT Procedure /

HT Chart IBR-1950
Dimensional Insp - Ovality, Thickness, Concentricity, Length Measurement 100% Drawing
Hardness after Normalising Measurement 100% Drawing / Specs.
Physical Testing :(Flattening-1, Flaring-1) Mech. 1Set of IBR-1950

Testing Test/Heat
3 INSPECTION OF SWAGED TUBE ENDS H -
Inspection after Swaging Visual 2% Drawing
Dimensional Insp -Ovality, Thickness, Concentricity, Length Measurement 2% Drawing
*INSP.BY TL -THERMAX IBR -IBR CLI -CLIENT/TPI

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO
4 HEAT-TREATMENT OF SWAGED TUBE ENDS H R
Heat-Treatment Cycle Review 100% HT Procedure /

IBR-1950
Heat-Treatment Compliance to Code Review of 100% HT Procedure /

HT Chart IBR-1950
5 WELDING OF MEMBRANE STRIP TO TUBE H -
Cleaning of Tubes Shot 100% Free from Mill Scale

Blasting & Clean from Inside
Pitches of Tubes Measurement 1st Panel Drawing

Segment
Weld Inspection Visual & 100% Drawing

Measureme
6 INSPECTION OF PANEL AFTER PACK BENDING H -
Inspection for Layout On layout *1Segment / Within 3mm

Boiler
*Most Restricted Bend of Total Panels
Ovality on Outer Tubes Measurement 2% Within 10%
Thinning on Outer Tubes Measurement 2% Drawing/

100/(4R/D+2) max.
Flow Area O.D less than 3" * Ball Test 100% Ball Size= {(0.9
OD-2.3SWT)-1.6mm}
*Note:Not applicable for Single & Both end swaging
7 SETUP OF BUTT JOINTS H H
Panel tube,Spools,Opening tubes & Loose tube joints
*INSP.BY IBR -IBR CLI -CLIENT/TPI

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO. STANDARD
SAUDI ARAMCO
8 WELDING OF BUTT WELD JOINTS H R
Visual Inspection Visual 100% Procedure VT
Panel Tube Butt Welds for Length Built-up RT 5% per Procedure RT

welder
Spool Butt Welds RT 5% per Procedure RT

welder
Opening Tubes Butt Welds RT 5% per Procedure RT

welder
Loose Tubes Butt Welds RT 5% per Procedure RT

welder
9 SAMPLE/FIRST PRODUCTION BEND FOR PANEL OPENING/LOOSE TUBES H R
Dimensions on Layout Layout 100% Within 3mm

Matching
Ovality Measurement 100% 10% Max.
Minimum Thickness Measurement 100% Drawing/

100/(4R/D+2) max.
Flow Area for Tubes O.D less than 3" Ball Test 100% Ball Size(Cold Bend)
={(0.9 OD-2.3SWT)-
1.6mm}
Bore Inspection Visual 100% No Score Marks, if

Mandrel is used
10 INSPECTION OF PANEL OPENING/LOOSE TUBES AFTER BENDING H R

Matching
={(0.9 OD-2.3SWT)-
1.6mm}

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

NO. STANDARD
SAUDI ARAMCO
11 FINAL INSPECTION OF LOOSE TUBES H H
Identification Marking Visual 5% Drawing
Site Weld Preperation (If Applicable) Visual 5% Drawing
End Identification Visual 5% Drawing
Document Review Review 100% Compillation of

stage IR's & MTC's,
Code
12 SETUP OF PANEL TUBES TO HEADER/S H H
Cleaning of Tubes from inside Air blowing 100% Free from foreign
material
Cleaning of header from inside Air blowing 100% Free from foreign
material
Setup Inspection Measurement 100% Drawing
Alignment & Squareness Measurement 10% Drawing
13 WELDING OF PANEL TUBES TO HEADER/S H -
Squareness of Header with Panel Measurement 100% Drawing
Straightness of Header Measurement 100% 1mm/mtr or 5mm max.
Weld Inspection Visual & 100% Drawing & Procedure

Measureme
NDE after full welding PT/MT 10% Procedure PT/MT
14 STRUCTURALS & ATTACHMENTS H -
Identification & Orientaion Visual 100% Drawing
Dimensional Inspection Measurement 100% Drawing
Inspection of Strip cutout with Template/ Gauge as appl. Verify 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5

NO. STANDARD
SAUDI ARAMCO
Weld Inspection Visual 100% Drawing
Stud Welding on Tubes Stud Layout 100% Drawing
Stud Weld Soundness Torque Test 10 Studs 2 Breakage in 10

min. Studs for 30ftlb Tor
que is Acceptable
15 MOCK UP OF PANEL WITH RESPECTIVE HEADER-FOR SITE ASSEMBLED HEADER ONLY
Alignment & overall major Dimensions Measurement 100% Drawing
Identification Punching / Marking of Header Verify 100% Drawing
16 CLEARANCE FOR PWHT OF PANEL TO HEADER JOINTS H -
Overall Dimensions Measurement 100% Drawing
Distortion / Flatness Visual 100% Drawing
Weld Inspection (Size & Finish) Measurement 100% Drawing

& Visual
NDE Clearance Review of 100% NDE Procedures

NDE Repor
Completion of all Welding Visual 100% Drawing
Identification Punching Rub-off 100% Drawing
17 PWHT OF PANEL TO HEADER JOINTS H R

IBR-1950

HT Chart IBR-1950
Compliance to Drawing for Scope Review 100% Drawing-BOM
Major Dimensions Measurement Critical Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 6

NO. STANDARD
SAUDI ARAMCO
Dimension
IA Stamp & Final Rub off Visual 100% IBR-1950, Legibility

of Stamp & Rub off

Specs.

Specs.

area, No rundowns,
Peel-offs, Cracks
Paint-DFT Measurement Random Drawing, Painting

Specs.
Cleaning of headers from inside Air blowing 100% Free from foreign
material

be Covered /Capped

of document

IRN
3.0 NOTES :


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 7

SAUDI ARAMCO
1) NDE Procedures
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 8

SAUDI ARAMCO
R Record Review Point RECORD REVIEW POINT is a recording operation in the operation / production WELDING PROCEDURE SPECIFICATIONS



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
BOILER SIDE/BAFFLE/FURNACE SIDE/REAR WALL (FM) DATE : 11-06-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO

NO. STANDARD

Spec.

Certificate

Certificate

HT Chart IBR-1950
Physical Testing :(Flattening-1, Flaring-1) Mech. 1Set of IBR-1950

Testing Test/Heat
Hardness Measurement 2% Drawing / Specs.

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO
4 NORMALISING OF SWAGED TUBE ENDS H R
Heat-Treatment Cycle Review 100% HT Procedure/

IBR-1950

HT Chart IBR-1950
Hardness Measurement 5% Drawing / Specs.
5 WELDING OF MEMBRANE STRIP TO TUBE H -
Cleaning of Tubes Shot 100% Free from Mill Scale

Blasting & Clean from Inside
Pitches of Tubes Measurement 1st Panel Drawing

Segment
Weld Inspection Visual & 100% Drawing

Measureme
6 INSPECTION OF PANEL AFTER PACK BENDING H -
Inspection for Layout On layout *1Segment / Within 3mm

Boiler
*Most Restricted Bend of Total Panels
Ovality on Outer Tubes Measurement 2% Within 10%
Thinning on Outer Tubes Measurement 2% 100/(4R/D+2) Max.
Flow Area O.D less than 3" * Ball Test 100% Ball Size= {(0.9
OD-2.3SWT)-1.6mm}
*Note:Not applicable for Single & Both end swaging
Panel tube joints, Spool joints & Opening tubes joints

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO. STANDARD
SAUDI ARAMCO
8 NDT SCHEDULE H R
Panel Tube Butt Welds for Length Built-up RT 5% per Procedure RT

welder
Spool Butt Welds RT 5% per Procedure RT

welder
Opening Tubes Butt Welds RT 5% per Procedure RT

welder
Inspection of Strip cutout with Template/ Gauge as appl. Verify 100% Drawing

que is Acceptable
Overall Dimensions Measurement Critical Drawing

Dimension
Site Weld Preparation (If Applicable) Template 10% Random Drawing
IA Stamp & Rub Off Visual 100% IBR-1950, Legibility

stage IR's & MTC's,
Code

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

NO. STANDARD
SAUDI ARAMCO
Surface Preparation Visual 100% Drg/Painting Specs.
Paint Shade Visual 100% Drawing, Painting

Specs.

area, No rundowns,
Peel-offs, Cracks
Paint-DFT Measurement random Drawing, Painting

Specs.
Cleaning of Tubes from Inside before capping Air blowing 100% Free from foreign
material

be Covered /Capped

of document
Inspection Release Note Issuance of 100%

IRN
3.0 NOTES :

1) NDE Procedures
+---+-----------+-------------------------------------------+

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5

+---+-----------+-------------------------------------------+
SAUDI ARAMCO
+---+-----------+-------------------------------------------+ WELDING PROCEDURE SPECIFICATIONS

+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 6

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
BOILER TUBES DATE : 28-05-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO

NO. STANDARD

Spec.

Certificate

Certificate

HT Chart IBR-1950
Hardness after Normalising Measurement 100% Matl. Specs.
Physical Testing :(Flattening-1, Flaring-1) Mech. 1Set of IBR-1950/Matl.

Testing Test/Heat Specs.
Hardness after Normalising Measurement 2% Matl. Specs.

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO
4 NORMALISING OF SWAGED TUBE ENDS H R

IBR-1950

HT Chart IBR-1950
5 FLAT STUD WELDING - PREPRODUCTION SAMPLE H -
Dimensions : Tube Size, Stud-Location, Spacing & Width Measurement 5% Drawing

& Visual

que is Acceptable
Concentricity Measurement 5% Drawing/Specs.
Bore Inspection Visual 100% Burnthrough Not

Acceptable
Undercut, Crack Visual 5% Procedure VT
Metal Splash Visual 5% Metal Splash upto

5mm Acceptable
6 FLAT STUD WELDING - INPROCESS INSPECTION H -
Undercut, Crack Visual 5% Procedure VT
Metal Splash Visual 5% Metal Splash 5mm Acc

que is Acceptable
Bore Inspection Visual 100% Burnthrough Not

Acceptable
7 TUBE BENDING-PREPRODUCTION SAMPLE (WITH MAX.DEGREE BEND) H R

Matching

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO. STANDARD
SAUDI ARAMCO
Minimum Thickness Measurement 100% Drawing /

100/(4R/D+2) max.
={(0.9 OD-2.3SWT)-1
.6mm}
Bore Inspection Visual 100% No Score Marks, if

Mandrel is used
Surface defects, Die Marks Visual 100% 0.5 mm deep max.

without sharp notche
s
Cracks, Wrinkles Visual 100% No cracks, wrinkles
8 TUBE BENDING - INPROCESS/FINAL INSPECTION H -
Layout Inspection Measurement 100% Drawing

& Visual

Matching
Ovality Measurement 5% Within 10%
Thinning Measurement 5% Drawing,

100/(4R/D+2) Max.
Surface defects, Die Marks Visual 100% 0.5 mm deep max

s
Cracks, Wrinkles Visual 100% No Cracks, Wrinkles
9 SETUP OF BUTT JOINTS (TUBE TO TUBE) H -
Set up dimensions Measurement 10% Drawing
Edge preparation Template 10% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

NO. STANDARD
SAUDI ARAMCO
10 NDT SCHEDULE H R
Butt Welds RT 5% per Procedure RT

welder

& Orient

que is Acceptable
Mock up of mating tubes of soot blower attach. with jig rod Verify 100% Drawing.

Matching
Flow Area for Tubes O.D less than 3" Ball Test 100% Ball Size ={(0.9
OD-2.3SWT)-1.6mm}
Site Weld Preperation (If Applicable) Visual 5% Drawing
Document Review Review 100% Drawing, Compilation

of stage IR's/ MTC

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5

NO. STANDARD
SAUDI ARAMCO
13 SURFACE PREPARATION H -

Specs.

Specs.

area, No rundowns,
Peel-offs, Cracks

Specs.
Cleaning of tubes from inside before capping Air blowing 100% Free from foreign
material
Capping / Blanking of all Tubes Visual 100% All Tubes Shall be

Covered /Capped
ID Marking (Boiler No./Drawing No./Mark/ Part No.) Visual 100% Drawing

of document

IRN
3.0 NOTES :


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 6
1) NDE Procedures
SAUDI ARAMCO
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 7

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
CONVECTION BANK MODULE ASSEMBLY DATE : 04-11-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO

NO. STANDARD
1 GROUND INSPECTION OF PRESSURE PARTS H H
Identification of Tubes & Headers Visual 100% Drg
Review & Verification of Test Certificates & Drawing Review 100% Drawing, Material
Spec.

Certificate

Certificate
3 WELDING OF BUTT JOINTS, (IF APPLICABLE) H R
Weld Inspection Visual 100% Drawing, Procedure

VT
4 SETUP OF TUBES TO HEADER H H
Identification & Orientation Measurement 100% Drawing
Cleaning of tubes from inside Air blowing 100% free from foreign
material
Cleaning of Header from inside Air Blowing 100% free from foreign
material
Tube Alignment Measurement 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO
5 WELDING OF TUBES TO HEADER H -
NDT on Root Run Weld PT/MT 100% Procedure PT/MT
Weld Inspection (Size & Finish) Measurement 100% Drawing / Procedure

& Visual VT
NDT after full weld PT/MT 100% Procedure PT/MT
6 CLEARANCE FOR PWHT H H
Overall Major Critical Dimensions Measurement 100% Drawing
Welding Insp.of Pressure Parts & Structural Attachments Visual 100% Drawing
NDE Clearance Review of 100% NDE Procedure

NDE Repor
7 PWHT H R

HT chart
8 HYDROSTATIC TEST, (IF APPLICABLE) H H
Hydro Test Verify 100% Drawing, Procedure

be Dry & Clean
Overall Assembly Inspection Visual 100% Drawing
Cleaning of header from inside before capping Air blowing 100% free from foreign
material

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO. STANDARD
SAUDI ARAMCO
Code Stamping Visual 100% IBR-1950
I.A.Stamp, Date & Rub-off Visual 100% IBR-1950, Legibility

stage IR's & MTC's,
Code

Specs.

Specs.

area, No rundowns,
Peel-offs, Cracks

Specs.
material
Capping / Blanking of all Tubes, Pipes, Openings Visual 100% All Tubes, Pipes,
Openings Shall be Co
vered /Capped

of document

IRN
3.0 NOTES :


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4
SAUDI ARAMCO
1) NDE Procedures
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
FINNED ECONOMISER ASSLY(FM) DATE : 09-09-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO

NO. STANDARD
Identification of Coils/Headers Visual 100% Drg
Spec.

Certificate

Certificate
3 GROUND INSPECTION OF ECONOMISER CASING & STRUCTURE H -
Visual Inspection Visual Random Drawing
Overall Assembly Inspection Measurement Random Drawing, free from

damage
Overall Dimensions , Diagonal Measurement Random Drawing
4 STRUCTURE & CASING H -
Compliance to Drg/ITP Review of 100% Drg/ITP No.N56 or

Insp.reco N59

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO
5 INSPECTION OF COIL BENDS H -
Dimensions on Layout On layout 10% Within 2mm
Ovality Measurement 10% Max.10%

100/(4R/D+2) Max.
Flow Area, (Cold Bending) Ball Test 100% Ball Size(Cold Bend)
(0.9OD-2.3SWT)-1.6mm
Flow Area, (Hot Bending) Ball Test 100% Ball Size(Hot Bend)(
0.85OD-2.3SWT)-3.2mm
Surface Defects, Die Marks VIsual 100% 0.5mm deep max.

(merge sharp notches
if any
Cracks, Wrinkles VIsual 100% No Cracks, Wrinkles
Post Bend Heat-Treatment If applicable Review of 100% Procedure

HT Chart Heat-Treatment
6 SETUP OF COIL BENDS TO FIN TUBES H H
Inspection Clearance of Coil Bends Verify 100% Drawing/IR

Matching
Tackweld Soundness PT 10% Procedure/Code
7 WELDING OF BUTT JOINTS H R
Weld Inspection (Size & Finish) Visual 100% Drawing & Procedure
VT
Excess Penetration (Flow area- Cold bending) Ball Test 100% Ball Size(0.9OD-2.3S
WT)-1.6mm

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO. STANDARD
SAUDI ARAMCO
Excess Penetration (Flow area- hot bending) Ball Test 100% Ball Size(0.85OD-2.3
SWT)-3.2mm
Weld Soundness RT Code or Procedure RT

Min.5% **
** Min. 5% per Welder
8 ALIGNMENT OF HEADERS ON STRUCTURE H -
Alignment Water level 100% Within 2mm

, Plumb
9 SETUP OF HEADER STUBS TO COILS H H
Cleaning of coils from inside Air blowing 100% free from foreign
material
Cleaning of Header from inside Air blowing 100% free from foreign
material
Setup Dimensions, Alignment Measurement 100% Drawing
10 WELDING OF HEADER STUBS TO COILS H R
VT
Weld Soundness RT Code or Procedure RT

Min.5% **
** Min. 5% per Welder
11 HYDROSTATIC TESTING H H
Hydro Test pressure Verify 100% Drawing
Pressure gauges range Verify 100% 1.5 to 2.5 times of

test pressure
Calibration validity of Pressure gauges Verify 100% Calibration report &

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

NO. STANDARD
SAUDI ARAMCO
due date
Pressure Gauges Verify 100% Record id.numbers
Cleaning of weld joints Visual 100% No rust or

extraneous mat.
Test pressure (on Pressure gauge) Visual 100% Test Pressure Shall
not exceed more than
6% at any time
Test Duration (Holding time) Measurement 100% Min.30 Minutes
Leakage Visual 100% No leakages
Pressure drop Visual 100% No Pressure drop

be Dry & Clean
13 FITMENT OF CASING & OTHER ATTACHMENTS H -
Overall Assembly Inspection Measurement 100% Drawing

& Visual
VT
14 AIR LEAK TEST H -
Sealing of Eco.Casing by Air Test 70mm WC/ 100% Drawing/specs.

Drawing
Overall Construction/ Fitment/ Alignment/ Appearance Measurement 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5

NO. STANDARD
SAUDI ARAMCO
& Visual
Compliance to Drawing for Scope Verify 100% Drawing
Code Stamping Visual 100% Design Code
I.A.Stamp, Date & Rub off Visual 100% Design Code,

Legibility
Document Review Review 100% Drawing, Design

Code, Technical Spec
ifications

Specs.

Specs.

area, No rundowns,
Peel-offs, Cracks

Specs.
vered /Capped

of document

IRN

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 6
3.0 NOTES :
SAUDI ARAMCO
1. WPS,PQR,WPQ and Welding Technology sheet(WTS) WELDING PROCEDURE SPECIFICATIONS

1) NDE Procedures
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 7

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
BARE TUBE ECONOMISER ASSLY(MODULAR TYPE) DATE : 04-11-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO

NO. STANDARD
Identification of Coils/Headers Visual 100% Drg/Shop Transfer

Note/IR
Spec.

Certificate

Certificate
3 GROUND INSPECTION OF CASING BEFORE COIL INSERTION H -
Visual Inspection Visual Random Drawing
Overall Assembly Inspection Measurement Random Drawing,free from

damage
Overall Dimensions , Diagonal Measurement Random Drawing
4 ALIGNMENT OF HEADERS ON STRUCTURE H -
Alignment Water level 100% Within 2mm

, Plumb

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO
5 SETUP OF COILS WITH HEADER/S H H
No blockage/obstacles inside the coil Ball Test 100% Free from foreign
Material
Cleaning of Header from inside Air Blowing 100% Free from foreign
Material
Tackweld Soundness PT 10% Procedure/Code
6 WELDING OF COILS WITH HEADER/S H R
** NDT on Root Run Weld PT/MT 100% Procedure PT/MT
** if items Fabricated at Sub-vendors
VT
NDT after full welding PT/MT 10% Procedure PT/MT
7 PWHT H R

HT chart
8 HYDROSTATIC TESTING H H
Hydro Test pressure Verify 100% Drawing
Pressure gauges range Verify 100% 1.5 to 2.5 times of

test pressure
Calibration validity of Pressure gauges Verify 100% Calibration report &

due date
Pressure Gauges Verify 100% Record id.numbers
Cleaning of weld joints Visual 100% No rust or

extraneous mat.

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO. STANDARD
SAUDI ARAMCO
Test pressure (on Pressure gauge) Visual 100% Test Pressure Shall
not exceed more than
6% at any time
Test Duration (Holding time) Measurement 100% Min.30 Minutes
Leakage Visual 100% No leakages
Pressure drop Visual 100% No Pressure drop

be Dry & Clean
10 FITMENT OF CASING & OTHER ATTACHMENTS H -
Overall Assembly Inspection Measurement 100% Drawing

& Visual
VT
Overall Construction/ Fitment/ Alignment/ Appearance Measurement 100% Drawing

& Visual
Compliance to Drawing for Scope Verify 100% Drawing
Code Stamping Visual 100% Design Code
I.A.Stamp, Date & Rub-off Visual 100% Design Code,

Legibility
Document Review Review 100% Drawing, Design

Code, Technical Spec
ifications

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

NO. STANDARD
SAUDI ARAMCO

Specs.

area, No rundowns,
Peel-offs, Cracks

Specs.
vered /Capped
Final Document Review Review 100% Drawing, Code,

Technical Specificat
ions
Inspection Release & Certification Issuance of 100% Drawing, Code,

IRN Technical Specificat
ions
3.0 NOTES :

1) NDE Procedures
+---+-----------+-------------------------------------------+

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
SAUDI ARAMCO
|2) |PT1 |Liquid Penetrant Examination | WELDING PROCEDURE SPECIFICATIONS
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 6

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
RISERS,DOWN COMERS,SUPPLY TUBES/PIPES DATE : 19-09-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO

NO. STANDARD
Spec.

Certificate

Certificate
2 INSPECTION OF SAMPLE/FIRST PRODUCTION BEND H R

& Visual

Matching
Ovality of Tubes Measurement 100% Within 10%
Thinning of Tubes Measurement 100% Drawing,

100/(4R/D+2) Max.
Surface defects, Die Marks Visual 100% 0.5 mm (deep) max.

s
3 INSPECTION OF TUBES AFTER BENDING H -

& Visual

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO

Matching

100/(4R/D+2) Max.

s
Weld Inspection Visual 100% Drawing, Procedure

VT
Risers,Downcomers,supply tubes/pipes <= 168.3 OD RT 10% Procedure RT
Risers,Downcomers,supply tubes/pipes > 168.3 OD RT 100% Procedure RT
Weld Soundness for Main DC RT 100% Procedure RT
Welder Identification Verify 100% Qualified Welder

List
6 SETUP OF BRANCH/FILLET WELD JOINTS H H
Alignment/ Squareness Measurement 100% within 1 degree or 3

mm Max.
Projection from Hdr C/L Measurement 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO. STANDARD
SAUDI ARAMCO
Tack weld soundness PT 100% Procedure PT
7 WELDING INSPECTION FOR BRANCH/FILLET WELD JOINTS H -
NDE after root run welding ** PT 100% Procedure PT
** If items are fabricated at sub-vendor
Visual Inspection after full welding Visual 100% Procedure VT
Weld Size & Finish After Full Welding Visual 100% Drawing
NDE of welds for Carban steel PT/MT 10%random Procedure PT/MT
NDE of welds for Alloy steel PT/MT 100% Procedure PT/MT
UT of Full penetration welds >=10 NPS or above 25 thk UT/RT 100% Procedure UT/RT
Orientaion Visual 100% Drawing
Weld Size & Finish Visual 100% Drawing
Weld Soundness PT 10% Procedure-PT
9 CLEARANCE FOR PWHT (IF APPLICABLE) H H
NDE Clearance Review 100% NDE Procedure
Code Punching Visual 100% IBR-1950
10 PWHT (IF APPLICABLE) H R
Heat-Treatment Compliance to Code Review of 100% Design Code +

HT chart Thermax Std.

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

NO. STANDARD
SAUDI ARAMCO
Compliance to Drawing for Scope Verify 100% Drawing-BOM
Code Punching,(As Applicable) Visual 100% IBR-1950
I.A.Stamp & Date,(As Applicable) Rub-off 100% IBR-1950 /

Legibility
Document review Review 100% Compillation of

stage IR's & MTC's,
Code

Specs.

Specs.

area, No rundowns,
Peel-offs, Cracks

Specs.
Cleaning from inside before capping Air blowing 100% Free from foreign
material
vered /Capped
ID Marking/Stenciling(Boiler No./Drg No./Mark/ Part No.) Visual 100% Drawing

of document
Inspection Release & Certification Issuance of

IRN

SAUDI ARAMCO
INSPECTION & TEST L NO. : ITP/ERPLN /P12

SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5

NO. STANDARD
SAUDI ARAMCO
3.0 NOTES :

1) NDE Procedures
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 6

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
COILS (ECO/SH COILS) DATE : 04-11-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO

NO. STANDARD
Spec.

Certificate

Certificate
2 SAMPLE/FIRST PRODUCTION BEND (WITH MAX.BEND DEGREE) H R

Matching
Thinning Measurement 100% Drawing /

100/(4R/D+2) max.
Flow Area for Cold Bending* Ball Test 100% Ball Size=(0.9OD-2.3
SWT)-1.6mm
Flow Area for Hot bending* Ball Test 100% Ball Size=(0.85OD-2.
3SWT)-3.2mm
*for Tubes O.D less than 3"
Surafce defects Visual 100% 0.5 mm deep max.

s
Wrinkles, Cracks, Die Marks Visual 100% Not Acceptable

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO
3 INSPECTION OF TUBES AFTER BENDING H -

& Visual

Matching
Ovality Measurement 1bend /coil Within 10%

on 5%
Thinning Measurement 1bend /coil Drawing,

on 5% 100/(4R/D+2) Max.

s
Setup Dimensions Measurement 10% random Drawing
Alignment Measurement 10% random Drawing
PMI on Alloy steel welds PMI 2% Random Procedure PMI
Weld Soundness after full welding except P15E materials RT Code or Min Procedure RT
5%*
*Minimum 5% per welder
Note :RT & PMI for P15E materials to be carried after PWHT.
6 INSPECTION & NDE AFTER PWHT FOR P15E MATERIAL H R
Butt Weld Soundness after Full Welding RT 100% Procedure RT
PMI for P15E materials PMI 10%Random Procedure PMI

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO. STANDARD
SAUDI ARAMCO
Attachment welds Visual 100% Drawing
NDE PT/MT 2% Procedure PT/MT
8 POST BENDING HEAT TREATMENT-IF APPLICABLE H R
Heat-Treatment Compliance to Code for 180 degree bend only HT Chart 100% Drg/HT Procedure
9 FINAL INSPECTION OF COILS H H
Inspection of Floor Layout Measurement 100% Drawing
Dimensions on Layout Layout 10%Random Within 3mm

Matching
Flow Area, (Cold Bending)* Ball Test 100% Ball Size(Cold Bend)
(0.9OD-2.3SWT)-1.6mm
Flow Area, (Hot Bending)* Ball Test 100% Ball Size(Hot Bend)(
0.85OD-2.3SWT)-3.2mm
Site Weld Preperation Template Random Drawing
End Identification Visual 10% random Drawing

stage IR's & MTC's,
Code

Specs.

area, No rundowns,
Peel-offs, Cracks

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

NO. STANDARD
SAUDI ARAMCO
Cleaning of coils from inside before capping Air Blowing 100% Free from foreign
material
Capping / Blanking of all Tubes Visual 100% All Tubes Shall be

Covered /Capped
ID Marking/Stenciling(Boiler No./Drg No./Mark/ Part No.) Visual 100% Drawing

of document

IRN
3.0 NOTES :

1) NDE Procedures
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
HEADERS DATE : 04-11-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO

NO. STANDARD
Spec.

Certificate

Certificate
Identification & stamp transfer Visual 100% Punching/Stencilling
2 INSPECTION OF SAMPLE/FIRST PRODUCTION HEADER BENT STUB H W

Matching
Ovality of Tubes Measurement 100% 10% Max.

100/(4R/D+2) Max.
Flow Area for Cold Bending* Ball Test 100% Ball Size=(0.9OD-2.3
SWT)-1.6mm
Flow Area for Hot bending* Ball Test 100% Ball Size=(0.85OD-2.
3SWT)-3.2mm
Surafce defects, Die marks Visual 100% 0.5 mm deep max.

s

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO
3 INSPECTION OF HEADER BENT TUBES AFTER BENDING H W
Dimensions on Layout Layout 5%% Within 2mm

Matching

100/(4R/D+2) Max.
Surafce defects, Die marks Visual 100% 0.5 mm deep max.

s
4 SETUP & WELDING OF BAFFLE PLATES,(IF ANY) H -
Setup Dimensions & Locations Measurement 100% Drawing
Weld Size & Finish After Full Welding Visual 100% Drawing & Procedure
VT
5 BUTT WELD SETUP & WELDING FOR HDR PIPE, (IF ANY) H H
Weld Visual Inspection Visual 100% Drawing & Procedure

VT
6 DRILLING MARKING INSPECTION H -
Pipe Straightness By String 100% 1mm/Mtr, 3mm Max.
Quadrant Distribution & Marking Combination 100% Max.difference of

Set 1/2 Degree
End Hole Location Measurement 100% Drawing
Hole Centre Punch Pitch Measurement 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO. STANDARD
SAUDI ARAMCO
Quadrant & LH/RH Marking Visual 100% Drawing
Drilled Hole Dimensions Measurement 100% Drawing
Ligament Measurement 100% Mark Min.Ligament
Hole Finish Visual 100% Free From Tool Marks

& Sharp Edges
8 INSP.OF MACHINED COMPONENTS H -
Identification & verification of stamp transfer Visual 100% Drawing
Weld Preparation Measurement 100% Drawing
Visual inspection of weld preparation Visual 100% No

Cracks/Laminations
Peripheral edges of End cover if mfg.from plate** PT/MT 100% Procedure PT/MT
**for end cover as per IBR-Fig.No.365/2A
9 BRANCH WELD SETUP & WELDING H H

mm Max.
** NDE after root run welding PT 100% Procedure PT
** If Headers are fabricated at sub-vendor

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

NO. STANDARD
SAUDI ARAMCO
NDE of welds for CS Hdr. PT/MT 10%random Procedure PT/MT
NDE of welds for AS Hdr. PT/MT 100% Procedure PT/MT
Note:For P15E materials NDE to be carried after PWHT
10 WELD SETUPS-HEADER PIPE/STUB TO REDUCER/FLANGE/END COVER; REDUCER TO FLANGE H W
11 WELDING OF ABOVE H R
Butt Weld Soundness after Final Welding except P15 materials RT 100% Procedure RT
Note:For P15E materials RT to be carried after PWHT
Peripheral edges & remaining exposed surface of weld jt.** PT/MT 100% Procedure PT/MT
Identification & Orientation Visual 100% Drawing
Weld Inspection (Size & Finish) Measurement 100% Drawing & Procedure
& Visual VT

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5

NO. STANDARD
SAUDI ARAMCO
13 INSPECTION BEFORE PWHT H -
Code Punching Visual 100% IBR-1950
PMI for Alloy Verificaion of Accessible welds PMI Check 100% Procedure PMI/
Specs.
PMI for Alloy Verificaion of Parent Material PMI Check Random Procedure PMI/
Specs.
Note:For P15E materials PMI to be carried after PWHT
14 PWHT H R
Heat-Treatment Compliance Review of 100% IBR-1950, Thermax

HT chart Standard
15 INSPECTION AFTER PWHT H -
Straightness of header Measurement 100% 1 mm/Mtr / 6 mm max

(whichever is less)
NDE of all weld joints (for alloy steel hdr only) MT/PT 100% Procedure MT/PT
Butt Weld Soundness after Full Welding for P15E materials RT 100% Procedure RT
PMI for P15E materials PMI Per Procedure PMI

procedure
16 MOCK UP OF PANEL WITH RESPECTIVE HEADER-FOR SITE ASSEMBLED HEADER ONLY H -
Alignment & overall major Dimensions Measurement 100% Drawing
Identification Punching/Marking of Header Verify 100% Drawing
Site Weld Preperation Visual 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 6

NO. STANDARD
SAUDI ARAMCO
material
I.A.Stamp & Date, (As Applicable) Final 100% IBR-1950 /

Rub-off Legibility

stage IR's & MTC's,
Code

Specs.

Specs.

area, No rundowns,
Peel-offs, Cracks

Specs.
material
vered /Capped

of document

IRN

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 7
3.0 NOTES :
SAUDI ARAMCO

1) NDE Procedures
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 8

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
HEADERS (SHOP ASSLY) DATE : 04-11-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO

NO. STANDARD
Spec.

Certificate

Certificate
2 SETUP & WELDING OF BAFFLE PLATES,(IF ANY) H -
Weld Size & Finish After Full Welding Visual 100% Drawing & Procedure
VT
3 BUTT WELD SETUP & WELDING FOR HDR PIPE, (IF ANY) H H
Weld Visual Inspection Visual 100% Drawing & Procedure

VT
4 INSP.OF MACHINED COMPONENTS H -
Weld Preparation Measurement 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO
Visual inspection of weld preparation Visual 100% No

Cracks/Laminations
Peripheral edges of End cover if mfg.from plate** PT/MT 100% Procedure PT/MT
5 DRILLING MARKING INSPECTION H -
Pipe Straightness By String 100% 1mm/Mtr, 3mm Max.
Quadrant Distribution & Marking Combination 100% Max.difference of

Set 1/2 Degree
End Hole Location Measurement 100% Drawing
Hole Centre Punch Pitch Measurement 100% Drawing
Centre Punching Inlinement By String 100% Within +/- 1mm
Quadrant & LH/RH Marking Visual 100% Drawing
Quadrantwise Hole Locations from End Measurement 100% Within +/-1mm
Drilled Hole Dimensions Measurement 100% Drawing
Ligament Measurement 100% Mark Min.Ligament
Inlinement of Drilled Holes Measurement 100% Within +/- 1mm
Hole Finish Visual 100% Free From Tool Marks

& Sharp Edges & sur
face defects
7 BRANCH WELD SETUP & WELDING H H

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO. STANDARD
SAUDI ARAMCO

mm Max.
** NDE after root run welding PT 100% Procedure PT
** If Headers are fabricated at sub-vendor
NDE of welds for CS Hdr. PT/MT 10%random Procedure PT/MT
NDE of welds for AS Hdr. PT/MT 100% Procedure PT/MT
UT of Full penetration welds >=10 NPS or above 25 thk UT/RT 100% Procedure UT2/RT
8 WELD SETUPS-HEADER PIPE/STUB TO REDUCER/FLANGE/END COVER; REDUCER TO FLANGE H W
Butt Weld Soundness after Final Welding RT 100% Procedure RT
Peripheral edges & remaining exposed surface of weld jt.** PT/MT 100% Procedure PT/MT

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

NO. STANDARD
SAUDI ARAMCO
Weld Inspection (Size & Finish) Measurement 100% Drawing & Procedure
& Visual VT
11 INSPECTION & NDE AFTER PWHT FOR P15E MATERIAL H R
Straightness of header Measurement 100% 1 mm/Mtr / 6 mm max

(whichever is less)
NDE of all weld joints MT/PT 100% Procedure MT/PT
Butt Weld Soundness after Full Welding RT 100% Procedure RT
12 CLEARANCE FOR ASSLY H R
Straightness Measurement 100% 1mm/Mtr, or 6mm Max.
PMI for Alloy Verificaion of Accessible welds PMI Check 100% Procedure PMI/
Specs.
PMI for Alloy Verificaion of Parent Material PMI Check Random Procedure PMI/
Specs.

stage IR's & MTC's,
Code
3.0 NOTES :


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5
SAUDI ARAMCO
1) NDE Procedures
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 6

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
ATTEMPERATOR ASSLY DATE : 02-06-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO

NO. STANDARD
Spec.

Certificate

Certificate
2 INSP.OF MACHINED COMPONENTS H R
Weld Edge Inspection Visual 100% No

Cracks/Laminations
3 INSPECTION OF MARKING FOR DRILLING ON HEADER PIPE H -
Marking Dimensions Measurement 100% Drawing
No.of Holes Count 100% Drawing
Straightness Measurement 90 Deg. 1mm/Mtr, Max.3mm

apart

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO
4 INSPECTION OF DRILLING & EDGE PREPERATION H R
Quadrant Line Punching for Reference Visual 100% Drawing
Surface Defects Visual 100% No

Cracks/Laminations
5 BUTT WELD SETUPS-SPRAY NOZZLE H H
7 SETUP OF STUBS/STAND PIPES WITH HEADER PIPE H H
8 WELDING OF STUBS/STAND PIPES WITH HEADER PIPE H R
Weld Visual Inspection Visual 100% Procedure VT
Weld Size Measurement 100% Drawing
NDE of fillet welds PT/MT 100% Procedure PT/MT

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO. STANDARD
SAUDI ARAMCO
9 SETUP & WELDING OF SLEEVE LOCKING PINS H -
Weld Inspection after full welding Visual 100% Drawing & Procedure
VT
Orientaion Visual 100% Drawing
Weld Size & Finish Visual 100% Drawing & Procedure

VT
Weld Soundness PT 10% Procedure-PT
Welder Identification Verify 100% Qualified Welder

List
11 INSPECTION BEFORE PWHT H H
PMI for Alloy Verification of accessible welds PMI Check 100% Procedure PMI /
Specs.
PMI for Alloy Verification of Parent Material PMI Check Random Procedure PMI /
Specs.
12 PWHT H R

HT chart
13 NDE AFTER PWHT H R
NDT on all welds for Alloy steel PT/MT 100% Procedure PT/MT
Straightness Measurement 100% 1 mm/Mtr; 6 mm max

(whichever is less)

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

NO. STANDARD
SAUDI ARAMCO
material
I.A.Stamp & Date, (As Applicable) Final 100% IBR-1950

Rub-off

stage IR's & MTC's,
Code

Specs.
Drawing, Painting Specs. Visual 100% Drawing, Painting

Specs.

area, No rundowns,
Peel-offs, Cracks

Specs.
Cleaning from inside before capping Air blowing 100% Free from foreign
material
vered /Capped

of document

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5

NO. STANDARD
SAUDI ARAMCO

IRN
3.0 NOTES :

1) NDE Procedures
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 6

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
INTEGRAL& NON INTEGRAL PIPING - IBR DATE : 02-06-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO

NO. STANDARD
Verification of MTC with Material Specs. & Drg Review 100% Drg / Matrl.Specs.
Correlation of MTC with Material Verify 100% TC
Dimensions Measurement 5% Drawing/TC
Hydrotest/NDE of Pipes at Makers Works Review 100% Drawing/TC
Identification & Stamp Transfer Visual 100% IA Stamp
2 INSPECTION OF SAMPLE/FIRST PRODUCTION BEND H R

& Visual

Matching

100/(4R/D+2) Max.
Surface defects, Die Marks Visual 100% 0.5 mm (deep) max.

s
3 INSPECTION OF TUBES AFTER BENDING H W

& Visual

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO. STANDARD
SAUDI ARAMCO
Matching

100/(4R/D+2) Max.

s
4 BUTT WELDS(PIPE TO PIPE,PIPE TO FLANGES/FITTINGS) H H
Tackweld Soundness by PT except for P15E Material PT 100% Procedure/Code
Weld Inspection Visual 100% Procedure VT
Weld Soundness for size > 178mm OD RT 100% Procedure RT
Weld Soundness for size >102mm OD & <=178 mm OD RT 10% Procedure RT
Weld Soundness for size <=102mm OD RT 5% ** Procedure RT
** 5% per welder
Note :NDE for P15E materials to be carried after PWHT.
6 SETUP & WELDING OF SOCKET WELDS & OTHER BRANCH WELDS H H
Setup Dimensions & Locations Visual 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO. STANDARD
SAUDI ARAMCO
7 CLEARANCE FOR PWHT (IF APPLICABLE) H -
Completion of all Welding Verify 100% Drawing
NDE Clearance Verify 100% Design Code
PMI for Alloy Verification of welds PMI Check 10% Random Procedure PMI/ Spec.
PMI for Alloy Verification of Parent Material PMI Check Random Procedure PMI/ Spec.
Note :PMI for P15E materials to be carried after PWHT.
8 PWHT (IF APPLICABLE) H R
Heat-Treatment Compliance to Code Review of 100% Design Code +

HT chart Thermax std.
9 NDE AFTER PWHT H -
PT on all alloy steel welds PT 100% Procedure PT
Weld Soundness of butt welds for 15E Materials RT 100% Procedure RT
Code Punching,(As Applicable) Visual 100% Design Code
I.A.Stamp & Date,(As Applicable) Rub-off 100% Design Code

stage IR's & MTC's,
Code
Surface Preparation . Visual 100% Drawing, Painting

Specs.
Site weld joints to be kept unpainted @1" portion Visual 100% Apply Packing tape
or Cap the ends afte

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

NO. STANDARD
SAUDI ARAMCO
CHARACTERISTICS METHOD EXTENT TL IBR CLI

r greasing
Drawing, Painting Specs. Visual 100% Drawing, Painting

Specs.

area, No rundowns,
Peel-offs, Cracks

Specs.
Cleaning from inside before capping/blanking Air blowing 100% Free from foreign
material
Capping / Blanking of all Pipes, Openings Visual 100% All Pipes, Openings
Shall be Covered /Ca
pped

of document

IRN
3.0 NOTES :

1) NDE Procedures
+---+-----------+-------------------------------------------+

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
SAUDI ARAMCO
|2) |PT1 |Liquid Penetrant Examination | WELDING PROCEDURE SPECIFICATIONS
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+
+---+-----------+-------------------------------------------+


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 6

SAUDI ARAMCO



SAUDI ARAMCO
INSPECTION & TEST PLAN (QA PLAN) FOR CONTROL NO. : ITP/ERPASME /P21
SAUDI ARAMCO
REVISION NO.: 0
NON-INTEGRAL PIPING DATE : 16-06-2011
PAGE : 1
1.0 JOB SPECIFIC DATA :
CUSTOMER :
SAUDI ARAMCO
SR. INSPECTION STAGES ACCEPTANCE STANDARD * INSP. BY

NO.
CHARACTERISTICS METHOD EXTENT REF.DOC./ PROCEDURE TL CLI
1 MATERIAL IDENTIFICATION H
Verification of MTC with Material Specs. & Drg Review 100% Drg / Matrl.Specs.
Correlation of MTC with Material Verify 100% TC
Dimensions Measurement 5% Drawing/TC
Hydrotest/NDE of Pipes at Makers Works Review 100% Drawing/TC
Identification & Stamp Transfer Visual 100% IA Stamp
2 BUTT WELDS(PIPE TO PIPE,PIPE TO FLANGES/FITTINGS) H
Tackweld Soundness by PT except for P15E Material PT 100% Procedure/Code
3 WELDING OF BUTT JOINTS H
Welder ID Verify 100% Qualified Welder

List
Weld Inspection Visual 100% Drawing ,code
Weld Soundness RT code or ** Procedure RT12
Minimum 5% per Welder
PMI for Alloy Verification of welds PMI Check 10% Random Procedure PMI
*INSP.BY CLI -CLIENT/TPI

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO.
SAUDI ARAMCO

4 SETUP & WELDING OF SOCKET WELDS & OTHER BRANCH WELDS H
Setup Dimensions & Locations Visual 100% Drawing
UT of Full penetration welds >=10 NPS or above 25 thk UT 100% Procedure UT
5 CLEARANCE FOR PWHT (IF APPLICABLE) H
NDE Clearance Verify 100% Design Code
PMI for Alloy Verification of welds PMI Check 10% Random Procedure PMI/ Spec.
PMI for Alloy Verification of Parent Material PMI Check Random Procedure PMI/ Spec.
Note :PMI for P15E materials to be carried after PWHT.
6 PWHT (IF APPLICABLE) H
Heat-Treatment Compliance Review of 100% PWHT Procedure

HT chart
7 NDE AFTER PWHT H
Weld Visual inspection Visual 100% Procedure VT,
PT/MT on all accessible alloy steel welds PT/MT 100% Procedure PT1/MT3
Weld soundness of Butt welds for P-Nos 3,4,5 materials if - RT Code ASME B31.3 Para
341.3
-required as per code
Hardness of production weld,hot bend & hot formed piping- Test Code ASME B31.3 para
331.1.7
-For P-Nos 3,4,5 materials

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO.
SAUDI ARAMCO

8 FINAL INSPECTION BEFORE PAINTING H
Identification Marking (Job no.,Drg.no.,Part no.) Visual 100% Drawing
9 PAINTING INSPECTION H
Surface Preparation for Painting Visual 100% Drawing/Specs.
Paint Shade, Make, Batch No., Expiry Date Visual 100% Drawing, Painting
Specs.,Application b
efore Expiry

area, No rundowns,
Peel-offs, Cracks
Paint-DFT Measurement Random Drawing/ Painting

Specs.
10 INSPECTION RELEASE NOTE H

of document

IRN
3.0 NOTES :


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

SAUDI ARAMCO



SAUDI ARAMCO
INSPECTION & TEST PLAN (QA PLAN) FOR CONTROL NO. : ITP/ERPLN /N01
SAUDI ARAMCO
REVISION NO.: 0
DUCTS / HOPPERS DATE : 28-07-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO

NO.
1 MATERIAL IDENTIFICATION H -
Material Specification Review 100% Drawing
Verification of Specification Review 100% MTC/Code
Check Test, if no MTC Check_Test As per Material Specs.

Code/ Spe
Dimensions Measurement 10% Drawing/Code
Surface Condition Visual 100% Free From Surface

Defects
2 FINAL INSPECTION OF PRE-FABRICATED PANELS(CORNER WELDING AT SITE) H -
Match Marking Visual 100% Drawing
Weld Inspection (Size & Finish) Visual 100% Drawing
Distortion / Flatness Measurement 100% Within 5mm

& Visual
3 FINAL INSPECTION AFTER WELDING (FULLY SHOP WELDED) H -

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO.
SAUDI ARAMCO

Ovality of round ducts Measurement 100% Within 1% & 10mm

max.
Completion of stiffner/ spider Welding (As applicable) Visual 100% Drawing/ Suitable
for Handling
VT
Aesthetics-Weld tacks,Hammer/Dent/Surface Marks,Sharp Corner Visual 100% Free from Surface

Discontinuities
4 SURFACE PREPARATION H -
Paint Shade, Make, Batch No., Expiry Date Verify 100% Drawing, Painting
Specs., Application
before Expiry

area, No rundowns,
Peel-offs, Cracks
Paint-DFT Measurement 2Spots/m2 Drawing/ Painting

Specs.
Centreline/ Match marking Visual 100% Drawing
Identification Marking (Job no.,Drg.no.,Part no., Weight*) Visual 100% Drawing
*- Marking of Weight on Item or DU Weighing >= 500kg. Visual

of document

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO.
SAUDI ARAMCO


IRN
3.0 NOTES :
IT IS MANDATORY FOR MANUFACTURER'S QUALITY CONTROL TO CARRY OUT
INSPECTION OF ALL THE STAGES COVERED IN THIS ITP.



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
DAMPER DATE : 28-07-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO
INSP. AGENCY: - ---

NO.
Check Test, if no MTC Chem.&Mech. 1 Sample/ Material Specs.

Test Lot

Defects
Overall Assembly Dimensions Measurement 100% Drawing
Open/Close Operation Verify 100% Drawing/Specs.
Compliance to Drawing to Scope Verify 100% Drawing-BOM

Discontinuities
Specs., Application

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO.
SAUDI ARAMCO

Before Painting

area, No rundowns,
Peel-offs, Cracks
Paint-DFT Measurement 2Spots/pc Drawing/ Painting

Specs.
Centreline Marking Visual 100% Drawing
Identification Marking (Job no., Drg.no.,Part no.) Visual 100% Drawing
Open/Close Marking Visual 100% Drawing
Final Document Review Review 100% Drawing, Technical

Specifications
Inspection Release & Certification Issuance of 100% Drawing, Technical

IRN Specifications
3.0 NOTES :



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 1
EXPANSION JOINTS DATE : 22-10-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO
INSP. AGENCY: - ---

NO.

Specs.

Defects
2 INSPECTION OF EXPANSION BELLOW H
Bellow Profile Template 100% Drawing
Welding by GTAW Process for sheet thk <= 2mm Visual 100% Weld
procedure/specs.
Alignment of Flanges Measurement 100% Drawing
Flange I/S Dimensions, Hole Pitches, Height, Diagonals Measurement 100% Drawing
Weld Soundness Kerosene/PT 100% Procedure

/Air Leak T
Location & Dimensions of Shear Transfer Pin Arrangement Measurement 100% Drawing
& Visual
Free Movement of Floating Plate Visual 100% Free Movement
Expansion Provision Dimensions Measurement 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 1
PAGE : 2

NO.
SAUDI ARAMCO

efore Expiry

area, No rundowns,
Peel-offs, Cracks

Specs.
Identification Marking(Job no.,Drg.no.,Part no.) Visual 100% Drawing
Flow Direction Marking by Arrow Visual 100% Drawing

Specifications

IRN Specifications
3.0 NOTES :



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 1
PAGE : 3

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 1
AIR FLOW MEASURING DEVICE (AEROFOIL) DATE : 22-10-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO
INSP. AGENCY: - ---

NO.

Spces.

Defects
2 INSP.OF AIR FOIL H
Profile Template 100% Avg.Gap 2mm
Air Hole Location Measurement 100% Drawing
3 ASSEMBLY INSPECTION H
Throat Size Measurement 100% Drawing
Orientation & Fitment of Air Piping Measurement 100% Drawing

& Visual
Blocking of Air Piping Air Blowing 100% No Blocking

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 1
PAGE : 2

NO.
SAUDI ARAMCO

4 PAINTING & FINAL INSPECTION H
efore Expiry

area, No rundowns,
Peel-offs, Cracks

Specs.

Specifications

IRN Specifications
3.0 NOTES :



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 1
PAGE : 3

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
STACK DATE : 28-07-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO
INSP. AGENCY: - ---

NO.
Verification of MTC Review 100% MTC/Code

Specs.

Defects
2 INSP.OF STACK TEMPLATE H
Butt Weld Dimensions of Sectors Measurement 100% Drawing
Dimensions-Thickness, ID,OD,PCD, Hole Equispacing Measurement 100% Drawing
Hole size & pitch Measurement 100% Drawing
Match Drilling Verify 100% Drawing
Identification/Match marking Verify 100% Drawing,Refer note
3 INSP.OF BASE RING H
Butt Weld Dimensions of Sectors Measurement 100% Drawing
Dimensions-Thickness, ID,OD,PCD, Hole Equispacing Measurement 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
STACK DATE : 28-07-2011
PAGE : 2

NO.
SAUDI ARAMCO

Hole size & pitch Measurement 100% Drawing
Backgauging after first side welding PT 100% Procedure PT
Match Drilling of Base Ring with Template Verify 100% Drawing,Refer Note
4 SETUP OF L-SEAMS H
Dimensions-OD, Ovality, Circulary & Mismatch, Height Measurement 100% Drawing
Backgauging after first side Welding PT 100% Procedure PT
5 SETUP OF C-SEAMS H
Mismatch & Alignment of Shells Measurement 100% Drawing
Backgauging after first side Welding PT 100% Procedure PT
6 FULL WELDING OF SHELL SEAMS H
Weld Inspection (Size & Finish) Visual & 100% Drawing

Measureme
Weld Soundness on all T-Joints RT T-joints Procedure RT
Weld Soundness of L-Seam RT 10% Procedure RT
UT of shell plate at Lifting Lug Locations UT 100% Drawing,Free from

Lamination
7 STRUCTURALS & ATTACHMENTS H

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
STACK DATE : 28-07-2011
PAGE : 3

NO.
SAUDI ARAMCO

UT of shell plate at Lifting Lug Locations ** UT 100% Drawing,Free from

Lamination
**If not covered earlier
8 ALIGNMENT OF STACK SHELLS (2 ADJACENT SHELLS) H
Levelling of Shells Water Level 100% 1mm/Meter or 10 mm

whichever is less
Base Ring Squareness with respect to Shell Plumb 100% Within 3mm
Shell to Shell Matching/Mismatch (at 120 deg.apart) Measurement 100% Drawing

& Visual
Overall Length,Continuity of Monkey Ladder&Wind Breaker Measurement 100% Drawing

& Visual
Straightness Measurement 100% 1mm/Mtr, 10mm Max.
Identification & Match Marking Visual 100% Drawing
9 MOCK-UP ASSLY OF PLATFORM & LADDER H
Assly of Platform & Ladders on Stack for bolted construction Verify 100% Drawing
Assly of Platform&Ladders on ground for welded construction Verify 100% Drawing
Painters Trolly Verify 100% Free Movement
Anchor Pitch & Orientation Measurement 100% Drawing

& Visual
Anchor Weld soundness Hammer Test Random No Breakages
Compliance to drawing for scope Verify 100% Drawing-BOM

Discontinuities

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
STACK DATE : 28-07-2011
PAGE : 4

NO.
SAUDI ARAMCO

Specs., Application
before Expiry

area, No rundowns,
Peel-offs, Cracks
Paint-DFT Measurement Min.2Spot / Drawing/ Painting

Shell Specs.
Centreline/ Match Marking Visual 100% Drawing
12 REFRACTORY APPLICATION ( IF APPLICABLE) H
Refractory Material Compliance Review of 100% Drawing, Specs.

Test Cert
Validity (Shelf Life) of refractory material Verify 100% Application before

expiry date
Dimensions of Refractory Measurement 100% Drawing
Review of curing chart Review 100% Procedure/Specs.
Visual Inspection after curing Visual 100% Procedure/Specs.
Refractory soundness Sound Test Random Procedure/Specs.

of document

IRN

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
STACK DATE : 28-07-2011
PAGE : 5
3.0 NOTES :
SAUDI ARAMCO


Template shall have "Boiler Front","Top,Bottom" marking on it
Shop template shall have only pilot drill of 8mm size & reference
of final drill size shall be mentioned on it.This drilling shall be done
along with base plate.
For bolted stack,flanges made from sector,such sector weld shall be

100% RT or UT & shall be machined on mating sides.

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
STACK DATE : 28-07-2011
PAGE : 6

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
BOILER CASING DATE : 28-07-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO
INSP. AGENCY: - ---

NO.
Check Test, if no MTC Check_Test As per Code Material Specs.

Defects
2 INSP.OF CASING PANELS H
Profile Layout 100% Within 3mm

Matching
Distortion / Flatness Measurement 100% Within 5mm

& Visual
Diagonals Measurement 100% Within 5mm
VT
3 INSP.OF LOOSE PARTS OF INSULATION STRUCTURALS/ATTACHMENTS H

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO.
SAUDI ARAMCO

Aesthetics-Weld tacks,Hammer/Dent/Surface Marks,Sharp CorneR Visual 100% Free from Surface

Discontinuities
efore Expiry

area, No rundowns,
Peel-offs, Cracks

Specs.

Specifications

IRN Specifications
3.0 NOTES :



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
BOILER STRUCTURE DATE : 28-07-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO
INSP. AGENCY: - ---

NO.

Defects
2 BUTT JOINTS IN MAIN LOAD CARRYING MEMBERS FOR LENGTH BUILT-UP H
Joint Location Review 100% Engg Approval
Setup Dimensions Measurement 100% Drg / Engg Document
Welding Inspection Visual 100% Drawing
Weld Soundness RT/UT 100% Procedure RT/ UT
3 SETUP OF BASE PLATE TO COLUMN H
Centre line matching Measurement 100% Within 3mm
Squareness of Base Plate Measurement 100% 1.5 gap in 12"

Length
Gap Between Base plate and Column Measurement 100% Avg.Gap 0.5to1mm &
& Visual Max.2mm at Local Spo
ts

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO.
SAUDI ARAMCO

4 SETUP & WELDING OF DIAPHRAGM PLATES H
Weld Soundness PT 10% Procedure / Code
5 FINAL INSPECTION OF SINGLE PIECE COLUMN H
Box Size Measurement 100% Drawing
Total Height of Column Measurement 100% 5mm Upto 10mtr & 8mm
max.
Level Marking Measurement 100% Within +/- 2mm
Orientation of Cleats/Brackets Visual 100% Drawing
Location of Cleats/Brackets Measurement 100% Within +/- 2mm
Squareness of Cleats/Brackets Measurement 100% 1.5 gap in 12"

Length
Straightness -(Camber/Sweep) Measurement 100% 1mm/Mtr, or 10mm

Max.
Twist & Levelling Water Level 100% 1.5%of Section

, Plumb Ht/Max.5mm; Water Le
vel Within 5mm
Identification & Match Marking Visual 100% Hard Punching /

Stenciling
6 MOCKUP ASSEMBLY OF SEGMENTED COLUMNS H
Box Size Measurement 100% Drawing
Total Height of Column Measurement 100% 5mm Upto 10mtr & 8mm
max.
Level Marking Measurement 100% Within +/- 2mm
Orientation of Cleats/Brackets Visual 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO.
SAUDI ARAMCO

Location of Cleats/Brackets Measurement 100% Within +/- 2mm
Squareness of Cleats/Brackets Measurement 100% 1.5 gap in 12"

Length

vel Within 5mm

Max.
Alignment of Full Length of Column Measurement 100% Drawing
Splice Joint Details & Locations Measurement 100% Drawing
Identification & Match Marking Visual 100% Hard Punching /

Stenciling
7 FINAL INSPECTION OF SEGMENTED COLUMNS AFTER SPLIT-UP H

Max.

& Visual
ID Marking by Tag Welding (Job no.,Drg.no.,Part no Visual 100% Drawing
8 TRIAL ASSLY FOR BOLTED STRUCTURE WITH FULLY TIGHTENED BOLTS H
Overall Assembly Inspection & Dimensional check : Measurement 100% Drawing
- Frame by Frame
- Platform stages
Alignment Verify 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

NO.
SAUDI ARAMCO

Completion of all Welding & Bolting arrangement Verify 100% Drawing
Match Marking with matchmark sketch Visual 100% Drawing
9 FINAL INSPECTION OF GIRDERS H
Length Measurement 100% +0/-3mm upto

12mtr,-9mm max.

Max.

vel Within 5mm
Cleat locations, orientation, dimensions Visual & 100% Drawing

Measureme
Weld Soundness of fillet welds for plate fabricated girders PT Min.10% * Procedure PT
* or drg. whichever is stringent
Weld Inspection (Size & Finish) Measurement 100% Drawing, Procedure

& Visual VT
NDE After removal of temporary supports,after dress up MPT 100% Procedure MT
10 FINAL INSPECTION OF BEAMS/BRACINGS H
Length Measurement 100% +0/-3mm upto

12mtr,-5mm max.

Max.

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 5

NO.
SAUDI ARAMCO


vel Within 5mm
Cleat locations, orientation, dimensions Visual & 100% Drawing

Measureme
Weld Inspection (Size & Finish) Measurement 100% Drawing, Procedure

& Visual VT
11 FINAL INSPECTION OF BUCKSTAYS H
Alignment & Levelling Water level 100% Within 5mm
Corner Links - Pin fitment Measurement 100% Drawing

Max.

& Visual
12 FINAL INSPECTION OF LADDERS H
Alignment Visual 100% Drawing
Straightness Measurement 100% 1mm/Mtr, or 10mm

Max.

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 6

NO.
SAUDI ARAMCO

13 FINAL INSP.OF STAIRCASES,HAND RAILINGS H
Inclination Angle Layout 100% Within 2mm

Matching
Straightness Measurement 100% 1mm/Mtr, or 10mm

Max.
Aesthetics-Weld tacks,Surface Marks, Sharp Corners Visual 100% Free from Surface
Discontinuities
14 FINAL INSP.OF CANOPY STRUCTURE H
Straightness & Alignment Visual 100% Drawing
15 FINAL INSP.OF MONORAIL STR, TEMP.ERECTION & PR.PART SUPPORTS H
Straightness & Alignment Measurement 100% Drawing
16 SURFACE PREPARATION H
Surface Preparation & Cleaning Visual 100% Drawing, Painting

Specs.

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 7

NO.
SAUDI ARAMCO

efore expiry

area, No rundowns,
Peel-offs, Cracks

Specs.
ID Marking by Tag Welding (Job no.,Drg.no.,Part no.) Visual 100% Drawing

of document

IRN
3.0 NOTES :



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 8

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
FOUNDATION BOLTS & PACKER PLATES DATE : 28-07-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO
INSP. AGENCY: - ---

NO.

Defects
Nut Proof Load in black condition Mech. 2 Samples Code

Testing /Size
2 FINAL INSPECTION (FOUNDATION BOLT) H
Bolt Dimensions: Overall Length, Thread Lenght Measurement 10% Drawing
Anchor Plate Dimensions: Length X Width x Thickness Measurement 10% Drawing
Plain Washers / Taper Washers Measurement 10% Drawing
Bolt thread, finish & Size Visual, 10% Drawing

Thread ga
Nut Proof Load in black condition Review Review Drawing/code
Nut,Locknut fitment with Bolt Threads Visual 10% Drawing/Code
Weld Inspection (Size & Finish) of anchoring Plates/Rods Measurement 10% Drawing
& Visual

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO.
SAUDI ARAMCO

3 FINAL INSPECTION (PACKER PLATES) H
Dimensions: Length x Width x Thickness Measurement 10% Drawing
Edge Finish Visual 10% Free From Burrs
Greasing/Oiling on Threaded Portion Visual 100% TBW Practice
Painting Visual 100% Drawing/ Painting

Specs.
Identification Marking (Size & Job no.) Visual 100% Drawing/PO
Final Document Review Review 100% Compillation of

stage IR's & MTC's
Inspection Release Note Issuance of 100% IRN

IRN
3.0 NOTES :



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

SAUDI ARAMCO



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
GRATINGS(GRILLS) DATE : 28-07-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO
INSP. AGENCY: - ---

NO.
Dimensions Measurement At Random Drawing/ Specs.

Defects
2 DIMENSIONAL INSPECTION H
Length & Width Measurement 10% +0/-5mm
Span Orientation Visual Random Drawing/ Pattern
Diagonals Measurement 10% Within 5mm
Ups & Downs of Load Members & Secondary Members Measurement 10% Within 1mm
Dimensions & Thickness Measurement At Random Drawing/ Specs.
Transverse Bow Measurement 10% Within 3mm
Logitudinal Bow Measurement 10% Within 5mm
Weld Inspection (Size & Finish) Visual 10% Free from

Significant Defects,
Spatters/Slag

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO.
SAUDI ARAMCO

3 CHECK TEST FOR GALVANISING,(IF APPLICABLE) H
Uniformity in thickness of coating Preece Test Sample IS:2633
Mass of Zinc coating Mass of Sample IS:6745

Zinc coat
Adherence of Zinc coating Adhesion Sample IS:2629

Test
DFT of Zinc coating Measurement Sample Drawing/IS:2629
4 PAINTING/COATING AND FINAL INSPECTION H
Compliance to Drawing/PO for Scope Verify 100% Drawing-BOM/PO
Surface Preparation Visual 100% Drawing/Specs.
efore expiry

area, No rundowns,
Peel-offs, Cracks

Specs.
Visual Inspection for Galvanised items (if Applicable) Visual 10% IS:2629
DFT of zinc coat for Galvanised items (If applicable) Measurement Random Drawing/IS:2629
Identification Marking (Grill Size, Job No., Mark no.) Visual 100% Drawing
Final Document Review Review 100% Compilation of IR's

& TC , Drawing
Inspection Release note Issuance of

IRN

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3
3.0 NOTES :
SAUDI ARAMCO





SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
DRUM INTERNALS & EXTERNALS DATE : 28-07-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO
INSP. AGENCY: - ---

NO.
1 MATERIAL IDENTIFICATION H XX

Defects
2 INSPECTION OF DRUM INTERNALS H XX
Orientation of Assembly w.r.to Boiler Front Visual 100% Drawing
3 INSPECTION OF DRUM EXTERNALS H XX
Dimensions on Layout Measurement 100% Drawing
NDE of Lifting Lug UT 100% Free from

Laminations
NDE of Saddle pad plates after rolling UT 100% Free from

Laminations
NDE on plates edges of > 8mm thick PT 100% Free from

Laminations
4 FINAL INSPECTION H XX
Completion of all Welding Visual 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO.
SAUDI ARAMCO

Application of Rust Prevension Oil on Drum Internals Visual 100% TBW Practice
Painting on Drum Externals Visual 100% Drawing/Specs.
Identification Marking (Job no.,Drg.no.,Part no Visual 100% Drawing
5 INSPECTION RELEASE NOTE H XX

Specifications

IRN Specifications
3.0 NOTES :



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

SAUDI ARAMCO


XX INTERNAL INSPECTION Inspection option for 'XX' points will be excercised by Thermax/Vendor QC and
will not applicable to TPI/Client Inspection.
*INSP.BY /TPI

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
BOILER BASE FRAME(FM) DATE : 28-07-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO
INSP. AGENCY: - ---

NO.

Defects
2 SPLICE JOINTS IN MAIN LOAD CARRYING MEMBERS H
Splice Joint Details Review 100% Engg Approval
Setup Dimensions Measurement 100% Drg/Engg Document
Welding Inspection Visual 100% Drawing
Weld Soundness RT 100% Procedure/Code
3 INSP.OF PAD PLATES H
Dimensions on Layout-Profile, Centre Height Layout 100% Within 1mm

Matching
Circumference & Alignment Layout 100% Drawing

Matching
Location & Size of Tell-Tale Hole & Squareness Measurement 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO.
SAUDI ARAMCO

4 FINAL INSPECTION H
Twist & Levelling Water Level 100% Within 5mm

, Plumb
Squareness Measurement 100% Within 5mm
Pad Plate Profile & Concetricity Template 100% Within 3mm
Compliance to drawing for Scope Verify 100% Drawing-BOM
Identification Marking (Job No.,Drg No.,Part No.) Visual 100% Drawing
Specs., Application
before Expiry

area, No rundowns,
Peel-offs, Cracks

Specs.
3.0 NOTES :


SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3
SAUDI ARAMCO
IT IS MANDATORY FOR MANUFACTURER'S QUALITY CONTROL TO CARRY OUT WELDING PROCEDURE SPECIFICATIONS


*INSP.BY - CLI -CLIENT/TPI

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
ECONOMISER CASING & STRUCTURE DATE : 28-07-2011
PAGE : 1
CUSTOMER :
SAUDI ARAMCO
INSP. AGENCY: - ---

NO.

Defects
2 INSPECTION OF COLUMNS H
Orientation of Assembly w.r.to Boiler Front Visual 100% Drawing
Level Marking Visual 100% Drawing
Squareness of Connections Measurement 100% 1.5 gap in 12"

length
Straightness - (Camber / Sweep) Measurement 100% 1mm/Mtr, or 10mm

Max.
Twist & Levelling Water level 100% Within 5mm

, Plumb
*INSP.BY - CLI -CLIENT/TPI

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 2

NO.
SAUDI ARAMCO

3 INSP.OF TOP & BOTTOM FRAME H
4 INSP.OF STUDS & U-BOLTS H
Verification of Stud Material and Size Verify 100% Drawing
Thread Length & Nut Fitment Verify 100% Free Fitment with
Stud/U-Bolt Threads
U-Bolt Dimensions on Layout Layout 100% Within 2mm

Matching
Application of Rust Prevension Oil Verify 100% TBW Practice
5 INSP.OF COIL SUPPORTS H
Location of Supports Measurement 100% Drawing
Matching of Holes with Respective Flats Verify 100% Drawing
6 INSP.OF CASING H
Opening Dimensions Measurement 100% Drawing

SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 3

NO.
SAUDI ARAMCO

efore Expiry

area, No rundowns,
Peel-offs, Cracks

Specs.

Specifications

IRN Specifications
3.0 NOTES :



SAUDI ARAMCO
SAUDI ARAMCO
REVISION NO.: 0
PAGE : 4

SAUDI ARAMCO



Inspection Test Plan

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Inspection Test Plan

Uploaded by

Copyright:

Available Formats

SAUDI ARAMCO

THERMAX LIMITED WELDING PROCEDURE SPECIFICATIONS

1.0 JOB SPECIFIC DATA : -

CONSULTANT : - PROJECT NO:

INSP. AGENCY: DESIGN CODE :

2.0 QUALITY STAGES & INSPECTION :

SR. INSPECTION STAGES ACCEPTANCE * INSP. BY

Correlation of MTC with Material Visual 100% Mill Test

Dimensional Inspection Measurement 5% Drawing/ Mill Test

Identification-Boiler/Heat/Plate/ Part/Shell No.& Mat.Specs. Visual 100% Identification

IA Stamp Transfer Verify 100% Stamp Transfer

Identification & Dimensional Inspection of Dished Ends Measurement 100% Drawing

Identification & Dimensional Inspection of Manhole Rims Measurement 100% Drawing

2 SETUP OF L-SEAMS OF SHELL ALONGWITH TEST COUPON H H

Production Test Coupon with L-Seam Verify One PTC / IBR-1950

Ovality, (Inside dia. Min & Max.) Measurement 100% 1% of Nominal ID or

*INSP.BY -THERMAX LI IBR -IBR CLI -CLIENT/TPI

Session : tccom9420m040 INSPECTION & TEST PLAN (QA PLAN) Contd...

SR. INSPECTION STAGES ACCEPTANCE * INSP. BY

CHARACTERISTICS METHOD EXTENT TL IBR CLIWELDING PROCEDURE SPECIFICATIONS

Shell length, Outside circumference Measurement 100% Drawing

Profile D/4 100% Drawing, IBR 1950

Weld Preparation Template 100% Drawing

Offset / Mismatch Measurement 100% 10%of Nominal plate

Flaw detection on weld edges PT/MT 100% Free from

Tack Weld Soundness PT 100% Procedure PT(Refer

Shell identification/IA Stamp Visual 100% Drawing, IA Stamp

Backgauging after 1st side welding PT/MT 100% Procedure PT/MT

Inspection after both side welding Visual 100% Procedure VT

Weld reinforcement - Flush ground from Outside Visual 100% IBR-1950

Inspection after Re-rolling of shell:

Profile D/4 100% Within 0.3% of ID

Ovality Measurement 100% 1%of ID or 5mm Max.

Welder/Welding Operator ID Visual 100% Qualified welder

Weld soundness RT & MT 100% Procedure RT, MT

4 PWHT & TESTING OF PTC H H

Heat-Treatment Cycle Review 100% IBR-1950

Heat-Treatment Compliance to Code Review of 100% IBR-1950

*INSP.BY -THERMAX LI IBR -IBR CLI -CLIENT/TPI

Session : tccom9420m040 INSPECTION & TEST PLAN (QA PLAN) Contd...

SR. INSPECTION STAGES ACCEPTANCE * INSP. BY

CHARACTERISTICS METHOD EXTENT TL IBR CLIWELDING PROCEDURE SPECIFICATIONS

Mech. Properties of PTC Mechanical One PTC / Material

Orientation Visual 100% Drawing

Total length Measurement 100% Drawing

Alignment of shell courses Visual & 100% 1mm/mtr, 5mm max.

Weld preparation Template 100% Drawing

Alignment / Root offset. Measurement 100% 10% of Nominal plate

Flaw detection on weld edges. PT/MT 100% Free from

Tack Weld Soundness PT 100% Procedure PT(Refer

IF WELD PROCESS & HT IS DIFFERENT THAN L-SEAM WELDING :

Production Test Coupon with C-seam Verify One PTC / IBR-1950

Backgauging after 1st side welding PT/MT 100% Procedure PT/MT

Inspection after both side welding Visual 100% Procedure VT

Weld reinforcement -Flush ground from outside Visual 100% IBR-1950

Welder/Welding Operator ID Verify 100% Qualified welder

Weld soundness RT & MT 100% Procedure RT, MT

Session : tccom9420m040 INSPECTION & TEST PLAN (QA PLAN) Contd...

SR. INSPECTION STAGES ACCEPTANCE * INSP. BY

CHARACTERISTICS METHOD EXTENT TL IBR CLIWELDING PROCEDURE SPECIFICATIONS

7 BUTT WELD SETUPS FOR NOZZLES/STUBS H H

Alignment Measurement 10% Drawing

Orientation Visual 100% Drawing

Setup Dimensions Measurement 10% Drawing