NILCON

(QC .01 Inspection & Test Plan for Piping Installation )

NILCON

Issue

Date

/ 2007

Sheet 1 of 8

QC. PROCEDURE

QC. 001

INDEX

1.0 2.0

PURPOSE INSPECTION & TEST PLANS

APPENDIX

1.

List of Client Documents applicable of Piping Systems e.g. Specifications, Engineering Practices etc. (To be complied for each individual project.

NILCON

Issue

Date

/ 2007

Sheet 2 of 8

QC. PROCEDURE

QC. 001

QUALITY CONTROL PROCEDURE INSPECTION & TEST PLAN FOR PIPING INSTALLATION 1.0 1.1 PURPOSE: The purpose of this procedure is to ensure that the receipt, storage, handling of piping materials, and erection of piping systems on the construction site is carried out in accordance with the Drawings, Specifications & Codes. All installation work shall conform to the following Specifications, Procedures and Codes. (a) Clients Documents: Attached, as Appendix 1 is the list of applicable Client Documents. (b) NILCON Procedures:

1.2

Quality Assurance: QA.001 Quality Assurance Manual Management Responsibilities, Policy, Authority , Organization. Quality Assurance Procedure for NonConformance Identification, Control , Correction. Quality Assurance Procedure for Approval of Material or Material Substitution. Quality Assurance Procedure for Inspection and Test Plan Status. Quality Assurance Procedure for Warehousing & Material Control. Quality Assurance Procedure for Field Storage, Protection, Preservation, Transport and Handling Material. Quality Assurance Procedure for Control of Welding Materials.

QA006

QA007

QA009

QA010

QA.011

QA012

NILCON

Issue

Date

/ 2007

Sheet 3 of 8

QC. PROCEDURE

QC. 001

Quality Control: QC.001 Quality Control Procedure for Pipe Test Package, Preparation, Co-ordination, Handling & Testing. Quality Control Procedure Inspection , Test Plan for Welding Operations. Quality Control Procedure for Coordination & Recording of NDT & Heat Treatment Operations. Quality Control Procedure for Pre-heating & Postweld Heat Treatment of Pipe Welds. Quality Control Procedure for NDT

QC.003

QC.004

QC.005

QC,006/1 to 3

(C) ANSI ASME.BB1.3 Chemical Plant and Petroleum Refinery Piping Note: In the event of any discrepancy between Codes and Standards and the Specifications that discrepancy shall be referred in writing to the Client for resolution. 2.0 2.1 INSPECTION & TEST PLANS: Refer following Inspection and Test Plans (Sheets 5 through 8) for operational sequence, check and inspection responsibilities Inspection and Test Plan abbreviations. CONST QC CLIENT I W H R N ( ) Construction Team. NILCONQuality Control Inspection. Client Inspection . Inspect. Witness. Hold Point. Inspect and keep record. Inspect and submit written report, if deficient/ defective. Spot or Partial.

2.2

NILCON

Issue

Date

/ 2007

Sheet 4 of 8

QC. PROCEDURE

QC. 001

INSPECTION & TEST PLAN PIPING INSTALLATION

INSPECTION BY No. INSPECTION ACTIVITY CONST QC CLIENT NILCON QA/QC PROC. CLIENT REF DOCUMENT/ ACCEPTANCE CRITERIA/ REMARKS

RECORD FORM

1.0

WARHOUSE RECEIPT INSPECTION & ONGOING STORAGE/ HANDLING INSPECTIONS Shipping damages. Heat numbers of straight length pipe and fittings correct and identifiable against Material Certificates. Correct spool marking of line number/ area number against shipping list. Check flange facing finish for damages (Replace flange protectors). Protection of material identification numbers on piping & piping components. Correct storage, handling and protection of all bulk materials, pipe spools, fittings and straight length pipe in warehouse, pipe yard and on site. I (W) (W) QA.011 N N (W) (W) (W) QA.010 QA.010

1.1 1.2

1.3

(W)

1.4

(W)

QA.011

1.5

1.6

2.0 2.1

FIELD ERECTION Check spool pieces for correct line number, area unit making. Where applicable, on random length piping, re-stamp heat number on all pieces to be cut from the pipe. Counter stamp by QA/QC. Where applicable record heat numbers on isometric / record sheet for all random length pipe and fittings used per each isometric. Piping in course of erection Generally in accordance with final inspection item 7.0 However specific check points as follows during erection stages: i) Proper storage, cleanliness, protection and end cap. ii) Flange face condition/ protection . iii) Adequately supported , no strain on flange faces, particularly pumps. iv) Dust blinds installed on pumps and RVs v)Alignment and tolerancesNo heating of pipe work to achieve alignment (except under controlled conditions agreed to by QA/QC and the Client). vi) Fit-up of flanged and threaded joints. vii) Welding:Fit up. Qualified Welders. Consumable control. Procedure. Visual. Welder stamp/mark. I (W) -

2.2

H/W

(W)

2.3

2.4

(W)

QC.003 QC.003 QA.012 QC.003 QC.003 QC.003

NILCON

Issue

Date

/ 2007

Sheet 5 of 8

QC. PROCEDURE

QC. 001

INSPECTION & TEST PLAN PIPING INSTALLATION

No. INSPECTION ACTIVITY INSPECTION BY CONST QC CLIENT RECORD FORM QA/QC PROC. CLIENT REF DOCUMENT/ ACCEPTANCE CRITERIA/ REMARKS

3.0 3.1

HEAT TREATMENT (Where applicable) Check for correct set-up and procedure to be applied. Check temperature record chart for heatingup, holding time and cooling rate. Complete hardness test as required. I W (W) QC.005

3.2

QC.004-06

QC.004 QC.005 QC.005

3.3

Qc.004-06

4.0 4.1

NON-DESRUCTIVE TESTING Radiographic or Ultrasonic examination of field welds. Liquid penetrate or magnetic particle inspection of field welds. R W QC.006-01 QC.006

4.2

QC.006-02 03

QC.006

5.0

ALLOY MATERIAL VERIFICATION (where applicable) 100& checks on pipe, flanges, fittings, valve bodies and bonnets, and weld metal. R W

6.0

INTERNALLY LINED OR COATED PIPE Check pre-lined coated sections for handling damages. Check on field- applied lining/ coating. Fit-up jointing and welding of cement lined pipe. I W (W)

6.1

6.2 6.3

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W W

W W

7.0 7.1

GENERAL LINE CHECK Piping installed in accordance with drawings, and isometric/ GA drawings. Sizes, flange ratings, schedule/ thickness and material specification correct. WATCH CAREFULLY FOR SPEC. BREAK CHANCES Cold set requirements, if any, incorporated. Lines, plumb and straight. Slopes/ falls satisfactory where called for. Lines routed to give good accessibility, clearance and spacing for insulation satisfactory. High point test vents installed (lines 2 and above shall have test vents) I I I I W W W W W W W W I W W

7.2

7.3 7.4 7.5 7.6

7.7

NILCON

Issue

Date

/ 2007

Sheet 6 of 8

QC. PROCEDURE

QC. 001

INSPECTION & TEST PLAN PIPING INSTALLATION

INSPECTION BY No. INSPECTION ACTIVITY CONST QC CLIENT CLIENT REF DOCUMENT/ ACCEPTANCE CRITERIA/ REMARKS

RECORD FORM

QA/QC PROC.

7.8

Supports a. Number, type and installation per drawings / specification. b. Field review any additional requirements. All pipe supports satisfactory for insulation (if applicable). All temporary supports, wooden blocks, wires removed. Ensure all temporary tack welds are removed on guides and sliding supports. Spring supportsCorrect type/rating/setting. g. Special supports installation correct. All bolts tightened correctly. HD bolts, shimming, grouting completed. Correct type and specification. Globe check and control valves installed with correct flow direction. Location/ orientation satisfactory for access/operation. Watch for cases where specific valve location/orientation is required to enable viewing of instruments. Clearance for rising stems satisfactory and not dangerous when extended. Chain wheel and extension spindle requirements (if any) . Gland tightening correct. Required lubrication completed (e.g. plug valves)

c.

d.

e.

f.

h. i. 7.9 Valves: a. b.

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W W

W W

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W W

W W

c.

d.

e.

f. g.

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W W

W W

7.10 7.11

Bellows installation correct. Orifice Flanges a. Tap orientation correct. b. Jack screws (if required) .

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W W

W W

7.12

Bolting a.

Correct type (stamping/ marking correct) and dia. To specification. Projection both sides equal and correct dimension.

b.

NILCON

Issue

Date

/ 2007

Sheet 7 of 8

QC. PROCEDURE

QC. 001

INSPECTION & TEST PLAN PIPING INSTALLATION

INSPECTION BY No. INSPECTION ACTIVITY CONST QC CLIENT CLIENT REF DOCUMENT/ ACCEPTANCE CRITERIA/ REMARKS

RECORD FORM

QA/QC PROC.

c. d. 7.13 Gaskets a. b.

Greased. Tight.

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W W

All gaskets installed. Correct type to specification. WATCH FOR SPEC. BREAK CHANES.

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W W

W W

7.14

Welding a. Fully complete and visually inspected. Specified amount of NDT taken and records in order. All tack welds removed and ground off. Heat treatment and hardness tests complete where specified and records/charts in order. I W W

b.

QC.004-02 -03

c.

d.

QC.004-06

7.15

Spectacle blinds/spades installed and of correct thickness.

8.0 8.1

HYDROSTATIC TESTING Foregoing item 7 pints inspected and system accepted for testing. Check preparation for testing. I H/R H/W

8.2

(W)

8.3

Apply pressure in required steps. Hold test pressure for time of inspection. (Minimum 1 hour) Check total system included per test pack and witness test. Open required vent points before emptying the test loop.

8.4

H/R

H.W

8.5

(W)

9.0

REINSTAMENT Following testing, reinstate pipe in accordance with isometric/ CA drawings. Ensure any temporary (non-spec.) gaskets installed for testing are removed and permanent gaskets installed.

10.0

FINAL PIPINC DOSSIER Check for completeness and required approvals. W W

NILCON

Issue

Date

/ 2007

Sheet 8 of 8

QC. PROCEDURE

QC. 001