MAIN MECHANICAL & PIPING WORK FOR PRODUCT PIPELINE PROJECT AT BINTULU,SARAWAK

INSPECTION AND TEST PLAN ( ITP ) - FABRICATION AND ERECTION WORKS FOR PIPING & STRUCTURES

SCOPE OF RESPONSIBILITY
OWNER - : SHELL MDS (Malaysia) Sdn Bhd (SMDS)
EPCM - : AMEC FOSTER WHEELER E& C (Malaysia) (AMEC-FW)
CONTRACTOR - : MISI SETIA OIL & GAS SDN. BHD
TPI - : THIRD PARTY INSPECTION

LEGENDS

X - Responsible for implementing the action and the quality of the final product . This is generaly used for the CONTRACTORS only

I - Responsible for inspecting work on a surveillance or monitoring basis

R - Responsible for Reviewing and authorizing submissions

W - Responsible for Witnessing and signing work release Or HOLD

NA - Not Applicable

Doc No.:

MSOG -M1611-QAQC-GP-002

Rev.:

Date:

23 Aug'2016

Page:

2of 5

Doc No.:

MAIN MECHANICAL & PIPING WORK FOR PRODUCT PIPELINE PROJECT AT BINTULU,SARAWAK
INSPECTION AND TEST PLAN ( ITP ) - FABRICATION AND ERECTION WORKS FOR PIPING & STRUCTURES

MSOG -M1611-QAQC-GP-002

Rev.:

Date:

23 Aug'2016

Page:

3 of 5

HOLD POINTS
Activity
No.

INSPECTION ACTIVITIES

1.0

DRAWING

1.1

Construction drawing / shop drawing, Pipeline

Drawings and Pipe Support layout drawing
details

2.0

DOCUMENTS APPROVAL

2.1

Welding Procedures Specification ( WPS )

2.2

Procedure Qualification Report ( PQR )

2.3

Welder Qualification Testing ( WQT )

2.4

NDE Procedures

REFERENCE DOCUMENT /
CONTROLLING PROCEDURES /
ACCEPTANCE STANDARDS

-P&ID, Isometricdrawing, 1243A-8270-B004

Rev.P1

INSPECTION PARAMETERS

Approved AFC Drawings

1243A-8720-A004 Rev.P1

-Approved Welding Procedure ( WPS )

- Check approval of Prequalified WPS / or

Establish New WPS

-ASME IX , API 1104, ASME B31.4

- Welding parameter, weld joint & preparation

details.

-ASME IX , API 1104, ASME B31.4

Welding consumables and welding process

-ASME IX , API 1104, ASME B31.4

Checklist of approval of welder

VERIFYING DOCUMENTS /
RECORDS

RESPONSIBLE
PERSON

FORM

REMARKS

MSOG

TPI

AMECFW

SHELL

AFC

Projct Engineer,
Engineering

NA

Weld Map

QC Inspector

NA

Approved WPS & WQT,Welder

Certificate

WPS Format

QAQC Lead / 'QC

Inspector

W,R

I, R

PQR Format

QAQC Lead / 'QC

Inspector

W,R

I, R

MSOG-QAQC-F-19

QAQC Lead / 'QC

Inspector

W,R

W,R

I, R

QAQC Lead / 'QC

Inspector

NA

W,R

I, R

WQT Record, Welder List,

ID Card

1243A-8230-PR-0002

1. Radiography Testing (RT)

-As per API 1104, ASME B31.4,AWS D1.1

Approved Procedure

N/A

2. Magnetic Particle Testing (MPI)

-As per API 1104, ASME B31.4,AWS D1.1

Approved Procedure

N/A

3. Penetrant Testing (PT)

-As per API 1104, ASME B31.4,AWS D1.1

Approved Procedure

N/A

4. Hardness Testing

-As per API 1104, ASME B31.4,AWS D1.1

Approved Procedure

N/A

3.0

RAW MATERIAL

3.1

Material receiving, verification and visual

Inspection

- Delivery Order (DO), Mill certificate

- Specification, P.O

Check quantity, grade,Identification and

Material Equipment Receiving
physical inspection: free from visible damage,
Inspection Report
dimensional check

MSOG-QAQC-F-22

Material Controller /
QC Inspector

N/A

I,R

3.2

Review Mill Certificate

- Specification, ASME B31.4

As per Project Specification Requirement

MSOG-QAQC-F-20

N/A

3.3

Client Free Issued Material

- Delivery Order (DO), Mill certificate

As per Project Specification Requirement

N/A

4.0

INSPECTION BEFORE AND AFTER WELDING

4.1

Welding - Piping
a. Dimension / Marking & Cutting

1243A-8230-PR-0002

Identification (Heat No Transfer) and ID

Marking

b. Fit-up Inspection

-ASME B31.4, WPS

Inspection high low condition, Dimension and

Fit-up Inspection Report ( Piping )
Alignment

MSOG-QAQC-F-50

QC Inspector

N/A

I,R

c. Visual Inspection

-ASME B31.4, WPS

Checking for under cut / spatter and

Visual Inspection Report ( Piping )

MSOG-QAQC-F-51

QC Inspector

N/A

I,R

Approved Drawing

insufficient welding condition

Weld Summary ( Piping )

MSOG-QAQC-F-52

QC Inspector

N/A

I,R

DLK-Q-FRM-0053

QC Inspector

N/A

I,R

DLK-Q-FRM-0054

QC Inspector

N/A

I,R

Mill Certificates
Mill Certificates

MSOG-QAQC-F-22

Dimensional check and orienation

4.2

Welding - Pipe Supports & Structure

a. Fit-up Inspection
b. Visual Inspection

MSOG-QAQC-F-22
1243A-8230-SP-0001

Inspection high low condition

D.E.P 31.38.01.29-G

Checking for under cut / spatter and

insufficient welding conditions

Fit-up Inspection Report

( Structural )
Visual Inspection Report
( Structural )

Testing
Witnessed 3RD
Party Inspector

Doc No.:

MAIN MECHANICAL & PIPING WORK FOR PRODUCT PIPELINE PROJECT AT BINTULU,SARAWAK
INSPECTION AND TEST PLAN ( ITP ) - FABRICATION AND ERECTION WORKS FOR PIPING & STRUCTURES

Activity
No.

INSPECTION ACTIVITIES

5.0

NDT EXAMINATION -PIPING

5.1

RT/MPI/PT

REFERENCE DOCUMENT /
CONTROLLING PROCEDURES /
ACCEPTANCE STANDARDS

-Approved NDT Procedure

MSOG -M1611-QAQC-GP-002

Rev.:

Date:

23 Aug'2016

Page:

4 of 5

HOLD POINTS
VERIFYING DOCUMENTS /
RECORDS

INSPECTION PARAMETERS

ASME Sec V ; ASME B31.4 - Acceptance

criteria

Non Destructive Test Request

-ASME Sec V

FORM

MSOG-QAQC-F-21

RESPONSIBLE
PERSON

QC Inspector

REMARKS

MSOG

TPI

AMECFW

SHELL

N/A

W,R

N/A

I,R

N/A

I,R

Third Party Report

Test Conducted
by 3RD Party NDT
Contractor

-API 1104; ASME B31.4

5.2

% of NDT - Piping & Structures

6.0

WELD REPAIR - Piping & Structures

7.0

7.1

7.2

As per Extent of Examnation (NDE) of Welds - 1243A-8830-PR-0002 Rev.F1

- Fit-up

- Approved WPS, ASME B31.4 Weld repair

Any member cut shall be dressed and

- Visual

1243A-8230-PR-0002

smooth edge or re-paint accordance spec.

- NDT Examination

AWS D1,1

Fit-up Inspection Report ( Piping )

MSOG-QAQC-F-50

Pressure Test ( Hydrotest )

QC Inspector

Visual Inspection Report ( Piping )

MSOG-QAQC-F-51

Non Destructive Test Request

MSOG-QAQC-F-21

N/A

W,R

N/A

W,R

W,R

N/A

W,R

W,R

TESTING

Line check before pressure test

QC Inspector

MSOG-QAQC-F-22

MSOG-QAQC-F-22

1243A-8820-PR-0006

Levelness, alignment, support & to check

welding completed, pipe shoe etc and:
a. To ensure internal pipe clean from dirt
before Installation.
b. Check holding pressure and time for
hydrotesting the pipe.

D.E.P 31.40.40.38

Test Pressure, Leakage & cleaning

- Approved Drawing / Test Package

QC Inspector ,
Construction
Manager, Project
Engineer

Punch List Form

MSOG-QAQC-F-129

Hydrotesting log

MSOG-QAQC-F-56

- ASME B31.4

Test Package Hydrotest

- Test Package

Isometric Drawing list

Piping Internal Cleaning

MSOG-QAQC-F-131

QC Inspector, Project
Engineer

N/A

W,R

W,R

QC Inspector

N/A

W,R

W,R

N/A

I,R

QC Inspector ,
Construction
Manager, Project
Engineer

- Equipment calibration cert.

7.3

7.4

8.0

Dewatering, Internal Pipes cleaning & Air

Blowing

Reinstatement

- Flushing & Blowing Procedure

Visual - Confirm flushing point to point and

- Test Package

ensure Internal Pipes cleanlines

-Test Package, P & ID, ISO Drawing

To confirm all Temporary Material

Punch List Form

MSOG-QAQC-F-129

Punch List Form

removed and permanent items are installed

Test Package

SURFACE PREPARATION
Refer MSOG-M1611-QAQC-GP-004
Refer Blasting and Painting ITP

9.0
9.1

INSTALLATION - Piping & Structures

MSOG-QAQC-F-22

Grout Padding Level

D.E.P 31.38.01.29-G,

Grouting of Structures & Pipe Supports

1243A-8720-A004 Rev.P1

9.2

Elevation & Verticality check

9.3

Fit-up

9.4

Visual Inspection all welds

9.5

Bolt tightening

9.6

Check alignment for anchor bolt structure

9.7

Non- Destructive Test - 5% DPT / MPI for all

joint member.)

- Check each Sleeper / foundation /

Approved drawing
Dimensional check
- Check levelling plates or grout pads in place
& grouted.

MSOG-QAQC-F-134 QC Inspector

Check level and line for bolts and nuts

position

Fit-up Inspection Report

( Structural )
Fit-up Inspection Report
True alignment and position
( Structural )
Weldment quality, Weld aapearance size and Visual Inspection Report
defect
( Structural )

MSOG-QAQC-F-053

QC Inspector

MSOG-QAQC-F-054

QC Inspector

Bolt tightening will be checked after

installation

MSOG-QAQC-F-134

QC Inspector

True alignment and position

AWS D1.1

External & Internal defects on weldments

Visual Inspection Report

( Structural )
Visual Inspection Report
( Structural )
Third Party report

TPI - Authority
DOSH Witness

Doc No.:

MAIN MECHANICAL & PIPING WORK FOR PRODUCT PIPELINE PROJECT AT BINTULU,SARAWAK
INSPECTION AND TEST PLAN ( ITP ) - FABRICATION AND ERECTION WORKS FOR PIPING & STRUCTURES

Activity
No.

INSPECTION ACTIVITIES

10.0

TIE-IN

10.1

Welding - Piping

REFERENCE DOCUMENT /
CONTROLLING PROCEDURES /
ACCEPTANCE STANDARDS

MSOG -M1611-QAQC-GP-002

Rev.:

Date:

23 Aug'2016

Page:

5 of 5

HOLD POINTS
INSPECTION PARAMETERS

VERIFYING DOCUMENTS /
RECORDS

FORM

RESPONSIBLE
PERSON

REMARKS

MSOG

TPI

AMECFW

SHELL

MSOG-QAQC-F-22

a. Fit-up Inspection

-ASME B31.4

Inspection high low condition, Dimension and

Fit-up Inspection Report ( Piping )
Alignment

MSOG-QAQC-F-50

QC Inspector

N/A

I,R

b. Visual Inspection

-ASME B31.4

Checking for under cut / spatter and

Visual Inspection Report ( Piping )

MSOG-QAQC-F-51

QC Inspector

N/A

I,R

Approved Drawing

insufficient welding condition

Weld Summary ( Piping )

MSOG-QAQC-F-52

QC Inspector

N/A

I,R

Non Destructive Test Request

MSOG-QAQC-F-21

QC Inspector

N/A

W,R

W,R

W,R

W,R

W,R

W,R

W,R

Dimensional check and orienation

10.2

NDT
a.Root, Hot Pass and Capping - 100 % MPI

-Approved NDT Procedure

b. RT 100 %

-ASME Sec V

ASME Sec V ; ASME B31.4 - Acceptance

criteria

Third Party Report

-API 1104; ASME B31.4

11.0

FINAL VISUAL INSPECTION

- P & ID, ISO Drawing

a. Final Walk Through

Final Visual Inspection Report

MSOG-QAQC-F-130

QC Inspector

- Punch List Summary

b. Inspection on completed fabricated

Punch List Form

MSOG-QAQC-F-129

Construction Manager

sections condition and marking.

Project Engineer

c. Check any defect.

d. Removal of temporary attachment.
e. Distorsion / dimension check.
f. Perform leak test.
g. Final Paint touch-up
12.0

DOCUMENTATION

Project Specification

Review all Quality records and compile

Test Package

QC Inspector

Test Conducted
by 3RD Party NDT
Contractor