A.J.P.

QUALITY ASSURANCE

INSPECTION AND TESTING FOR UNDERGROUND PIPING WORKS REVISION 0 DATED OCT 2006

Inspection and Testing for Under Ground Piping Works

( QA/P 1451.Doc )

Oct.-2006 DATE

0 REVISION

M.D PREPARD BY 1

G.S REVIEWED BY

S.B APPROVED BY

A.J.P.E

QUALITY ASSURANCE

INSPECTION AND TESTING FOR UNDERGROUND PIPING WORKS REVISION 0 DATED OCT 2006

Table Of Contents
1. 2. 3. 4. 5. 6. 7. PROCEDURE NO. SCOPE AMD PURPOSE APPLICABILITY RESPONSIBILITY GENERAL DEFINITIONS PROCEDURE 7.1 Receiving Inspection 7.2 Field Shop Fabrication Inspection 7.3 Post Weld Inspection Of Spool 7.4 Painting and Wrapping of Spools 7.5 In Process Inspection and Testing For field fabrication and Installation of Underground Piping 7.6 Radiographic Inspection 7.7 Pressure Testing of Spools 7.8 Trenching 7.9 Installation 7.10 Wrapping 7.11 Piping Completion and Inspection ( Punch Out ) 7.12 Pressure Testing 7.13 Testing 8. 9. 10. RECORDS REFERENCES ATTACHMENTS

A.J.P.E

QUALITY ASSURANCE

INSPECTION AND TESTING FOR UNDERGROUND PIPING WORKS REVISION 0 DATED OCT 2006

1.

PROCEDURE NO. P1451

2.

SCOPE AND PURPOSE This procedure covers the Inspection and Testing for the fabrication and installation of Under Ground Piping Works in accordance with Client/Consultant requirements and specifications. The purpose of this procedure is to define a documented and recorded methodology for Inspection and Testing activities and to ensure that under Ground Piping Work is executed in accordance with Client/Consultant Requirements, drawings and specifications.

3.

APPLICABILITY Petroleum Product Storage Terminal at Hamriyah Free Zone.

4.

RESPONSIBILITIES . . . . . . . Project Manager Construction Manager Discipline Engineer Discipline Foreman QA/QC Supervisor QC Inspector Material Controller

5.

GENERAL 5.1 The responsibility for the Inspection and Testing of the Under Ground Piping Rests primarily with the material controller , the Discipline Engineer and the Discipline Foreman with assistance from and audit by the QA/QC Supervisor and QC Inspector. The Discipline Engineer will, under normal circumstances, assign quality control tasks outlined herein to appropriate members of his staff. He may not delegate his responsibility for overall or specific Inspection and Testing activities. The Discipline Engineer and the Discipline Foreman shall ensure the required work permits are available and in place on a daily basis. Similarly they shall ensure that utilized drawings are latest revisions.

5.2

5.3

5.4 The Project QA/QC Supervisor shall verify compliance to this procedure by Audit , and shall perform reviews on all Quality related contractual documentation.

A.J.P.E

QUALITY ASSURANCE

INSPECTION AND TESTING FOR UNDERGROUND PIPING WORKS REVISION 0 DATED OCT 2006

5.5 5.6

The QC Inspector shall be responsible for witnessing tests and execution of inspections and ensuring appropriate documentation. QA/QC Supervisor shall ensure that all welding procedures ( WPS ) , PQR and WPQ are approved and welders are issued with Wallet cards before start of piping fabrication. Welding Procedure should be displayed in fabrication workshop Only piping material required for shop fabrication should be issued during fabrication stage. Site installation material like valves, gaskets, bolts and equipment etc. should be released from stores only at installation stage. Welding consumables as per WPS requirements should be available in warehouse. Baking, storage and handling of welding consumables shall be as recommended by manufacturer. NDE Equipment and crew should be available at site parallel to stop fabrication work and NDE procedures and crew should be duly approved. Painting/ Coating yard, Painting/Coating procedures, and approved material should be ready before starting of fabrication works. Hydrostatic test procedure, test media , and equipment should be ready for testing spools as necessary. Testing Procedure shall be approved by Client/Consultant/ Third Party.

5.7 5.8

5.9

5.10 5.11 5.12

6.

DEFINITIONS Under Ground Piping: Any piping entirely or partially running ground shall be covered by this procedure.

7.

PROCEDURE 7.1 Receiving Inspection 7.1.1 7.1.2 7.2 Materials shall be in accordance with the specifications and Client requirements and from approved sources. Receiving Inspection shall be as per Procedure P155

Field Shop Fabrication Inspection 7.2.1 Responsibility for field shop inspection rests primarily with the Shop Fabrication Foreman with assistance from the QC Inspector.

A.J.P.E

QUALITY ASSURANCE

INSPECTION AND TESTING FOR UNDERGROUND PIPING WORKS REVISION 0 DATED OCT 2006

7.2.2

All fabrications shall be constructed in strict accordance with the pipe spool drawings and contract specifications, except overall fabrication length which may be adjusted to accommodate handling capabilities, all shop fabrication will be in accordance with specifications. Preheating Extent of Preheating requirements shall be as noted for each pipe material line class in the piping and welding specifications and shall normally be accomplished by means of local fuel firing or electric resistance. Prior to Welding, check for : Fit-up Use of proper material and electrode for specific line class Condition of electrodes Material to be welded must be free of dirt, rust, scale, or any foreign debris. All fabrication shall be checked for the following: Adherence to welding procedure for material classification. Dimensional accuracy Proper protection of flange and pipe openings and threads. Conformance to material and fabrication specifications. That all welds are properly identified with welders symbol. Threaded joints which are to be seal welded, do not have thread compound or tape applied to threads. And that seal welds of thread joints completely cover exposed threads. Socket welds are fit-up with proper gaps between end of pipe and bottom of socket.

7.2.3 7.2.3.1

7.2.4 7.2.4.1 7.2.4.2 7.2.4.3 7.2.4.4 7.2.5 7.2.5.1 7.2.5.2 7.2.5.3 7.2.5.4 7.2.5.5 7.2.5.6 7.2.5.7

7.3

Post Weld Inspection of Spool QC Inspector shall inspect the spool after welding. Accordingly, Form P144-7A, shall be completed. Approval and signature of Form P144-7A, shall be release the spool for NDE. NDE shall be executed as per Client/Consultant/Third Party approved Procedure. Each type of NDE shall have its respective report forms. Unless visual inspection is passed, form filled and signed, no NDE activities shall be allowed to proceed. After NDE completion, form P144-7A shall be completed. At this stage, the spool shall be released for painting, erection and pressure test.

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A.J.P.E QUALITY ASSURANCE INSPECTION AND TESTING FOR UNDERGROUND PIPING WORKS REVISION 0 DATED OCT 2006

7.4

Painting and Coating of Spools Painting and Coating of Pipe Spools shall be carried out as per QA/P 143.

7.5

In process Inspection and Testing for Field fabrication and Installation of Underground Pipe. 7.5.1 Responsibility for field fabrication and erection inspection rests primarily with the Discipline Foreman with assistance from the QC Inspector. 7.5.2 Fabrication and erection shall be in strict accordance with the fabrication specification and the pipe spool drawings. 7.5.3 Ensure that welding operations being performed in areas, which are subjected to the elements, are properly protected from wind, dust, rain, etc 7.5.4 Check Preheating requirements as noted in section 7.2.3 7.5.5 All fabrication shall be checked for the following: 7.5.5.1 7.5.5.2 7.5.5.3 7.5.5.4 7.5.5.5 Adherence to welding procedure. Dimensional accuracy General configuration That all welds are properly identified with welders symbol Material code markings to ensure usage of correct pipe, fittings and other components.

7.5.6 Items which require special attention are: 7.5.6.1 7.5.6.2 Valves which must be mounted with special flow direction such as check valves, control valves, globe valves, diaphragm valves which divert flow more than one direction, etc,. Correct installation and type of flange gaskets and bolts.

7.5.7 Prior to installation, lines should be internally inspected, where possible, to ensure a system free of debris. 7.5.8 Test and inspect coated and wrapped pipe by means of a holiday detector after installation in ditch and prior to bedding and padding. The client/Consultant/Third Party Representative should witness the test. QA/QC site office should maintain results on the Holiday Test Record Sheet. 7.5.9 Inspect backfill of coated and wrapped piping, and ensure operations and material are as required by Drawings and Specifications.

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A.J.P.E QUALITY ASSURANCE INSPECTION AND TESTING FOR UNDERGROUND PIPING WORKS REVISION 0 DATED OCT 2006

7.6

Radiographic Inspection The QA/QC Supervisor shall submit Radiographic Inspection Procedure to Client/Consultant/Third Party Representative. Radiographic activity start only after procedure is approved. Forms and proper files shall be prepared for keeping records. Only Qualified Technicians shall execute the work Welds as required by code shall be radiographed, films processed and interpreted , reports submitted and records kept in files. Rejected welds shall be repaired and re- radiographed or cut out if Client/Consultant/ Third Party Representative believes necessary. The QA/QC Supervisor will submit to client/Consultant representative , as required , a monthly report of the welder symbols of all welders responsible for weld defects. The report will identify the welder symbol and number of weld defects by the welder. Total weld defects in the last month and total weld defects.

7.7

Pressure Testing of Spools: 7.7.1 Pressure Testing is carried out to client/Consultant/Third Party approved Hydro Test Procedure and is planned well in advance of fabrication. It is always preferred to have integral piping system consisting of inter connecting lines tested together. However, some limitations will force individual line/spool to be tested separately. 7.7.2 Hydrostatic Test Pack It is a pack of documents that may include, as follows. 1. 2. 3. 4. 5. 6. 7. Form P144-10, Test Pack Index Form P144-11, Test Pack Line List Form P144-7A, Field and Shop Welding Inspection Summary sheet with NDE report Form P144-9, Piping Punch List Form P144-14A, System Flushing Report Form P144-15, line Reinstatement Checklist Form P144-16, Gasket Installation Checklist

7.7.3 As per approved Test Pack test is prepared and carried out. All documentation in the Test Pack is recorded and signed.

A.J.P.E

QUALITY ASSURANCE

INSPECTION AND TESTING FOR UNDERGROUND PIPING WORKS REVISION 0 DATED OCT 2006

7.8

Trenching 7.8.1 Trench shall be excavated, dressed, compacted and in compliance with Drawings and specifications with particular emphasis on safe working practices.

7.9

Piping Completion and Inspection ( Punch Out ) Organization . . A completion / Inspection team should be organized and ready to function when the first system is reported 100% completed. The team should include, but not necessarily be limited to. . . . Discipline engineer Discipline Foreman QA/QC Supervisor

Responsibility . . The ultimate responsibility for effective control of piping completion / inspection tests with the Discipline engineer. It is recognized that job conditions may vary and therefore some of the outlined duties may be delegated to other individuals as seen fit by Discipline Engineer.

7.10

Pressure Testing 7.10.1 Field Pressure Testing of Piping systems and integral components shall be in strict accordance with Client /Consultant/Third Party approved Hydro Test Procedure and all other contract specifications and standards. Familiarize with contract pressure testing specifications is essential. Test Preparation The Discipline Engineer shall inspect each piping test system. The purpose of this inspection is to ascertain that each piping test system is in fact ready for test. Items which normally present problems and should be checked are: a) Pressure source and test gauge should be upstream of check valve. If not, then check valve should have flapper removed or jacked-up. b) Ensure that all items such as control valves, relief valves, rupture discs, orifice plates, expansion joints, etc which could be damaged during pressure test have been removed or located as indicated on the pressure test drawings.

7.10.1.1 7.10.1.1.1

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A.J.P.E QUALITY ASSURANCE INSPECTION AND TESTING FOR UNDERGROUND PIPING WORKS REVISION 0 DATED OCT 2006

c) Check open and close position of all valves. d) Check for proper installation of vents and drains 7.10.1.1.2 7.11 Testing In general Pressure Testing will be carried out in accordance with approved Hydro testing Procedure QA/P 165. The discipline Engineer shall prepare all piping systems ready for pressure test in accordance with applicable specifications. 7.11.1 7.11.2 7.11.2.1 The checks required in the test pack should be completed forms filled in and signed in order to release the piping system for test. The QA/QC Supervisor shall notify Client Representative about the Hydrostatic Testing operation schedule using R.F.I. A Hydro Test report shall be prepared by the QA/QC Supervisor upon the execution of line Hydro Test and shall be supported by all supplementary. Permanent gaskets are used to replace temporary and form P144-16 may be filled. Any deficiencies found during this inspection should be listed using a punch list form.

7.11.3. 8. RECORDS

All records relevant to above procedure shall be maintained at the site office for the duration of the Project and repatriated to the Area Head Office to be achieved , and kept for a period of Three years , following the achievement of the project. 9. REFERENCES A.J.P.E Corporate Quality Assurance Manual Non Destructive Testing Procedures 10. ATTACHMENTS . . . . . . . Form P144-7A, Form P144-9, Form P144-10, Form P144-11, Form P144-14A, Form P144-15. Form P144-16, Field and Shop Welding Inspection Summary Sheet Piping Punch List Test Pack Index Test Pack Line List System Flushing Report Line Reinstatement Checklist Inspection Check sheet for Gasket Verification.