A 03.08.

2013 First Issued E DA ED

Rev. Prepared Checked Contr. By Chek. ------------
Date Description
No. ORIGINATOR Published
 EDOPEC ENERJ PETROL MHENDSLK SANAY VE
TCARET LMTED RKET

Head Office : Document Title

Palmiye Mah. Adnan
menderes Bulv. Oktay INSPECTION AND TEST PLAN FOR
Sitesi No: 9/8
PK = 33100 CATHODIC PROTECTION SYSTEMS
Yeniehir /Mersin
TURKEY
P:+90 324 3260595
Document No.
F:+90 324 3260596 EDO PLN COE COR INT XXX 013 049 50 Rev B
www.edopec.com. Co. Doc Disc. Unit Prj. Prj. Prj. Pro.Doc. DCC Page Scale
Org. Seq.
info@edopec.com Type Code Code type NO Year Seq.No
No 22
Cod
 INDEX
INDEX......................................................................................................................................................... 2
1 SCOPE................................................................................................................................................ 3
1.1 DEFINITIONS....................................................................................................................................3
1.2 APPLICABLE DEFINITION.............................................................................................................3

2 REFERENCES CODES AND STANDARDS.................................................................................. 4

2.1 GENERAL...........................................................................................................................................4
2.2 STANDARDS AND CODES..............................................................................................................4

3 ENVIRONMENTAL SITE CONDITION........................................................................................ 5

4 GENERAL REQUIREMENTS......................................................................................................... 6

5 INSPECTION PROCEDURE........................................................................................................... 8

6 INSPECTION AND TEST TIME SCHEDULE............................................................................... 9

7 PRE-INSPECTION MEETING...................................................................................................... 10
7.1 PURPOSE..........................................................................................................................................10
7.2 DISCUSSION AT PRE-INSPECTION MEETING..........................................................................10
7.2.1 Vendor's quality control system....................................................................................................10
7.2.2 Inspection items............................................................................................................................10

8 WITNESS INSPECTION AND TESTS.......................................................................................... 11

9 INSPECTION ACTIVITIES DURING MANUFACTURING..................................................... 12

9.1 GENERAL.........................................................................................................................................12
9.2 INSPECTION VISIT.........................................................................................................................12
9.3 INSPECTION SCHEDULE..............................................................................................................12
9.4 NON- CONFORMITY CONTROL..................................................................................................13

10 INSPECTION RELEASE NOTE.................................................................................................. 14

11 VENDOR INSPECTION RECORD............................................................................................. 15

12 INSPECTION AND TEST PLAN (ITP)....................................................................................... 16

12.1 CP REFERENCE ELECTRODES..................................................................................................16
12.2 CP BOXES......................................................................................................................................17
1 SCOPE

This documents covers the inspection and test plan for acceptance test to be
carried out by the contractor before delivery of any equipment for Cathodic
Protection System .
Inspection and test activities not covered by this document shall be decided after
getting approval from client/ contractor prior to the start of fabrication.
The inspections performed according to the present document shall not release
the manufacturer from his obligations under the warranty .
DEFINITIONS

Owner/ Client ------------

Project ------------
Contractor ------------
The Company which has been selected by Client to inspect the
Third Party
materials & equipment supplied for the project and will issue
Inspector
release note for inspected materials and equipment.
The Company which has been selected to supply the materials &
Manufacturer/
equipment and will produce technical documentation mainly
Supplier/Vendor
related to the production of the ordered supply.

The Word "Shall" Indicates a Mandatory Order.

The Word "Should" Indicates a Recommendation or Advice Only.
The Word "May" Indicates a Complete Discretion.
APPLICABLE DEFINITION
Quality Assurance and Quality Control (QA/QC): The vendor organization
system to ensure the acceptable quality using a certified management system.
Inspection Test Plan (ITP): The quality control activities imposed on materials &
equipment.
Purchase Order: The documents and attachments in which the order is
described.
NDE/NDT: Non destructive examination and tests which will be done by vendor.
Requisition: The document which establishes the several technical and
commercial purchase conditions.
2 REFERENCES CODES AND STANDARDS

GENERAL
The cathodic protection equipments shall be designed, fabricated and tested in
accordance with applicable sections of the latest edition (including all revisions
and addenda current at the time of order placement) of the following codes and
standards:
- International Electro technical Commission (IEC)
- British Standards Institution (BSI)
- American Petroleum Institute (API)
- Iranian Petroleum Standard (IPS)
- National Association of Corrosion Engineers (NACE)
- American Society of Testing and Materials (ASTM)
STANDARDS AND CODES
IEC (INTERNATIONAL ELECTROTECHNICAL COMMISSION)

IEC 60502 Extruded Solid Dielectric Insulated Power Cables for Rated Voltages of 1 kV up
to 30 kV
IEC 60529 Specification for Classification of Degrees of Protection Provided by Enclosures
IEC 60051 Recommendation for Indicating Electrical Measuring Instruments and Their
Accessories
IEC 60439-1 Low voltage switchgear and control gear assemblies
IEC 60076 Power Transformers
IEC 60146 Semiconductor Converters
IEC 60269 Low Voltage Fuses
IEC 60391 Marking of Insulated Conductors
IEC 60445 Identification if Apparatus Terminal Marking Using an Alphanumeric Notation
IEC 60417 Recommended Graphical Symbols

BRITISH STANDARD (BS)

BS 7361 Pt.1 Cathodic protection Code of practice for land and marine applications
BS 1377Methods of Testing Soils for Civil Engineering Purposes
BS 7430 Code of Practice for Earthing
BS 5467Specification for Cables with Thermosetting Insulation for Electricity Supply
BS 6004Specification for PVC Insulated Cables (Non Armoured) for Electrical Power and
Lighting
BS 6346 Specification for PVC Insulated Cables for Electricity Supply
BS 2914Surge Diverters

NATIONAL ASSOCIATION OF CORROSION ENGINEERS (NACE)

NACE-RP0169 Control of External Corrosion on Underground or Submerged Metallic
Piping Systems
NACE-RP0177 Mitigation of Alternating Current and Lightning Effects on Metallic
Structures and Corrosion Control Systems
NACE-RP0572 Design, Installation, Operation, and Maintenance of Impressed Current
Deep Ground beds
NACE-RP0286 The Electrical Isolation of Catholically Protected Pipelines
NACE-RP0193 External Cathodic Protection of on-grade Carbon Steel Storage Tank
Bottoms
3 ENVIRONMENTAL SITE CONDITION

The Cathodic Protection equipment, on this scope of work shall be suitable for reliable
application in continuous operation in atmosphere containing dusts and saline air. The
design, manufacturing and method of installation shall take full account of the
environmental and condition for FACLTES specified as below:

ITEM UNIT DATA

Elevation Above Sea Level m ---
Barometric Pressure Kg/cm2 a ----
Ambient Air Temperature
Maximum recorded temperature C ----
Average recorded temperature C -----
Minimum recorded temperature C -----
Equipment Exposed to Sunlight C ----
Relative Humidity
Maximum % ----
Minimum % -----
Wind Velocity
Maximum m/sec -----
Average m/sec -----
Rainfall Rate
Maximum mm/day ----
Average mm/day ----
Snow Load
Slop of the Roof, 5 or Less Kg/m2 ---
According to UBC; 2A
Seismic Zone --- According to Iranian Seismic
Code 2800;3
4 GENERAL REQUIREMENTS

In order to assure that the equipment shall conform to the requirements of the requisition,
specification and other related documents, vendor shall perform inspection and tests
program and schedules for materials and equipment to be supplied by vendor and his
sub-vendor(s) whenever necessary. Vendor shall submit to contractor his inspection
procedure Quality Control Plan (QCP) including fabrication schedule for owner and
contractor approval as required in the procurement documents.

Contractor will perform inspection and test necessary to maintain the quality and
workmanship of materials and equipment in accordance with the requirements stipulated
in the relevant requisition and approved data sheet and specifications. Contractor shall
also have the right to review the inspection test records or other quality related
documents of any materials and equipment. Inspection will be performed by contractor
and owner inspectors and/or his agent i.e. third party inspection company. Contractors
approval and/or third party inspector company approval or release note shall not relieve
the vendor from the responsibility to meet all the requirements specified on the purchase
order.

Owner and/or contractor reserve the right free access at all reasonable time to the shop
where fabrication or inspection and testing on materials and equipment being performed.
Vendor shall provide with necessary equipment, facilities and skilled personnel for
specified inspection and test for the owner and/or contractor inspector at free expense
and charge.

The vendor shall provide a safe working environment for the inspector and to alert to
inspector of potential hazards. If the working conditions are unsafe, in opinion of
inspector, he may not perform his work.

Vendors QA/QC manual shall be available anytime at vendors shop upon request by the
inspector.

Owner and/or contractor have the right to hold a Pre-Inspection meeting with vendor in
order to check the vendors QC and inspection methods and also establish a
communication channel with vendor.

The vendor shall submit the entire sub-vendor list, who undertakes fabrication of the
equipment and/or supply the material partially or wholly for owner/contractors approval.
Further the vendor shall control QC of sub-vendors and shall supply the necessary
specification to sub-vendors.

The drawings and inspection documents which are approved by Contractor/Owner

and/or by authorities as specified by them shall be binding for the inspections.

In the case of modifications required after the drawings have been approved, these
modifications shall be confirmed & approved in writing by Contractor/Owner and, if
applicable, by the authorities. Verbal agreements shall in no case be accepted.
Type and extent of inspection and tests shall not be less than the requirements of
reference codes and standards and signed contract.
5 INSPECTION PROCEDURE

Vendor shall develop his own detail inspection procedure incorporated with "Inspection &
Test Plan", attached herewith and any requirements in the purchase order, and submit it
to the contractor for approval.

Inspection procedure shall consist of:

- Inspection and test items

- Q.C procedure/code

- Acceptance criteria

- Inspection authority

- Inspection & test report/data to be submitted

Any change and deviation from purchase order requirements are subject to "Written
Approval" by the contractor/owner, however the approval of vendor prints shall not be
regarded as foregoing "Written Approval".
6 INSPECTION AND TEST TIME SCHEDULE

Based on the inspection program and the delivery date given in the purchase order,
vendor shall provide for contractor a preliminary time schedule showing the expected
inspection program of materials and equipment.
7 PRE-INSPECTION MEETING

PURPOSE

The purpose of a pre-inspection meeting is primarily to ensure that the quality

requirements of the purchase order are being handled satisfactorily and that all
requirements in the purchase order, the applicable specifications, standards and
drawings are fully understood by all concerned.

The pre-inspection meeting is normally held at the manufacturer's shop with the
contractor's and/or owners or third party inspection agencys inspector or inspection
coordinator. The contractor shall decide the necessity and schedule of the meeting.

DISCUSSION AT PRE-INSPECTION MEETING

7.1.3 Vendor's quality control system

The Vendor's quality control program, including details of the fabrication, manufacturing
and production sequences witness points for inspection, and the quality control system
shall be studied.

The Vendor's quality control and inspection organization shall be checked and reviewed
for its ability to retain the required quality of workmanship.

7.1.4 Inspection items

Each inspection item of the purchase order, procedures and methods, including
inspection measure should be discussed in detail. Acceptance standards for the
inspection should be clearly established at this meeting so that the inspector can judge
conformance with it during inspection.

Coordination procedures such as communication channels between the parties

concerned and submissions of records etc. should be clearly understood by vendor at
this meeting.
8 WITNESS INSPECTION AND TESTS

Inspection and tests plan attached herewith shows inspection and test requirements to be
witnessed by contractor and owner.

This plan is complementary to any additional requirements that also may be specified in
the individual purchase order requirement.

The extent of inspection and test for the materials and equipment not listed in shall be
based on vendors detail inspection plan approved by contractor and owner.
9 INSPECTION ACTIVITIES DURING MANUFACTURING

GENERAL

Upon receiving the vendor's application for inspection, the contractor's and/or owner's or
third party inspection agency's inspector shall witness and review the items specified in
compliance with the purchase order and technical related documents. The contractors
inspector, however, may visit vendor's shop for checking vendor's quality control and
correctness of fabrication without a vendor's application.

INSPECTION VISIT

The contractors and/or owner's or third party inspection agency's inspector shall check
and evaluate the vendor's quality control, correctness of fabrication procedures and the
adequacy of the vendor's performance during his visit. The records of inspection and test
previously performed by vendor shall be submitted to the contractor's and/or owners or
third party inspection agencys inspector for his review before inspection.

INSPECTION SCHEDULE

Vendor shall submit overall fabrication schedule, clearly indicating vendor's inspection
and test points including witness point of the contractor/owner or third party inspector in
accordance with purchase order requirements within 4 weeks after issuance of purchase
order but prior to the start of fabrication.

Contractor and/or owner shall notify witness points of contractor and/or owner to vendor
after review of vendors inspection schedule.

Monthly schedule

Vendor shall submit the monthly inspection schedule, for the upcoming month to the
contractor on the 25th day of each month.

Application for inspection

Vendor shall submit to the contractor "Application for inspection" which should reach the
contractor at least twenty (20) working days prior to the actual inspection and test date.

Contractor shall notify to Owner's designated representative the "Application for

inspection according to inspection and test plan", which should reach owner at least ten
(10) days prior to the actual inspection date.
When any change of inspection date occurs for some reason, vendor shall promptly
notify the contractor of the revised inspection date by facsimile or e-mail.

NON- CONFORMITY CONTROL

Vendor is requested to report a non-conformance immediately to the contractor and

owner for approval, if any non-conformance is found during inspection and/or fabrication.
In this event, the document shall be summarized including the condition of non-
conformance and recommended corrective action.
10 INSPECTION RELEASE NOTE

Inspection release note shall be issued to the vendor by owner/third party inspector after
accepting the item for delivery from the vendors shop.

Vendor shall not proceed with shipment of them without inspection release note issued by
owner/third party inspector.
11 VENDOR INSPECTION RECORD

Within twenty (20) working days from the date of final inspection, vendor shall submit to
contractor the inspection folder including also copies of all inspections and tests records
carried out during the fabrication, written in English. The vendors inspection record shall
state the vendors inspections and tests have been properly performed and accepted by
the inspector.
12 INSPECTION AND TEST PLAN (ITP)

This part indicates minimum extent of inspection to be performed by contractor, and

owner and/or his third party company inspector, and is to be incorporated in to
vendor/sub-vendor's own inspection procedure.

This plan is complementary to any requirement that may also be specified in the
individual purchase order requirements. The extent of inspection and test activities for the
equipment and materials not listed in the inspection and test plan shall be based on the
vendor's inspection test procedure approved by the contractor.

The following are shown abbreviations and notes to be used with the Inspection and Test
Plan table.

CP REFERENCE ELECTRODES
Test Inspection
Product Category Test Method
Description Records M C N
According to the
Visual and Test
approved detailed
dimensional Sheet P W R
drawing. With Applied to
Test Submitted
the whole of supply
With respect to
Test
Cu/CuSO4 Reference
Routine Potential Test Sheet P R R
Reference Electrode. Applied to the
Production Submitted
Electrode whole of supply
Tests
Test
Cable IEC60439-1. Applied to
Sheet P R R
Insulation Test 10% of whole supply
Submitted
Test
As per client
Packing Sheet P W R
specifications
Submitted
LEGEND:
M: Manufacture/Subcontractor,
C: Contractor/Nominated Inspection Agency,
N: Client/End User
"P" Perform, "W" Witness, "V" Verification, "R" Review of Document as Appropriate,
"CHP" Customer Hold Point Shall Identified In Column "N"
 CP BOXES

Inspection
Description Category Test Description Test Method
Records M C N
Raw Material Test According to the
M/S Certificate R R R
(Steel Sheet Plate) manufacture Standards
Raw Material Test According to the Manufacture
R R R
(Terminals) manufacture Standards Catalogue
According to the
Visual and approved detailed Test Sheet
P W R
dimensional Test drawing. With Applied to Submitted
all of the boxes
Quality
CP Boxes IEC60439-1. Applied to Test Sheet
Control Tests Insulation Test P R R
10% or boxes each type Submitted
Applied to 10% of boxes
during coating process
Test Sheet
Coating Test separately applied for all P R R
Submitted
of Primer, Intermediate
coat and finish
As per client Test Sheet
Packing P W R
specifications Submitted

LEGEND:
M: Manufacture/Subcontractor,
C: Contractor/Nominated Inspection Agency,
N: Client/End User
"P" Perform, "W" Witness, "V" Verification, "R" Review of Document as Appropriate,
"CHP" Customer Hold Point Shall Identified In Column "N"
 14.1.CP TRANSFORMER RECTIFIER UNIT
Inspection
Description Category Test Description Test Method
Records M C N
The insulation resistance of primary and
Power Transformer secondary circuits to dead metal parts
Insulation and shall be sufficient to withstand a 2500 Test Sheet
P R R
winding resistance volt signal within an insulation resistance Submitted
test grater then 100 Mega Ohms to ensure
Power Leakage current will be less than 5 mA.
Transformer The efficiency of the transformer with the
Tests rectifier adjusted to supply rated output
at rated load shall be greater than 95%
Power Transformer Test Sheet
and shall be determined by measuring P R R
Efficiency Test Submitted
with wattmeter and comparing the total
power at the transformer secondary
output, and primary input.
The insulation characteristics of Input
and Output of the Rectifier Unit to dead
Insulation& metal parts shall be sufficient to
Test Sheet
dielectric withstand a 2500 volt, signal applied as P W W
Submitted
Breakdown Test per IEC60146. Leakage current shall be
less than 5 mA, and no amount of arcing
is acceptable.
Shall be conducted on each supplied
CTR unit to ensure that;
Controlled TR Unit The transformer does not saturate at Test Sheet
Rated Output Test P W W
high line Submitted
The rectifier is capable of providing the
rated output at low line
Shall be conducted to ensure the
Transformer Nominal Operating nominal operating parameters such as Test Sheet
P W W
Rectifier Tests Test AC input voltage and Current DC output Submitted
voltage and Current and Output Ripple
Shall be conducted on each supplied
Outupt regulation Test Sheet
unit to ensure that Regulation is stepless P W W
Test Submitted
within minimum of 1% accuracy
The efficiency of the T/R adjusted to
supply rated output at rated load shall be
Rectifier Efficiency Test Sheet
greater than 80% and shall be P W W
Test Submitted
determined by measuring with
wattmeter.
Shall be conducted to minimum of one
of each type on each batch for each;
Temperature Rise Test Sheet
Transformer Temperature Rise P R R
Test Submitted
Oil Temperature Rise
Rectifier Element Temperature Rise

LEGEND:
M: Manufacture/Subcontractor, C: Contractor/Nominated Inspection Agency,
N: Client/End User "P" Perform, "W" Witness, "V" Verification, "R" Review of Document
as Appropriate, "CHP" Customer Hold Point Shall Identified In Column "N"
14.2.MMO ANODES
Inspection
Product Category Test Description Test Method
Records M C N
Acid test pin hole in To be applied to one sample of Test Sheet
P R R
coating each batch (15% H2SO4 , 10h) Submitted
chemical analysis of To be applied to one sample of Test Sheet
P R R
Type Tests titanium substrate each batch (As per ASTM B 338) Submitted
To be applied to one sample of
chemical analysis of Test Sheet
each batch (As per IPS-M-TP- P R R
Backfill Submitted
750/2)
IEC60439-1. Applied to 100% of Test Sheet
Cable Insulation Test P R R
whole supply Submitted
CANISTER
MMO ANODES to 100% of whole supply
Pullout strength Test Sheet
cableanode connection P R R
(tensile) test Submitted
(>100kg)
Routine
Anode to cable to 100% of whole supply Test Sheet
Production P R R
resistance test (0.03 ohms) Submitted
Tests
According to the approved
Visual and Test Sheet
detailed drawing. With Applied to P W R
dimensional Test Submitted
the whole of supply
Test Sheet
Packing As per client specifications P W R
Submitted

LEGEND:
M: Manufacture/Subcontractor,
C: Contractor/Nominated Inspection Agency,
N: Client/End User
"P" Perform, "W" Witness, "V" Verification, "R" Review of Document as Appropriate,
"CHP" Customer Hold Point Shall Identified In Column "N"
14.3.FERRO SILICON ANODES
Inspection
Product Category Test Description Test Method
Records M C N
Chemical Analysis of
As per ASTM A 518 Third Party R R R
material
Manufacturers certificate
Manufacturer
Anode Cable Test with standard electrical test R R R
Certification
according to IEC
Visual Inspection For
Type Tests Visual & Dimensional dimension and surface
Ferro-silicon Test Sheet Submitted P W R
Routine Test Quality, applied to 10% of the
Anode
Production Tests anodes on each batch
<0.03 Ohm, applied to at
Anode-to-Cable
least 5% of anodes on each
Electrical Resistance Test Sheet Submitted P R R
batch,
Test
as per ASTM B 539
Pull-Out Strength equals 115
Pull-Out Strength Tests Test Sheet Submitted P R R
kg applied to 10% of anodes

LEGEND:
M: Manufacture/Subcontractor,
C: Contractor/Nominated Inspection Agency,
N: Client/End User
"P" Perform, "W" Witness, "V" Verification, "R" Review of Document as
Appropriate, "CHP" Customer Hold Point Shall Identified In Column "N"
 14.4.OTHERS
Test Inspection
Description Category Standards/Method
Description Records M C N
According to the
Visual and
Warning Tape, approved detailed Test Sheet
Quality dimensional P W R
Cable Lug, drawing. With Applied Submitted
Control Test
Earthing to 10% of the supply
Tests
system As per client Test Sheet
Packing P W R
specifications Submitted

LEGEND:
M: Manufacture/Subcontractor,
C: Contractor/Nominated Inspection Agency,
N: Client/End User
"P" Perform, "W" Witness, "V" Verification, "R" Review of Document as
Appropriate, "CHP" Customer Hold Point Shall Identified In Column "N"