ZapSibNeftekhim LLC

ZapSib-2 Project, Detail Engineering

Ethylene Cracker Unit (ECU)

Document Title:
Inspection & test plan (ITP)
Tank Flare Package
27-FL-1901 A/B

Document Number:
2719-0012DI3630-128-0001

Refer Fixed flare ITP (T-SV 1400.001)

for other typical comments.

Client: ZapSibNeftekhim, LLC

Contractor: Linde AG
Contractor Office: Pullach, Germany
Contractor Project No.: 3110 ATH2
Contractor Project Code: Tobolsk_02
Contract No.: ZSN.0387
20130516

Comments: Dpt.: Date:

20130516
20130516

Comments: Dpt.: Date:

CODE P ENCS 27. Sep 2017 1 ENEE 26. Sep 2017

3 ENQ 20. Sep 2017 Name:
Name: Herin Vijayan
Jayesh Delvadiya
ChiragK Patel

REASON FOR APPROVED BY

REV DATE ORIG CHKD
ISSUE Contractor Client
0 23-Mar-17 Issued for review F.GROSSE N.PIERRE
1 13-July-17 Issued for review F.GROSSE N.PIERRE
2 06-Sep-17 Issued for use F.GROSSE N.PIERRE

LindeDoc.No.: 0012DI36302719TSV1100.001(EN)
Suppl.Doc.No.: MFLP00389BITP
Suppl.Rev.No.: 02

RefertoprotectionnoticeISO16016

Page 1 of 21
ZapSib-2 Project, Detail Engineering Inspection & test plan (ITP)
Ethylene Cracker Unit (ECU) 2719-0012DI3630-128-0001
Contract No.: ZSN.0387 Rev: 2 Date: 06-Sept-17

REVISION RECORD SHEET

Rev. Date Update/ Amendment Details

0 23-Mar-17 Issued for review

1 13-July-17 Issued for review

2 06-Sept-17 Issued for use

LindeDoc.No.: 0012DI36302719TSV1100.001(EN)
Suppl.Doc.No.: MFLP00389BITP
Suppl.Rev.No.: 02

RefertoprotectionnoticeISO16016 Page2of21
ZapSib-2 Project, Detail Engineering Inspection & test plan (ITP)
Ethylene Cracker Unit (ECU) 2719-0012DI3630-128-0001
Contract No.: ZSN.0387 Rev: 2 Date: 06-Sept-17

TABLE OF CONTENTS

1. DEFINITIONS & ABBREVIATIONS ........................................................................................................ 4

2. REFERENCE DOCUMENTS ................................................................................................................... 5
3. ITP General Activities (All TAGs) ............................................................................................................ 9
4. ITP Manufacturing Activities FLARE TIP ASSEMBLY - Tank flare tip 27-FL-1901A ......................... 11
5. ITP Manufacturing Activities FLARE TIP ASSEMBLY - Tank flare tip 27-FL-1901B ......................... 13
6. ITP Manufacturing Activities PANEL ASSEMBLY (All TAGs) ............................................................. 15
7. ITP Manufacturing Activities Lifting Equipments (All TAGs) ............................................................. 16
8. ITP Manufacturing Activities Loose Items (Junction boxes, cables, instrumentation, valves)
(All TAGs) ............................................................................................................................................... 18
9. ITP Manufacturing Activities COMMON DERRICK STRUCTURE ASSEMBLY Tank flare
27-FL-1901 A/B ................................................................................................................................... 20
10. ITP Manufacturing Activities RISER AND UTILITY LINES Tank flare 27-FL-1901 A .................... 21
11. ITP Manufacturing Activities RISER AND UTILITY LINES Tank flare 27-FL-1901 B .................... 21
12. ITP Manufacturing Activities ELECTRICAL HEAT TRACING SYSTEM FOR FLARE UNIT
ASSEMBLY Tank flare 27-FL-1901 A/B ......................................................................................... 22

Quality check of boughout/

balance items to be
mentioned
1. Hydraulic jake (for tank
flare)
2. Manual winch(s)
3. All boughtout/Free issue
material (for example
Instrumentation) to FFG
skid panel

LindeDoc.No.: 0012DI36302719TSV1100.001(EN)
Suppl.Doc.No.: MFLP00389BITP
Suppl.Rev.No.: 02

RefertoprotectionnoticeISO16016 Page3of21

ZapSib-2 Project, Detail Engineering Inspection & test plan (ITP)
Ethylene Cracker Unit (ECU) 2719-0012DJ1420-128-0001
Contract No.: ZSN.0387 Rev: 2 Date: 06-Sept-17

1 DEFINITIONS & ABBREVIATIONS

OWNER CJSC Sibur Holding ZapSibNeftekhim (ZSN), LLC

Complex ZapSib-2 Project Manufacturing Facility , will constitute new grass-root
Process Units Ethane Cracker Unit (ECU) , PP , HDPE, LLDPE/HDPE , &
ASSOCIATED Utilities Infrastructure & Off-sites.
LINDE Linde AG-Linde Engineering Division
Site Construction site for Complex including temporary facilities and related
fabrication sites.
VENDOR Company fully responsible for the design and the fabrication as well as the
compliance of the Package Unit with this specification.
Package Unit (PU) Package Units are parts of a plant that are capable of functioning as a unit and
comprise goods and services from different trades (i.e. disciplines) put together
and supplied by one vendor.
ACB (Accredited Certification Body) an entity registered in the Unified Register of
certification bodies and testing laboratories of the Customs Union (Russia,
Belarus, and Kazakhstan)
TPI Third Party Inspector

LindeDoc.No.: 0012DI36302719TSV1100.001(EN)
Suppl.Doc.No.: MFLP00389BITP
Suppl.Rev.No.: 02

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ZapSib-2 Project, Detail Engineering Inspection & test plan (ITP)
Ethylene Cracker Unit (ECU) 2719-0012DJ1420-128-0001
Contract No.: ZSN.0387 Rev: 2 Date: 06-Sept-17

2 REFERENCE DOCUMENTS

GENERAL INTERNATIONAL CODES & RUSSIAN STANDARDS

TR CU 004 / 2011 Technical regulations of the Customs Union. On safety of low-voltage

equipment
TR CU 010 / 2011 Technical Regulation of the Customs Union On safety of machines and
equipment
TR TC 012 / 2011 Technical Regulation of the Customs Union On safety of equipment intended
for use in explosive environments
TR CU 020 / 2011 Technical Regulation of the Customs Union "Electromagnetic compatibility of
technical equipment"
TR CU 032 / 2013 Technical Regulation of the Customs Union "on safety of high pressure
equipment"
IEC 62086-1:2001 Electrical apparatus for explosive gas atmospheres - Electrical resistance trace
heating - Part 1: General and testing requirements
ASME V Non-destructive testing
ASME B31.3 Piping
ASME IX Welding Specification
ASME II Material
ATEX Explosion Proof Equipment
EN 10204:2004 Metallic Products Types of inspection documents.
GOST 12.3.016-87 The occupational safety standards system. Construction. Anti-corrosion works.
Safety requirements
GOST 14192-96 Marking cargo
GOST 24294-87 Verification of purchased products. Organization and methods of control
OST 26.260.18-2004 Technological blocks for oil and gas industry. General specifications
OST 26.260.758 Steel structures. General technical requirements
Electrical installation code Electrical installation code (PUE), affirmed by Order of Ministry of Energy of
(PUE) Russian Federation dated 08.07.2002 No.204
RD 34 15.132-96 Welding and quality control of welded joints of metal structures during the
construction of industrial facilities
PB 10-573-03 Rules of designing and safe operation for installation and safe operation of the
process pipelines
RTN 779 On Approval of the safety manual Flare Systems

LindeDoc.No.: 0012DI36302719TSV1100.001(EN)
Suppl.Doc.No.: MFLP00389BITP
Suppl.Rev.No.: 02

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ZapSib-2 Project, Detail Engineering
Ethylene Cracker Unit (ECU)
Contract No.: ZSN.0387
RTN Order No784
SA 03-005-07
&AA-2000-A-SX 1001 (EN)
&AA-2000-N-SP 1002 (EN)
&SIBUR-N-SA 1001 (EN)
&AA-2000-T-SS 2301 (EN)
&AA-2000-K-SL 1001 (EN)
&AA-2000-T-SX 1100 (ER)
&AA-2000-A-SP 5001 (EN)
&AA-2000-T-SG 1001 (EN)
&AG2100E-PA251.1001(EN)
&SIBUR E-SA 1015
&AA 2000 B-GE 1960 (EN)
JOHN ZINK HAMWORTHY COMBUSTION GENERAL QUALITY STANDARDS (For internal use only)
JZHC-GQS-002
JZHC-GQS-019 & 019.1
JZHC-GQS-004
JZHC-GQS-005
JZHC-GQS-023
JZHC-GQS-016
JZHC-GQS-024
RefertoprotectionnoticeISO16016
Inspection & test plan (ITP)
2719-0012DJ1420-128-0001
Rev: 2 Date: 06-Sept-17
Safety manual recommendations for installation and safe operation of the
process pipelines
Technological pipelines of refining, Petrochemical, and chemical industries.
Requirement for design and operation
LINDE SPECIFICATION
Vendor Shipping Instructions
Specification for Fabrication of Structural Steel
General structural specification
Painting Identification and Requirements
Annex to Order Packing, Marking and Dispatch
Nameplate for Pressure Vessels and Vessels
Purchase Order Execution Procedure
Instruction for Issue of Final Documentation
Specification for Electrical Equipment for Package Units
Electrical Heat Tracing Specification
List of Attachments for Flare Packages
Pre-Inspection Meeting
Coating Inspection / Coating Inspection and Test Records Appx
Welding Standards
Inspection Test Plan
Weld Inspection
Pressure Test Inspection
Packaging and Crating Standards
LindeDoc.No.: 0012DI36302719TSV1100.001(EN)
Suppl.Doc.No.: MFLP00389BITP
Suppl.Rev.No.: 02
Page6of21
ZapSib-2 Project, Detail Engineering Inspection & test plan (ITP)
Ethylene Cracker Unit (ECU) 2719-0012DJ1420-128-0001
Contract No.: ZSN.0387 Rev: 2 Date: 06-Sept-17

JOHN ZINK HAMWORTHY COMBUSTION LUXEMBOURG INTERNAL PROCEDURES

2719-0012DJ1420-122-0002 Dye penetrant examination

2719-0012DJ1420-122-0003
2719-0012DJ1420-122-0003
2719-0012DJ1420-126-0002
2719-0012DJ1420-128-0004
2719-0012DJ1420-112-0002-05
2719-0012DJ1420-112-0001-02
Hydrostatic pressure test
Positive material identification
Paint procedure
Welding book
Workshop detail drawings
General arrangement drawing

LindeDoc.No.: 0012DI36302719TSV1100.001(EN)
Suppl.Doc.No.: MFLP00389BITP
Suppl.Rev.No.: 02

RefertoprotectionnoticeISO16016 Page7of21
 JOHN ZINK INTERNATIONAL LUXEMBOURG SARL
Inspection and test plan for Tank Flare Package (27-FL-1901 A/B)
Client : ZapSibNeftekhim, LLC, LINDE AG Date : 06.09.2017

Linde project No: 3120 ATH2 JZHC Document No. : MFLP00389-BITP

JZ Ref. : MFLP00389 Linde PO number: 0012DI3630 Created by : N. PIERRE
Item : Flares Technical PO : &AA2000B-GE-1960 Revision-No. : 2 Approved by : F. GROSSE

No. ACTIVITY REFERENCE ACCEPTANCE DEPART Sub Signature John Signature ACB Signature LINDE Signature Owner Signature VERIFYING
DOCUMENTS CRITERIA -MENT contract Zink DOCUMENT
COMMON DERRICK ASSEMBLY (Subcontracted manufacturing, including
9.
Platform,Ladder,Handrails and gratings)
Ident. of Material (Type / Grade) Bill of Materials / AA_2000_T-SA_1002 AA_2000_T-SA_1002
9.1 Impact Test Sub manufacturer ASME II STORE RE RE R R EN 10204 3.1
( -46C for ASME CS or -50C for EN CS) proced.
Bill of Materials Material
9.2 Material Traceability / Transfer of Marking
Low stress stamp shall be used
Sub manufacturer
proced.
Drawings
23118 SHOP RE R R R Identification Records

JZHC-GQS-023 &022
9.3 Visual Completed Welding AWS D1.1 / GOST 23128 2012 QA W W R R Endorsed Q/Insp. plan
SHOP
Sub manufacturer Procedure
9.4 Magnetic Testing of module AA_2000_T-SA_1002 AWS D1.1 / GOST 23128 2012 QA W R R R NDT Inspection Report
interconnection flanges (100%) Approved weld & test plan
AA_2000_T-SA_1002
9.5 Radiography of derrick legs Sub manufacturer Procedure AWS D1.1 / GOST 23128 2012 QA R R R R NDT Inspection Report
(100% on T joints) Approved weld & test plan
JZHC-GQS-022 Report +
9.6 Dimensional Check Sub manufacturer Procedure Drawings SHOP W W W R "As-built" Drawings

9.7 Trial assembly (By face or modules Drawings Drawings SHOP W W W W Endorsed Q/Insp. plan
to ensure all connections are verified) Report

9.8 Galvanization Sub manufacturer Procedure &AA-2000-T-SS 2301 (EN) SHOP M SW R R Report
&AA-2000-T-SG 1101 (ER)
&AA-2000-T-SS 2301 (EN)
9.9 Surface treatment / painting Sub manufacturer Procedure &AA-2000-T-SG 1101 (ER) SHOP R W R R Endorsed Q/Insp. plan
JZHC-GQS-019
Proced. Proced. Report +
9.10 Weighing JZL-DOC-0000001296 JZL-DOC-0000001296 SHOP W R R R "As-built" Drawings

Drawings Report+ Drawing Report +

9.12 Check of marking for assembly and Sub manufacturer Procedure + Certificate SHOP W SW W R "As-built" Drawings
check of identification marking ( 100%)
Test Certificates
9.12 Material Certificate as Specified Material Specification ASME II QA R R R R Material
EN 10204 Identification Records
Welders Welders
9.13 Review Welders Qualifications Records Qualifications AWS D1.1 QA R R R R Qualifications
of Sub-Manufacturer Records Records
EN 473
9.14 Review NDT Operators Qualifications ASNT Level II QA R R R R NDT Qualifications
of Sub-Manufacturer
Review of final documentation
9.15 including MDB / MRB Technical passort PO PO QA H H R R Approved final documentation
Operating and Maintenance Manual ,TRCU AA-2000 T-SA 1002 par 11 AA-2000 T-SA 1002 par 11

9.16 Final Inspection & release note (IRN) PO Packing list PROJ. H W H R Release Note

JZHC-GQS-024 2720-0012DI1420-104-0029
9.17 Packing and preservation &AA-2000-K-SL 1001 (EN) PO PACKING RE W R R Endorsed Q/Insp. plan
Proced. JZL-DOC-0000001273 2719-0012DI1420-128-0001

Add "&AA-2000-T-SG
1100" (Preservation form)

RE : Review SW : Spot Witness

H : Hold Point W : Witness
Inspection Notification Period : 21 Working Days

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 JOHN ZINK INTERNATIONAL LUXEMBOURG SARL
Inspection and test plan for Tank Flare Package (27-FL-1901 A/B)
Client : ZapSibNeftekhim, LLC, LINDE AG Date : 06.09.2017

Linde project No: 3120 ATH2 JZHC Document No. : MFLP00389-BITP

JZ Ref. : MFLP00389 Linde PO number: 0012DI3630 Created by : N. PIERRE
Item : Flares Technical PO : &AA2000B-GE-1960 Revision-No. : 2 Approved by : F. GROSSE

No. ACTIVITY REFERENCE ACCEPTANCE DEPART Sub Signature John Signature ACB Signature LINDE Signature Owner Signature VERIFYING
DOCUMENTS CRITERIA -MENT contract Zink DOCUMENT

10. RISERS ASSEMBLY & UTILITY LINE - 27-FL-1901A (Subcontracted manufacturing)

Ident. of Material (Type / Grade) Bill of Materials EN 10204 3.1

10.1 Impact Test Sub manufacturer ASME II SHOP R R R R EN 10204
( -46 C for ASTM CS or -50C for EN CS) proced. AA-2000 T-SA 1002
Bill of Materials Material
10.2 Material Traceability / Transfer of Marking Sub manufacturer Drawings SHOP R R R R Identification Records
Low stress stamp shall be used proced.
AA-2000 T-SA 1002 / SA 03-005-07
10.3 PMI Examination (on all SS parts) Sub manufacturer Drawings / PB10-573-03 / RTN Order No784 QA H W R R Report
(100% material and weld) proced. Approved weld & test plan
Approved WPS
10.4 Inspection Tack welds and welding Sub manufacturer ASME IX SHOP M RA R R Endorsed Q/Insp. plan
activities proced.
JZHC-GQS-023 &022
10.5 Visual Completed Welding Sub manufacturer ASME B31.3 QA W W R R Endorsed Q/Insp. plan
proced. SHOP & Report

10.6 Mechanical testing on weld test coupon , SA 03-005-07 , RTN order N784 , SA 03-005-07 , RTN order N784 QA H R R R Report
Weld test plan , PB10-573-03 Weld test plan ,, PB10-573-03 SHOP
JZHC-GQS-023
10.7 Cleaning of Welds Sub manufacturer ASME B31.3 QA W W R R Endorsed Q/Insp. plan
proced. SHOP & Report
AA-2000 T-SA 1002 / SA 03-005-07
10.8 Radiography of flare riser Sub manufacturer ASME VIII div 1 / PB10-573-03 / RTN Order No784 QA R R R R NDT Inspection Report
(100% BW) proced. Approved weld & test plan
AA-2000 T-SA 1002 / SA 03-005-07
10.9 Dye Pentrant of Flare riser Sub manufacturer ASME VIII div 1 / PB10-573-03 / RTN Order No784 QA W M R R NDT Inspection Report
(100 % FW including Lifting lugs ) proced. Approved weld & test plan
AA-2000 T-SA 1002 / SA 03-005-07
10.10 Dye Penetrant of utility line Sub manufacturer ASME B31.3 / PB10-573-03 / RTN Order No784 QA W M R R NDT Inspection Report
(100% FW ) proced. Approved weld & test plan
AA-2000 T-SA 1002 / SA 03-005-07
10.11 Radiography of utility line Sub manufacturer ASME B31.3 / PB10-573-03 / RTN Order No784 QA R R R R NDT Inspection Report
(100% BW) proced. Approved weld & test plan
JZHC-GQS-022 Report +
10.12 Dimensional Check Sub manufacturer Procedure Drawings SHOP W W W W "As-built" Drawings
(visual,dimension, marking and name plate check) AA-2000-T-SA 1002 para 9.6
Report +
10.13 Trial assembly Drawings Drawings SHOP W W W W "As-built" Drawings
(Min 3 sections by 3 sections ) JZHC-GQS-QC-00022 MTOL1001 / 1002 /1003

10.14 Pressure test of utility line Hydrotest procedure ASME B31.3 SHOP H M R R Report
JZHC-GQS-016 AA-2000-T-SA 1002 para 9.4
Test Certificates
10.15 Material Certificate as Specified Material Specification ASME II QA R R R R Material
EN 10204 3.1 Identification Records
&AA-2000-T-SS 2301 (EN)
10.16 Surface treatment / Painting Specific QCP &AA-2000-T-SG 1101 (ER) SHOP H W R R Endorsed Q/Insp. plan
JZHC-GQS-019
Proced. Proced. Report +
10.17 Weighing JZL-DOC-0000001296 JZL-DOC-0000001296 SHOP H R R R "As-built" Drawings

Welders Welders
10.18 Review Welders Qualifications Records Qualifications ASME IX QA R R R R Qualifications
Records Records
EN 473
10.19 Review NDT Operators Qualifications ASNT Level II QA R R R R NDT Qualifications

Review of final documentation

10.20 including MDB / MRB Technical passort PO PO QA H H R R Approved final documentation
Operating and Maintenance Manual ,TRCU AA-2000 T-SA 1002 par 11 AA-2000 T-SA 1002 par 11

10.21 Final Inspection & release note (IRN) PO Release note PROJ. R H H R Release Note
INSTR.
JZHC-GQS-024 2720-0012DI1420-104-0029
10.22 Packing and preservation &AA-2000-K-SL 1001 (EN) PO PACKING RE W R R Endorsed Q/Insp. plan
Proced. JZL-DOC-0000001273 2719-0012DI1420-128-0001

Add "&AA-2000-T-SG
1100" (Preservation form)

RE : Review SW : Spot Witness

H : Hold Point W : Witness
Inspection Notification Period : 21 Working Days

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