ADNOC Classification: Internal

THE CONTENTS OF THIS DOCUMENT ARE PROPRIETARY AND CONFIDENTIAL.

ADNOC GROUP PROJECTS & ENGINEERING

PROCUREMENT INSPECTION AND CERTIFICATION REQUIREMENT IN PROJECTS Specification

APPROVED BY:

NAME: Abdulmunim Al Kindy TITLE: Executive Director PT&CS EFFECTIVE DATE:

AGES-SP-13-002

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ADNOC Classification: Internal

GROUP PROJECTS & ENGINEERING FUNCTION/ PT&CS DIRECTORATE

CUSTODIAN

Group Projects & Engineering / PT&CS

DISTRIBUTION

Specification applicable to ADNOC & ADNOC Group Companies

REVISION HISTORY

DATE

REV.

NO

PREPARED BY (Designation/ Initial)

REVIEWED BY (Designation/ Initial)

10-Nov-2021 01

Hossam El Batali / Quality Eng. Project

Hussain Al Harthi / HOD QA/QC- GPE

ENDORSED BY (Designation /

Initial)

ENDORSED BY (Designation / Initial)

Najem Qambar / VP Group Eng.- GPE

Ebraheem AlRomaithi / SVP- GPE

The Group Projects & Engineering Function is the owner of this Specification and responsible for its custody, maintenance and periodic update.

In addition, Group Projects & Engineering Function is responsible for communication and distribution of any changes to this specification and its version control.

This document will be reviewed and updated in case of any changes affecting the activities described in this document.

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INTER-RELATIONSHIPS AND STAKEHOLDERS

1.1

The following are inter-relationships for implementation of this Specification:

(a)

ADNOC Upstream and ADNOC Downstream Industry, Marketing & Trading Directorate.

(b)

ADNOC Onshore, COMPANY, ADNOC Sour Gas, ADNOG Gas Processing. ADNOC LNG, ADNOC Refining, ADNOC Fertilisers, Borouge, Al Dhafra Petroleum, Al Yasat

1.2

The following are stakeholders for the purpose of this Specification:

(a)

ADNOC PT&CS Directorate

1.3

This Specification has been approved by the ADNOC PT&CS is to be implemented by each ADNOC Group COMPANY included above subject to and in accordance with their Delegation of Authority and other governance-related processes to ensure compliance.

1.4 Each ADNOC Group COMPANY must establish/nominate a Technical Authority responsible for

compliance with this Specification.

Definitions:

‘ADNOC’ means Abu Dhabi National Oil COMPANY.

‘ADNOC Group’ means ADNOC together with each COMPANY in which ADNOC, directly or indirectly, controls fifty percent (50%) or more of the share capital.

‘Approving Authority’ means the decision-making body or employee with the required authority to approve Policies and Procedures or any changes to it.

‘Business Line Directorates’ or ‘BLD’ means a directorate of ADNOC which is responsible for one or more Group Companies reporting to, or operating within the same line of business as, such directorate.

‘Business Support Directorates and Functions’ or ‘Non- BLD’ means all the ADNOC functions and the remaining directorates, which are not ADNOC Business Line Directorates.

‘CEO’ means chief executive officer.

‘Group COMPANY’ means any COMPANY within the ADNOC Group other than ADNOC.

‘Standard’ means normative references listed in this specification.

‘COMPANY’ means ‘Abu Dhabi National Oil COMPANY or any of its group companies. It may also include an agent or consultant authorized to act for, and on behalf of the COMPANY’.

‘CONTRACTOR’ means the party which carries out the project management, design, engineering, procurement, construction, commissioning for ADNOC projects.

‘SHALL’ Indicates mandatory requirements “Group COMPANY” means any COMPANY within the ADNOC Group other than ADNOC.

CONTROLLED INTRANET COPY

The intranet copy of this document [located in the section under Group Policies on One ADNOC] is the only controlled document. Copies or extracts of this document, which have been downloaded from the intranet, are uncontrolled copies and cannot be guaranteed to be the latest version.

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ADNOC Classification: Internal

TABLE OF CONTENTS

1

GENERAL

SECTION A - GENERAL

2

3

4

REFERENCE DOCUMENTS

DOCUMENT PRECEDENCE

SPECIFICATION DEVIATION / CONCESSION CONTROL

SECTION B – QUALITY MANAGEMENT SYSTEM REQUIREMENTS

5

6

7

8

9

GENERAL

QUALITY ASSURANCE REQUIREMENTS

RESPONSIBILITIES

QUALITY SURVEILLANCE/ AUDIT

MANUFACTURER/ VENDOR SELECTION AND EVALUATION

10 QUALIFICATION AND COMPETENCY OF INSPECTION PERSONNEL

11 APPROVAL OF INSPECTION PERSONNEL BY COMPANY

12 NON-CONFORMANCE CONTROL

13

PREVENTION AND CONTROL OF COUNTERFEIT MATERIAL

SECTION C – INSPECTION AND TESTING REQUIREMENTS

14 CRITICALITY RATING (CR)

15

INSPECTION CLASSES (IC):

16 MANUFACTURER/ VENDOR/ SUB-VENDOR TECHNICAL DOCUMENTS

17

18

19

INSPECTION AND TEST PLAN (ITP)

INSPECTION NOTIFICATION

PRE-INSPECTION MEETING (PIM)

20 ACCESS TO MANUFACTURER/ VENDOR / SUB-VENDOR FACILITIES

PACKAGES/ SKIDS

EXAMINATION OF THE EQUIPMENT/MATERIAL DURING PRODUCTION/ MANUFACTURING 28

21

22

23

24

EXAMINATION OF THE EQUIPMENT/MATERIAL FOR DISPATCH

SPARE PARTS

25 REPORTING, RELEASE AND DOCUMENTATION

SECTION D – MATERIAL CERTIFICATION REQUIREMENTS

26 MATERIAL CERTIFICATION

SECTION E

APPENDIX A MINIMUM INSPECTION AND TESTING ACTIVITIES

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5

10

10

11

12

13

13

13

14

15

15

15

16

16

17

18

18

18

20

21

23

24

27

27

29

29

30

33

33

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ADNOC Classification: Internal

1

GENERAL

1.1

Introduction

This Specification describes minimum inspection, testing and certification requirements to be performed by MANUFACTURER/ VENDOR/ CONTRACTOR and/or COMPANY on the equipment and material procured for ADNOC or ADNOC Group of Companies Projects.

COMPANY may utilize the services of Third-Party Inspection Agencies (TPIA) for inspection and testing during procurement of equipment and materials in Projects.

The complete listing of inspection, tests, material certification requirements, and parties involved shall be agreed in the approved Inspection and Test Plans (ITP).

1.2

Purpose

The purpose of this document is to guide MANUFACTURER/ VENDOR/ CONTRACTOR and/or COMPANY, (according to supply chain) in verifying equipment and material being supplied in compliance with COMPANY requirements, and as stated in the Contract / Purchase Order (Requisition).

This specification also covers the requirements for Certification of material used in the manufacture and construction in COMPANY Projects.

The indicated “Inspection Class” (IC) shall not relieve CONTRACTOR and his assigned MANUFACTURER / VENDOR from their contractual obligations to ensure conformance to the specified Contracts or Purchase Requisition.

All inspection Interventions required by a given class of inspection, shall be included as a minimum in the ITP which is part of the MANUFACTURER’S/ VENDOR’S overall Quality Plan.

If required by COMPANY and where relevant, data collection for equipment (i.e. Works Identification Number (WIN) /Unique Tracking Commodity (UTC) / Equipment Number Inspection Data Sheets and their attachments) shall be conducted as appropriate in accordance with the relevant ADNOC data sheets and specification. Equipment Data Collection should be read in conjunction with this document.

1.3

Definitions and Abbreviations

The following defined terms are used throughout this specification:

“COMPANY” means ADNOC, ADNOC Group or an ADNOC Group COMPANY, and includes any agent or consultant authorized to act for, and on behalf of the COMPANY.

“CONTRACTOR” means the parties that carry out all or part of the design, engineering, procurement, construction, commissioning or management for ADNOC projects.

‘SUB-CONTRACTOR’ means any party engaged by the CONTRACTOR to undertake any assigned work on their behalf. COMPANY maintains the right to review all proposed SUB-CONTRACTORs; this right does not relieve the CONTRACTOR of their obligations under the Contract, nor does it create any contractual relationship between COMPANY and the SUB-CONTRACTOR.

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ADNOC Classification: Internal

‘VENDOR’ means the party entering into a Contract with CONTRACTOR and/or COMPANY, as applicable, to provide the materials, equipment, supporting technical documents and/or drawings, guarantees, warranties and/or agreed services in accordance with the requirements of the purchase order and relevant specification(s). VENDOR could be also the main assembler / skid manufacture.

‘MANUFACTURER’ means the Original Equipment MANUFACTURER (OEM) who produces or fabricates equipment or materials, or MANUFACTURER of one or more of the component(s) which make up a sub-assembly or item of equipment assembled by the main VENDOR.

‘MAY’ means a permitted option

‘SHALL’ indicates mandatory requirements

‘SHOULD’ means a recommendation

The abbreviations used throughout this specification are shown in Table 1.

3LPE

3LPP

AHU

API

ASME

ASTM

ASU

AVL

BS

CCTV

CMMS

CR

CRA

CS

CV

DCS

DSS

DX

EDP

EN

EOT

EPC

ESD

Abbreviations

3-Layer Polyethylene

3-Layer Polypropylene

Air Handling Units

American Petroleum Institute

American Society of Mechanical Engineers

American Society for Testing and Materials

Air Separation Units

Approved Vendor List

British Standard

Closed-Circuit Television

Computerized Maintenance Management Systems

Criticality Rating

Corrosion Resistant Alloy

Carbon Steel

Curriculum Vitae

Distributed Control System

Duplex Stainless Steel

Direct Expansion Cooling

Emergency Depressurisation

European Standard

Electric Overhead Travelling

Engineering, Procurement & Construction

Emergency Shutdown

ESDV

Emergency Shutdown Valves

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ADNOC Classification: Internal

F & G

FAT

FBE

FE Test

FEED

FMS

FR

FRU

GRP

GRE

GRVE

GTG

HDPE

HFW

HIC

HIPPS

HOT

HP

HSE

Abbreviations

Fire & Gas

Factory Acceptance Test

Fusion Bonded Epoxy

Fugitive Emission Test

Front End Engineering and Design

Fault Monitoring System

Flash Report

Field Replacement Unit

Glass Reinforced Plastic

Glass Reinforced Epoxy

Glass-fibre Reinforced Vinyl Ester

Gas Turbine Generator

High-density Polyethylene

High Frequency Welding

Hydrogen Induced Cracking

High-Integrity Pressure Protection System

Hand Operated Overhead Travelling

High Pressure

Health, Safety, Environment

HSECES

Health, Safety, Environment Critical Equipment and Systems

HSS

HSSD

HVAC

IAP

IC

ICSS

IEC

IFAT

IJ

IMTE

IN

IR

IRN

ISO

ITP

LP

Heat Shrink Sleeve

High Sensitivity Smoke Detection

Heating, Ventilation, and Air Conditioning

Inspection Assignment Package

Inspection Class

Integrated Control & Safety System

International Electrotechnical Commission

Integrated Factory Acceptance Test

Insulating Joints

Inspection, Measuring, and Test Equipment

Inspection Notification

Inspection Report

Inspection Release Note

International Organisation for Standardisation

Inspection Test Plan

Low Pressure

LTCS

Low Temperature Carbon Steel

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ADNOC Classification: Internal

MRB

MDR

MPS

MR

MSDS

MTC

NACE

NCR

Abbreviations

Manufacturing Record Book

Manufacturing Data Report

Manufacturing Procedure Specification

Material Requisition

Material Safety Data Sheets

Mill Test Certificate

National Association of Corrosion Engineers

Non-Conformance Report

NDE / NDT

Non-destructive Examination / Testing

OLCMS

Online Condition Monitoring System

OEM

PAGA

PFI

PIM

PLC

PMI

PO

PPE

PQP

PQR

PR

PSA

PWHT

QA / QC

QMS

Original Equipment Manufacturer

Public Address and General Alarm

Pipe Fabrication Standard

Pre-Inspection Meeting

Programmable Logic Controller

Positive Material Identification

Purchase Order

Personal Protective Equipment

Project Quality Plan

Procedure Qualification Record

Purchase Requisition

Pressure Swing Adsorption

Post Weld heat Treatment

Quality Assurance / Quality Control

Quality Management System

QR Code

Quick Response code

RFI

RTP

RTU

SAT

SAW

SCMS

SDH

SDSS

SPIR

SS

SSCC

Request for Inspection

Reinforced Thermoplastic Pipe

Remote Terminal Unit

Site Acceptance Test

Submerged Arc Welding

Substation Control & Monitoring System

Synchronous Digital Hierarchy

Super Duplex Stainless Steel

Spare Parts Interchangeability Record

Stainless Steel

Sulfide Stress Corrosion Cracking

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ADNOC Classification: Internal

STG

TPIA

TSO

UTC

UPS

VDRL

WHCP

WHHP

WHRU

WIN

WPQ

WPS

WQR

Abbreviations

Steam Turbine Generator

Third Party Inspection Agency

Tight Shut Off

Unique Tracking Commodity

Uninterruptible Power Source

Vendor Document Requirement List

Well Head Control Panel

Well Head Hydraulic Panel

Waste Heat Recovery Unit

Works Identification Number

Welder Performance Qualification

Welding Procedure Specification

Welder Qualification Record

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ADNOC Classification: Internal

SECTION A - GENERAL

2

REFERENCE DOCUMENTS

2.1

International Codes and Standards

The following Codes and Standards shall form a part of this specification. When an edition date is not indicated for a Code or Standard, the latest edition in force at the time of the contract award shall apply.

This specification is to be read in conjunction with AGES-SP-13-001 Criticality Rating Specification.

AMERICAN PETROLEUM INSTITUTE (API)

API 588

Recommended Practice for Source Inspection and Quality Surveillance of Fixed Equipment

BRITISH STANDARDS INSTITUTION (BSI)

BS EN 10204

Metallic products — Types of inspection documents

BS 381C

Specification for Colours for Identification, Coding and Special Purposes

INTERNATIONAL ORGANISATION FOR STANDARDISATION (ISO)

ISO 9001

ISO 10005

ISO 10006

ISO 9004

ISO 19011

ISO 29001

Quality Management Systems –Requirements

Quality Management Systems - Guidelines for Quality Plans

Quality Management Systems Management in Projects

-Guidelines

for Quality

Quality management — Quality of an organization — Guidance to achieve sustained success

Guidelines for Auditing Management Systems

Petroleum, petrochemical and natural gas industries — Sector- specific quality Management systems — Requirements for product and service supply organizations

Pipe Fabrication Standard (PFI)

PFI ES-22

Recommended Practice for Color Coding of Piping Materials

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ADNOC Classification: Internal

2.2

ADNOC Group References

HSE-OS-ST29

Health Safety Environment Management System HSECES Management Standard

AGES-GL-13-001

Contractor QA/QC Requirements

AGES-GL-13-002

Positive Material Identification of Equipment and Piping

AGES-SP-13-001

Criticality Rating Specification

AGES-SP-13-003

Traceability of Shop & Field Piping Materials

3

DOCUMENT PRECEDENCE

The specifications and codes referred to in this specification shall, unless stated otherwise, be the latest approved issue at the time of contract award.

It shall be the CONTRACTOR’s responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.

The CONTRACTOR shall notify the COMPANY of any apparent conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein.

Resolution and/or interpretation precedence shall be obtained from the COMPANY in writing before proceeding with the design/manufacture.

In case of conflict, the order of document precedence shall be:

UAE Statutory Legislation requirements.

ADNOC Standards, regulations and Codes of Practice.

Equipment datasheets and drawings.

Project specifications.

COMPANY Specifications

National/International Standards

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ADNOC Classification: Internal

4

SPECIFICATION DEVIATION / CONCESSION CONTROL

Any deviation / concession to this Specifications and its attachments including, but not limited to, the Data Sheets, Drawings and Narrative Specifications shall be sought by the CONTRACTOR, VENDOR and MANUFACTURER only through concession / deviation request format. Deviations / concessions are requested by the CONTRACTOR either on their behalf or on behalf of their VENDOR(s) and / or MANUFACTURER(s), after receiving the award of the Contract or Purchase Order.

A Deviation/ concession require COMPANY’s review and approval prior to the implementation of the proposed changes. Changes implemented prior to COMPANY approval are liable to be rejected at COMPANY’s sole discretion.

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ADNOC Classification: Internal

SECTION B – QUALITY MANAGEMENT SYSTEM REQUIREMENTS

5

GENERAL

5.1

5.2

CONTRACTOR / VENDOR/ MANUFACTURER’s Quality Management System shall cover the organizational structure, procedures, processes interaction, resources and include all those planned and systematic actions necessary to ensure and assure project Quality, and ensure that the specified project requirements, objectives are fulfilled, and satisfy the requirements of Quality Standard ISO 9001 and/or ISO 29001 (latest edition).

CONTRACTOR / VENDOR/ MANUFACTURER’s Quality Management System shall be certified by an internationally accredited certifying agency, MANUFACTURER/ VENDOR/ CONTRACTOR’s shall keep the Certification valid for the entire duration of the project.

5.3

CONTRACTOR’s shall develop and implement a Project Quality Management System in accordance with ISO 10006 latest - Guidelines for Quality Management in Projects or equivalent.

6

QUALITY ASSURANCE REQUIREMENTS

6.1

6.2

6.3

6.4

6.5

MANUFACTURER/ VENDOR Project Quality System and associated documents to be implemented in the project shall be subject to review and comments by CONTRACTOR and COMPANY. All applicable documentation shall be reviewed for the need of any revision before initiating or implementing any change and revised documentation shall be resubmitted for CONTRACTOR and COMPANY review for comment and subsequent approval.

MANUFACTURER/ VENDOR Project Quality System shall ensure that all applicable Project Specifications and COMPANY Engineering Standards, Codes of Practice, Specifications, Procedures, Manuals and Project General Specifications as referenced in the contract are fully complied with.

CONTRACTOR / VENDOR/ MANUFACTURER’s shall maintain sufficient Inspection, testing, Quality Assurance and Quality Control personnel independent from their other divisions/ work processes to ensure adequate implementation of the project Quality requirements. CONTRACTOR shall maintain and update the records & registers of the COMPANY approval and interview of the Quality personnel.

CONTRACTOR shall organize Quality Induction Training and awareness of all personnel on Project including CONTRACTOR/ Sub-CONTRACTORs / VENDORs and MANUFACTURER of Package Equipment and Critical Items.

All activities and services associated with the scope of project shall be performed by CONTRACTOR/ Sub-CONTRACTOR/ VENDOR/ MANUFACTURER approved by COMPANY; the latest Approved Vendor List (AVL) shall be utilized.

6.6

COMPANY does not allow the Use of Sub-CONTRACTORs and Sub-VENDORs for any services / functions without specific written approval.

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ADNOC Classification: Internal

6.7

6.8

CONTRACTOR / VENDOR/ MANUFACTURER shall ensure that all actions and activities that impact Quality are systematically planned in advance of the start of the activity. That adequate review of contract/ P.O. and other pertinent documents is performed in order to conduct a full analysis of the tasks and requirements prior to the commencement of work.

CONTRACTOR is advised to seek clarification from COMPANY regarding any conflict between standards or confirm their interpretation of the requirements stated in standards, which are considered unclear. COMPANY interpretation shall be binding.

6.9

CONTRACTOR / VENDOR/ MANUFACTURER shall ensure that the Quality of work is to the satisfaction of COMPANY, Contractor shall inspect any work prior to proceeding to next stage.

6.10

Inspection and approval by the COMPANY do not absolve CONTRACTOR of their responsibility to deliver the product meeting the explicit or implicit requirements.

6.11

According to Material/ Equipment Criticality rating, VENDOR and/or MANUFACTURER might be required to develop Project Specific Quality Plan; the Quality Plan shall be developed in accordance with ISO 10005 (Quality Management-Guidelines for Quality Plans) and COMPANY relevant Quality requirements. CONTRACTOR shall submit the PQP within 30 DAYS from the EFFECTIVE DATE of award of Contract, and the VENDOR and/or MANUFACTURER shall submit the PQP within 15 DAYS from the EFFECTIVE DATE of placement of P.O.

7

7.1

7.2

7.3

RESPONSIBILITIES

CONTRACTOR / VENDOR/ MANUFACTURER are responsible to maintain a documented system to ensure that required inspection activities are planned, performed, witnessed and verified and to provide adequate assurance that all equipment, materials fabrication, installation and tests fully comply with the requirements of project specification and design code requirements.

CONTRACTOR / VENDOR/ MANUFACTURER’s QMS shall provide an auditable trail verifying that inspection and Certification requirements satisfy COMPANY standards, indicative of equipment or system criticality as determined by CONTRACTOR and approved by COMPANY.

CONTRACTOR shall provide the overall Procurement Inspection Plan/ Strategy covering all project’s purchase orders for COMPANY review/ approval, The Plan and associated CONTRACTOR’s procedures shall clearly define responsibilities within the CONTRACTOR’s organization for specifying and approving inspection activities. CONTRACTOR shall ensure the followings as a minimum:

test plans and performing

inspection &

Approval of Inspection Plans prior to manufacture, fabrication, installation and test.

Performing necessary inspection and verification activities to ensure equipment, materials and installation conform in every respect with relevant approved Project specifications and design codes.

Issue of Deviation Requests for approval, where deviations from Project Inspection requirements are requested.

Ensuring that inspection requirements are cost effective and fully comply with relevant

Project specifications.

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ADNOC Classification: Internal

8

QUALITY SURVEILLANCE/ AUDIT

8.1

8.2

9

9.1

9.2

9.3

COMPANY performs Surveillance/ Audit visits at MANUFACTURER/ VENDOR/ Sub-VENDOR works, this is to ensure that the effectiveness of the CONTRACTOR/ VENDOR/ MANUFACTURER’s Quality system and their ability to provide COMPANY an acceptable Quality level. CONTRACTOR/ MANUFACTURER/ VENDOR shall provide required access, HSE guidance and assistance including photographic permission.

CONTRACTOR / MANUFACTURER / VENDOR / Sub-VENDOR shall immediately rectify findings resulting from any Audit / Quality Surveillance at their own cost and without affecting project schedule. Upon receipt of COMPANY Quality Surveillance/ Audit report CONTRACTOR/ MANUFACTURER/ VENDOR / Sub-VENDOR shall respond within 2 weeks providing Corrective action and preventive measures along with target close out dates for COMPANY review and approval.

MANUFACTURER/ VENDOR SELECTION AND EVALUATION

CONTRACTOR shall develop a project specific documented procedure covering procurement / sub- contract process; and coordination requirements involving Third Party Agencies. The documented system procedure shall address the requirements from MANUFACTURER / VENDOR assessment and selection through evaluation of bids to award to ensure that the bid conforms to procurement requirements and shall be submitted to COMPANY for approval.

All Technical bid clarifications that may affect final product specification and/ or performance shall be formally recorded as part of Purchase Order. COMPANY may determine to receive a copy of such clarifications. The bid evaluation criterion shall include Quality, technical, historical supply data, lifecycle cost, maintainability, operability, redundancy, delivery schedule and commercial aspects. CONTRACTOR shall submit the Technical Bid Tabulation for review and approval of COMPANY.

CONTRACTOR shall establish Procedures and methods for verification of purchased equipment, material, and services by inspection, surveillance, and compliance audit. The procedures shall provide for interfaces necessary to co-ordinate with COMPANY or COMPANY appointed THIRD PARTY as required.

10

QUALIFICATION AND COMPETENCY OF INSPECTION PERSONNEL

10.1 Qualifications, experience, Certification and competency of CONTRACTOR/ VENDOR/ MANUFACTURER and/ or their nominated Third Party Inspection Agencies (TPIA) personnel engaged in inspection, testing and Certification activities of COMPANY equipment and material shall meet the requirements of Company Quality Personnel requirements in Projects and Project Scope of Work.

10.2 CONTRACTOR/ VENDOR/ MANUFACTURER’s Inspection Personnel shall not be permitted to proceed on their tasks unless approval of the COMPANY is obtained. Inspections performed by unapproved Inspection personnel are subject to rejection until re-inspected by approved personnel.

10.3 COMPANY appointed Third Party Inspection Agencies (TPIA) will perform Inspections on behalf of COMPANY for monitoring & surveillance, this does not waive off CONTRACTOR responsibility of any Inspection requirements and monitoring their MANUFACTURER/ VENDOR / Sub-VENDOR performance.

10.4 CONTRACTOR/ VENDOR/ MANUFACTURER’s shall maintain Competency Matrix of approved

inspectors and submit to COMPANY periodically for review, record and reference.

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ADNOC Classification: Internal

11

APPROVAL OF INSPECTION PERSONNEL BY COMPANY

11.1 CONTRACTOR/ VENDOR/ MANUFACTURER’s proposed Quality/ Inspection personnel Curriculum Vitae (CV)’s shall be submitted for COMPANY review / approval. CV shall be accompanied with valid copy(s) of their Qualifications and Certifications.

11.2 CONTRACTOR/ VENDOR/ MANUFACTURER’s shall ensure that 2 CVs as a minimum to be proposed 10 working days in advance for COMPANY assessment so that approved Inspectors are timely mobilized for inspection without affecting the Inspection schedule.

11.3 CONTRACTOR/ VENDOR/ MANUFACTURER’s shall facilitate the interview for the proposed

Inspectors (Telephonic or face-to-face interview) prior to their engagement in the work.

11.4 CONTRACTOR/ VENDOR/ MANUFACTURER’s inspection personnel approval is subject to re- evaluation at any point of time of the project, if the performance found questionable, COMPANY will notify to CONTRACTOR/ VENDOR/ MANUFACTURER’s for their replacement. COMPANY reserves the right to reject any CV without providing justification.

11.5 CONTRACTOR/ VENDOR/ MANUFACTURER’s shall maintain continuity in the deployment of the approved personnel on the job and shall not change them until completion of Purchase Order. Any change in the deployment of approved personnel shall require COMPANY prior approval.

11.6 CONTRACTOR shall ensure that the same Third Party Inspection Agencies (TPIA) or the Inspector being utilized by the COMPANY or VENDOR or Sub-CONTRACTOR or Sub-VENDO is not employed for the same scope of work and avoid Conflict of Interest.

12

NON-CONFORMANCE CONTROL

12.1

In case of Non-conformance due to failure or defect on equipment and material, the requirements and control specified in ADNOC/ COMPANY Procedure for Project Nonconformity Management or Scope of Work Or COMPANY Approved CONTRACTOR Nonconformity Management Procedure shall be implemented.

12.2 When Non-conformance is detected, CONTRACTOR shall issue NCR. Non-conformance raised by CONTRACTOR/ COMPANY personnel to MANUFACTURER/ VENDOR / Sub-VENDOR for necessary corrective action shall be reported to COMPANY Quality Control team on the same day.

12.3 CONTRACTOR shall ensure that NCR issued by MANUFACTURER/ VENDOR / Sub-VENDOR/ CONTRACTOR are submitted to COMPANY and shall not be closed out without obtaining COMPANY Project Quality Concurrence.

12.4

In case of Non-Conforming items where Inspection and testing requirements are extended for assurance to other items by COMPANY through NCR disposition approval, such Inspection and testing shall be carried out by CONTRACTOR/ MANUFACTURER/ VENDOR / Sub-VENDOR without any additional cost and impact on delivery schedule. The cost of all such additional inspections and visits of COMPANY shall be borne by CONTRACTOR /VENDOR/ Sub-VENDOR.

12.5 No material or equipment shall shipped from CONTRACTOR/ MANUFACTURER/ VENDOR / Sub- VENDOR premises to the Fabrication Yard and SITE with an outstanding Non Conformance without prior written approval from COMPANY.

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ADNOC Classification: Internal

13

PREVENTION AND CONTROL OF COUNTERFEIT MATERIAL

13.1

It is CONTRACTOR responsibility to ensure that all the purchased material and equipment are not counterfeit material. The requirements related to prevention, detection and control of counterfeit material should be addressed in CONTRACTOR Procedure.

13.2 CONTRACTOR/ VENDOR/ Sub-VENDOR/ MANUFACTURER shall obtain original material certificates; in case of practical difficulty, they shall provide authenticated/ attested true copies of certificates, any alterations to the text of a certificates/ document, Corrections or overwriting is not permitted.

13.3

All Material Certificates shall clearly be identifiable by reference to COMPANY Project Name, CONTRACTOR’s purchase order and the sub contract number, as applicable.

13.4 CONTRACTOR/ SUB-CONTRACTOR/ VENDOR/ SUB-VENDOR shall provide suitable training to

their QC/ inspection Personnel on Counterfeit prevention and Control.

13.5 QC personnel from all parties shall be vigilant while inspecting stockist Materials and verifying supplied Certificates and look for any possible alteration in Material certificates and/or Material markings that raises suspicion on genuineness of material.

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SECTION C – INSPECTION AND TESTING REQUIREMENTS

14

CRITICALITY RATING (CR)

14.1 Criticality Rating (CR) is a formalized technique for assessing the importance of an installation or piece of equipment with respect to its design, manufacture, construction and installation and the consequences of failure during use, the Criticality Rating (CR) is used to determine the Inspection Class (IC) in order to optimize the required inspection and testing interventions on equipment and materials during procurement phase.

14.2

TABLE 2 below establishes the relation between the Criticality Rating (CR) and Inspection Class (IC):

Criticality Rating (CR) 1

2

3

4

RANK

High Risk

Medium Risk

Low Risk

Little Risk

Definition

Inspection class (IC)

• Failure would result in immediate danger to life, environment and

significant loss of revenue and assets.

• Non-performance would result in critical project delays. • Failure could lead to dangerous situations to health, environment or

property.

• Non-performance would have some impact on project schedule. However, at premium costs / actions, schedule will be maintained. • Allowed to remain temporarily out of service without serious effect

to operations.

• Non-performance would have little impact on project schedule. • Allowed to remain temporarily out of service with no effect to

operations.

• Non-performance would have no impact project schedule.

1

2

3

4

15

INSPECTION CLASSES (IC):

15.1

15.2

15.3

15.4

The TABLE 2 above determines the required Inspection Class (IC) that define the minimum inspection and test requirements to be performed by MANUFACTURER/ VENDOR/ CONTRACTOR as well as by COMPANY on materials and equipment, which shall be subject to inspection and test witness at source of manufacturing/ supply. Inspection and test requirements shall be agreed in Inspection and Test Plans (ITP) and approved by COMPANY prior commencing any fabrication activities.

A Criticality Rating (CR) shall be determined based on COMPANY Criticality Rating Specification, AGES-SP-13-001, by CONTRACTOR for all project equipment and material, and shall be indicated on the Equipment Data Sheets and Material Requisition. Criticality Rating shall be reviewed and approved by COMPANY, the inspection class shall be derived based on the criticality rating and the same shall be the means for developing the overall inspection strategy.

Inspection class for procured material/ equipment is based on the Criticality Rating. The Inspection class assigned to material/ equipment on the Project is the minimum amount of inspection coverage deemed necessary to ensure that equipment and material procured conforms to the requirements.

The minimum inspection intervention requirements are based on “Inspection Class” 1 through 4, which is directly related to that of the Criticality Rating 1 through 4, (i.e. a CR of 1 will require a minimum IC of 1, a CR of 2 will require a minimum IC of 2, etc.).

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15.5 COMPANY reserves the right to increase the Minimum Inspection Class (IC) already established on the Project if either the MANUFACTURER/ VENDOR recommended by the CONTRACTOR for a particular requisition has had a not-so satisfactory/ poor performance in the past or the VENDOR executing the Purchase Order is not meeting the specified performance requirements in the purchase order. The change in Inspection class to the next highest Inspection Class for the purchase order shall be without additional cost to COMPANY. In addition, inspection class may be elevated by COMPANY based on criticality of procured materials, lessons learned, performance on projects already executed and during the execution of the project, qualification of personnel etc.

15.6

The TABLE 3 below define the minimum intervention required by each concerned party against each Inspection Class (IC):

Inspection Class

CLASS I

CLASS II

CLASS III

CLASS IV

       CONCERNED
               PARTIES

Main Activities Vs Intervention

Pre-award Production Capability & Qualification Audit

Nominated Inspector (Residence)

Review and approve Suppliers Project Quality Plan

Review and approve Inspection & Test Plan

Approve MANUFACTURER/ VENDOR documents and procedures as per agreed VDRL** Pre-inspection meeting

Review and approval of MANUFACTURER personnel Qualifications & certificates Verify equipment and IMTE calibration

Inspection of material at source (Raw)

Inspection of material on receipt, sub-components and review MTC

Inspect prefabrication - layout, cutting, forming, machining and other preparations Inspection of fit-up, alignment and assembly.

Stage Inspection (Welding, fabrication, etc.)

1

2

3

4

5

6

7

8

9

10

11

12

13

R E R U T C A F U N A M

R O T C A R T N O C

Y N A P M O C

R O D N E V

H

H

H

R E R U T C A F U N A M

R O T C A R T N O C

Y N A P M O C

R O D N E V

H

H

H

R E R U T C A F U N A M

R O T C A R T N O C

Y N A P M O C

R O D N E V

H

H

R

R E R U T C A F U N A M

R O T C A R T N O C

Y N A P M O C

R O D N E V

H

R

R

H

H

H W

H

H W W

H

H W WR

H W WR

R

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

R

A

A

A

A

R

A

A

R

A

A

A

A

A

A

A

A

A

A

A

R

H

H

H

H

H

H

H

H

H

H

H W

H

H W

R

H

A

A

A

H

A

A

A

H

A

A

A

H

A

A

R

H

A

A

A

H

H

H W

H

H

A

A

A

H W W

H

H

A

R

R

H

A

R

R

H W WR

H W WR

R

H

H W W

H

H W W

H

H W WR

H W WR

R

H

H W W

H

H W W

H

H W WR

H W WR

R

H

H W W

H

H W W

H

H W WR

H W WR

R

H

H W W

H

H W W

H

H W WR

H W WR

R

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14 Welding Inspection, witness NDE inspection and other special processes

15 Destructive testing (as applicable)

16

Final visual and dimensional inspection; checks for size, location, orientation & configuration 17 Witnessing of all final pressure and

performance tests.

18 Surface preparation; Coating and

painting processes

19 Performance Test, FAT, IFAT &

SAT

20

internal and external Cleaning, flushing, drying; pickling and passivation, (as applicable) 21 Verification of preservation,

packing and marking identification.

22

23

Issuance Certificate of Conformance

Inspection Release by Purchaser’s inspection representative

24 Review final documentation package / Record Book

NOTE

H

H W W

H

H W W

H

H W WR

H W WR

R

H

H

H W

H

H W W

H

H W WR

H W WR

R

H

H

H W

H

H W W

H

H W WR

H W WR

R

H

H

H W

H

H W W

H

H W WR

H W WR

R

H

H W W

H

H W W

H

H W WR

H W WR

R

H

H

H

H

H

H

H

H

H

H W

W

H W WR

R

H

H W W

H

H W W

H

H W WR

H W WR

R

H

H

H W

H

H W W

H

H W WR

H W WR

R

H

H

H

A

H

H

H

A

H

H

A

R

H

H

H

A

H

H

H

A

H

H

A

R

H

H

H

A

R

H

A

R

H

A

A

A

H

A

A

A

H

A

A

A

H

A

A

A

VENDOR as applicable for the PO, this may include Sub-VENDOR if any

H= HOLD, W= Witness; WR = Witness Random; R= Review; A= Approve (Please refer to

sec-17)

** VDRL VENDOR Document Requirement List

It is MANDATORY that the Inspection Interventions of MANUFACTURER/ VENDOR/ CONTRACTOR shall be at a higher level than COMPANY. Inspection Intervention shall be HOLD for all, if COMPANY Intervention is HOLD.

16

MANUFACTURER/ VENDOR/ SUB-VENDOR TECHNICAL DOCUMENTS

16.1 Upon placement of Purchase Order (P.O.), CONTRACTOR and COMPANY shall approve all relevant technical documents including manufacturing procedure specification, design calculations, data sheets, drawings, calculations, and QA/QC documents.

16.2 MANUFACTURER/ VENDOR Quality Control shall be fully documented and approved by CONTRACTOR and COMPANY. MANUFACTURER/ VENDOR/ SUB-VENDOR deliverables shall be based on the VENDOR Document Requirement List (VDRL) issued along with the Material/ Purchase Requisition, and the following documents as a minimum shall be submitted (as applicable to P.O.):

VENDOR Deliverable Register (mark-up of Key documents). VENDOR’s fabrication including sequence/ manufacturing schedule. MANUFACTURER/ VENDOR Quality Control Organization Chart.

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Data sheets, Drawings, Design calculation etc. Project Quality Plan.

Inspection and Test Plan (ITP).

Status of sub-orders with sub-VENDOR full name and location. Type Certification of base-stock materials (per EN 10204). Welding Procedures and Qualifications. Qualified Welders List. Calibration certificates of Inspection, measuring, and test equipment (IMTE). Material Traceability Procedure. Non-conformance Procedure NDE Procedures. NDE and Inspection Personnel Qualification and certification. Post Weld heat Treatment (PWHT) Procedure. Hardness Testing Procedure. Pressure Testing Procedure. Flushing & Drying Procedure. Positive Material Identification (PMI) procedure. Pickling & Passivation Procedure. Painting/Coating Procedures. Baseline survey procedures (If applicable). Factory Acceptance Test (FAT) Procedures. Packing, Storage and preservation procedure.

16.3

The CONTRACTOR is responsible to ensure that all documents produced by MANUFACTURER/ VENDOR/ SUB-VENDOR comply with the requirements of the Contract.

16.4 MANUFACTURER/ VENDOR/ SUB-VENDOR shall develop Project / P.O specific Inspection and Test Plan (ITP) for the review and approval of CONTRACTOR and COMPANY. The minimum Inspection Interventions shall be based on the Criticality Rating and inspection Class as detailed in Section 15, reflecting all Contract requirements, defining responsibilities, and references in compliance with this document.

17

INSPECTION AND TEST PLAN (ITP)

17.1 MANUFACTURER / VENDOR shall develop project specific Inspection & Test Plan (ITPs) for each equipment / material and package, complying with the minimum inspection class and submitted for CONTRACTOR and COMPANY approval.

17.2

17.3

Project / P.O. Specific Inspection & Test Plan (ITP) shall be developed considering the minimum inspection and testing interventions for MANUFACTURER/ VENDOR/ CONTRACTOR/ COMPANY as specified under Section 15 and the minimum inspection and testing activities as detailed in APPENDIX-A, and the material certification requirements addressed in Section 26.

Inspection & Test Plan (ITP) for the equipment and materials which are not listed in APPENDIX-A, the MANUFACTURER/ VENDOR shall prepare an ITP (Inspection & Test Plan) in compliance with the relevant COMPANY Standard, International/ National Standards referred in to Purchase Order description and shall be submitted for CONTRACTOR and COMPANY Approval prior to manufacturing.

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17.4

Project specific ITP shall cover all major inspection related activities in a sequential order from review of documents, drawings through manufacturing, process controls, examination, testing, Quality documentation review, certification, pre-dispatch inspection and up to final release.

17.5

The content of ITPs developed in a tabulated form by MANUFACTURER/ VENDOR, and shall be address the below as a minimum;

Inspection and testing activities.

Responsible person.

References (applicable Project specifications/Drawings/ Data Sheets, etc.)

Characteristics to be verified.

Material Certification level.

Acceptance Criteria.

QC verified Record.

for concerned parties MANUFACTURER/ VENDOR/ CONTRACTOR/

Intervention COMPANY

Remarks.

17.6

Any deviation in approved ITP stages and interventions shall require COMPANY Quality Control Department approval.

17.7

LEGEND & DEFINITION:

A = APPROVE A point at which relevant documents or test results shall be approved by the Concerned party per the approved Inspection & Test Plan (ITP) prior to proceeding with further activities.

R = REVIEW A point at which relevant documents or test results shall be reviewed by the Concerned party per the approved Inspection & Test Plan (ITP) prior to proceeding with further activities.

H = HOLD An Inspection point, at which the concerned party shall perform 100% inspection & clear the activity as per the approved Inspection & Test Plan (ITP). No further activities shall proceed without prior written permission; Inspection Notification is mandatory.

W = WITNESS (100%) An inspection point at which the concerned party shall witness the activity as per the approved Inspection & Test Plan (ITP); Inspection Notification is mandatory.

The MANUFACTURER/ VENDOR shall:

• Not proceed the activity until the notification time agreed is lapsed.
• Proceed with the activity if COMPANY abstained without any information. In this case, the CONTRACTOR shall inform COMPANY immediately via fax or e-mail.

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WR: WITNESS RANDOM

An inspection point at which the CONTRACTOR/ COMPANY shall witness the activities as per the approved Inspection & Test Plan (ITP). Items selected at random from the inspection lot (of each specification and dimensions) that are to be witnessed as per the approved Inspection and Test Plan (ITP), witness point (as a minimum) shall be carried out as per the following table:

No. of items in group

2 to 4

5 to 8

9 to 12

13 to 40

Over 40

Min. number of item to be inspected

2

4

6

9

25%

Wherever Witness Random inspection interventions are marked up in the approved ITP, it is responsibility of CONTRACTOR/ VENDOR / MANUFACTURER to ensure that sample items for random or percentage basis inspection are offered to COMPANY for selection from the lot, and such sampling lot are offered on progressive basis based on the percent completion of items manufactured.

For Witness Random inspection interventions, it is VENDOR / MANUFACTURER responsibility to perform internal inspection / test for total (100%) quantity and reports/ records shall be made available to CONTRACTOR and COMPANY for review prior to selection of samples for witness. WR is not applicable to MANUFACTURER/ VENDOR

On random or percent witness inspections if there is any failure or rejection occurs, the extent of inspection shall be doubled and in case of further failure or rejection extent of CONTRACTOR witness shall be increased to 100%. Same control may apply to COMPANY Inspection interventions.

M: Monitoring

An Inspection point, at which the CONTRACTOR/ COMPANY will visit any work to inspect the activity during processing as per the approved Inspection & Test Plan (ITP).

18

INSPECTION NOTIFICATION

18.1 CONTRACTOR shall prepare inspection and test program so as to provide COMPANY with adequate notice of all such activities for which it may wish to, exercise its option to participate. CONTRACTOR shall submit 3 weeks integrated manufacturing and inspection look ahead schedule to COMPANY; and shall include look ahead schedule for PIM and FAT activities.

18.2 CONTRACTOR shall give COMPANY not less than 14 days’ notice of planned inspection visits and not less than four (4) weeks’ notice for Pre-Inspection Meeting (PIM) and Factory Acceptance tests (FAT), however re-confirmation has to be given 72 hours prior to actual activity. Any delays due to late notification or late cancellation shall be borne by CONTRACTOR.

18.3 CONTRACTOR’s Inspection Notification (IN) format shall be developed for each project and shall

contain the following information as a minimum:

Project Name and logo.

Inspection notification (IN)’s unique Reference number, Date & Revision.

MANUFACTURER, VENDOR, CONTRACTOR and COMPANY details.

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Inspection Location, date, time & contact details of the MANUFACTURER/ VENDOR’s contact persons (name, e-mail & phone number).

PO / PR Number, complete detail of item to be inspected: Tag no/Description/QTY.

Reference to ITP number/ step no. /ITP Intervention (H, W, and R) etc. / document.

Inspection document numbers (NDT procedures, ITP, FAT procedure, etc.)

18.4 CONTRACTOR shall submit “Inspection assignment package (IAP)” for each P.O. to COMPANY with Inspection Notification IN, this IAP shall contain the latest approved copies of CONTRACTOR’s unpriced P.O./ Purchase Requisition(PR)/ Material requisition(MR) with attachments, Sub-VENDOR unpriced P.O. copies and the latest VENDOR documents such as data sheets, drawings, Manufacturing Procedure Specification (MPS), ITP, inspection and testing procedures etc. CONTRACTOR shall also continually update COMPANY with the latest revisions of drawings, and documents related to individual Purchase Orders throughout the course of the order life. Each update shall be Purchase Order specific.

18.5 CONTRACTOR shall ensure that MANUFACTURER/ VENDOR inspect and test all equipment/ material as per approved ITP prior to issuance of Inspection Notification (IN) to COMPANY, to avoid any cost implication.

18.6

For equipment and packages, CONTRACTOR shall submit FAT notification along with FAT readiness checklist to COMPANY to demonstrate that all prerequisite such as key document approval for FAT commencement are completed and notification will not result in abortive visits by COMPANY Representatives. CONTRACTOR shall provide the VENDOR deliverable approval status register for verification by COMPANY.

19

PRE-INSPECTION MEETING (PIM)

19.1 CONTRACTOR shall conduct Pre-Inspection Meeting at the MANUFACTURER/ VENDOR / Sub- VENDOR facilities where the work is to be executed. The CONTRACTOR Quality Representative is the person responsible for organizing the PIM. CONTRACTOR Discipline Engineer(s) and Project Engineer/ Manager shall also attend the PIM for Engineered Items.

19.2 COMPANY QUALITY representative shall attend the PIM as defined in Table-3 under Section 15.6;

however, COMPANY relevant disciplines shall attend in accordance with P.O.

19.3 CONTRACTOR shall ensure that the approval status of the key deliverables (at least Approved with Comments), and issuing PIM Notification to COMPANY at least 4 weeks prior to the PIM. The PIM Notifications shall be issued to COMPANY supported by the VENDOR Documents Status. The following documents as a minimum are considered key documents,

Sub-VENDOR Lists

Concession Requests, if any.

Inspection & Test Plan(s) – MANUFACTURER/ VENDOR / Sub-VENDOR.

Project Quality Plan (PQP).

Manufacturing Procedure Specification (MPS).

WPS/PQR and WPQ Records.

General Arrangement Drawings & Detailed Drawings.

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Manufacturing Procedures and Post Weld Heat Treatment Procedures (as applicable).

Weld Maps including applicable NDT (as applicable).

NDE Procedures.

NDE and Inspection Personnel Qualification and certification.

Positive Material Identification (PMI) Procedure.

Pressure Testing Procedure.

Surface Preparation and Painting Procedures.

FAT, IFAT, Calibration and Other Main Procedures (as per Contract).

MRB Index.

19.4

PRE-INSPECTION MEETING (PIM) AGENDA

The Following items (as a minimum) shall be discussed and concluded during the PIM. CONTRACTOR/ VENDOR shall prepare and submit the records of meeting notes to COMPANY Review and endorsement.

HSE induction; HSE program, HSE policy and Safety Moment.

Introduction of participants; PIM Objectives, Brief Overview about VENDOR Organization

Review of Purchase Orders & Appendices to verify completeness and confirmation to

contract specifications, procedures, drawings etc.

Acknowledgement of P.O by VENDOR, Review Salient Sections of Purchase Order and

verify scope of supply, Review specifications, codes, standards procedures.

Records of formal exceptions/deviation taken and agreed to the purchase order.

Review of Production Schedule, and Inspection Look Ahead Schedule.

Quick Shop tour by all participant.

Confirm contacts and methods of communication for Inspection Notification for Hold &

Witness points, Witness Random. Discuss process of issuing Inspection Notification.

Review of VDRL Documentation against VENDOR Document register and their approval.

Include status review of sub VENDOR documents.

Discussion on CONTRACTOR and/or COMPANY comments on PQP, if applicable.

Discussion on CONTRACTOR and/or COMPANY comments on the Project specific

Organization Chart for Quality.

Inspection and Testing. Testing requirements vs. capabilities, Raw Materials, Sub-VENDOR processes & manufacturing / testing locations.

Review of implementation of MAUNFACTURER/ VENDOR’S Quality System, Organization, Control & adequacy on Sub-VENDORs, Verification of QMS/ASME/API certification as applicable.

Discussion on CONTRACTOR and/or COMPANY comments on the Personnel qualifications against the applicable standards and specific project requirements if any for Welding, NDE, Painting, and IECEx Certification.

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Discussion on CONTRACTOR and/or COMPANY comments on the Manufacturing

Procedure Specification and Qualifications (if applicable).

Review & Discuss on approved sub VENDOR list against COMPANY AVL (No deviation to the AVL is permitted), Identify the communication of Project Specifications to Sub-VENDORs, Review the control exercised on Sub-VENDOR. Review Sub-VENDOR scope, ITP and release mechanism.

Use of Stock items if any List of stock items, source of stock items.

Certification Requirements for PO Material.

Review and Final Mark Up of MANUFACTURER/ VENDOR Inspection and Test Plan, Confirm it covers full scope of supply and confirm Hold, Witness, Surveillance Points, reference and acceptance criteria including applicable reports and certifications.

Discuss process in event of Concession being required/requested.

Discuss Process in event of issue of Non-conformance, Disposition of any Non-Conforming

Product.

Repair & Information to purchaser and approvals.

Project/ PO Audit at VENDOR/Sub-VENDOR Location during execution.

Any language and translation issues. All documents to shall be in English.

Review requirements for Manufacturing Record Book (MRB) and electronic Deliverables.

MRB Index Approval Hardcopy & Soft Copy.

Verify Specific Inspection and testing requirements such as NDE/PMI/Ferrite/Heat treatment/Painting/Helium leak testing/FE testing/FAT requirements, Storage, Preservation and Packing, base line survey, etc.

Third Party Inspection/ Resident Inspector and their access at VENDOR and Sub-VENDOR Location, Also provide office and communication means.

SPIR (Spare Parts Interchangeability Record) forms to be filled by VENDOR complying with COMPANY requirements.

Discuss Inspection release and Punch listing requirements and formats to be used during Inspection,

Quality surveillance tour covering manufacturing facilities, testing facilities, Material traceability, handling and storage, and checking of Calibration status of Measuring and test instruments.

Review of latest QMS Audit Report, Review of Lessons Learned etc.

Areas of Concern, and any Other business

Produce Report/Minutes Recording Pre-Inspection Meeting and forward to Project Office

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20

ACCESS TO MANUFACTURER/ VENDOR / SUB-VENDOR FACILITIES

20.1

In order to facilitate the COMPANY representative(s) involvement, the MANUFACTURER/ VENDOR / Sub-VENDOR and/ or CONTRACTOR shall allow free access to production facilities at all times and, when applicable, they shall arrange similar access at their Sub-VENDOR facilities including lower tier Sub-VENDORs. This shall include permit to take photographs conforming to applicable security requirements.

20.2 MANUFACTURER/ VENDOR / Sub-VENDOR shall provide HSE induction and subsequent guidance

/ support to COMPANY/ CONTRACTOR at the time of visit and/ or inspection.

21

PACKAGES/ SKIDS

21.1

For packaged items and skids, while preparing ITP, VENDOR/CONTRACTOR shall ensure that all items covered in P.O; along with each MANUFACTURER/ Sub-VENDOR name and location covered are included in the Master ITP along with Inspection interventions of all parties.

21.2 Main Package VENDOR shall ensure that this master ITP is available at all MANUFACTURER/ Sub- VENDOR locations at the time of inspection and shall be the basis for all inspection interventions of CONTRACTOR and COMPANY.

21.3

For items inspected at MANUFACTURER/ Sub-VENDOR locations, CONTRACTOR shall issue IRN for each Sub-VENDOR items covered in the Master ITP approved by COMPANY.

21.4 CONTRACTOR/VENDOR proposal for IRN exemption for the equipment manufacturing at MANUFACTURER/ sub-VENDOR works shall be approved by COMPANY and shall be described in Master ITP.

21.5

VENDOR shall follow project specific punch list system, unless otherwise agreed with COMPANY, all punch lists shall be closed at the MANUFACTURER/ Sub-VENDORs works prior to dispatch of items to main VENDOR location or Site.

21.6

SUB-VENDOR CONTROL:

21.6.1 VENDOR shall ensure that inspection testing and certification requirements applicable in this document including extent of testing and inspection interventions by COMPANY and all Project approved documents are communicated to each MANUFACTURER/ Sub-VENDOR and are complied.

21.6.2 VENDOR shall also ensure that necessary project documents and their status of COMPANY approval shall be available for COMPANY nominated TPIA verification at MANUFACTURER/ Sub-VENDOR location.

21.6.3 During inspections and verification of documents, VENDOR QC personnel and CONTRACTOR

personnel shall ensure compliance to all the above.

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22

EXAMINATION OF THE EQUIPMENT/ MATERIAL DURING PRODUCTION/ MANUFACTURING

22.1 Concerned parties shall conduct inspection and confirmatory checks as per ITP inspection interventions during various stages of manufacturing at MANUFACTURER/ VENDOR/ SUB- VENDOR premises to check implementation of Project specification and procedure and to confirm that there are no deviations from the specifications and approved documents.

22.2 Non-destructive examinations (NDE) conducted by MANUFACTURER/ VENDOR/ SUB-VENDOR shall be witnessed by concerned parties to the extent required in approved ITP, and the relevant reports will be endorsed by concerned Inspectors who shall also verify calibration of NDE instruments and check the qualifications and certifications of NDE personnel.

22.3 Concerned parties shall also examine the testing bed; instruments etc. and verify the accuracy of the

testing equipment.

22.4 Concerned parties shall witness functional, performance, tests on the equipment/material and

endorse the testing report.

22.5 MANUFACTURER/ VENDOR/ SUB-VENDOR shall carryout Baseline survey of pressurized equipment as per project approved Baseline survey procedure under CONTRACTOR and COMPANY witness.

22.6 During inspection, findings/ outstanding works observed by CONTRACTOR/ COMPANY shall be notified to the MANUFACTURER/ VENDOR/ SUB-VENDOR for rectification. In this regard, the observations shall be recorded in Joint inspection report / Minutes of Meetings for action and signed off by all parties at the inspection location.

22.7 During inspection, CONTRACTOR/ COMPANY inspectors shall confirm that comments on MANUFACTURER/ VENDOR/ SUB-VENDOR documents have been implemented on the work and shall reflect confirmatory statement along with deliverable approval status of key VENDOR/Sub- VENDOR documents in their Inspection reports.

22.8

FAT and final inspection shall be carried out only with COMPANY final approved documents. If any deviations are observed against the approved documents, Non-conformance report shall be issued directly to CONTRACTOR/ MANUFACTURER/ VENDOR/ SUB-VENDOR during the inspection visit and copy shall be sent to COMPANY on the same day.

22.9 Upon final inspection, concerned parties shall also identify, categorize punch list items and agree with COMPANY prior to dispatch. All Category A punch list items shall be closed and accepted by CONTRACTOR and COMPANY prior to dispatch, and CONTRACTOR shall ensure this prior to issue Inspection Release Note (IRN). CONTRACTOR shall be responsible for tracking CONDITIONAL INSPECTION RELEASE NOTE.

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23

EXAMINATION OF THE EQUIPMENT/MATERIAL FOR DISPATCH

23.1

Prior to material/ equipment dispatch, CONTRACTOR and COMPANY shall additionally check the following aspects as a minimum:

Verify NCR close outs acceptance by COMPANY.

Verify all previous inspection reports including those attended by other inspectors to ensure that there are no pending action by MANUFACTURER/ VENDOR or unresolved issues / observations.

Verify Marking, nameplates and colour coding as applicable.

Verify Regulatory requirements and Code stamp where required.

Preparation for shipping and stocking: i.e. greasing, immobilize moving parts, plugging of

holes, packing, etc.

Preservation in accordance with project approved procedure/VENDOR recommendations.

MANUFACTURER/ VENDOR Data Books/WIN/UTC/Equipment Number/CMMS Data

Sheets have been completed.

All punch list items have been completed except those specifically agreed with COMPANY

to be carried over to Fabrication yard/Offshore.

Inspection and Testing documentation is reviewed and endorsed by all concerned Inspectors.

All MANUFACTURER/ VENDOR work has been deemed acceptable by the CONTRACTOR/ COMPANY inspection personnel in accordance with the requirements of Codes, Standards and Project specifications.

24

SPARE PARTS

24.1

All purchase orders issued by CONTRACTOR for equipment shall contain a clause as follows “Vendor shall undertake to continue to manufacture, or in lieu of manufacture to stock pile, all components, Field Replacement Units (FRUs) or spare parts required to maintain the supplied systems and equipment in proper service for the design life years after the purchase date for the equipment.” Or otherwise specified by the Company.

24.2

All purchase orders issued by CONTRACTOR shall request vendors to provide a spare parts escalation formula for a period of 5 years beyond the initial validity period for direct purchase by COMPANY or CONTRACTOR from the VENDOR.

24.3

The CONTRACTOR shall submit the Spare Parts Document package that include as a minimum the following:

Relevant Material and Test Certificates as applicable to each type of material i.e. the Spares shall be subjected to the same level of Inspection as the Original Equipment/ Material. The ITP’s shall also include a stage for Spare Parts Inspection, wherever applicable.

Preservation and maintenance actions carried out until the time of Hand Over.

Packing lists with shipping and inspection certificates. All OPERATING SPARES supplied by

VENDOR to provide conformity certificates from MANUFACTURER.

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25

REPORTING, RELEASE AND DOCUMENTATION

25.1 CONTRACTOR shall issue their inspection report to COMPANY within maximum of Three (03)

working days.

25.2

Inspection reporting format shall be agreed with COMPANY. CONTRACTOR shall include the following information as a minimum in the inspection reports;

Identification to Purchase Order.

Project Specification/Standards applicable. MANUFACTURER / VENDOR (including all Sub-VENDORs/Suppliers including location).

Item detail and Qty.

Document approvals and their COMPANY approval status including a confirmatory statement that approval condition/Comments on documents have been verified on the Job at the time of inspection and do not impact the inspection acceptance given during the visit. Inspection activities carried out (including activity reference no. and intervention) including a statement on the result of the inspection.

Next inspection due. Observations, NCRs & Deviations. Area of concern. Pictures of Inspection activities (with date and time). Reviewed, endorsed and stamped copies of Material certificates, Test reports, must be

attached with proper traceability to the report, etc.

25.3 Report number shall be made up of COMPANY Project number/PO No. /Report type (flash report transmitting

/Sequential no. (While

FR/Inspection report electronically. The report number shall be used as file name).

IR/Inspection release note

IRN)

25.4

25.5

All inspection documents issued by the MANUFACTURER/ VENDOR/ SUB-VENDOR shall be reviewed and endorsed (with full name and dated) by CONTRACTOR and COMPANY. These documents include: material certification, works test certificates, FAT report, compliance certificates, PMI, NDT records, and heat treatment charts.

inspection documents

All issued by CONTRACTOR and TPA shall be legible and in English language only.

the MANUFACTURER/ VENDOR/ SUB-VENDOR,

25.6 CONTRACTOR inspection personnel shall issue Inspection release notes (IRN) duly endorsed by COMPANY. IRN submitted by CONTRACTOR without COMPANY endorsement shall not be accepted. Exemptions for minor items may be agreed with COMPANY at the beginning of project.

25.7 CONTRACTOR and COMPANY shall ensure that at the time of issuance of IRN all Key VENDOR documents are approved with COMPANY final approval Code (approved with no comments).

25.8 CONTRACTOR Inspection personnel shall verify that all Category ‘A’ Punch list items are attended to by MANUFACTURER/ VENDOR/Sub-VENDOR. In case of outstanding engineering related Punch ‘A’ items CONTRACTOR shall verify and confirm that appropriate COMPANY approved Technical Query / Concession Request has been presented by MANUFACTURER/ VENDOR/SUB-VENDOR.

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25.9 CONTRACTOR shall put in place a release note/Inspection completion scheme which identifies for all P.O documents are approved, there are no outstanding technical queries, Concession requests, that all non-conformances are closed out and that the Inspector is fully aware of the updated status prior to release of material and equipment.

25.10 CONTRACTOR shall maintain a Tracking Register to monitor closeout of all Observations / Open issues raised in CONTRACTOR/ COMPANY/ VENDOR Inspection Reports and Inspection Release Notes.

25.11 CONTRACTOR shall submit a duly endorsed Pre-IRN check list supported by necessary back up documents that include but not limited to VENDOR document approval status, ITP activities completion, closure of NCRs / Concession requests / Area of concerns / Observation from Inspection reports, Punch lists status etc.to COMPANY along with final inspection release RFI, for review and acceptance.

25.12 CONTRACTOR Inspection personnel shall issue IRN for Sub-VENDOR items to be delivered to main VENDOR works or directly dispatched to site, and such IRN’s shall also be endorsed by COMPANY prior to shipping.

25.13 The Sub-VENDOR items requiring IRN shall be to the extent required by COMPANY approved ITP

and as agreed at PIM.

25.14 Final Inspection Report shall be followed up with Inspection Release note.

25.15

Inspection Release Note format shall be agreed with COMPANY. However, CONTRACTOR and Inspector and COMPANY (As required) shall include following information as a minimum in their Inspection Release Notes;

Identification to Purchase Order.

Project Specification/ Standards applicable.

MANUFACTURER (including all sub-VENDORs/ suppliers including location)

Item detail and qty.

Item Completion status (Yes/No.) and P.O. completion status (Yes/No).

Key Document references along with final (Code1) approval status of CONTRACTOR and

COMPANY.

25.16 Certificates, inspection reports and records shall be signed and dated by inspection personnel, whose

name and position, including his/her COMPANY name shall be clearly indicated in the document.

25.17 VENDOR shall prepare and provide ‘dispatch dossier’ at the time of issue of IRN. The dossier shall contain Material test certificates summary, NDT completion summary, Heat treatment reports, Pressure test reports corrosion test summary, FAT reports, Painting reports, ASME data reports, NCR close out summary, Punch list close out summary.

25.18 VENDOR shall compile the Manufacturing data Report (MDR) in line with a preapproved Index and submit to COMPANY within the time frame as per CONTRACTOR. In order to facilitate this, the VENDOR shall progressively compile a Manufacturing data Report (MDR) during manufacturing and this should be made readily available to the CONTRACTOR and COMPANY inspectors for verification during regular routine visits to the VENDORs works or upon request.

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25.19

Inspection release at MANUFACTURER/ VENDOR/Sub-VENDOR works by CONTRACTOR shall not relieve the MANUFACTURER/ VENDOR/Sub-VENDOR from responsibilities for repairing or replacing any defective material or workmanship that may be subsequently discovered at site, the repair and replacement of the MANUFACTURER/ VENDOR/Sub-VENDOR without any impact on the Project schedule.

the equipment/materials shall be made at

the cost of

Confirmatory statement that approval condition/Comments on documents have been verified on the Job at the time of inspection and do not impact the inspection acceptance given during the visit.

Inspection activities carried out (including activity reference no. and intervention)

Including a statement on the result of the inspection.

Next inspection due.

Observations, NCRs & Deviations.

Area of concern.

Pictures of Inspection activities (with date and time).

Reviewed, endorsed and stamped copies of Material certificates, Test reports, must be

attached with proper traceability to the report.

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ADNOC Classification: Internal

SECTION D – MATERIAL CERTIFICATION REQUIREMENTS

26

MATERIAL CERTIFICATION

26.1

INTRODUCTION

26.1.1 This section defines the minimum Project requirements for Material Certificates as they pertain to equipment and materials. MANUFACTURER/ VENDORS shall furnish material certificates in accordance with the requirements of EN 10204, and any additional requirements of this document. All such material shall be fully traceable to the certification through all stages of manufacture.

26.1.2 For material certification, refer to Table A1.1 to A1.11 of this document. In case of conflict in Material Certification between this document and the individual ADNOC Business Unit specifications for various components – the most stringent certification requirement shall be applied; however where these are not defined in COMPANY standards, these shall be identified in define (FEED) phase of Project and approved by COMPANY.

26.1.3 The correct identification of materials of construction is essential. The fundamental requirement is that all materials used to form the pressure envelope of any piping systems, and equipment, shall be traceable to material test certificates.

26.1.4 Material certificates referred to in this specification are those issued by the material producer (mill), material processor, MANUFACTURER, VENDOR, or in combination shall attest to the correctness of materials.

26.2 REQUIREMENTS FOR CERTIFICATES

26.2.1 Certificates shall be written in the English language and shall be complete, unambiguous, legible and suitable for electronic scanning. Certificates in other languages will only be accepted if they are supplied with an endorsed English translation by an authority acceptable to the COMPANY.

26.2.2 All data shall be shown in SI units, in accordance with ISO 1000 International System of Units (“SI”)

and its application.

26.2.3 Certificates shall state compliance to the latest editions of the Code / Standard or the editions applicable to the Purchase Order, Material Certification to Obsolete editions, unspecified editions etc. of the Code / Standard are unacceptable.

26.2.4 Material Certificates with the QR Code are preferred, as they facilitate verification of the Certificate

and thereby eliminate the concerns related to counterfeit material.

26.2.5 Stockiest Material Certificates shall not substitute the Manufacture (Origin/ Mill) Certificates and shall

be unacceptable.

26.2.6 VENDOR/ CONTRACTOR shall maintain the Original Material Certificate or its Certified True Copy

for COMPANY Verification upon request.

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26.2.7 Where sour service is required, the certificate shall explicitly mention compliance with NACE MR-

0175/ISO 15156 or NACE MR-0103, as applicable, for process wetted or pressure retaining parts.

26.2.8 Certificates shall be signed and dated by an authorized person, whose name and position including

that of his/ her Agency, shall be clearly indicated on the document.

26.2.9 VENDOR/ CONTRACTOR shall ensure that material certification documents do not contain any

alterations.

26.2.10 Where the item supplied has been manufactured from certified, semi-finished, material supplied by a different MANUFACTURER (i.e. welded fittings made from plate or pipe), the certificate for the semi- finished material shall be attached to the certificate for the finished item. The MANUFACTURER shall ensure that the certificate supplied for the base or parent material complies with this specification.

26.3

TYPES OF CERTIFICATE

26.3.1 Inspection is commonly related to be one of two types: non-specific or specific.

DEFINITIONS ACCORDING TO BS EN 10204:

a) NON-SPECIFIC INSPECTION: Defined as an inspection carried out by the MANUFACTURER in accordance with their own procedures to assess whether products defined by the same product specification and made by the same manufacturing process, are in compliance with the requirements of the order or not.

Under the basis of non-specific inspection, there are two differing inspection document options:

• Type 2.1. Declaration of compliance with the order without test results • Type 2.2. Statement of compliance with the order and indicate of test results of non-specific

inspection.

Note that under non-specific inspection, the products inspected are not necessarily the products actually being supplied. This is not batch specific and only gives average values for that material produced by MANUFACTURER (Mill) over a manufacturing period.

b) SPECIFIC INSPECTION: Defined as an inspection carried out, before delivery, according to the product specification, on the products to be supplied or on test, units of which the products supplied are part, in order to verify that these products comply with the requirements of the order.

26.3.2 When considering specific product inspection (on a batch specific basis), the inspection document

options are:

• Type 3.1. Statement of compliance with the order with indication of results of specific inspection including test results. Validated by a MANUFACTURERs authorized inspection representative, independent of manufacturing and based on inspections before delivery.

• Type 3.2. Statement of compliance with the order with indication of results of specific inspection including test results. Validated by a MANUFACTURERs authorized inspection representative independent of manufacturing and a third party such as the PURCHASER’s authorized inspection representative or an inspector designated by official regulations.

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26.3.3 For material covered under 3.2 certification, PURCHASER’s authorized inspection representative in additional to mechanical testing, shall also verify traceability, witness and verify other critical inspection and testing activities such as applicable NDE, HIC/ SSCC, Corrosion tests, PMI etc. to validate compliance to Project specification, Standards and Material requisition referred in Purchase order.

26.4

TYPE 3.2 ‘INTENT’ - STOCKIEST MATERIAL

26.4.1 Where Type 3.2 certification is required but, to meet critical project schedule for small quantities, it is only possible to obtain materials from STOCKIEST with a Type 3.1 certification – Type 3.2 ‘Intent’ may be proposed by CONTRACTOR for review & approval of COMPANY.

26.4.2 It is also essential to confirm the basis of testing is ‘true’ Certification for stockiest material to complement existing Type 3.1 certification with additional testing. Simply, a paperwork review of certification at STOCKIEST by PURCHASER’s authorized inspection representative (or TPI approved by COMPANY) does not permit re-certification of inspection documents Type 3.1 to Type 3.2. Neither does test house update based on any additional testing, as the test house is not classed as a MANUFACTURER.

26.4.3 With safety and reliability being a key concern for certain applications, there is a requirement to further validate the properties and traceability of the materials being utilized. To provide this additional surety and ‘intent of’ Type 3.2 certification, the CONTRACTOR shall repeat all specified mechanical testing of the material by taking a new test sample from cut-off or from a sacrificial part of the actual lot of material. The CONTRACTOR shall utilize a COMPANY approved third party organization to witness the test sampling and the new/additional testing, confirm markings, and afterwards to countersign and issue a report stating the basis of the ‘intent of’ certification and clearly label it as such. This typically includes a review of the steelmaker’s certificate of origin and verification of marking including a review of traceability back to ladle chemical analysis. This will also typically include sample dimensional checks.

26.4.4 CERTIFICATION SELECTION

26.4.5 GENERAL NOTES:

i.

ii.

Type 3.2 Certificate issued by MANUFACTURER might be endorsed by PURCHASER (CONTRACTOR/ VENDOR) Representative and does not require deputation of an exclusive Third Party in addition to the PURCHASER Representative. In this case, for inspection Class 1 & 2, the Inspection & Test Plan (ITP) shall identify the inspection interventions points including Material Traceability, Destructive & Non-Destructive Testing, and Chemical Composition & Corrosion Tests etc. as Hold Points for the PURCHASER (CONTRACTOR/ VENDOR).

The required type of Certificate listed on the below tables for the equipment / material shall be the minimum requirement. However It is the CONTRACTOR responsibility to propose the required type of certificate and shall submit Technical Query for clarification and approval by COMPANY under the following condition:-

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• When the requirements are not shown in this specification or project specifications. • When the higher class of material Certificate type than those specified herein is required, based on criticality assessment agreed by CONTRACTOR / COMPANY or due to lack of confidence in MANUFACTURERs Quality capabilities / implementation.

• When other applicable project specification, data sheet, and / or requisition specify more

stringent or specific requirement, it shall prevail.

iii. Where the item supplied has been manufactured from certified, semi-finished, material supplied by a different MANUFACTURER (e.g. welded pipes, fittings made from plate or pipe, etc.) the Certificate Type for the semi-finished material shall be same Type as that indicated for the final product and shall be attached to the certificate for the finished item. The MANUFACTURER shall ensure that the certificate supplied for the base or parent material complies with this specification.

iv.

IECEx Certification shall apply for Material/ Equipment in Hazardous Areas, and for Non- hazardous areas, the Certification requirement shall be as stated in the respective Specifications and/or Datasheets. Type Test, Routine Test, and Performance Test Reports shall be submitted, as stated in the respective Specifications and/or Datasheets.

v. Material / items marked as Type 3.1 Certification and not covered within BS EN 10204 scope, hence the manufacturer shall declare that; the supply complies with the purchase requisition (specification / datasheet) and includes the test results / reports of the material / component specific to the purchase order. The manufacturer’s Inspection department validates test results, which is independent of the manufacturing department.

vi.

Inspection Class and Certification level specified for Material/ Components / Items in the below Tables shall be applicable for Material/ Components / Items within Packages / Skids as well.

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A1.1.

PIPING

Equipment / Item Description

Manual Valves

A1.1 Piping

Inspection Class

Minimum Criticality Rating

Material Certification to BS EN 10204

All services: 600# and above for all sizes; 300# 18’ and above

Critical Service (Sour/Cryogenic/Amine/Steam) CS / LTCS ≥ 6”

and / or ≥ 150#

CRA valves Critical service (Sour /Cryogenic): all sizes

CRA Non sour (e g Chemical injection, Utility, etc.) for sizes > 4”

Valves for TSO, Hot Tap, stoppling: all sizes and ratings

Valves in Cyclic Service: all sizes and ratings

Manual Valves: other rating & sizes not covered in (1) above

Seamless Pipe (CS, LTCS & SS) - Non sour

1

2

3

3.1

Seamless Pipe (CS, LTCS & SS) Sour & Severe, Lethal Service

4

5

Seamless Pipe in CRA other than SS (i.e. SDSS, Ni alloy, alloy steel, Monel, etc.)

Cladded Pipes / Fittings / Flanges

6 Welded Pipe (CS, LTCS & SS)- Non sour

6.1 Welded Pipe (CS, LTCS & SS)- Sour & Severe, Lethal Service

6.2 Welded Pipe (CS, LTCS & SS) Cyclic Service

7

8

8.1

CRA Welded Pipe other than SS (e.g. SDSS, DSS, Ni alloy …etc.)

Fittings & Flanges (CS LTCS & SS)- Non sour

Fittings & Flanges (CS LTCS & SS)- Sour & Severe, Lethal ServiceSour & Severe Service

8.2

Fittings & Flanges (CS LTCS & SS)- Cyclic Service

9

10

11

12

13

14

15

CRA Fitting & Flanges other than SS (e.g. DSS, SDSS, Ni alloy, etc.)

GRE, GRVE & HDPE Pipes, Flanges & Fittings (all Non-metal material)

Flame Arrestors

Insulating Gaskets / Kits

Gaskets (metallic)

Gaskets (non-metallic)

Fasteners

16 Mechanical Valve Interlocking System

17

Hub Connectors & Compact Flanges

1

1

3.2 (Note a)

2

2

1

1

1

2

1

1

1

2

1

1

1

1

2

2

2

3

2

2

1

2

2

1

1

1

2

1

1

1

2

1

1

1

1

2

2 (Note b)

2 (Note b)

3

2 (Note b)

2 (Note b)

1

3.1

3.1

3.2

3.2

3.2

3.1

3.2

3.2

3.2

3.1

3.2

3.2

3.2

3.2

3.1

3.1

3.1

3.1

3.1

3.1

3.2

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A1.1 Piping

Equipment / Item Description

18

19

20

21

22

23

24

Strainers Critical service (Sour/Cryogenic/Amine/Steam)

Strainers ( not covered above)

Chemical Injection Quill

Hose & Hose Couplings* (Note b)

Pipe Support Material (Spring Supports)

Pipe Support Material (Sliding Plate)

Pipe Support Material (Rolled Sections)

NOTE:

Inspection Class

Minimum Criticality Rating

Material Certification to BS EN 10204

2

2

2

3

3

3

3

2

2 (Note b)

2 (Note b)

3

3 (Note d)

3

3

3.2

3.1

3.1

3.1

3.1

3.1

3.1

a) Type 3.2 Certification is applicable for Pressure containing parts to Casting or Forging, Type 3.1 is

applicable for Trim, and Type 2.2 for fasteners, packing etc.

b) Means that Inspection Class could be reduced to (3) after assessment & approval by COMPANY

(Case by Case).

c) For Marine hoses (Under buoy and floating) and Expansion Bellow – not included in the table above

– Type 3.2 Certification is applicable.

Means that Inspection Class could be increased to (2) after assessment & approval by Company (Case by Case)

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A1.2.

PIPELINE

A1.2 Pipeline

Equipment / Item Description

1 Welded Line Pipe (SAW)

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Seamless Line pipe (CS, all sizes)

High Frequency Electric Welded (HFW) Line Pipe

CRA MLP and Metallurgical bond Internal Lined Pipes

Non-Metallic Line Pipe (GRE, HDPE & RTP)

Barred Tee (Body & Bars)

Coatings (3LPP, 3LPE, FBE, Shrink sleeves, etc.) of Line pipes, Bends, & Fittings External & Internal.

Pipeline Field Joint Coating HSS Sleeves

All Flanges and Fittings

Pipeline Induction Bend

Pipeline Isolating / Insulating Joints (IJ)

Pipeline Pig Signaller Pipeline Positive Seal Coupling Groove Coupling

Pipeline Valves

Pipeline Pig Traps (Receivers & Launchers) & End Enclosures

16 Hot Tap Split Tees, Sandwich Valve and Plugs

17

Pipeline Anchor Flanges

18 Welding Consumables

NOTE:

Inspection Class

Minimum Criticality Rating

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

3

1

1

1

1

1

1 (Note b)

1

1 (Note b)

1 (Note b)

1 (Note b)

1 (Note b)

2 (Note a)

1 (Note a)

1 (Note b)

1 (Note b)

1 (Note b)

1 (Note b)

3 (Note c)

Material Certification to BS EN 10204 3.2

3.2

3.2

3.2

3.2

3.2

3.2

3.1

3.2

3.2

3.2

3.1

3.1

3.2

3.2

3.2

3.2

3.1

a) Means that Inspection Class could be reduced to (3) after assessment & approval by Company (Case

by Case).

b) Means that Inspection Class could be reduced to (2) after assessment & approval by Company (Case

by Case).

c) Means that Inspection Class could be reduced to (4) after assessment & approval by Company (Case

by Case).

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A1.3.

STATIC EQUIPMENT

A1.3 Static Equipment (Note c)

1

2

3

4

5

6

7

8

9

Equipment / Item Description

Pressure vessels (including all Vessels, Filters, Columns), Heat exchangers, Air coolers fabricated from carbon steel

Pressure vessels (Including all Vessels, Filters, Columns, Air coolers, Heat exchangers) – SS and CRA

Column Internals

Separator:

• Production
• Test

Separator Internals

Slug Catchers

Vessel Internals

Scrubber

Tanks (Shop & Field Fabricated)

10 Cryogenic Tanks

11 Spheres

12 Pressure vessels - Cladded

NOTE:

Minimum Criticality Rating

Inspection Class

Material Certification to BS EN 10204

2

1

2

1

2

1

2

1

2

1

1

1

2 (Note a)

1

2 (Note b)

1

2 (Note b)

1

2 (Note b)

1

2

1

1

1

3.2

3.2

3.1

3.2

3.1

3.2

3.1

3.2

3.1

3.2

3.2

3.2

a) Means that Inspection Class could be increased to (1) after assessment & approval by Company

(Case by Case)

b) Means that Inspection Class could be reduced to (3) after assessment & approval by Company (Case

by Case)

c) National Board registration requirement has been defined in the relevant ADNOC Specification.

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A1.4.

ROTATING EQUIPMENT

A1.4 Rotating Equipment

Equipment / Item Description

1

Centrifugal Pumps – production and process critical

2

3

4

5

6

7

8

9

Centrifugal Pumps - utility applications, production and process non-critical.

Fire Water Pumps and Fire Water Jockey Pumps.

Pumps - Reciprocating and Rotary Positive Displacement

Centrifugal Compressors, Expanders, Rotary Positive Displacement Compressors, Reciprocating Compressor Packages handling Hydrocarbon gases including CO2, N2 and auxiliaries

Centrifugal, Screw, Reciprocating Compressors in utility, air service and air dryer packages

Turbine (Steam, Gas)

Emergency Diesel Generator Packages

Power Generation - STG / GTG

Minimum Criticality Rating

Inspection Class

Material Certification to BS EN 10204

1

2

1

2

1

2

1

1

1

1

2

1

2

1

2

1

1

1

3.1 / 3.2 (Note a)

3.1

3.1 / 3.2 (Note a)

3.1

3.1 / 3.2 (Note a)

3.1

3.1 / 3.2 (Note a)

3.1

3.1

NOTE:

a) Type 3.2 Certification is applicable for the casing only (casting or forging).

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A1.5.

EQUIPMENT PACKAGES

A1.5 Equipment Packages

Minimum Criticality Rating (Note b)

Inspection Class

Material Certification to BS EN 10204

1

2

3

4

5

6

7

8

9

10

11

Equipment / Item Description

Flare Package (HP and / or Cold)

Flare Package (LP)

De-Salter Package

Gas Dehydration Package, Glycol Regeneration (or injection), Chlorination Package

Fired Heaters

Storage Tanks - GRP

Boiler Package

Reaction furnace

Incinerators

Nitrogen Bottle Rack Package

Refrigeration Units

12 Waste Heat Recovery Units (WHRUs)

13 Water Treatment Packages

14

Nitrogen Generation Package (Membrane, Pressure Swing Adsorption (PSA) or Air Separation Units (ASUs))

15

Chemical Injection Packages

Electric or Hand operated Overhead Travelling (EOT / HOT) Cranes, Hoists (Manual, electrical), Gantry cranes etc.

2

2

1

2

1

2

1

2

1

2

2

1

2

2

2

3

2

2

1

2

1

2

1

2

1

2

2

1

2

2

2

3

Solid Handling Equipment for Sulphur granules.

(Note a)

(Note a)

Loading Arms for products (handling, HC)

Process and Utility Refrigeration Packages (water / glycol mixture cooling for process applications, VFD cooling etc.)

Chillers & Air Handling Units (AHU), DX Units (HVAC items). CR = 2 or 3 based on complexity

1

2

3

1

2

3

16

17

18

19

20

NOTE:

3.2

3.2

3.2

3.2

3.2

3.1

3.2

3.2

3.2

3.1

3.1

3.2

3.1

3.1

3.1

3.1

3.1

3.2

3.1

3.1

a) To be decided based on production criticality of that component.

b)

If a package component has a higher criticality rating, then the higher value shall be used for that component.

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ADNOC Classification: Internal

General

• National Board registration requirement for pressure vessels within the packages has been defined

in the relevant ADNOC Specification.

• Type 3.2 Certification shall apply for Chain for Marine service, shackles, Mooring hawser, Marine

Breakaway Coupling.

• Type 3.2 Certification shall apply for all wetted / pressure / stress bearing parts / Body / shell plate

and arm piping. And for CRA material.

• Type 3.1 Certification shall apply for flange bolting, non-pressure/ non-stress bearing parts, structural

parts and spare parts.

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ADNOC Classification: Internal

A1.6.

INSTRUMENTATION

A1.6 Instrumentation

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Equipment / Item Description

Choke Valves

Emergency Shutdown Valves (ESDV), HIPPS & EDPs

Surface Safety Valve

Motor/ Remote Operated & ON / OFF Valves

Manual Valves Retrofitted with Electric Actuators

Control Valves

V-type Actuated Valves

Pressure Relief Valves / Safety Valves & Rupture discs/ Safety Relief Devices

Analyzer System

Fiscal Metering (Custody Transfer Instrumentation)

Integrated Control & Safety System (ICSS) Cabinets and other package control system.

ICSS- DCS

ICSS- ESD

ICSS- F&G

ICSS- RTU & PLC

Well Head Control Panel (WHCP)

Well Head Hydraulic Panel (WHHP)

High Integrity Pressure Protection System (HIPPS) Equipment

Control Panel ( Not covered above)

ECMS system

Hydraulic Panel

DCS Configuration

Turbine Control System / Tank Gauging System / Custody Transfer Metering / Package Unit PLC / Machine Monitoring system - Hardware Configuration

Electronic Transmitter (SMART & FF) & Loop Powered Indicator Level Transmitters (Interface /Radar)

Multi-Phase Flow Meters Coriolis Mass Flow Meter

Minimum Criticality Rating

Inspection Class

Material Certification to BS EN 10204

1

1

1

2

2

1

2

1

2

2

2

1

1

3

2

1 (Note a)

3.1

1 (Note a)

3.1

1 (Note a)

2

2

1

2

1

2

2

2

1

1

3

2

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

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ADNOC Classification: Internal

A1.6 Instrumentation

Equipment / Item Description

Elector-Magnetic Flow Meters

16

All IPF instrumentation

Turbine Flow Meter Ultrasonic Flow Meter V-Cone Flow Meter Rotameter & Purge Assembly

Gas Chromatograph

Self-Acting Regulators

Hydraulic Package Unit

FND Field BUS / Barrier Junction Boxes & Connectors

Condition & Vibration Monitoring System

Flow Orifice Assembly / Plate & Restriction Orifice / Plate

Averaging Pitot Tubes (Annubars)

Venturi Meters

Instrument Cables

Fire & Gas Detectors

Fire & Gas Detectors (Acoustic Leak Detectors)

Control Valve Retrofitted with new FF Positioner

Tubes (SS, Ni alloys …etc.)

Tube Fittings

Air Distribution & other Manifolds

Drip Rings

Emergency Shutdown Push button

Unistrut

Tube Clamps

Multi-cable Transit

Cable Tray

Cable Gland

Fibre Optic cables

Multiport Selector Manifold

Metering Skid

Passive Cooling Shelter

New ECMS/ Existing ECMS System Modification

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

Minimum Criticality Rating

Inspection Class

Material Certification to BS EN 10204

1

2

2

3

2

2

2

2

3

2

3

1

1

3

3

3

3

3

2

3

3

4

3

2

2

1

2

2

1

1

2

2

3

2

2

2

2

3

2

3 (Note b)

1

1

3

3

3

3

3

2

3

3

4

3

2 (Note c)

2

1

2

2

1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

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ADNOC Classification: Internal

A1.6 Instrumentation

45

46

47

48

49

50

51

52

53

54

Equipment / Item Description

Pressure Gauges & Differential Pressure Gauges

Temperature Gauges

Temperature Elements / Thermowells

Level Gauges- Transparent /Glass

Level Gauges- Magnetic

Multipoint Thermocouples & Resistance Temperature Detectors (RTDs)

Displacer /Radar LVL TXS

High Sensitivity Smoke Detection (HSSD)

Dissolved Gas Analysis Monitors

Instrument Sunshades

Minimum Criticality Rating

Inspection Class

Material Certification to BS EN 10204

3

3

3

3

3

3

3

1

3

4

3

3

3

3

3

3

3

1

3

4

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

NOTES:

a) Means that Inspection Class could be reduced to (2) after assessment & approval by Company (Case

by Case)

b) Means that Inspection Class could be increased to (2) after assessment & approval by Company

(Case by Case).

c) Means that Inspection Class could be reduced to (3) after assessment & approval by Company (Case

by Case).

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ADNOC Classification: Internal

A1.7.

ELECTRICAL

A1.7 Electrical

Equipment / Item Description

Power Transformer - 105 MVA and above

Distribution Transformers /

Phase Shift Transformer

Process Electric Heater

33KV Switchgear

33KV Switchgear Modification

132KV Switch Gear Modification

132KV GIS Switchgear

11KV & 3.3KV Switchgear

11KV Ring Main Unit

415V /LV Switchgear

LV Switchgear Modification

33KV Switch Board

11KV Switch Board

Harmonic Filters and Power Factor Equipment

33Kv - 2.5 MVAR Capacitor Banks & Harmonic Filter

415V Main Distribution Boards

LV Distribution Board

Online Condition Monitoring System (OLCMS-T and OLCMS-M)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

UPS (AC, DC, & AC-DC) with Batteries

16

17

18

19

20

21

22

23

24

Substation Control & Monitoring System (SCMS)

SCMS Modification

Local Control Station & Switch

Power Supply Skid - Packaged Substation

Solar Power System & Batteries

Electric Motors (HV and LV)

Adjustable Speed Drives

Neutral Earthing Transformer Package

Low Voltage Bus Duct

Fault Monitoring System (FMS)

Minimum Criticality Rating

1

2

2

2

2

2

1

2

2

2

2

2

2

2

1

2

2

2

2

2

2

3

2

3

Inspection Class

1 (Note a)

2

2

2

2

2

1

2

2

2

2

2

2

2

1 (Note a)

2

2

2

2

2

2

3

2

3

Material Certification to BS EN 10204

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

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ADNOC Classification: Internal

A1.7 Electrical

Equipment / Item Description

Minimum Criticality Rating

HV Cables

HV Cable Termination Kit

LV Power Control and Earthing Cables

33KV Subsea Composite Cable

Earthing and Lightning Materials

Electrical Cable Glands

Power Receptacles and Switches

Capacitors (Lights & AC … etc.)

Cable Trays and Accessories for E&I

Electrical Junction Boxes

Trefoil Cleats, Cable Clamps, Cable Tags, and Route Marker

Overhead Lines (OHL) 132 kV and 33 kV Lattice Steel Towers OPGW 132 kV and 33 kV Surge Arresters 132 kV and 33 kV Load Break Switches 132 kV and 33 kV XLPE cable

Fault Limiting Reactor

Hazardous Bulk Materials

Non-Hazardous Bulk Materials

Small Power, Lighting, UPS Distribution Board

Heat Tracing

2

2

3

2

3

2

3

4

3

3

3

2

2

2

3

3

3

Inspection Class

2

2 (Note b)

3

2

3

2 (Note b)

3

4

3

3

3

2

2

2 (Note b)

3

3

3

Material Certification to BS EN 10204

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

3.1

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

NOTES:

a) Means that Inspection Class could be reduced to (2) after assessment & approval by Company (Case

by Case).

b) Means that Inspection Class could be reduced to (3) after assessment & approval by Company (Case

by Case).

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ADNOC Classification: Internal

A1.8.

TELECOMS

A1.8 Telecom

1

2

3

4

5

Equipment / Item Description

Telecoms Systems (SDH, CCTV, PAGA, Radio, Well site)

Telecom System Package

Fibre Optic Cables

Fibre Optic Accessories

Telecoms Bulk Materials

Minimum Criticality Rating

Inspection Class

Material Certification to BS EN 10204

3

3

2

3

3

3

3

2

3

3

3.1

3.1

3.1

3.1

3.1

A1.9.

CIVIL / STRUCTURAL

A1.9 Structure/Civil

1

2

3

4

5

6

7

8

9

10

11

12

13

Equipment / Item Description

Supply, Fabrication and painting / Galvanizing of Structural Steel Support for Process Items (Beams, ladders, stairs, platforms, handrails, checkered plates, etc.)

Supply, Fabrication and painting / Galvanizing of Structural Steel Support for other structures (Beams, ladders, stairs, platforms, handrails, checkered plates, etc.)

Reinforcement Steel

Anchor and Structural bolts & nuts

Hot dip Galvanised Items

Concrete Aggregates & admixtures

Cements

Asphalt based materials

Cast Iron Covers

Floor Gratings

Fencing

Architectural - Fire Rated Assemblies

Architectural - Blast Resistant Doors

Minimum Criticality Rating

Inspection Class

Material Certification to BS EN 10204

1

2

2

1

3

4

4

4

4

4

4

1

1

1

2

2

1 (Note b)

3

4

4

4

4 (Note c)

4 (Note c)

4 (Note c)

1

1

N/A (a)

N/A (a)

3.1

3.1

3.1

N/A (a)

N/A (a)

N/A (a)

3.1

3.1

3.1

N/A (a)

N/A (a)

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ADNOC Classification: Internal

14

15

16

17

18

Architectural - Water Proofing Materials

Architectural - Security and Vault Equipment

Architectural - Cable Support and Fabric Structures

Architectural – Pre-Engineered Structures/Building/Shelters

Architectural - HVAC, Plumbing, Electrical Specialities/Systems

19

Architectural - Fire Retardant and Intumescent Seals

20

21

Architectural - Solar Energy Systems/Collectors & Solar Control Devices

Architectural - Floor and Wall Tiles, Natural Stone and Ceramic Tiles

22

Architectural - Artwork, Signage and Graphics

23

24

25

Architectural - Pre-Finished Furniture/Systems and Pre- assembled Systems

Architectural - Hollow Block Work, Ironmongery, Architectural Metal Work

Architectural - Window Washing & Building Facade Maintenance Equipment

26

Architectural - Aluminium Window Doors

27

Architectural - Sloping Glazing Systems, Glazing and Door Assemblies

28

Architectural - Sanitary

3

3

3

3

3

4

4

4

4

4

4

4

4

4

4

3

3

3

3

3

4

4

4

4

4

4

4

4

4

4

N/A (a)

N/A (a)

N/A (a)

N/A (a)

N/A (a)

N/A (a)

N/A (a)

N/A (a)

N/A (a)

N/A (a)

N/A (a)

N/A (a)

N/A (a)

N/A (a)

N/A (a)

NOTE:

a) Certification is not applicable however for material / item other than steel means that the manufacturer declares that the supply complies with the purchase requisition (specification / datasheet) and includes the test results / reports. The manufacturer’s Inspection department validates test results, which is independent of the manufacturing department.

b) Means that Inspection Class could be reduced to (3) after assessment & approval by Company (Case

by Case).

c) Means that Inspection Class could be increased to (3) after assessment & approval by Company

(Case by Case).

General:

• Type 3.2 Certification is applicable to Special and Primary Category Structural Steel that include the

Plates, Beams, and Tubulars.

• Type 3.1 Certification is applicable to Secondary and Tertiary Category Structural Steel that include

the Plates, Beams, Tubulars, Pipes, and Angle etc.

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ADNOC Classification: Internal

A1.10. CORROSION PROTECTION

A1.10 Corrosion Protection

1

2

Equipment / Item Description

Cathodic Protection

Pipeline Corrosion Monitoring & Access Fittings

Minimum Criticality Rating

3

3

Inspection Class

Material Certification to BS EN 10204

3

3

3.1

3.1

A1.11. HSE

A1.11 HSE

1

2

3

4

5

6

Equipment / Item Description

Deluge valves Skid and Spray Nozzles

Clean Agent system

Fire Fighting Equipment - Fire Extinguishers, Fire Blankets, Hose Reels, etc.

Personal Protective Equipment (PPE)

Safety Signs

Lifeboats

NOTES:

Minimum Criticality Rating

Inspection Class

Material Certification to BS EN 10204

1

1

2

3

4

1

1

1

2 (Note a)

3 (Note b)

4

1 (Note a)

3.1

3.1

3.1

3.1

3.1

3.1

a) Means that Inspection Class could be reduced to (3) after assessment & approval by Company (Case

by Case).

b) Means that Inspection Class could be reduced to (4) after assessment & approval by Company (Case

by Case).

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ADNOC Classification: Internal

SECTION E – MINIMUM INSPECTION AND TESTING ACTIVITIES

APPENDIX A

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ADNOC Classification: Internal

APPENDIX A

MINIMUM INSPECTION AND TESTING ACTIVITIES

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

TABLE OF CONTENTS

SECTION-A: GENERAL……………………………………………………………………………………….. 56

SECTION-B: ABBREVIATION……………………………………………………………………………….. 57

SECTION-C: INSPECTION TEST PLANS………………………………………………………………….. 59

ITP–101 UNFIRED PRESSURE VESSEL & COLUMNS … 60

ITP–102 SHELL & TUBE HEAT EXCHANGERS … …………………………………………..64

ITP–103 AIR COOLED EXCHANGERS … 68

ITP–104

SHOP FABRICATED PIPE WORK … 72

ITP–105 WELDABLE STRUCTURAL STEEL MATERIAL … 75

ITP–106

STRUCTURAL STEEL WORK FABRICATION……………………………………………..80

ITP–107 VALVES FOR PIPELINES AND PROCESS UNITS … 82

ITP–108

SAFETY RELIEF VALVES … 86

ITP–110

FLANGES, FORGINGS INCLUDING HUB CONNECTORS & FITTINGS … 91

ITP–111

EXPANSION BELLOW … 94

ITP–112

SACRIFICIAL ANODES … 97

ITP–113

STORAGE TANKS … 99

ITP–114

COLUMN INTERNALS … 106

ITP–115

EMERGENCY DIESEL GENERATOR … 108

ITP–116

FLARE PACKAGE … 112

ITP–117 GLASS FLAKE LINING … 116

ITP–119 GRVE- RTR PIPES & FITTINGS … 124

ITP–120

INSULATING GASKET KITS … 126

ITP–121 AUSTENITIC SS, DSS, SDSS, INCOLOY AND INCONEL PIPES & FITTINGS . 128

ITP-122

PUMPS … 131

ITP–123

COMPRESSORS - CENTRIFUGAL … 134

ITP–124

COMPRESSORS - RECIPROCATING … 137

ITP–126 HVAC EQUIPMENT … 143

ITP–202

33KV & BELOW OIL FILLED POWER TRANSFORMERS AND SHUNT REACTORS … 152

ITP–203 DRY TYPE POWER TRANSFORMERS … 156

ITP–204

132KV GAS INSULATED SWITCHGEAR … 158

ITP–205

11KV & 6.6KV AIR INSULATED SWITCHGEAR … 164

ITP–206

415V SWGR … 166

ITP–207

ECMS/PMS/EAMS … 168

ITP–208 NEUTRAL EARTHING RESISTOR … 171

ITP–209

132KV SUBMARINE CABLE … 174

ITP–211

ELECTRICAL CABLES … 180

ITP–212 AC UPS … 182

ITP–213 DC UPS … 186

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–214 HV/MV ELECTRIC MOTORS … 189

ITP–216 VARIABLE SPEED DRIVES … 196

ITP–217

ELECTRICAL HEAT TRACING … 199

ITP–218 NAVIGATIONAL AIDS … 201

ITP–219

SOLAR POWER SYSTEMS … 203

ITP–220

CATHODIC PROTECTION SYSTEM … 205

ITP–221 GRP CABLE TRAYS & LADDERS … 207

ITP–222

ELECTRIC TRACTION LIFT … 209

ITP–223

PNEUMATIC & HYDRAULIC ACTUATORS … 211

ITP–224 MOTORIZED ACTUATORS … 213

ITP–225 ANALYZER SYSTEM … 215

ITP–226 DISTRIBUTION PANEL BOARD … 217

ITP–227

FLOW METER … 219

ITP–228

INSTRUMENT TUBING (SMLS TUBE) … 221

ITP–229

LEVEL TRANSMITTER … 223

ITP–230

TELECOM SYSTEM (LAN / WAN SYSTEM) … 225

ITP–231 WELLHEAD CONTROL PANELS … 228

ITP–232

LV DIESEL DRIVEN ALTERNATORS … 232

ITP–233 MAC DCS, ESD & F&G SYSTEMS … 234

ITP–234 REMOTE TELEMETRY UNIT (RTU) … 242

ITP–235

CONTROL AND INSTRUMENTATION CABLES… 244

ITP–236

CONTROL VALVES … 247

ITP-238 MACHINE MONITORING SYSTEM … 252

ITP–239 HVAC CONTROL SYSTEM … 254

ITP–240

TEMPORARY REFUGE ROOM … 257

ITP–301

LINE PIPE … 259

ITP–302 HOT INDUCTION BEND … 262

ITP–303 BARRED TEE … 265

ITP–401

CRANES JIB & OVERHEAD … 268

ITP–501 MARINE HOSES … 270

ITP–502 MOORING BUOYS AND PLEM … 272

ITP–503 MOORING HAWSERS … 275

ITP–504

CHAINS FOR MARINE SERVICES … 277

ITP–505 RUB STRIPS AND FENDERS … 279

ITP–506 HYDRAULIC CLAMP … 281

ITP–507

CONNECTORS … 284

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

SECTION-A: GENERAL

a) This APPENDIX-A defines the minimum inspection and testing activities that shall be considered and addressed by MANUFACTURER/ VENDOR/ Sub-VENDOR while developing related Inspection & Test Plan (ITP), the minimum inspection and testing interventions concerned parties are specified under Section 15, and the minimum Material Certification requirements are addressed in Section 26 of this specification.

b) The project specific requirements and any additional inspection and testing requirements

addressed in the technical contractual documents shall be included in the ITP.

c) For equipment and material which do not have an Inspection & Test Plan (ITP) listed under this APPENDIX-A, MANUFACTURER/ VENDOR shall prepare an ITP (Inspection & Test Plan) in compliance with the relevant COMPANY Standard, International/ National Standards referred in to Purchase Order description and shall be submitted for CONTRACTOR and COMPANY Approval prior to manufacturing.

d) ITP shall cover all major inspection related activities in a sequential order from review of documents, drawings through manufacturing, process controls, examination, testing, Quality documentation review, certification, pre-dispatch inspection and up to final release.

e) The content of ITPs developed in a tabulated form by MANUFACTURER/ VENDOR, and shall

address the below as a minimum.

• • • • • • • • •

Inspection and testing activities. Responsible person. References (applicable Project specifications/Drawings/ Data Sheets, etc.) Characteristics to be verified. Material Certification level. Acceptance Criteria. QC verified Record. Intervention for concerned parties MANUFACTURER/ VENDOR/ CONTRACTOR/ COMPANY Remarks.

f) Any deviation from the approved ITP stages and interventions shall require COMPANY Quality

Control Department approval.

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

SECTION-B: ABBREVIATION

Abbreviation

Description

ADNOC

Abu Dhabi National Oil Company

AIS

API

ASME

Air Insulated Switchgear

American Petroleum Institute

American Society of Mechanical Engineers

BASEEFA

British Approvals for Electrical Equipment in Flammable Atmospheres

BS

CMMS

CoP

CP

CPR

CR

CR

CSA

CV

DCS

DIN

DFT

British Standard

Computerized Maintenance Management System

Code of Practice

Cathodic Protection

Contract Purchase Requisition

Concession Request

Criticality Rating

Canadian Standards Association

Curriculum Vitae

Distributed Control System

Deutsches Institut Fur Normung

Dry Film Thickness

EEMUA

Engineering Equipment and Materials Users Association

ESD

GIS

FAT

F & G

GRP

H2S

HIC

HSE

HV

HVAC

LAN

LV

ID

ITP

KV

Emergency Shutdown System

Gas Insulated Switchgear

Factory Acceptance Test

Fire & Gas System

Glass Reinforced Pipe

Hydrogen Sulphide

Hardness Induced Cracking

Health, Safety & Environment

High Voltage

Heating, Ventilating & Air Conditioning

Local Area Network

Low Voltage

COMPANY Asset Integrity division

Inspection and Test Plan

Kilo-Volt

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

Abbreviation

Description

KVA

KW

MOC

MR

Kilo-Volt-Ampere

kilowatt

Management of Change

Material Requisition

MSS SP

Manufacturers Standardization Society Standard Practice

NDE

NCR

NDT

NPSH

OCIMF

PIM

PLEM

PMI

PMT

PMC

PCP

PO

PQR

Non-Destructive Examination

Non-conformance Report

Non–Destructive Testing

Net Positive Suction Head

Oil Companies international marine Forum

Pre-Inspection Meeting

Pipeline End Manifold

Positive material Identification

COMPANY Project Management Team

COMPANY Project management Consultant

Project Change Proposal

Purchase Order

Procedure Qualification Records

QA/QC

Quality Assurance/Quality Control

QAS

QC

QMS

RFI

SSCC

STD

TEMA

TPA

TPIA

TPI

TSD

UPS

UTC

VDRL

WAN

WIN

WPS

Quality Assurance System

Quality Control

Quality Management Systems

Request for Inspection

Sulphide Stress Corrosion Cracking

Standard

Tubular Exchanger Manufacturers Association

COMPANY appointed Third Party Inspector

Third Party Inspection Agency

Third Party Inspector

Technical Standard Documents

Uninterruptable Power Systems

Unique Tracking Commodity

Vendor Document Requirement List Requirement List

Wide Area Network

Work Identification Number

Welding Procedure Specification

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

SECTION-C: INSPECTION TEST PLANS

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–101

Unfired Pressure Vessel & Columns

ACTIVITY

E C N E R E F E R

T N E M U C O D

t c e j o r P e c n e r e f e R

(

) n o i t a c i f i c e p s

y b y d o b n o i t a c i f i t r e C

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s a (

the

list covers

Scope This test requirements in a Vendor’s works for unfired vessels designed and constructed in accordance with ASME Section VIII, PD 5500 or any other recognized Codes.

inspection and

SL. NO.

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I

Following list details COMPANY’s minimum requirements for pressure vessel inspection & certification.

1.1 Vendor approval

2. Pre- Inspection Meeting

3. General - Preliminary Work

3.1 Data sheet

3.2 Calculations

3.3 GA and detailed Drawings including sub-vendors

Vendor’s fabrication schedule

Vendor’s QA Plan

Sub-vendor approval

Status of sub-orders

3.4

3.5

3.6

3.7

Vendor activities)

ITP

3.8

(including Sub-vendor Order

3.9

3.10

3.11

Raw Material test and certification, identification and traceability Welding Procedure Specification (WPS)and Procedure qualifications Record (PQR) and weld map

Qualified welders list

3.12

NDT Procedures - MT, PT, RT, UT, Phased Array, TOFD and etc., as applicable

3.13

3.14

PWHT Procedures

NDE Personnel Qualifications

PMI, Ferrite and Hardness testing procedure (as applicable)

3.15

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ITP–101

Unfired Pressure Vessel & Columns (cont’d)

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

E C N E R E F E R

T N E M U C O D

t c e j o r P e c n e r e f e R

(

) n o i t a c i f i c e p s

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

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SL. NO.

ACTIVITY

3.16 Internal cladding / Lining procedure

3.17 Hydro testing and Painting procedure

3.18 Sensitive leak test procedure

3.19 Pickling and passivation procedure

3.20 Base line survey procedure

3.21

Packing, storage preservation Procedure

(including

internals) and

4. Production

4.1

Material Traceability and Examination Chemical analysis, Mechanical, Impact test, corrosion and heat resistant properties Piping components SS, DSS, Inconel and CRA shall conform to specification

Vendor Data Book / MTC ASME Sec II & VIII,

4.2 PMI

Formed Head inspection (Profile, minimum Thickness after forming and NDE, Bonding check as applicable)

4.3

4.4 Dished Heads forming test coupon

4.5 Fit-up of Long and Circular Seams

4.6 Fit-up of Dished Ends to shell

4.7 Fit-up of Nozzles, clips and supports

4.8 Fit-up of skirt with vessel

4.9 Fit-up of Internal Attachments

4.10 Production Welding

4.11

vessel: weld

Clad overlay progressive inspections - PT on first layer, and Ferrite, UT for lack of fusion between weld and base metal, chemical analysis

4.12 Heat Treatments (after forming / welding)

4.13

4.14

Vessel /Column Heat Treatment verification test coupon Clad vessel: PT 100% prior to Hydrostatic test (followed by PWHT)

4.15 Pickling and Passivation, and Ferroxyl testing

Project Spec./ P.O. Description Project specification

Drawings

Drawings

Drawings

Drawings

WPS/Weld Map and Assembly drawing

NDE procedures and specification

Project Spec./ P.O. Description Codes, Std. Procedure

ASME sec VIII

Project Specification Project specification / ASTM A380

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–101

Unfired Pressure Vessel & Columns (cont’d)

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

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SL. NO.

ACTIVITY

4.16 Internal Lining or Coating

4.17 Tell-tale/vent hole closure

4.18 Impact testing Production test plates

4.19 Trial Assembly of Internals

Examination

5.1 Visual Dimensional Check

5.2

Non-Destructive Examination before and after Heat treatment

Clad vessel Final NDE: 100% PT and Hardness, PMI, Ferrite check UT for CRA Weld overlay deposited thickness check Ultrasonic Test of clad plates and disbandment checks (UT 100% of the interfacial area)

Clad vessel: attachments /Nozzle weld area 100% UT prior to fit-up

Painting & Coating Examination including PQT

5.3

5.4

5.5

5.6

5.7

5.8 Holiday testing / Pin hole Testing, if Applicable

5.9 Name plate verification and Code stamping

5.10 ASME Name Plate attachment

5.11 Punch List close-out

Testing

6.1 PMI (Where applicable)

6.2 Hydrostatic Test

6.3 RF pad Pneumatic testing

6.4 Sensitive leak test (If applicable)

6.5 Pickling and Passivation, and Ferroxyl testing

6.6

Draining, drying and inspection

internal cleanliness

6.7 Base line Survey

Document No: AGES-SP-13-002

E C N E R E F E R

T N E M U C O D

t c e j o r P e c n e r e f e R

(

) n o i t a c i f i c e p s

Project Spec./ P.O. Description Codes & Std.

Project specification Project specification/P rocedure

Approved Project Spec. Drawings Codes, Std. & Procedure

Project specification

ASTM SA-578

ASTM SA-578

Project Spec./ P.O. Description

Codes, Std. & Approved

Codes & Std

Project Spec./ P.O. Description ASME VIII

Project Spec./ P.O. Description Project specification / ASTM A380

Project Spec./Std.

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–101 Unfired Pressure Vessel & Columns (cont’d)

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N O T A C F T R E C

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

E C N E R E F E R

T N E M U C O D

t c e j o r P e c n e r e f e R

(

) n o i t a c i f i c e p s

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Project Spec./ Codes & Std.

SL. NO.

ACTIVITY

6.8 Hardness Test

6.9 Ferrite test

7. Preparation for Dispatch

7.1 Marking / Name Plate

P.O Spec., Std.

7.2 Cleaning, Preservation and Surface Treatment

P.O Spec., Std.

7.3

Preparation for Shipment and Packing with internal and external protection

P.O Spec., Std.

7.4 Compliance certificate by Manufacturer

7.5 National Board Registration certification

7.6

Inspection Release Note (IRN)

Project specification

8. Reports, Test Certificates & Vendor Data Book

8.1

Vendor Data Report (As specified by above activities)

Project specification

8.2

Raw Material Test Certificates (Compliance to all Project / PO inspection and testing requirements)

8.3

WIN / UTC / CMMSDATA Sheet (To Be Completed by Vendor wherever applicable)

8.4

Vendor Data Books endorsement, and issue of release note by TPA

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R O T C A R T N O C

ITP–102 Shell & Tube Heat Exchangers

SL. NO.

ACTIVITY

Scope

This list covers shell and tube heat exchangers to TEMA class “R”, refer to section “5” for the pressure containment parts e.g. shells, bonnets, channels etc.

1.1 Vendor approval

Pre-production/Pre-Inspection Meeting

3. General - Preliminary work

3.1 Data sheet

3.2 Bundle Calculations

3.3 GA and detail Bundle Drawing

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Applicable Project Spec., P.O. Description TEMA “R”

COMPANY Pre- qualification

Q

Applicable Project Spec., P.O. Description P.O Spec. TEMA “R” Applicable Project Spec., P.O. Description Codes, Std.

3.4 Vendor’s Fabrication Schedule

Production Plan

3.5 Vendor’s QA Plan

3.6 Sub-vendor approvals

3.7 Status of sub-orders

QA Manual

COMPANY Pre

Production Plan

3.8

3.9

Material test and certification Piping components SS, DSS and CRA shall conform to ITP-122 WPS and PQR for Tube Welding & Welding Cladding Procedure and Qualification, and Weld map

Applicable Project Spec., P.O. Description Codes, Std. & and Drawings

3.10 Qualified welders list

3.11 Tube Expansion Procedure specification (TEPS)

ASME Sec. VIII

3.12

Tube sheet expansion and tube sheet welding control and repair procedure

3.13

Procedures:

for welds, RT, NDT plates/cladded, MT, PT (including tube to tube sheet welds)

UT

Applicable Project Spec., P.O. Description Codes, Std. Applicable Project Spec., P.O. Description Codes & Std.

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R O T C A R T N O C

Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–102 Shell & Tube Heat Exchangers (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

3.14 Dished Head forming and NDE procedure

3.15 PWHT Procedures

3.16

3.17

3.18

3.19

3.20

Procedures for PMI, Ferrite, Hardness, Clad UT thickness check, as applicable Hydrostatic Test procedure (including draining, drying, cleaning around internals) Pneumatic test procedure (for attachments, etc.,) Painting and assembled exchanger interior surface protection procedures (for including CRA material, Cladded internal), as applicable Packing and Preservation and monitoring procedure

3.21 Nitrogen blanketing procedure

3.22 Baseline Survey procedure

3.23 Personnel Qualifications

Production

4.1 Material Traceability and Examination

4.2

4.3

Raw materials: HIC resistant materials for tube sheet, tube, shell, channel, baffle, nozzle, head, cover and ring. Raw material PMI and ferrite check for CRA and cladded on receipt of material

4.4

Fit-up of Long seam, Circular seam

4.5 Check MTC for tubes Eddy current tested

4.6

4.7

4.8

4.9

4.10

Fit-up of Main Components, Supports, Lifting Device etc. Tube sheet and its holes (including cleanliness, surface finish and tolerance, tube ends and Baffle Inspection Fit-up of Dished Head to Flange, and Shell to Tube sheets Tube Bundle Assembly inspection (inside visual condition of shell before insertion) U-Tube bundles for looseness of tubes in Bend area

4.11 Shell Internal Inspection

4.12 Tube Bundle insertion to shell inspection

Codes, Std.

Applicable Project Spec., P.O. Description Codes, Std.

Applicable Project Spec., P.O. Description Codes, Std. Project specification

Vendor Data Book

Project Spec., Codes, Std.

Approved Drawings

Approved Drawings

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–102 Shell & Tube Heat Exchangers (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

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L E V E L N O T N E V R E T N

I

I

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R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

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L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

4.13 Check clearance all around shell and tube sheet

4.14

4.15

Shell and tube sheet assembly / Flange management Production welding of all components

WPS / Drawings

4.16 Tube sheet expansion and welding

4.17

4.18

Tubes Extend from the front of the tube sheet check Tube expansion: Wall thickness reduction check (behind and in front of the tube sheet)

Approved WPS, project specification, procedures

4.19 PT on the tube-to-tube sheet weld

4.20 Heat Treatments

4.21 Final Machining

4.22 Bolting and Gasket

Examination

5.1 Visual and Dimensional Check

5.2 Non-Destructive Examination

5.3 Heat Treatment charts

5.4

Internal Visual inspection-pressure and non- pressure welds

5.5

Flange management

Applicable Project Spec., Codes & Std.

Drawings

Drawings

Applicable Project Spec., P.O. Description Codes, Std & Approved Procedure

5.6

5.7

Painting & Coating Examination (including test panel) Internal application

protection/inhibitor

corrosion

5.8 Code stamping

Testing

6.1

PMI, Ferrite (Where applicable)

6.2

HIC Test

6.3

Impact Testing

6.4

Leak test of U- Bundles after bend and weld

6.5

Helium leak testing – tube to tube sheet prior to hydrostatic test

6.6 Hydrostatic Test / Tube Test for Leaks

6.7

Pneumatic Test for attachments/RF pads

6.8

After Hydrostatic test: Internal Drying and cleaning

6.9

Baseline Survey

Applicable Project Spec., P.O. Description Codes, Std & Approved Procedure

Applicable Project Spec., P.O. Description TEMA Codes & Std

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–102

Shell & Tube Heat Exchangers (Cont’d)

I

N O T A C F T R E C

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

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R O T C A R T N O C

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L E V E L N O T N E V R E T N

I

Y N A P M O C

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L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

6.11 Hardness Test (including wetted parts)

6.12

Load Test and MT/PT (prior to and after testing)

Approved Procedure,

Preparation for Dispatch

7.1 Marking / Name Plate

TEMA &

7.2

Cleaning, Preservation and Surface Treatment P.O Spec., Std.&

7.3

Compliance certificate by Manufacturer

7.4

National Board Registration certification

7.5

Inspection Release Note (IRN)

7.6

Preparation for Shipment, Packing, handling, preservation and storage

Project specification

P.O Spec., Std.

Reports & Test Certificates & Vendor Data Books

8.1

Vendor Data Report

8.2

Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–103

Air Cooled Exchangers

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

SL. NO.

ACTIVITY

Scope This list covers air cooled exchangers to be used in hydrocarbon services only. Inspection and testing of fabricated pressure containment parts e.g. headers and associated pipe work will be covered by requirement for inspection by an COMPANY approved TPA. Acceptance of the exchanger will be by the TPA.

This procedure is not intended to define all the duties and responsibilities of the independent TPA as these are as stated in the code requirements, and to do so is to make them less than independent.

Nevertheless, for clarification, the following list details COMPANYs’ minimum requirements for air cooled heat exchanger inspection and certification, as some items (e.g. structures, painting, packing etc.) are additional to Code requirements.

1.1

Vendor approval

Pre-production/Pre-Inspection Meeting

General - Preliminary work

3.1

Data sheets

3.2 Drawings and Calculations

3.3

Vendor’s Fabrication Schedule

3.4

Vendor QA Plan

3.5

Sub-vendor approvals

3.6 Status of sub-orders

3.7

Material test and certification Piping components SS, DSS and CRA shall conform to ITP-122

3.8

Tube Welding or Welding Cladding Procedure and Qualification (WPS & PQR)

3.9 Qualified welders list

COMPANY Pre- qualification

Codes & Std

Production Plan

QA Manual

Production Plan

Applicable Project Spec., P.O. Description Codes, Std. & Applicable Project Spec., Design Codes, Std & Drawings

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ITP–103 Air Cooled Exchangers (Cont’d)

E C N E R E F E R

T N E M U C O D

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r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

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L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

General - Preliminary work (cont’d)

3.10 NDT Procedures

3.11 PMI, Hardness procedure

3.12 Noise level test procedure

Approved Project specification, procedures, Codes & Std.

3.13

Hydrostatic Test Procedure (including draining, dry-out and cleaning)

3.14 Helium leak test procedure

3.15 PWHT Procedures

3.16 Function /Shop Run in test procedure

3.17 Painting procedure

3.18 Galvanization procedure

3.19 Preservation procedure

Codes, Std. Approved Project Spec. and procedure /P.O. Description

3.20 Tube Expansion Procedure specification (TEPS)

ASME Sec. VIII

3.21 Baseline Survey Procedure

3.22 Personnel Qualifications

Production

Project specification

4.1 Material Traceability and Examination

Vendor Data Book

4.2

4.3

4.4

Fit Up of Main Components, Supports, Lifting Device etc. U bending of Tubes (check thinning and flattening, Heat treatment if required) Fin tubes manufacturing Tubes and fins material certificates Visual and dimension check

4.5

Check Tube wall thickness reduction after expansion

4.6

Internal visual inspection prior to insertion

Drawings

P.O Spec. Approved project specification, Drawings, Codes and Stds.

4.7

Tube assembly inspection

4.8

Tube Assembly and Insertion

4.9

Tube Expansion / Welding

4.10 Heat Treatments

4.11 Final Machining

4.12 Bolting and Gasket

Drawings

WPS/Weld Map and Assembly drawing

Codes & Std.

Drawings

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–103

Air Cooled Exchangers (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Examination

5.1

Visual Dimensional Check

5.2

Check Tube sheet holes, the tube ends and holes

5.3

shop-air test after tube-to-tube sheet welding

5.4

Non-Destructive Examination

5.5

Prior to welding, PT or MT on all edges and plate bevels prepared for welding

5.6

PT or MT on the root and final weld passes welds

5.7

Painting & Coating Examination

5.8

Steel Structures

5.8.1 Review material certificates

5.8.2

Check Hot-dip galvanization visual and thickness

5.8.3 Welding book review

5.8.4 NDE: MT, PT, RT, UT, as applicable

5.8.5

PT on the tube-to-tube sheet welded joints

5.8.6

Visual and dimension

5.8.7

U-Tube bundles bend area looseness check

5.8.8

Painting examination

5.8.9

Hot dip galvanizing inspection

5.8.10

Fire proofing application and PQT, as applicable

5.9

Bought out components, Motor, Vibration sensors, Fans etc.

5.9.1 Certification review

5.9.2

Visual Examination

Testing

6.1

6.2

PMI (Where applicable)

Hardness Test

6.3

Hydrostatic Test

6.4

After the final pressure test: Plug Joints and gasket joints air leak test

6.5

Leak testing for Tube to Tube sheet

P.O Spec. & Approved Drawings

Codes and Standards & Approved Procedure

Project Specification P.O Spec. Codes and std.

Project Specification P.O Spec. Codes & Sds.

Project Specification/ P.O Spec. & Codes & Std

Document No: AGES-SP-13-002

Rev. No: 01 Page 70 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–103 Air Cooled Exchangers (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

6.6 Thermal Performance Test, if Specified

6.7

Factory Acceptance Test (FAT) / Shop run test

6.8 Vibration and Noise level check

6.9

Baseline Survey

6.10 Load Test (MT/PT prior to and after test)

Approved Procedure,

Preparation for Dispatch

7.1 Marking / Name Plate

P.O Spec., Std.

7.2 Code stamping

7.3

Drying, Cleaning, Preservation and Surface Treatment (corrosion protection)

P.O Spec., Std

7.4

7.5

7.6

Compliance certificate by Manufacturer

Inspection Release Note (IRN)

Preparation preservation protection)

for Shipment- Packing and internal and external (with

P.O Spec., Std

7.7

Inspection Release Note (IRN)

Project specification

8. Reports & Test Certificates & Vendor Data Books

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed by Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 71 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–104

Shop Fabricated Pipe Work

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Scope

These lists are applicable to pipe work shop- fabricated to the requirements of applicable ANSI B31.3 / B31.1.

Sub-Contractor approval

ANSI B31.3

COMPANY Pre- qualification

SL. NO.

1

Pre-production/Pre-Inspection Meeting

3. General - Preliminary work

3.1 Status of sub-orders

Production Plan

3.2

Drwgs. & isometrics/drawings

Calculations,

and

Baseline

CP-00

3.3 Vendors Fabrication Schedule

Production Plan

QA Manual

Codes, Std. & Design Codes, Std & Drawings

3.4 Vendors Quality Plan

3.5

Material test and receiving inspection)

certification

(Material

3.6 Welding Procedure (WPS& PQR)

3.7 Qualified welders list

3.8 Pre-Fabrication and welding procedure

3.9

GRE Piping Bonding/lamination procedure

Pre-fabrication

and

3.10 Repair Welding procedure

3.11 Painting procedure

3.12 Hot dip galvanizing procedure, if applicable

Project specification

3.13 Fire Proofing procedure

3.14 Flange Management procedure

3.15

Instrument, Measuring and Test Equipment (IMTE) Procedure

3.16 Material Procurement procedure

3.17 NDT Procedures

3.18 PWHT Procedures

Codes & Std.

Codes, Std.

Document No: AGES-SP-13-002

Rev. No: 01 Page 72 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–104 Shop Fabricated Pipe Work (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

General - Preliminary work (cont’d)

3.19

Hydro test, Sensitive leak test (If applicable) Procedure

3.20 Personnel Qualifications

3.21 Procedure for spool identification

Codes, Std.

3.22

Calculation for reinforced branch connection or pipe to pipe

3.23

Materials /equipment Storage, Packing and preservation procedure

3.24 Baseline survey procedure

Production

Codes, Std.

Codes, Std. manufacturer specification/ data sheet Project specification

4.1

Material (receiving inspection)

Traceability

and

Examination

Vendor Data Book

4.2

Fit Up

4.3

Production Welding

4.4

GRE Lamination/Bonding

4.5 Heat Treatments

4.6

Lining and Coating/painting

4.7

Pickling and Passivation ; Ferroxyl testing

Examination

5.1

Visual Dimensional Check

WPS / Weld Map and Assembly drawing

Codes & Std.

Codes & Std.

Project specification / ASTM A380

P.O Spec. & Approved Drawings

5.2

Non-Destructive Examination

5.3

UT Technique approval on the job (simulation)

5.4

Mechanical testing - If Specified in PO.

Codes & Std.

5.5

Bolts/studs torqueing, Hydraulic tensioning, as applicable; visual examination of Gaskets

5.6

Special Test as Required e.g. HIC

Examination (cont’d)

5.7

Painting & color coding including PQT

5.8

Hot-dip galvanizing and testing

Project spec.

Document No: AGES-SP-13-002

Rev. No: 01 Page 73 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–104

Shop Fabricated Pipe Work (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

5.9 Passive Fire Proofing application and

testing including PQT

Testing

6.1

PMI (Where applicable)

6.2

Ferrite check (where applicable)

6.3

Hydrostatic Test

Pneumatic test (if applicable)

6.5

Baseline Survey

6.6

Hardness Test

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Codes & Std

Codes, Std.

Codes & Std.

6.7

Load Test (Where applicable)

Approved PRO,

Preparation for Dispatch

7.1

7.2

Marking, Tagging/Stress marking & Color Coding

free permanent

Cleaning, Treatment, and end protection

Preservation

and

P.O Spec., Std

Surface

7.3

Bevel Protectors/ End caps

7.4

Preparation for Shipment and Packing

P.O Spec., Std

Project specification

7.5

Inspection Release Note (IRN)

Reports & Test Certificates

8.1

Vendor Data Report

8.2

Raw Material Test Certificates

8.3

WIN/UTC/CMMSDATA Sheet (To Be Completed By Vendor Wherever Applicable)

8.4 Vendor Data Books by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 74 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–105 Weldable Structural Steel Material

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Project Spec., P.O. Description Codes & Std.

COMPANY Pre- qualification

SL. NO.

ACTIVITY

Scope

This list covers weldable structural steel material (plates, welded tubular, seamless tubular, rolled & hollow sections).

1.1 Vendor approval

Pre-production/Pre-Inspection Meeting

General - Preliminary work

3.1 Vendor Manufacturing Schedule

3.2 Vendor QP

3.3 Status of sub orders

3.4

Material Test Certificates: Raw material Mill Test certificate review Visual Inspection and traceability Chemical Analysis, mechanical tests NDT reports

Prod. Plan

QA Manual

Prod. Plan

Project Spec., P.O. Description, Codes, Stds. &

3.5 Welding Procedure & PQR Where Applicable

Project Spec., P.O. Description Codes, Stds, Drawings,

3.6 Qualified Welder List Where Applicable

3.7 NDT Procedures

3.8 PWHT Procedure

Project Spec., P.O. Description Codes & Std.

3.9

Forming (Cold and Hot) and Heat treatment procedure

3.10 Weld Repair procedure

3.11

Shipping, procedure

storage and preservation

3.12 Non-conformance control procedure

3.13 Personnel Qualification

3.14

Tubular Specification (MPS)

Manufacturing

Procedure

3.15

Manufacturing Testing Record (MPQT)

Procedure Qualification

Project Spec., P.O. Description

Document No: AGES-SP-13-002

Rev. No: 01 Page 75 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–105 Weldable Structural Steel Material (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

Production Plates Only

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

)

l

b

i l

(

4.1 Plates Manufacturing Procedure Qualification

Approved MPS

4.2 Sampling, Chemical Analysis (Cast & Product)

4.3 Heat Treatment

4.4 Marking Test Samples & Test Specimens

4.5 Mechanical Test

4.6 Calibration of UT equipment

4.7 Visual Examination

4.8 Dimensional Inspection

Approved MPS, Codes & Stds.

Approved PRO, Codes & Stds.

Project Spec., P.O. Description Codes & Stds.

4.9

4.10

Marking (Stenciling, Color Coding, Die Stamping for TPA, Shipping Mark) Documents including Laboratory Tests, NDT Records etc.

Certificates,

Mill

Project Spec., P.O. Description Codes & Stds

5. Production Welded Tubulars (Including Piles, Cans & Legs) Only

5.1 Calibration of UT Equipment at plate inspection

5.2 Chemical Analysis Records (Cast & Product)

5.3 Steel plate mill certificates & NDT records

Project Spec., P.O. Description Codes & Stds.

5.4 Visual Inspection of Plates & Material traceability

5.5

Tubular Manufacturing Procedure Qualification (Forming, Welding, Testing)

Codes, Stds & Certificates

Approved MPS

5.6 WPS, PQR

5.7 Welder Qualification

5.8 Cold forming of tubulars

5.9

Fit-up of weld alignment)

joints (edge preparation,

Welding, Repair Welding

5.10

5.11 Check dimension and ovality

Project Spec., Approved Procedures, Codes, Stds.

Document No: AGES-SP-13-002

Rev. No: 01 Page 76 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–105 Weldable Structural Steel Material (Cont’d)

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

Production Welded Tubulars (Including Piles, Cans & Legs) Only (cont’d)

5.12 PWHT

Calibration of UT equipment (Welded seams & Tubular Ends)

Approved Procedures

5.13

5.14 UT, RT & MPI

5.15 Radiographic films

5.16 Marking Test Samples & Test Specimens

5.17 Mechanical Tests

5.18

Visual & Dimensional Inspection including Bevel ends: bevel angle, root face

5.19 Measuring Tubular Length

P.O. Description Approved project spec. Procedures, drawings Codes, Stds.

5.20

Marking (Stenciling, Color Coding, Die Stamping for TPA, Shipping Mark)

5.21 Bevel Protector (If Any)

P.O. Spec.

5.22

5.23

5.24

5.25

Any other necessary Inspection & test as per ( PO ?…..) Dimension, visual, marking, packing and Final inspection Endorsement of Documents including Mill Certificates, Laboratory Tests, NDT Records etc. CONTRACTOR Inspection Release Note (IRN)

Production Seamless Tubular only

6.1 Raw Material

6.2

6.3

6.4

6.5

Procedure

Manufacture

Tubular Qualification (MPQT) Material Receiving Inspection Visual inspection Material certificates Dimensional inspection Chemical Analysis Records (Casts & Product), deoxidation method and formability Manufacturing process Visual and dimensional inspection Heat Treatment MPQT sampling / marking test coupon a. chemical analysis b. Mechanical testing & impact test

Approved project spec. Procedures, drawings

Project specification

Codes & Stds.

Approved procedure

Project Spec., P.O. Description Codes & Stds.

Document No: AGES-SP-13-002

Rev. No: 01 Page 77 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–105 Weldable Structural Steel Material (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

SL. NO.

ACTIVITY

Production Seamless Tubular only (cont’d)

6.6 Calibration of NDT Equipment

NDT Performance: Check Full body UT by longitudinal and transverse for laminar imperfections. Pipe ends Manual UT (if not scanned by automatic UT equipment)

6.7

6.8 Marking Test Samples & Test Specimens

6.9

Visual (Including Bevel)

&

Dimensional

Inspection

6.10 Measuring Tubular Length

6.11

Marking (Stenciling, Color Coding, Die Stamping for TPA, Shipping Mark)

6.12 Bevel Protector

P.O. Spec.

6.13

6.14

Any other necessary Inspection & test as per Endorsement of Documents including Mill Laboratory Tests, NDT Certificates, Records etc.

6.15 Inspection Release Note (IRN)

Production Rolled Sections & Hollow Sections

7.1

7.2

7.3

Raw Material Material Receiving Inspection Visual inspection Material certificates Dimensional inspection Manufacture Procedure Specification (MPS) Qualification Manufacturing process Visual and dimensional inspection Heat Treatment NDT Check Full body UT by longitudinal and transverse for laminar imperfections. Manual UT for ends (if not scanned by automatic UT equipment)

7.4 Visual Inspection

7.5 Dimensional Inspection

Codes & Stds.

Approved procedure

Project Spec., P.O. Description Codes & Stds.

Document No: AGES-SP-13-002

Rev. No: 01 Page 78 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–105 Weldable Structural Steel Material (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Production Rolled Sections & Hollow Sections (cont’d)

7.6

Mechanical Tests: MPQT sampling /marking test coupon a. chemical analysis b. Mechanical testing c. Impact testing

P.O. Description Project Spec., Codes & Stds.

7.7 Length Measurement

7.8

Marking (Stenciling, Color Coding, Die Stamping for TPA, Shipping Mark)

Codes & Stds.

7.9

Endorsement of Documents including Mill Certificates, Laboratory Tests, NDT Records etc.

Project specification

7.10 Inspection Release Note (IRN)

Preparation for Dispatch

8.1 Marking & Tagging

8.2 Protection for Shipment and storage

8.3

Vendor Data Books endorsement, and issue of release note by TPA

P.O Spec., Std.&

P.O Spec., Std.&

Document No: AGES-SP-13-002

Rev. No: 01 Page 79 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–106

Structural Steel Work Fabrication

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

ACTIVITY

Scope

This list covers general fabricated structural steel work

Vendor / Sub-Contractor approval

Pre-production/Pre-inspection Meeting

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

E C N E R E F E R

T N E M U C O D

SP-,

AWS D1.1, EEMUA 158 COMPANY Pre- qualification

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q. P

3.3 Status of sub orders

3.4 Material test and certification

3.5

3.6

Procedures for Fabrication and associated activities

Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR)

3.7 Qualified welders list

3.8 NDT Procedures

3.9 PWHT Procedures

3.10 Personnel Qualifications

3.11 Baseline Survey procedure

4. Production

4.1

4.2

4.3

4.4

4.5

plates, Walkways,

Material Traceability and Examination Material receiving inspection Fit-up, Size & Root run For Main members, Sole Platforms, Bridges, Jackets, Ladders, Openings, and Drain holes. Production Welding Repair welding NDE operator demonstration for T, K, Y Joints (with mock-up joints) Stage-wise inspection release for trial assembly

Production Plan

QA Manual

Production Plan

, Codes, Std. &

Project specification, Design Codes, Std & Drawings

Codes & Std.

Codes, Std. &

Project specification,

Vendor Data Book

WPS/Drawin gs, Project specification, Codes, Std.

Document No: AGES-SP-13-002

Rev. No: 01 Page 80 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–106 Structural Steel Work Fabrication (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

4.6

Trial Fit-up and assembly (before and after welding) inspection

4.7 Final Dimensional check by surveyor

4.8 As-Built drawings

WPS/Drawings , Project specification, , , Codes, Std.

4.9

Fire proofing / Painting (including PQT and production test panel)

, Codes & Std.

4.10

4.11

Bolting management

Weighing of structural assembly prior to load out

Project specification

5. Examination

Order specification and Approved Drawings

Codes & Std.

Project specification,

HSE-100, Codes, Std.

P.O Spec., Std.& Project specification Project specification, P.O Spec., Std.&

5.1 Visual and Dimensional Check

5.2 Non-Destructive Examination

5.3 Baseline survey (offshore structures)

5.4

5.5

Painting and Fire proofing Examination (including PQT) Load testing / NDE of Pad-eye as applicable (before and after load test)

6. Preparation for Dispatch

6.1 Marking & Tagging

6.2

Inspection Release Note (IRN)

6.3

Protection for Shipment, and sea fastening and loadout (as applicable)

7. Reports & Test Certificates

7.1 Vendor Data Report

7.2 Raw Material Test Certificates

7.3

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 81 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–107

Valves for Pipelines and Process Units

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

Scope

test and

list covers

inspection This requirements (at vendor premises only) for isolation valves and check valves used in pipelines and process units. The type of these Valves are: Gate Valves Ball Valves Check Valves Butterfly Valves. Globe Valves Triple Offset Butterfly Valves Plug Valves

1.1 Vendor approval status

3.1

Pre-production/Pre-inspection Meeting

General - Preliminary work

COMPANY Material Specification Sheet. (If applicable)

3.2 Data sheet

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Project Spec., P.O. Description COMPANY

COMPANY Pre- qualification

Ref. Drawing

Project Spec., Design Codes & Std

3.3 Vendor’s Fabrication Schedule

Production Plan

3.4 Vendor QA Plan

3.5 Status of sub-orders

3.6

Check Material test and certification for chemical analysis, mechanical properties, and traceability of: Body, closure, Ball, Stem, Trunnion, Gland, seat units, seat insert, springs, O- rings, stem spacer, Flange and fittings drain and vent valves.

3.7 Non-pressure parts and fasteners

3.8

overlay Welding

Procedure CRA Qualification and Welders Qualification (WPS and PQR)

3.9 NDT Procedures (MT, PT, RT, UT)

3.10

Procedure for CRA overlaying and thickness measurement

QA Manual

Production Plan

Codes, Std &

Project Spec., P.O. Description, Design Codes & Std

Document No: AGES-SP-13-002

Rev. No: 01 Page 82 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–107

Valves for Pipelines & Process Units (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

3.11 Impact Test for LTCS

3.12 PMI, Hardness survey procedure

3.13 Valve Drawings (Dimensions & Materials)

3.14

Hydrostatic Pressure Test procedure

test and Pneumatic Low-

3.15 Body and Seat Gas leak test

API 6A

3.16 Open/close cycling dynamic pressure test

API 6A

3.17 Functional Test procedure

3.18 Fugitive emission test procedure

3.19 Torque Test procedure

3.20 Cavity Relief Test procedure

3.21 Antistatic test procedure

3.22 Fire proof test procedure

3.23 Drift Test procedure (full bore valves only)

3.24

Procedure for valve Dry-out, cleaning and rust prevention coating

3.25 Surface preparation and Painting procedure

3.26 Fire Safe Certification

Project specification, API 6D, API 6A, API 6DSS API

Project specification, API 607

3.27

FE, FM/UL, ATEX/IP certification ( as applicable)

Project specification

4. Production

4.1 Material Traceability and Examination

4.2 Body & Bonnet

4.3

Trim, Ball, seats, gates & Plugs

4.4

CRA weld overlay at seal housing area (seal between body – cover and body – bonnet)

4.5

PT and PMI on overlay surfaces

4.6

Corrosion Testing, Weld overlay UT thickness measurement

4.7 Heat Treatments

Project specification, GA drawing

Project specification, GA drawing

Project Specification

.

Document No: AGES-SP-13-002

Rev. No: 01 Page 83 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–107 Valves for Pipelines & Process Units (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

4. Production (cont’d)

4.8 Gasket surface

4.9

4.10

4.11

Hardness Test including those on RTJ grooves, as applicable Flanges, Bolting, Gasket Packing, etc. Actuators & operators (if required), the inspection requirements of test and Pneumatic and Hydraulic Actuators are covered by ITP-213 and ITP-214 for Motorized Actuators.

Examination

Project Spec., P.O. Description

5.1

5.2

Visual Dimensional Check Valve body thickness verification Non-Destructive Examination (UT, RT, MT, PT, PMI)

including

Project Spec., P.O. Description

Testing

6.1

PMI (Where applicable)

6.2

Hydrostatic Test & Pneumatic test: (Body & Seat including low pressure air test)

6.3 Strip down test

6.4

a. Fire Proof Test

b. Antistatic test

6.5 Hardness Test

6.6

Functional Test (with or without actuator) (if with Actuator, refer to ITP 223)

6.7

Pneumatic Low-Pressure Test

6.8 Body gas test and seat gas test

6.9 Dynamic cycling open/close pressure test

6.10 Load Test (Where applicable)

Codes & Std

BS EN 12266 / API 598 Project specification BS EN 12266

Codes & Std.

Codes & Std

Project Spec., P.O. Description Project Spec., P.O. Description Codes & Std., Project specification, Data sheet

Document No: AGES-SP-13-002

Rev. No: 01 Page 84 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–107 Valves for Pipelines & Process Units (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Project spec. API 6A, API 6D, API 6DSS COMPANY Stds.

Project Spec., P.O. Description &

Project specification

SL. NO.

ACTIVITY

Testing (cont’d)

6.11 Fugitive Emission Type test

6.12 Fugitive Emission Test (production test)

6.13 Torque Test

6.14 Cavity Relief Test

6.15 For Piggable valves (Drift Check)

6.16

Gear Box: number of turns shall not exceed 80 (N/A for actuated valves)

6.17

Final visual and dimensional inspection of valve and actuator assembly

7.1

Surface Preparation (including PQT panel) inspection

and

painting

7.2

Valve internal Dry-out, cleaning and rust prevention coating

7.3

7.4

Marking / Name Plate & Tagging, marking Flow direction and actuator orientation

Preparation for Shipment -Packing and preservation

7.5

Inspection Release Note (IRN)

Reports & Test Certificates

8.1 Vendor Data Report

8.2

8.3

Raw Material Test Certificates and final documentation approval Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 85 of 285

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/19588

Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–108

Safety Relief Valves

SL. NO.

ACTIVITY

Scope

list covers

This inspection requirements (at vendor premises only) for safety relief valves

test and

1.1 Vendor approval status

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Project Spec., P.O. Description

COMPANY Pre- qualification

3.1

Pre-production/Pre-inspection Meeting

General - Preliminary work

COMPANY Material Specification Sheet. (If applicable)

Ref. Drawing

3.2 Vendor’s Fabrication Schedule

3.3 Vendor QA Plan

3.4 Status of sub-orders

3.5 Material test and certification

Prod. Plan

QA Manual

Prod. Plan

3.6 Drawings & Data Sheets

3.7

procedure

Welding specification (WPS)and Procedure qualification record (PQR)

3.8 Valve Testing procedure

Codes, Std & Project Spec., P.O. Description

3.9 NDE procedure

3.10 PMI procedure

3.11

Surface procedure

preparation

and

Painting

3.12 Shipping and preservation procedure

4. Production

4.1

Material Traceability and chemical and mechanical properties of: Body, bonnet, Nozzle, disc, spring

4.2

Flange rating & surface finish

4.3 Orifice design & area

4.4 Heat Treatments & hardness check

4.5 Bellows & spring

4.6 Resilient seals

4.7 Alignment of springs & carriers

4.8 Bolting & Gasket

Document No: AGES-SP-13-002

Vendor Data Book, project specification

Project Spec., P.O. Description Codes & Std Project Spec., P.O. Description

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

Rev. No: 01 Page 86 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–108 Safety Relief Valves (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

4. Production (cont’d)

4.9

Pilot Valve

4.10

Surface preparation and painting, including PQT and production test panel.

5. Examination

5.1 Visual and Dimensional Check

5.2 Non-Destructive Examination

6. Testing

Project Spec., P.O. Description

6.1

PMI (Where applicable)

Codes & Std

6.2 Hydrostatic Test

6.3 Bellow tightness (back pressure) test

6.4 Seat tightness test

6.5 Bonnet tightness test

6.6

Set pressure test / Air pressure test (pop up test)

Project Spec., P.O. Description API 526 & API 527

6.7

Load Test (Where applicable)

Approved PRO,

Preparation for Dispatch

7.1

Surface Preparation and painting visual, DFT, colour code

7.2 Marking / Name Plate & Tagging

7.3

Preparation storage and preservation

for Shipment, Packing,

7.4 ASME Code Stamping

7.5

Inspection Release Note (IRN)

Project Spec., P.O. Description & ASME VIII

Project specification

Reports & Test Certificates & Vendor Data Books

8.1 Vendor Data Report

Project spec.

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed Vendor Wherever Applicable) Vendor Data Books, approval and issue of inspection release note by TPA

By

Document No: AGES-SP-13-002

Rev. No: 01 Page 87 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–109 Weld Overlay Pipes, Flanges and Fittings

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

list covers

Scope This inspection requirement for Weld Overlay Pipes with UNS N06625.

test and

Vendor approval

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5

3.6

Welding Procedure Qualification including repair welding & Welder Qualification NDT Procedure & NDT Qualification

Personnel

3.7 Leak Test Procedure

3.8

3.9

Manufacturing Drawings Pickling and Passivation, and Painting Procedure review

3.10 PMI Procedure review

HIC Testing Procedure

Project Spec. P.O. Description

COMPANY Pre- qualification

Project Spec. P.O. Description,

Prod. Plan

QA Manual

Prod. Plan

Project Spec. Codes, Std &

Project Spec. P.O. Description Codes & Std

4. Production, Inspection & Testing

4.1 Receipt inspection of Carbon Steel Pipes

4.1 Pipe Material Traceability and Examination

4.1.1

Verification of Pipe Mill Certificates and Tally Sheets

4.1.2 Verification of Traceability Markings

4.1.3 Inspection of physical Condition/packing,

4.1.4 Visual and Dimensional Checks

4.2

Receipt Consumables

inspection

of

Welding

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Document No: AGES-SP-13-002

Rev. No: 01 Page 88 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–109 Weld Overlay Pipes, Flanges and Fittings (Cont’d)

SL. NO.

ACTIVITY

4.3 Verification of Process Variables

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

4.3.1

4.3.2

WPS/PQR approval against corresponding base material to be used in production. Review and consumables Certificates.

of welding

disposition

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

E V E L N O T N E V R E T N

R O D N E V

I

E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

E V E L N O T N E V R E T N

Y N A P M O C

I

E V E L N O T N E V R E T N

4.3.3 Review and disposition of welding gases. WPQ/WOPQ qualification for validity and range qualified.

4.3.4

4.3.5 Control of inter-pass temperature

4.3.6

4.3.7

Valid calibration records of instrument used for product / process measurement. Verify manufacturing requirements of weld overlay pipe requirements.

for compliance

to client

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards ASTM G48 ASTM A 923 ASTM A 380

4.4 Surface Preparation

4.5

Pre-machining at Ends

4.6 CS Wall Thickness Survey by UT

4.7 Weld Overlay

4.8

Chemical Analysis including Fe content and PREN

4.9 Corrosion Tests (method as applicable)

4.10 Visual Inspection

4.11 Ultrasonic Testing for Disbondment

4.12 Radiographic test

4.13 Ultrasonic Testing – CRA Thickness

4.14 CRA Thickness Inspection

4.15 Liquid Penetrant Testing 100%

4.16 Weld Repair (If required)

4.17 Pipe end preparation

4.18

Liquid Penetrant Testing of machined surface

4.19 Hydrostatic Testing

4.20

Positive Material Identification (PMI) and Ferrite content on each component

4.21

Hardness Test (on the HAZ at unmixed zone and on weld overlay)

4.22 Dimensional Inspection

Document No: AGES-SP-13-002

Rev. No: 01 Page 89 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–109 Weld Overlay Pipes, Flanges and Fittings (Cont’d)

SL. NO.

ACTIVITY

4.3 Verification of Process Variables (Cont’d)

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

4.23

Surface (Pickling, passivation and ferroxyl test)

Treatment

Cleaning

and

ASTM A 380

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

4.24 Final Visual Inspection

Project Spec.

4.25 End protection, Rust Prevention, Marking,

Project spec.,

4.26 Color coding, and Storage

5. Preparation for Dispatch

5.1

5.2

Punch clearance inspection and Quality records review

Visual component Marking, checks

dimensional

and

checks,

5.3

Packing inspection and marking control of all goods

Inspection Release Note (IRN)

5.4 Manufacturing Record Book

6. Reports & Test Certificates

6.1 Vendor Data Reports

6.2 Raw Material Test Certificates

Project Spec. P.O. Description & Approved Drawings, procedures, International Codes & Standards

Vendor Document Requirement List

6.3

6.4

vendor

WIN/UTC/CMMS data sheet completed by Applicable) Vendor Book endorsement, and Issue of Release Note by TPAA

(to be (Wherever

Inspection

Data

Document No: AGES-SP-13-002

Rev. No: 01 Page 90 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–110

Flanges, Forgings Including Hub Connectors & Fittings

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

list covers

Scope This inspection requirement (at vendor premises only) for carbon, alloy, stainless-steel & CRA flanges forgings including hub connectors and fittings to relevant ASTM & BSI Standards.

test and

Vendor approval status

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Data sheets and GA drawings

3.2 Vendor’s Fabrication Schedule

3.3 Vendor QA Plan

3.4 Status of sub-orders

3.5 Raw Material test and certification

Project Spec./P.O. Description

COMPANY Pre- qualification

Production Plan

QA Manual

Production Plan Project spécification

Codes, Std &

3.6

Welding Procedure Qualification and Welders Qualification for CRA weld overlay

Design Codes & Std.

3.7 Manufacturing Procedure Specification

3.8 NDE Procedure (MT, PT, UT), as applicable

3.9 NDE personnel approval

3.10 Heat Treatment procedure

3.11 Hardness Testing procedure

3.12 Impact test procedure

3.13 HIC Test Procedure

3.14 Rust prevention painting procedure

3.15

Marking, Packing, Handling, preservation, shipping and storage procedure

3.16 HIC Test Certificates for Sour Service

Project specification, , codes and Stds.

Document No: AGES-SP-13-002

Rev. No: 01 Page 91 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–110

Flanges, Forgings Including Hub Connectors & Fittings (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

SL. NO.

ACTIVITY

4. Production

4.1

Raw Material Traceability, chemical and mechanical visual Examination

properties

and

4.2 Forging and Heat treatment

4.3 Hardness testing on rough forging

4.4

4.4.1

4.5

4.6

Manufacturing procedure qualification test (MPQT) Chemical analysis and Mechanical testing (per heat and heat per batch) Flange groove pre-machining (prior to weld overlay) and UT check, as applicable RTJ Groove welding (CRA overlay), as applicable

4.7 Final machining

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Vendor Data Book

Project specification, approved procedure, Codes &Std

4.8 Heat Treatments & Hardness check

4.9 HUB Clamps Hot dip Galvanizing

Codes & Std

Project specification

4.10 HUB clamp Painting

4.11 HUB seal ring - PTFE coating

4.12

Flange, Forging and fitting rust preventive coating

5. Examination

5.1

5.2

Visual and Dimensional Check (Verify ID for Pipeline Bends, Barred tee etc.) Formed Fittings Thickness check after forming

5.3 Non-Destructive Examination (MT, PT, UT)

5.4

5.5

5.6

5.7

5.8

5.9

Production hardness testing including RTJ groove PMI, grain size, Ferrite, Corrosion tests (as applicable) HUB seating area and seal ring Hardness check Hub connector Bolting Galvanizing) HUB Clamp painting visual and DFT check (ensure area to be left unpainted as per vendor to Compact Flanges and HUBs) HUB Seal Ring PTFE coating DFT, Adhesion test, cure test and final visual check

recommendation

(Hot Dipped

applies

Project specification

ASME Sec. V

Document No: AGES-SP-13-002

Rev. No: 01 Page 92 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–110 Flanges, Forgings Including Hub Connectors & Fittings (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

SL. NO.

ACTIVITY

6. Testing

6.1

PMI (Where applicable)

6.2 HIC testing per Heat, as applicable

6.3

Hydrostatic Test (if applicable) / Proof Burst Test

6.4

Impact Tests (Material type, location, method, sample size)

6.5 Load Test (Where applicable)

Preparation for Dispatch

7.1

Painting & Surface Preparation, Protective coating, end covers and packaging

7.2 Marking & Tagging

7.3

Preparation for Shipment, Packing and preservation coating and storage

7.4

Inspection Release Note (IRN)

Reports & Test Certificates & Vendor Data Books

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 93 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–111

Expansion Bellow

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

ACTIVITY

Scope

list covers

This requirement for Expansion Bellow.

test and

inspection

Vendor approval status

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Drawing & Specification

3.2

COMPANY Material Specification Sheet (If applicable)

3.3 Vendor Production Schedule

3.4 Vendor QA/Plan

3.5 Status of Sub Orders

3.6 Material Test & Certificates

3.7

3.8

Welding Procedure Qualification & Welder Qualification (if applicable) NDT Qualification (If applicable)

Procedure & NDT

Personnel

3.9 Test Procedures

4. Production

4.1 Bellow & Ring Manufacture

4.1.1 Identify Material & check Mill Certificates

4.1.2 Longitudinal weld Fit up

4.1.3 Roll Convolution

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Project Specification. P.O. Description COMPANY Pre- qualification

Drawing & Specification Approved Drg & Spec.

Prod. Plan

QA Manual

Prod. Plan

Codes, Std. & Project Specification . P.O. Description Design Codes & Std.

Approved Drg./Project Specification. P.O. Description/ Certificates Approved Drg./Project Specification. P.O. Description/ WPS Project Specification. P.O. Description,

Document No: AGES-SP-13-002

Rev. No: 01 Page 94 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–111 Expansion Bellow (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

4.2 Flange & Pipes

4.2.1 Identify Material & check Mill Certificates

4.2.1 Butt weld Fit up in Gimble Pipe

4.3 Hinge Restrains & Keeper Plates

4.3.1 Identify Material & check Mill Certificates

4.4 Tie Bar Assemblies

4.4.1 Identify Material & check Mill Certificates

4.5 Sleeve Manufacturing

4.5.1 Identify Material & check Mill Certificates

4.5.2 Butt weld Fit up in sleeve tube

4.6 Assembly

Approved Drg, Project Specification. Mill Certificates Approved Drg./Project Specification. WPS

Approved Drg. Project Specification. Certificates

Approved Drg. Project Specification. P.O. Description/ Certificates

Approved Drg. Project Specification. Certificates Approved Drg. Project Specification. WPS

4.6.1 Fit up Attachment Pipe to Flange

4.6.2

4.6.3

Fit up bellow to flange & pipe assembly and sleeve to pipe Fit up hinge & gimble assemblies, and support lug on to center pipe

Approved Drg. Project Specification. WPS

5. Examination

5.1

5.2

5.3

Visual & dimensional Bellow & Ring prior to assembly. Visual & Dimensional Flange & Pipes prior to assembly. Visual& Dimensional Hinge Restrain & Keeper Plate prior to assembly.

Approved Drg. Project Specification. WPS

Document No: AGES-SP-13-002

Rev. No: 01 Page 95 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–111

Expansion Bellow (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

5. Examination (Cont’d)

5.4

Visual & Dimensional Sleeve prior to assembly.

5.5 Visual & Dimensional Final Assembly

5.6

5.7

X-Ray bellow longitudinal butt weld prior to forming X-Ray bellow longitudinal butt weld in gimble pipe

5.8 MPI of fillet weld of pipe to Flange

5.9 DP Bellows attachment welds

5.10

MPI of load bearing fillet weld of hinge & gimble assemblies

6. Testing

6.1 Hydro Testing

7. Preparation for Dispatch

7.1 Marking

7.2 Cleaning, Preservation

7.3

Preparation for Shipment & Packing and storage (Including immobilizing)

7.4 Inspection Release Note (IRN)

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

Vendor Data Book approval and Issue of Release Note by TPA

Approved Drg. Project Specification, Procedure, WPS

Approved Test Procedure, Project Spec.,

Project Specification. Drawing

Project Specification.

Project specification

Project spec. and procedure

Document No: AGES-SP-13-002

Rev. No: 01 Page 96 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–112

Sacrificial Anodes

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

SL. NO.

1

ACTIVITY

Scope

list covers

This requirement for Sacrificial Anodes.

test and

inspection

Vendor approval status

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Drawing & Specification

3.2

COMPANY Material Specification Sheet (If applicable)

3.3 Vendor Production Schedule

3.4 Vendor QA/Plan

3.5 Status of Sub Orders

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

E C N E R E F E R

T N E M U C O D

Project Specification. P.O. Description COMPANY Pre- qualification

Drg & Spec.

Approved Drg & Project Specification. P.O. Description

Prod. Plan

QA Manual

Prod. Plan

3.6 Material Test & Certificates

Codes Std. &

3.7

3.8

Welding Procedure Qualification & Welder Qualification (if applicable) NDT Procedures & NDT Personnel Qualification (If applicable)

3.9 Test Procedures

3.10 MPS

4. Production

4.1

Raw Material Traceability and examination – Aluminium and steel insert

4.2

4.3

Al. Element: chemical analysis by spectra every melt Steel Core chemical and mechanical properties

4.4 Insert Preparation

Project Specification. Design Codes & Std.

Vendor Data Book & Material Test Certificates Approved WPS, NDT Procedure, Project Specification. Description, Approved Drg

Document No: AGES-SP-13-002

Rev. No: 01 Page 97 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–112 Sacrificial Anodes (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

4. Production (Cont’d)

4.5 Anode Casting

5. Examination

5.1 Visual

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Project Specification. Drawings

5.2 Dimension and straightness check

5.3 Non-Destructive Examination

5.4 Surface Preparation for Anode Insert

Project Spec. Approved Drawings

5.5 Anode Weight

6. Testing

6.1

6.2

Destructive Testing – every anode type and size (sampling)

Short Term Voltage Test/Open circuit Potential – 1 sample/melt

6.3 Short term capacity test – 1 sample/melt

Project Spec. Approved Drawings

Project Spec, MPS

6.4 Electro Chemical Test

7. Preparation for Dispatch

7.1 Marking

7.2 Cleaning, Preservation

7.3

Preparation Shipment and storage

for

Handling,

7.4 Inspection Release Note (IRN)

Project Spec. Drawing

packing,

Project Spec.

Project specification,

8. Reports & Test Certificates & Vendor Data Books

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

specification

8.3

Vendor Data Book approval, and Issue of Release Note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 98 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Project Spec. P.O. Description API 650, COMPANY Specifications

ITP–113

Storage Tanks

SL. NO.

ACTIVITY

Scope

This list covers the inspection and test requirements in a Contractor’s works for Storage Tanks designed and constructed in accordance with API 650 or any other recognized Codes. Inspection and testing will be covered by the requirements for inspection by an COMPANY approved TPA. Acceptance of the Tanks will be by the TPA. This procedure is not intended to define all the duties and responsibilities of the independent TPA as these are as stated in the code requirements, and to do so is to make them less than independent. Nevertheless, for clarification, the following minimum list requirements for Storage Tanks inspection and certification, as some items (e.g. painting) Code requirements.

COMPANY’s

additional

details

are

to

Sub-contractor / Vendor approval status

Pre-production/Pre-inspection Meeting

1

3. General - Preliminary work

3.1

COMPANY Material Specification Sheet (If applicable)

3.2 Vendor Production Schedule

3.3

Data sheets Drawings approval

,Design Calculations and

3.4 WPS /PQR Approval

3.4.1 Review of pre-qualified WPS & PQR

3.4.2

Procedure qualification and Lab testing for new procedure Qualifications (WPS & PQR)

API 650, Project Spec. P.O. Description

Prod. Plan

API 650, D. Sheets, Project Spec. Approved Drg.

API 650 ASME Sec-IX Project Spec. P.O. Description

Document No: AGES-SP-13-002

Rev. No: 01 Page 99 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–113 Storage Tanks (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

3.5.1

Approval of qualified welders

3.5.2

3.6

3.7

Visual qualification

inspection and approval of welders

Vendor QA/Plan

Status of Sub Orders

3.8

Material Test & Certificates

3.9

NDT Procedure & NDT Personnel Qualification

3.10

PWHT procedure (as applicable for nozzles)

3.11

Painting and internal lining Procedure

3.12

Base Line survey procedure

3.13

3.14

Under Tank leak detection sensor calibration and installation procedure

All other relevant procedure, construction method statement etc.

Fabrication & Examination

4.1

Material Receiving Inspection

4.1.1

Steel Plates for shell, roof and bottom,

4.1.2

Prefabricated nozzle spools, piping spools and Pipes, Fittings, flanges,

4.1.3

Tank bottom Leak detection sensors

4.1.4

Structural Steel, Bolt & Nuts, All other miscellaneous items

4.2

Foundation

4.2.1

Civil material Inspection and Approval (Cement, Sand Aggregate, Crushed stone ring wall material, fill material, Erosion Protection, Geotextile, Base Course Bedding material, Water, Clean sand beneath the tank bottom etc.)

4.2.2

Sample test for supplied material

4.2.3

Trial Mix design (as applicable)

4.2.4

Sub grade preparation and related testing

4.2.5

Filling work and related testing

4.2.6

Final surface inspection

4.2.7

Levelness Check of ring beam / sloping of sand fill

E C N E R E F E R

T N E M U C O D

QA Manual

Prod. Plan

Project Spec. P.O. Description, Codes, Std. &

Project Spec. P.O. Description, Codes & Std. API 650

API 650, Data sheet Project Spec. P.O. Description, Approved Drawings

API 650 Project Spec. P.O. Description, Approved Drawings

Document No: AGES-SP-13-002

Rev. No: 01 Page 100 of 285

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/19588

Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–113 Storage Tanks (Cont’d)

SL. NO.

ACTIVITY

4.2.8

Dimension & Orientation

4.2.9

Foundation release from Civil

E C N E R E F E R

T N E M U C O D

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

4.2.10

4.2.11

4.3

Installation of Sumps and pipes below the tank bottom CP systems installation in conjunction with leak detection Fabrication Inspection for Nozzles, manholes, Sump and Cleanout Fittings (where applicable) in the Shop (Cont.’d)

4.3.1

Visual & Dimensional Inspection

API 650 Project Spec. P.O. Description, Approved Drawings, PRO

4.3.2 MT, PT & RT, if applicable

4.3.3

PWHT Record Review, if applicable

4.3.4

4.3.5

Surface Preparation & Painting, applicable

if

Water fill Installation

testing of Sump before

API 650 Project Spec. P.O. Description, Approved Drg, PRO,

4.4

Inspection for Annular Plate & Central Sketch Plates, Sumps

4.4.1

Dimensional inspection for overlap (plate to plate), Slope, Offset of three lap joints.

4.4.2 Weld visual inspection

4.4.3

RT Film Review

4.4.4

Vacuum Testing

API 650 Project Spec. P.O. Description, Approved Drawings, PRO

4.4.5

Hardness Test (if applicable)

4.4.6

MT or PT after removal of all temporary attachment weld area

4.5

Marking of the Internal Radius on Annular Bottom plates

4.5.1

Visual & Dimensional Test (Marking of Inner / outer Radius)

Approved Drawings

4.6

Inspections on Shell Plate

4.6.1

4.6.2

Dimensional inspection for Plumbness, Roundness and Levelness, Staggering / offset of shell vertical joints Fit-up of horizontal and vertical joints before welding

API 650 Project Spec. Approved Drawings, Procedures

Document No: AGES-SP-13-002

Rev. No: 01 Page 101 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–113

Storage Tanks (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

SL. NO.

ACTIVITY

4.6.3

MT/ Visual inspection after back gouging to ensure sound metal before welding the second side

4.6.4 Visual Inspection of shell joints welds

4.6.5

MT or PT after removal of all temporary attachment weld area

4.6.6 RT Film Review

4.6.7 Hardness Test (if applicable)

4.6.8

Peaking (vertical weld joints) and bending (horizontal weld joints) dimensional test on vertical and horizontal joints

E C N E R E F E R

T N E M U C O D

Project specification, Approved Drawings, Procedures

4.7 Inspection for Roof Plate, Top Girder Roof Structure and Roof to Shell joint

4.7.1

4.7.2

4.7.3

4.7.4

4.7.5

tightness of

Fit-up and visual Inspection for Roof Trusses / Structure and roof plates Weld visual inspection of roof plates, roof structure Bolt applicable Vacuum or Pressure Testing for roof plate welds & roof to shell plate welds, where applicable MT or PT after removal of all temporary attachment weld area

trusses where

roof

API 650 Project Spec. P.O. Description, Approved Drawings, Procedures

4.8 Internal Piping and Heating Coil Installation as applicable

4.8.1 Fit-up and dimensional Inspection

4.8.2 Weld visual inspection

4.8.3 RT Film review (where applicable)

4.8.4 MT or PT (where applicable)

4.8.5 Hydro testing of Heating coils

4.9 Nozzles and Manholes installation

4.9.1

Fit-up and dimensional location, projection of nozzles & manholes

Inspection

for

4.9.2 Weld visual inspection of nozzles & manholes

4.9.3 Air leak Testing of RF Pads, where applicable

4.9.4

4.9.5

MT or PT of nozzle/manhole welds (where applicable) MT or PT after removal of all temporary attachment weld area

4.9.6 Hardness Test (if applicable)

API 650 Project Spec. P.O. Description, Approved Drawings, Procedures

API 650 Project Spec. P.O. Description, Approved Drawings, Procedures

Document No: AGES-SP-13-002

Rev. No: 01 Page 102 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–113

Storage Tanks (Cont’d)

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

4.10 Welds of Bottom to Shell

4.10.1

Fit-up and dimensional Inspection shell to bottom joint

4.10.2 Final Survey for Verticality

4.10.3 Weld visual inspection

4.10.4

Shell to bottom joint Oil penetration test (Inside)

4.10.5 Shell to bottom joint MT/PT test (Outside)

4.10.6

MT or PT after removal of all temporary attachment weld area

API 650 Project Spec. P.O. Description, Approved Drawings, Procedures

4.11 Appurtenance, Name plate bracket, External/Internal attachments

4.11.1 Fit-up and dimensional Inspection

4.11.2 Weld visual inspection

4.11.3 MT or PT (where applicable)

API 650 Project Spec. Approved Drawings, Procedures

4.12 Positive Material Identification for SS Tank works

4.12.1

4.12.2

Positive Material Identification Procedure demonstration Positive Material material at ware house (where applicable)

Identification of bulk

4.12.3 Positive Material Identification of welds

API 650 Project Spec. Approved Drawings, Procedures

Final Inspection

5.1

5.2

5.3

inspection

completeness

Final for for installation of pressure, Non-pressure, appurtenances on inside, outside tank Final visual inspection on tank bottom plates for erection damages / incomplete welds and internal cleanliness Tank Bottom Installation check Under tank leak detection Sensor calibration report check

leak detection

sensors

5.4 Walk down before clearance for hydro test

6. Hydro test, Base Line & Coating

6.1 Water Filling Test

6.2 Air leak test of roof joint during hydrotest

6.3 Settlement Check of Foundations

6.4

Tank Bottom Leak detection (by drain pipe) check

Document No: AGES-SP-13-002

API 650 Project Spec. Approved Drawings, Procedures

API 650 Project Spec. P.O. Description, Approved Drawings, Procedures

Rev. No: 01 Page 103 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–113 Storage Tanks (Cont’d)

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

6.5 Base Line survey

6.6

Coating Inspection including Internal Glass flake lining (Including PQT) (separate ITP for painting

Approved Procedure

7. Double Deck assembly (External Floating roof)

7.1

7.2

7.3

7.4

Fit up inspection of double deck roofs lap joints and internal assemblies (Bulkhead Rim plates, pontoon compartments Visual inspection of weld of pontoon compartments and rim plates joints, double deck roofs lap joints Leak testing of compartment weld and deck seams Deck accessory items installation (Deck support still well & accessory installation

legs,

API 650 Project Spec. P.O. Description, Approved Drawings, Procedures, Weld Map API 650 Project Spec. P.O. Description, Approved Drawings, Procedures

8. Hydro test of external floating Roof Tank

8.1

Leak Detection Test for Lower Deck Plate Joints

8.2 Leak Test for shell joints above water level

8.3 Leak Test for Roof Drain Pipe

8.4 Floatation Test

Tank Calibration (Gauging)

API 650 Project Spec. P.O. Description, Approved Drawings, Procedures

Tanks clearance for Box up

internal

inspection

after

11. Punch clearance and Tank Box up

12. Preparation for Handover

12.1 Marking / Name Plate

12.2

Cleaning, Treatment

Preservation

and

Surface

12.3 Preparation for Shipment and Packing

API 650 Project Spec. P.O. Description, Approved Drawings, Procedures. a Separate ITP Shall Be Prepared for Coating as Applicable

Document No: AGES-SP-13-002

Rev. No: 01 Page 104 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–113

Storage Tanks (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

12.3 Inspection Release Note (IRN)

Project specification

13. Reports & Test Certificates

13.1

Vendor Data Report (As specified by above activities)

13.2 Raw Material Test Certificates

Project Spec.,

13.3

Vendor Data Books endorsement, and issue of release note by TPA

Project Spec.,

Document No: AGES-SP-13-002

Rev. No: 01 Page 105 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–114

Column Internals

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

E V E L N O T N E V R E T N

R O D N E V

I

E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

E V E L N O T N E V R E T N

Y N A P M O C

I

E V E L N O T N E V R E T N

SL. NO.

1

ACTIVITY

Scope

list covers

This requirements for Column Internals.

test and

inspection

Sub-contractor / Vendor approval status

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Data sheets and drawings

3.2 Vendor fabrication schedule

3.3 Vendor Q.P

3.4 Status of sub orders if any

3.5 Material test and certification

3.6

3.7

3.8

Welding Procedure Qualification & Welder Qualification NDT Qualification Manufacturer procedures

Procedure & NDT

inspection and

Personnel

testing

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description, Standards

COMPANY Pre- qualification

Project Spec. P.O. Description, Standards,

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description, Stds,

3.9 Painting Procedure, if applicable review

3.10 PMI Procedure review

4. Material Receiving

4.1 Visual & Dimensional Check

4.2 Raw material Mill Certificate Check

5. Fabrication & Examination

5.1 Punching

5.2 Bending

5.3 Welding

5.4 NDT if any

5.5 Ferrite Test as applicable

5.6 Verify fit up

Project Spec. PApproved Drgs,

Documents,

Codes & Stds.

Project Spec. Approved Drgs

Documents,

Codes & Stds.

Document No: AGES-SP-13-002

Rev. No: 01 Page 106 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–114 Column Internals (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

6. Final Inspection

6.1 Trial Assembly & Marking

6.2

Visual & Dimensional Check for Internal S, Hardware, Spare Parts & Tools of any

6.3 Hardness

6.6 PMI

7. Preparation for Dispatch

7.1

7.2

7.3

7.4

Punch clearance inspection and Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Shipment packing, preservation and storage condition

7.5 Manufacturing Record Book

7.6

Inspection Release Note (IRN)

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed Vendor Wherever Applicable) Vendor Data Books endorsement and, issue of release note by TPA

by

Project Spec. P.O. Description & Approved Drgs

Documents, International Codes & Stds.

Project Spec. P.O. Description & Approved Drgs

Documents,

Codes & Stds.

Project specification

As per Approved Vendor Document Requirement List (VDRL)

& DST-003 Part 1

Document No: AGES-SP-13-002

Rev. No: 01 Page 107 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–115

Emergency Diesel Generator

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Project Spec. P.O. Description, Standards

COMPANY Pre- qualification

Project Spec. P.O. Description, Standards,

Prod. Plan

QA Manual

Prod. Plan

SL. NO.

1

ACTIVITY

Scope

list covers for

This requirements Generator.

test and

inspection Emergency Diesel

Sub-contractor / Vendor approval status

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders if any

3.4 Material test and certification

3.5 Manufacturing Drawings

3.6 Packing & Preservation Procedure

Examination

(NDE)

and

Project Spec. procedures, , Codes & Stds.

Procedures Specification

3.7

3.8

3.9

Non-Destructive Procedures Weld Qualification Records Surface Procedure

preparation

and

Painting

Inspection and Test Procedure

3.11 FAT Procedure

4. Production, Inspection & Testing

4.1 Material receiving Inspection

4.1.1

Engine, Alternator, Radiator, Noise attenuated DG enclosure inspection

4.1.2 Instrumentation calibration certificate

4.2 Engine

4.2.1 Full Load Speed 1500 RPM

4.2.2 Engine Power Step Load

4.2.3 Fuel Rate Measurement

Project Spec. Approved Drgs

Documents, International Codes & tds.

Project Spec. Approved

Drgs,

Codes & stds

Document No: AGES-SP-13-002

Rev. No: 01 Page 108 of 285

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/19588

Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–115

Emergency Diesel Generator (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

SL. NO.

ACTIVITY

4.2.4 Oil Pressure Measurement

4.2.5 High Idle Check Measurement

4.2.6 Governor Test Maker Spec.

4.3 Generator

4.3.1 Visual & Construction Inspection

4.3.2

No load test - Magnetic curve (Incl. over speed)

4.3.3 Measurement or Temperature rise

4.3.4 Waveform deviation and distortion factor

Project Spec. P.O. Description & Approved Drgs/

4.3.5

4.3.6

Voltage response with sudden change Sudden three phase short-circuit test at residual voltage

load

Documents, International Codes & Stds.

4.3.7 Calculation reactance Xd & Xd’

4.3.8 Insulation test

4.3.9 High Voltage test

4.3.10 Noise Test

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & Stds

4.4 Emergency Generator Set (Assembled Engine and Alternator With the Panel 1st Vender Shop)

4.4.1 Visual & Construction Inspection

4.4.2 Starting Test (Startup Time)

4.4.3 Performance Test (Load Test)

4.4.4 Voltage Regulation Test

4.4.5 Frequency Regulation Test

4.4.6 Governor Test

4.4.7 Voltage Adjustment Range Measurement

4.4.8 Safety Device Test

4.4.9 Vibration measurement

4.4.10 Painting inspection DFT, Adhesion

Document No: AGES-SP-13-002

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & Stds

Rev. No: 01 Page 109 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–115

Emergency Diesel Generator (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

4.5 Control Panel

4.5.1 Visual & Construction Inspection

4.5.2 Insulation resistance test

4.5.3 Wiring check

4.5.4 Protection circuit

4.5.5 Function test

4.5.6 Painting Inspection

4.6 Fuel Tank

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & Stds

4.6.1 Pre-weld Fit up Inspection

4.6.2

Final Weld/NDE (MT) for Skid Base Lifting Eyes

4.6.3 Dimensional Check

4.6.4 Pressure Test for Skid Base Fuel Tank

4.6.5

Surface Preparation Contamination)

(Roughness/Salt

4.6.6 Painting Inspection DFT, Adhesion

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & Stds.

4.7 Enclosure/Acoustic panels

4.7.1 Welding Inspection

4.7.2 Visual and Dimensional Check

4.7.3

Surface Preparation (Roughness/Salt Contamination)

4.7.4 Painting Inspection DFT, Adhesion

4.7.5

Fire Proof/Surface Preparation (Salt Contamination)

4.7.6 Fire Proof/Welding Inspection

4.4.7 Fire Proof Painting Inspection (DFT)

4.8 CO2 System

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & Stds

4.8.1

Functional test for the CO2 suppression system as well as F &G detection system

4.8.2 CO2 Dump Test

4.8.3

Final Inspection for the CO2 Suppression Skids

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & Stds

Document No: AGES-SP-13-002

Rev. No: 01 Page 110 of 285

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/19588

Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–115

Emergency Diesel Generator (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

4.9

Radiator

4.9.1

Surface Preparation (Roughness/Salt Contamination)

4.9.2 Painting inspection DFT, Adhesion

4.9.3 Hydrostatic Inspection

4.9.4 Visual and Dimensional Check

4.10 Silencer (2500kW)

4.10.1

Surface Preparation (Roughness/Salt Contamination)

4.10.2 Painting inspection DFT

4.10.3 Visual and Dimensional Check

Preparation For Dispatch

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & Stds

Project Spec. P.O. Description & Approved Drgs, Codes & Stds

5.1

5.2

5.3

5.4

and

dimensional

Punch clearance inspection and Quality records review Visual checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

5.5 Manufacturing Record Book

5.6

Inspection Release Note (IRN)

Reports & Test Certificates

6.1

Vendor Data Report

6.2

6.3

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor Wherever Applicable)

Vendor Data Books endorsement and, issue of release note by TPA

Project Spec. P.O. Description & Approved Drgs, Codes & Stds.

Project specification

As per Approved Vendor Document Requirement List (VDRL)

Document No: AGES-SP-13-002

Rev. No: 01 Page 111 of 285

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/19588

Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

L E V E L

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–116

Flare Package

SL. NO.

1

ACTIVITY

Scope

list covers

This test and requirements for Flare Package.

inspection

Sub-contractor / Vendor approval status

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

Data sheet

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders if any

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Project Spec. P.O. Description, Standards,

Project specification

Prod. Plan

QA Manual

Prod. Plan

3.4

Material test and certification procedure (permanent and welding consumables)

Project Spec. Stds,

3.5 GA and Manufacturing Drawings

3.6 Packing & Preservation Procedure

3.7

3.8

3.9

Examination

Non-Destructive Procedures Weld Procedures Specification Qualification Records (WPS & PQR) Surface preparation Procedure

and

(NDE)

and

Painting

3.10 Inspection and Test Procedure

3.11 FAT Procedure

4. Production, Inspection & Testing

4.1 Procurement

4.1.1

Review of Material test certificate and consumable batch certificate

4.1.2

Material Identification and Traceability and chemical and mechanical properties analysis (including welding consumables)

4.1.3 PMI verification on material receipt

Project Spec. P.O. Description, Codes & Stds.

Project Spec. P.O. Description, Approved Drgs

Documents, International Codes & Stds.

Document No: AGES-SP-13-002

Rev. No: 01 Page 112 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–116 Flare Package (Cont’d)

SL. NO.

ACTIVITY

4.2 Sonic Tip

4.2.1 Weld Prep and fit-up

4.2.2 Production welding per WPS

4.2.3 Visual inspection of Welds

4.2.4

Production welding and PT on hot pass and on all final welds (100%)

4.2.5 RT 100% Butt Welds

4.2 Sonic Tip (Cont.’d)

4.2.6 UT Full Penn Branch Arm Welds

4.2.7 PT 100% Fillet Welds

4.2.8 Visual & Dimensional inspection after FAB

4.2.9 Positive Material Identification and ferrite

4.2.10 Hardness Testing of Weld

4.2.11 Hydro Test – Pilot Manifold

4.2.12

Pickle & Passivation of Tip, and ferroxyl test

4.3 Pilots

4.3.1 Weld Prep and fit-up

4.3.2 Production welding per WPS

4.3.3 PT on hot pass (100%)

4.3.4 Visual inspection of Welds

4.3.5 PT on all final welds (100%)

4.3.6 Fabrication. Trial Fit up

4.3.7

Visual & Dimensional inspection after fabrication

4.3.8 Positive Material Identification and ferrite

4.3.9 Hardness Testing of Welds

4.3.10 Pickling & Passivation and ferroxyl test

E C N E R E F E R

T N E M U C O D

I

N O T A C F T R E C

I

I

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & stds

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & stds

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & Stds.

Project specification, Codes & Std ASTM A 380

Document No: AGES-SP-13-002

Rev. No: 01 Page 113 of 285

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/19588

Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–116 Flare Package (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

4.4 Continuum Ignitors

4.4.1 Weld Prep and fit-up

4.4.2 Production welding per WPS

4.4.3 PT on hot pass (100%)

4.4.4 Visual inspection of Welds

4.4.5 PT 100% on all final welds

4.4.6 Fabrication. Trial Fit up

4.4.7

Visual & Dimensional inspection after fabrication

4.4.8 Positive Material Identification and ferrite

4.4.9 Hardness Testing of Welds

4.4.1 0

Pickling & Passivation and ferroxyl test

4.5 Ignition Controls

4.5.1 Check Explosion Proof Certificates

4.5.2

Verify Electrical components, pressure transmitters, actuators (Including fire front Flame Generator)

4.5.3 Fabrication. Trial Fit-up

4.5.4

4.5.5

Visual & Dimensional inspection after FAB circuit Control panel assembly and wiring inspection

4.5.6

surface preparation and painting

4.5.7

Paint Inspection including DFT test, PQT and production test panel

4.5.8 Factory Acceptance Test

4.6 Structural Control Stand

4.6.1 Weld Prep and fit-up, and welding

4.6.2 Visual inspection of Welds

4.6.3 Fabrication. Trial Fit up

4.6.4

Visual & Dimensional inspection after fabrication

4.6.5 PT Lifting Lug Welds

4.6.6

Surface preparation and painting, including PQT and production test panel

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Project Spec. P.O. Description, Approved

Drgs,

International Codes & Stds

ASTM A 380

Project Spec. P.O. Description & Approved

Drgs/

International Codes & Stds

Project Spec. Approved Drgs/ International Codes & Stds

Project Spec. Approved Drgs/ International Codes & Stds.

Document No: AGES-SP-13-002

Rev. No: 01 Page 114 of 285

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/19588

Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–116 Flare Package (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

4.6 Structural Control Stand (cont’d)

4.6.7

Paint Inspection including DFT test and Adhesion Test.

Preparation for Dispatch

5.1

Punch clearance inspection and Quality records review

5.2

5.3

5.4

and

Visual checks, component Marking, serial number, tag number and Name Plate checks

dimensional

Packing inspection and marking control of all goods, including spare parts

Inspection Release Note issuance Verification of Punch list clearance

E C N E R E F E R

T N E M U C O D

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

Project Spec. P.O. Description & Approved

Drgs,

International Codes & Stds

5.5 Manufacturing Record Book

5.6

CONTRACTOR Inspection Release Note (IRN)

Project specification

Reports & Test Certificates

& approved Vendor Document Requirement List

6.1 Vendor Data Report

6.2

WIN / UTC / CMMS DATA Sheet (To Be Vendor Wherever Completed Applicable)

By

6.3

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 115 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–117

Glass Flake Lining

I

N O T A C F T R E C

I

I

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

ACTIVITY

Scope

list covers

This requirements for Glass Flake Lining.

test and

inspection

Sub-contractor / Vendor approval status

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders if any

Material test and certification; Lining material selection per service temperature

3.4

3.5

3.6

Glass Flake Lining application and repair, and related Procedures review Glass Procedure Qualification Test (PQT) procedure

3.7

Inspection and Test Procedure

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Project Spec. P.O. Description, Standards,

Prod. Plan

QA Manual

Prod. Plan Project Spec. P.O. Description, Stds,

Project Spec. Approved Drgs, Codes & Stds.

4. Pre-qualification, Production, Inspection & Testing

4.1 Equipment inspection

Material Receiving Inspection: Minimum specifications glass flake filled coating/lining as per ISO 16961, Table 2. Fibre glass lining system as per ISO 16961, Table 2. Qualification tests shall be carried out on representative test plates as the same procedure, system and thickness

4.2

4.3

Project specification ISO16961 Drgs, manufacturer

Data sheet ISO 16961,

Document No: AGES-SP-13-002

Rev. No: 01 Page 116 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–117

Glass Flake Lining (Cont’d)

I

N O T A C F T R E C

I

I

y b y d o b n o i t a c i f i t r e C

r e r u t c a f u n a M

) e l b a c i l

p p a

s a (

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

PQT shall be same the method of coating, repairs and stripping of defective

4.4

4.5 Surface Preparation for Production

4.5.1

Abrasive Material check for cleanliness (Vial test) and independent lab test for soluble chloride and conductivity.

4.5.2

Cleanliness of Compressed Air (Blotter Test)

Project Spec. P.O. Description & Approved Drgs/

Substrate shall be high pressure fresh water wash with or without emulsifying agent.

Documents, International Codes & stds

Abrasive blast cleaned using grit or garnet. Ambient conditions check to be recorded at least 3 times daily at regular intervals Substrate Condition to be checked for manufacturing or handling defects after blast cleaning Prepared surface to be re-blasted if not coated, within 4 hours of blasting or if visible rusting is evident Prior to coating, surfaces to be rendered free of dust and grit by blowing off with clean dry air - internal Surface cleanliness Salt Contamination Testing One test per Shift (Tanks as per )

check,

profile

level

and

Dust Level Testing One test per Shift

Project Spec. Approved Drgs/

Documents, Codes & stds

ISO 16961

4.5.3

4.5.4

4.5.5

4.5.6

4.5.7

4.5.8

4.5.9

4.5.10

4.5.11

4.6 Coating

4.6.1

4.6.2

Application of compatible and suitable for services primer Application shall be by airless spray, brush or roller. Stripe coat on weld area.

4.6.3 Application of Poly-glass

4.6.4

Application equipment with motorized lance.

shall be airless pump

Project Spec.

ISO 16961 Approved Drgs/ Codes & Stds

Document No: AGES-SP-13-002

Rev. No: 01 Page 117 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–117

Glass Flake Lining (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

E V E L N O T N E V R E T N

R O D N E V

I

E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

E V E L N O T N E V R E T N

Y N A P M O C

I

E V E L N O T N E V R E T N

E C N E R E F E R

T N E M U C O D

Project Spec.

ISO 16961 Approved procedures, Drgs, Codes & Stds

SL. NO.

4.6.5

4.6.6

4.6.7

4.6.8

4.6.9

4.6.10

ACTIVITY

flake

Application to nozzles and awkward areas Caulking compound shall be applied on weld seams, lap joints to provide uniform gradual transition Application by brush, trowel or scraper blade Ambient conditions check to be recorded at least 3 times daily at regular intervals lining shall be applied Glass minimum in two (2) coats or more to specified thickness, but one coat of glass flake or reinforced vinyl ester to minimum DFT of 750 mm Coating which did not meet over coating intervals shall be abraded by abrasive paper or sweep blasting’ prior to application of further coat. A sample production test coupon shall be prepared simultaneously and tested (with date of application)

4.7 Testing Procedure Qualification on Test Plate

4.7.1

Visual inspection

4.7.2

Thickness measurements (SSPC-PA 2)

4.7.3

4.7.4

4.7.5

Holiday pin hole detection test (NACE SP0188) Destructive testing:

1. Adhesion test (ASTM D4541),
2. Hardness test (ASTM D 2583)
3. Bending test (ASTM D522): Machine bending guides with upward and lining downward PQT and certification by Glass Flake Lining manufacturer

endorsement

reports

lining

Project Spec. , ISO 16961 Approved Drgs/ Codes & Stds

4.8 Testing for Production

4.8.1

The DFT of coats/lining shall be measured

4.8.2

Visual inspection to be carried out for defects

4.8.3

Holiday pin hole detection Test - high voltage spark type holiday detector

4.8.4

Curing hardness test - barcol hardness tester

Project Spec. , ISO 16961 SSPC-PA-2 NACE SP0188 ASTM D2583 Codes & Stds

Document No: AGES-SP-13-002

Rev. No: 01 Page 118 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–117 Glass Flake Lining (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project Spec.

ISO 16961 SSPC-PA-2 NACE SP0188 ASTM D2583 Codes & Stds

Project Spec. P.O. Description & Approved Drgs, Codes & Stds.

Project Spec. Approved Drgs/ ISO 16961 Codes & Stds

and approved Vendor Document Requirement List

SL. NO.

ACTIVITY

4.8 Testing for Production

4.8.5

Adhesion test - prepared sample plate during the application immersing sample plate in water (60 °C) for 24 h or represent the different service liquid and actual immersion conditions

4.9 Repairs

4.9.1

4.9.2

4.9.3

4.9.4

Pinholes and areas with low DFT shall be repaired by using brush / trowel - Coated Area with pinholes throughout lining Areas in excess of 100mm x 100mm shall be repaired by spray. Areas less than 100mmx100mm shall be repaired by hand. Repair areas shall be re-tested with holiday detector as per clause 4.6.3

Preparation for Dispatch

5.1

5.2

5.3

Punch clearance inspection and Quality records review Visual and component Marking, checks Packing inspection and marking control of all goods

dimensional

checks,

5.4 Manufacturing Record Book

Stage Inspection Release Note (IRN)

Reports & Test Certificates

6.1 Vendor Data Report

6.2 Material Test Certificates

6.3

6.4

By

WIN / UTC / CMMS DATA Sheet (To Be Completed Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 119 of 285

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/19588

Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–118

GRE Piping & Fittings

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

ACTIVITY

Scope

list covers

This requirements for GRE Piping & Fittings.

test and

inspection

Vendor approval status

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders if any

3.4 Material test and certification

3.5 Manufacturing Drawings where applicable

3.6 Packing & Preservation Procedure

3.7

3.8

Examination

Non-Destructive Procedures Bonding Procedures Specification and Qualification Records where applicable

(NDE)

3.9 Surface preparation and coating Procedure

3.10

Inspection and Test Procedure (Burst test etc.)

4. Production, Inspection & Testing

4.1

Review of Report & Potable Water Certification

4.1.1 Coefficient of Thermal Expansion Test

4.1.2 Tensile Test of Pipes

4.1.3 Diametrical Crushing of Pipes

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Project Spec. P.O. Description, Standards,

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description, Stds,

Project Spec. P.O. Description, Codes & Stds.

Project Spec. Approved procedures,

Drgs

International Codes & Stds.

Document No: AGES-SP-13-002

Rev. No: 01 Page 120 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–118 GRE Piping & Fittings (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Production, Inspection & Testing (cont’d)

4.1.4 Potable Water Certification

4.2 Raw Material Testing

4.2.1

Refractive Index of Epoxy Resin- Hardener Mix

4.2.2 Viscosity of Epoxy Resin

4.2.3

4.2.4

4.2.5

Resin Gel Time, Cure Time and Peak Temperature Glass Fibres:

• Moisture content
• Size/Binder content
• Tex properties C-Glass Veil & W/R Mat:
• Moisture content
• Size/Binder content and density
• Gms. / Sq. Mt.

4.3 Design Qualification Test

4.3.1

Long Term Hydrostatic Strength Test (HDB), Maximum Hoop Strength & Pressure Rating & 1000 hr survival tests

4.3.2 Prototype test for Flanges

4.3.3

Pipe Stiffness (Specific Tangential Initial Stiffness of Pipe)

4.3.4

Beam Bending Modulus Test (Beam Strength)

4.3.5

Short Term Rupture Strength Test of Pipe, Joint & Flange (Hydrostatic Strength)

4.3.6

Short Term Rupture Strength Test of Elbow (Hydrostatic Strength)

4.3.7

Short Term Rupture Strength Test of Tee (Hydrostatic Strength)

4.3.8

Joint Integrity Test

project specification BS EN ISO 14692

project specification BS EN ISO 14692 ASTM D 2105-01

4.3.9

4.3.10

Long – Term Hydrostatic test one representative size Axial tensile modulus of elasticity and ultimate axial tensile strength

ASTM D 2992

ASTM D 2105-01

Document No: AGES-SP-13-002

Rev. No: 01 Page 121 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–118

GRE Piping & Fittings (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

4.4

Production Testing/Inspection

4.4.1

4.4.2

4.4.3

Degree of curing (Tg-Value) DSC Method Water Absorption test: 24 hours Water immersion fittings (Destructive test) Loss-on-ignition test:- Structural Glass Content of Pipe (Destructive test)

test pipes and

4.4.4 Barcol Hardness

4.4.5 Dimensional Control

4.4.6 Visual Inspection (Appearance)

4.4.7

Specific Tangential Initial stiffness test of pipe

4.4.8 Axial Tensile strength of the pipe

E C N E R E F E R

T N E M U C O D

Project specification BS EN ISO 14692 ASTM D 570 ASTM D 2587

project specification BS EN ISO 14692 ASTM D 638

4.4 Production Testing/Inspection (Cont.’d)

4.4.9

Hydrostatic Pressure Test of pipes and Testable (Flanged/Flanged)

Fittings

spools

/

4.4.10 Polyurethane Top Coat Measurement

4.4.11 Short Term Rupture Strength Test

4.5

Testing Equipment Calibration

Preparation for Dispatch

5.1

5.2

5.3

5.4

and

dimensional

Punch clearance inspection and Quality records review Visual checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

5.5 Manufacturing Record Book

5.6

Inspection Release Note (IRN)

project specification BS EN ISO 14692

project specification BS EN ISO 14692

Project specification,

Document No: AGES-SP-13-002

Rev. No: 01 Page 122 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–118 GRE Piping & Fittings (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

Reports & Test Certificates

6.1

Vendor Data Report

6.2

6.3

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

E C N E R E F E R

T N E M U C O D

Approved Vendor Document Requirement List

Project specification

Company std.

Document No: AGES-SP-13-002

Rev. No: 01 Page 123 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–119

GRVE- RTR Pipes & Fittings

SL. NO.

1

ACTIVITY

Scope This requirements Fittings.

list covers

test and

inspection for GRVE- RTR Pipes &

Vendor approval

Pre-production/Pre-inspection Meeting Key Design Documents shall be submitted and and by CONTRACTOR prior to Pre-production Meeting

COMPANY

approved

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders if any

3.4 Material test and certification

3.5 Manufacturing Drawings where applicable

3.6 Packing & Preservation Procedure

3.7

3.8

Examination

Non-Destructive Procedures Bonding Procedures Specification and Qualification Records where applicable

(NDE)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Project Spec. P.O. Description,

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description, Codes & Stds. BS EN 14692

3.9 Surface preparation and coating Procedure

3.10 Inspection and Test Procedures

4. Production, Inspection & Testing

4.1 Raw Material Testing

4.1.1 Viscosity of Resin

4.1.2

4.1.3

4.1.4

Resin Gel Time, Cure Time and Peak Temperature Glass Fibres:

• Moisture content
• Size/Binder content
• Tex properties C-Glass Veil & W/R Mat:
• Moisture content
• Size/Binder content
• Gms. / Sq. Mt.

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & Stds.

Document No: AGES-SP-13-002

Rev. No: 01 Page 124 of 285

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/19588

Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–119 GRV- RTR Pipes & Fittings (Cont’d)

SL. NO.

ACTIVITY

4.2 Production Testing/Inspection

4.2.1

4.2.2

4.2.3

4.2.4

Specific Tangential Initial Stiffness (STIS) of Pipe (DN ≥ 80 mm) (Destructive Test) Axial Tensile Strength of Pipe (DN ≥ 80 mm) (Destructive Test) Hoop Tensile Strength of Pipe (DN ≥ 80 mm) (Destructive Test) Loss-on-ignition test: - Structural Glass Content of Pipe (Destructive test)

4.2.5 Barcol Hardness

4.2.6 Dimensional Control

4.2.7 Visual Inspection (Appearance)

4.2.8 1000 hr survival tests

4.2.9

4.2.10

4.2.11

fittings/spools

Hydrostatic pressure test of pipes and testable (Flanged/Flanged) Long – Term Hydrostatic test one representative size Axial tensile modulus of elasticity and ultimate axial tensile strength

4.3 Testing Equipment Calibration

Preparation For Dispatch

5.1

5.2

5.3

5.4

dimensional

Punch clearance inspection and Quality records review Visual checks, and component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

5.5 Manufacturing Record Book

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & stds

ASTM D 2992 ASTM D 2105-01

Project Spec. Approved Drgs

Documents,

5.6

Inspection and Release Note (IRN)

Project Spec.

Reports & Test Certificates

6.1 Vendor Data Report

6.2

6.3

By

WIN / UTC / CMMS DATA Sheet (To Be Vendor Wherever Completed Applicable) Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

Rev. No: 01 Page 125 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–120

Insulating Gasket Kits

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

ACTIVITY

Scope

list covers

This requirements for Insulating Gasket Kits.

test and

inspection

Vendor approval

Pre-production/Pre-inspection Meeting Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Data sheet

3.2 Vendor fabrication schedule

3.3 Vendor Q.P

3.4 Status of sub orders if any

3.5 Material test and certification

3.6

NDT Qualification if applicable

Procedure & NDT

Personnel

3.7

Inspection & Test Procedure review

3.8 Hardness and PMI Procedure review

4. Production, Inspection & Testing

4.1 Raw material receiving inspection

4.2

Material Testing: a. Material test for compressive strength, flexural strength, dielectric strength and low fluid absorption. b. Sealing Material lamination and suitable for service temperature, c. Insulation sleeve size and type d. coating/laminate e. Metallic Washer protective coating

Insulation Washer

thickness and

thickness and

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Project Spec. P.O. Description, Standards,

Project Specification ,

Prod. Plan

QA Manual

Prod. Plan

Project Specification ,

Project specification

NEMA

4.3 Hardness testing

4.4

Assemble Gaskets (Seal Type – single/double)

Document No: AGES-SP-13-002

Rev. No: 01 Page 126 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–120

Insulating Gasket Kits (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

4.5

Inspection of Marking & Identification

4.6

PMI where applicable

Salt spray test for Kit assembly

Fire safe ( if applicable)

API 6FB

4.7 NDE where applicable

4.8

Gasket color coding Electroplated /HDG Inspection for all parts

for nuts /bolts.

4.9

Package Gaskets with Kits

4.10 Gasket Kit Inspection

4.11

Final Inspection Including document review, Visual and dimensional inspection

Preparation for Dispatch

5.1

5.2

5.3

5.4

dimensional

Punch clearance inspection and Quality records review Visual checks, and component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

5.5 Manufacturing Record Book

Reports & Test Certificates

Project specification Data sheet, ASTM B633

Project Spec. P.O. Description & Approved Drgs

Documents, International Codes & Stds

6.1 Vendor Data Report

VDRL

6.2 Raw Material Test Certificates

6.3

6.4

By

WIN / UTC / CMMS DATA Sheet (To Be Completed Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 127 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–121

Austenitic Stainless Steel, DSS, SDSS, Incoloy and Inconel Pipes & Fittings

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

Scope

list covers

This inspection requirements for Exotic material used in ADNOC Projects

test and

Vendor approval

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor manufacturing schedule

3.2 Vendor Q.P

3.3 Status of sub orders if any

3.4 Raw Material test and certification

3.5

3.6

Welding Procedure Qualification & Welder Qualification NDT Procedure (including PT, full body UT) & NDT Personnel Qualification Eddy current testing for surface and sub surface flaws per applicable ASTM std.

3.7 PMI Procedure review

3.8

Manufacturing procedure specification

3.9 Hydrostatic Test procedure

4. Production, Inspection & Testing

4.1 Billets Receiving Inspection

4.1.1

Visually and Dimensional Inspection Raw material mill test certificate – visual, dimensional and traceability

4.1.2 Chemical Composition Analysis

4.1.3

Mill Test Certificate of Raw Material Mechanical properties check

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Project Spec. P.O. Description, Standards,

Prod. Plan

QA Manual

Prod. Plan

P.O. Description Project Spec., Codes & Stds, ASTM std as applicable, WPS ASTM A 388 ASTM A 745 ASME Sec V

Project specification ASTM G48 ASTM A923 ASTM E562 B16.25 ASTM A380

Document No: AGES-SP-13-002

Rev. No: 01 Page 128 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–121

Austenitic Stainless steel, Duplex stainless steel, SDSS, Incoloy and Inconel Pipes and Fittings (Cont’d)

ACTIVITY

E C N E R E F E R

T N E M U C O D

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

4.2

4.2.1

4.2.2

4.4

4.5

in Process

Pipe manufacturing Inspection and Testing Heat Treatment (Solution annealing / stabilization heat treatment), as applicable Pipe Chemical Composition Analysis per heat Dual certification, as applicable Pitting Resistance Equivalent (PREN) Mechanical Property Test per heat Tensile Test Harness Test Flattening Test Guided Bend Test Heat Treatment check Corrosion Tests - Intergranular Corrosion Test; Ferrite check & PREN verification Metallographic examination (for each lot) Grain size and Ferrite content check For welded pipes – corrosion tests on weldment and HAZ

Repair welding, if applicable

Non-Destructive tests (each pipe)

4.6

Hydrostatic Test (each pipe after all manufacturing process including repair and heat treatment completed) NDE – PT, full body UT, repair NDE (PT and UT), bevel ends

4.7 Pipe Dimension Check Visual inspection

4.8 Visual Check Dimensional inspection

Bevel ends inspection

4.9 PMI Test (100%) on all finished pipes

PMI on welded pipes (100%) in addition to filler material. Pickling and passivation Ferroxyl testing Color Coding & Marking (including Heat and heat treatment)

4.10

Pipe end protection

4.11 Final inspection & Certificates Review

Project specification ASTM G48 ASTM A923 ASTM E562 B16.25 ASTM A380

Document No: AGES-SP-13-002

Rev. No: 01 Page 129 of 285

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/19588

Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–121

Austenitic Stainless steel, Duplex stainless steel, SDSS, Incoloy and Inconel Pipes and Fittings (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

Preparation for Dispatch

5.1

5.2

5.3

dimensional

Punch clearance inspection and Quality records review Visual and component Marking, checks Handling, storage and Packing inspection and marking control of all goods (protection environment from contamination (moisture, dust, water, etc.)

checks,

5.4 Manufacturing Record Book

5.5

Inspection Release Note (IRN)

Reports & Test Certificates

6.1 Vendor Data Report

6.2 Raw Material Test Certificates

E C N E R E F E R

T N E M U C O D

P.O. Description, Project Spec. procedures, Codes & Stds

Vendor Document Requirement List

6.3

6.4

By

WIN / UTC / CMMS DATA Sheet (To Be Completed (Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

Vendor

Document No: AGES-SP-13-002

Rev. No: 01 Page 130 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP-122

Pumps

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

ACTIVITY

Scope

list covers

This requirements for centrifugal, Reciprocating & rotary pumps.

Inspection and Test

Vendor approval

E C N E R E F E R

T N E M U C O D

Project Spec./P.O. Description, API 674 & API 676

COMPANY Pre- qualification

2. Requirements with tender

2.1 Assessment of technical capability

2.2 Appraisal of quality system

3. Pre-production Meeting

4. General - Preliminary work

4.1 Design verification

4.2 Design Validation

4.3 Design Review

4.4

sheets, Approval

Data of Design Documentation / GA and detail drawings, performance curves

4.5 Vendor fabrication schedule

4.6 Vendor Q.P

4.7 Status of sub orders

4.8 Material test and certification

4.9 Welding Procedure

4.10 List of qualified welders

4.11 Approval of HT procedures

4.12

4.13

4.14

Approval of NDT, Hardness and PMI procedure Approval of handling, preservation and packaging procedure Performance and mechanical running test procedure

4.15 FAT Procedure

Prod. Plan

QA Manual

Prod. Plan

Codes, Std &

Design Codes, Std & Drawings

4.16

4.17

preparation

Surface procedure Installation, Operating and maintenance Manual

painting

and

4.18 Manufacturer spares for 2 years operation

Document No: AGES-SP-13-002

Rev. No: 01 Page 131 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–122 Pumps (Cont’d)

SL. NO.

ACTIVITY

Production

5.1

Examination and manufacturing facility

approval

of

5.2 Material Traceability and Examination

5.3

Production welding

5.4

Casing including balance line, Seal Gland, and (Pipe Columns & Discharge Flange for Vertical pumps)

5.5 Rotating elements

5.6

Bearings, Seals, Mechanical sealing system, Couplings & Gear box

5.7 Driver (motor / S.T /diesel engine)

E C N E R E F E R

T N E M U C O D

Vendor Data Book

Codes & Std

P.O Spec. & Std

5.8 Base plate

5.9

5.10

Piping & piping components Piping components SS, DSS and CRA shall conform to ITP-122 Cylinders & liners, Distance pieces, Valves & Pulsation dampeners (for reciprocating pumps)

Approved spec. Drawings, procedures, Data sheet ITP-122

5.11 Lubrication & instrumentation

5.12 Bolting and Gasket

Examination

6.1 Visual, Dimensional Check

6.2

Lifting / Handling Proves

Approved Drawings

6.3 Non-Destructive Examination

Codes & Std

6.4

Painting production test panel)

Examination

6.5 Welding surveillance

(PQT

and

Approved PRO

6.6 Visual examination of completed welds

6.7 Verifying pump clearances

6.8

6.9

Physical examination of Seals, shafts and bearings Check oil system for contamination and foreign matter

6.10 Examine protective coatings

6.11

Check rotational direction and rotational arrow

Approved specification, WPS, Project procedures, data sheet, drawings

Document No: AGES-SP-13-002

Rev. No: 01 Page 132 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–122 Pumps (Cont’d)

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Examination (cont’d)

6.12

Heat treatment shall be checked. Reports and charts need to be stamped approved

6.13 Witness equipment being weighed

Testing

7.1 Hardness test, PMI (Where applicable)

Codes & Std

7.2

Hydrostatic, Mechanical run, NPSH, vibration Performance & Noise control tests

7.3 Witness Alignment checks

7.4

Static / Dynamic balancing & NPSH tests (for centrifugal pumps)

7.5

Performance Test

7.6 Complete Unit Test

7.7

Lube oil Skid test (if applicable)

7.8 Verify coupling

7.9

Witness measurement and record bearing clearances

Preparation for Dispatch

8.1

8.2

Marking & Tagging, Bearing assembly protection Preservation Shipment

preparation

and

for

P.O Spec., Std.&

P.O Spec., Std.&

Inspection Release Note (IRN)

Reports & Test Certification & vendor Data Books

9.1 NDT reports

9.2 Vendor Data Report

9.3 Raw Material Test Certificates

Project spec.

Vendor Document Requirement List

9.4

9.5

9.6

9.7

By

WIN / UTC / CMMS DATA Sheet (To Be Vendor Wherever Completed Applicable) Vendor Data Books endorsement, and issue of release note by TPA Review and maintenance/operation manual

approval

of

Review and approval of performance /functional test data

Document No: AGES-SP-13-002

Rev. No: 01 Page 133 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–123

Compressors - Centrifugal

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

API 617

COMPANY Pre- qualification

Design Codes, Std, approved data sheet, project specification, Drawings and procedures

SL. NO.

1

ACTIVITY

Scope This requirements for centrifugal compressors.

list covers

test and

inspection

Vendor approval

2. Requirements with tender

2.1 Assessment of technical capability

2.2 Appraisal of quality system

3. Pre-production Meeting

4. General - Preliminary work

4.1 Design verification

4.2 Design Validation

4.3 Design Review

4.4

sheets, Approval

Data of Design Documentation /GA and detail drawings, performance curves

4.5 Welding Procedure

4.6 List of qualified welders

4.7 Approval of HT procedures

4.8 Approval of NDT procedure

4.9

4.10

Approval of handling, preservation and packaging procedure Testing Procedures including Wheel shaker test, Mechanical Running Test procedure

4.11 Gas leak Test procedure

4.12

FAT, Performance test and post-test inspection of internal and spare parts test procedure

4.13 Manufacturer spares for 2 years operation

4.14

4.15

Installation, Operating and maintenance Manual Surface procedure

preparation

painting

and

5. Production

5.1

Examination and manufacturing facility

approval

of

Vendor Data Book

5.2 Material Traceability and Examination

5.3 Production welding

Codes & Std

Document No: AGES-SP-13-002

Rev. No: 01 Page 134 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–123 Compressors (Centrifugal) (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

5. Production (cont’d)

5.4 Casing including headend

5.5 Rotating elements

5.6

5.7

Seals, Dry gas seal system, Bearing, Housing & Gear box Driver (Elec motor /Steam Turbine/Gas Turbine )

P.O Spec. & Std

5.8 Base plate

5.9

Piping & piping components Piping components SS, DSS and CRA shall conform to ITP-122

Approved specification & Drawings

5.10 Lubrication & instrumentation

5.11 Bolting and Gasket

Examination

6.1 Visual Dimensional Check

6.2

Lifting / Handling Proves

6.3 Non-Destructive Examination

6.4 Welding surveillance

P.O Spec. & Approved Drawings

6.5 Visual examination of completed welds

6.6 Verifying Compressor clearances

6.7 Verifying driver’s direction

Codes and Standards

6.8

6.9

6.10

Physical examination of Seals, shafts and bearings Check oil system for contamination and foreign matter Painting production test panel)

Examination

(PQT

and

6.11 Examine protective coatings

6.12

6.13

Check rotational direction and rotational arrow Heat treatment shall be checked. Reports and charts need to be stamped approved

6.14 Witness equipment being weighed

Testing

/ Approved PRO

7.1 Hardness test, PMI (Where applicable)

Codes & Std

7.2

Hydrostatic, Helium Leak Test, & Noise control tests, Impeller over speed test & Vibration reading

Document No: AGES-SP-13-002

Rev. No: 01 Page 135 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–123 Compressors (Centrifugal) (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

7. Testing (cont’d)

7.3

Static / Dynamic balance tests (for centrifugal compressors)

7.4 Performance Test (PTC-10)

Complete Unit Test (If applicable)

API 614 Lube system Test

7.5 Verify coupling

7.6

Witness measurement and record bearing clearances

8. Preparation for Dispatch

8.1 Marking & Tagging, packing list

Complete equipment Preservation checked and recorded Equipment Lifting points identified and marked Openings covered and Protection Shipment

for

8.2

8.3

Inspection Release Note (IRN)

P.O Spec., Std. &

9. Reports & Test Certification & vendor Data Books

, VDRL

Project spec., procedures

, specification

9.1 Vendor Data Report

9.2 NDT reports

9.3 Raw Material Test Certificates

9.4

9.5

9.6

9.7

By

WIN / UTC / CMMS DATA Sheet (To Be Vendor Wherever Completed Applicable) Vendor Data Books endorsement, and issue of release note by TPA Review and approval of maintenance /operation manual Review and approval of performance / functional test data

Document No: AGES-SP-13-002

Rev. No: 01 Page 136 of 285

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/19588

Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

L E V E L

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

L E V E L N O T N E V R E T N

I

I

N O T N E V R E T N

I

R O T C A R T N O C C P E

L E V E L

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

I

N O T N E V R E T N

I

A P T

L E V E L

ITP–124

Compressors - Reciprocating

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope

1

list covers

This requirements compressors.

Vendor approval

test and for

inspection Reciprocating

COMPANY Pre- qualification

2. Requirements with tender

2.1 Assessment of technical capability

2.2 Appraisal of quality system

3. Pre-production Meeting

4. General - Preliminary work

4.1 Design verification

4.2 Design Validation

4.3 Design Review

4.4

sheets, Approval

Data of Design Documentation /GA, detail drawings and performance curves

4.5 Welding Procedure

4.6 List of qualified welders

4.7 Approval of HT procedures

4.8 Approval of NDT, Hardness, PMI procedure

4.9

4.10

Approval of handling, preservation and packaging procedure Testing Procedures including Wheel shaker test, FAT, Mechanical Running Test procedure

4.11 Gas leak Test procedure

Design Codes, Std & Drawings

4.12

4.13

Performance test and post-test inspection of internal and spare parts test procedure Surface painting procedure

preparation

and

4.14 Manufacturer spares for 2 years operation

4.15

Installation, Operating and maintenance Manual

5. Production

5.1

Examination and manufacturing facility

approval

of

Pre-Qualification

5.2 Material Traceability and Examination

Vendor Data Book

Document No: AGES-SP-13-002

Rev. No: 01 Page 137 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–124 Compressors (Reciprocating) (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

E C N E R E F E R

T N E M U C O D

WPS/PQR,

Approved specification, procedures & Drawings

Approved, spec., Drawings

Codes and Standards

SL. NO.

ACTIVITY

5. Production (cont’d)

5.3

Production welding

5.4 Casing including headend

5.5 Rotating elements

5.6 Seals, Bearing, Housing & Gear box

5.7 Driver (motor)

5.8 Base plate

5.9

5.10

Piping & piping components Piping components SS, DSS and CRA shall conform to ITP-122 Cylinders & liners, Distance pieces, Valves & Pulsation dampeners

5.11 Lubrication & instrumentation

5.12 Bolting and Gasket

Examination

6.1 Visual Dimensional Check

6.2

Lifting / Handling Proves

6.3 Non-Destructive Examination

6.4 Examine piston rods and bores after test

6.5

Verify that relief valve tested/ reset pressure is recorded

6.6 Welding surveillance

6.7 Visual examination of completed welds

6.8

6.9

Verify that the compressor rod run out is within the clearance Check for joint leaks during the test and examine piston bores and rods after the test

6.10 Verifying compressor clearances

6.11

Verify bearing clearances, Crank shaft deflection

6.12 Verifying driver’s direction

6.13

6.14

Physical examination of Seals, shafts and bearings Check oil system for contamination and foreign matter

6.15 Examine protective coatings

Document No: AGES-SP-13-002

Rev. No: 01 Page 138 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–124 Compressors Reciprocating (Cont’d)

SL. NO.

ACTIVITY

Examination (cont’d)

6.16

6.16

6.17

(PQT

Examination

Painting production test panel) Check rotational direction and rotational arrow Heat treatment shall be checked. Reports and charts need to be stamped approved

and

E C N E R E F E R

T N E M U C O D

Approved PRO

Specification, procedures

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

6.18 Witness equipment being weighed

Testing

7.1 Hardness test, PMI (Where applicable)

Codes & Std

7.2

Hydrostatic, Helium Leak Test, & Noise control tests Vibration reading

API 618

7.3

Performance Test

Complete Unit Test (If applicable)

7.4 Verify coupling

Approved PRO,

7.5

Witness measurement and record bearing clearances

7.6 Checking alignment Details

Preparation for Dispatch

8.1 Marking & Tagging, Packing List

8.2

8.3

8.4

equipment

Preservation

Complete checked and recorded Equipment Lifting points identified and marked Openings Shipment

Protection

covered,

for

P.O Spec., Std. &

8.5

Inspection Release Note (IRN)

Reports & Test Certification & vendor Data Books

9.1 Vendor Data Report

VDRL

9.2 NDT reports

9.3 Raw Material Test Certificates

9.4

9.5

9.6

9.7

by

WIN / UTC / CMMS DATA Sheet (To Be Vendor Wherever Completed Applicable) Vendor Data Books endorsement, and issue of release note by TPA Review and approval of maintenance / operation manual Review and approval of performance / functional test data

Document No: AGES-SP-13-002

Rev. No: 01 Page 139 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–125

Gas Turbines

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

ACTIVITY

Scope

list covers

This inspection requirements for Gas Turbines used as drivers or generators.

test and

Vendor approval

E C N E R E F E R

T N E M U C O D

COMPANY

COMPANY Pre- qualification

2. Pre-production Meeting

2.1 Assessment of technical capability

2.2 Appraisal of quality system

3. General - Preliminary work

3.1 Design verification

3.2 Design Validation

3.3 Design Review

3.4

sheets, Approval

Data of Design Documentation/GA and Detail drawings, performance curves

3.5 Vendor fabrication schedule

3.6 Vendor QP

3.7 Status of sub orders

Prod. Plan

QA Manual

Prod. Plan

3.8 Material test and certification

Codes, Stds &

3.9 Welding Procedure

3.10 List of qualified welders

3.11 Approval of HT procedures

3.12 Approval of NDT procedure

Design Codes, Stds & Drawings

3.13

3.14

3.15

Approval of handling, preservation and packaging procedure Approval of hydrostatic and pneumatic test procedures Testing FAT, Performance Test, complete unit run test, package test, over speed test

procedure

including

3.16 Manufacturer spares for 2 years operation

3.17

3.18

Installation, Operating and maintenance Manual Surface procedure

preparation

painting

and

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

ITP–125 Gas Turbines (Cont’d)

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

4. Production

4.1

Examination and manufacturing facility

approval

of

4.2 Material Traceability and Examination

4.3

Production welding

4.4 Casings

4.5

Rotating elements (rotor, couplings, blades & wheels)

4.6 Seals, Bearing, & Gear box

4.7 Base plate

Vendor Data Book

WPS & PQR

P.O., code & Std Approved spec. Procedure, Drawings

4.8

Piping & piping components (Fuel Piping & Lube oil piping, seal air piping), Piping components SS, DSS and CRA shall conform to ITP-122

4.9 Combustion chambers, Nozzles/Burner

Approved project spec. & Drawings

4.10 Lifting points & lugs

4.11 Bolting and Gasket

Examination

5.1 Visual Dimensional Check

5.2 Non-Destructive Examination

5.3

Painting Examination (including PQT and Production test panel)

5.4 Calibration Checks

5.5 Contamination on oil filters and strainers

5.6

Examine bearings, blading and gearing for damage

5.7 Witness equipment being weighed

5.8 Examine protective coatings

5.9

Heat treatment shall be checked. Reports and charts need to be stamped approved

Testing

P.O, Approved project Spec. Data sheet, procedures & Drawings Codes & Std

6.1 Hardness test, PMI (Where applicable)

Codes & Std

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–125 Gas Turbines (Cont’d)

SL. NO.

ACTIVITY

6.4 Vibration reading / noise

6.5

6.6

trip

Mechanical running test, Performance test, speed regulating devices, over speed & exhaust temperature. Auxiliary equipment, instrumentation and control soak test and Post-Test inspection of internals

valves

/

E C N E R E F E R

T N E M U C O D

API 616

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

6.7

Load Test (Where applicable)

Approved PRO,

Preparation for Dispatch

7.1 Marking & Tagging, packing list

7.2

7.3

7.4

equipment

Preservation

Complete checked and recorded Equipment Lifting points identified and marked Openings Shipment

Protection

covered,

for

P.O Spec., Std. &

7.5

Inspection Release Note (IRN)

Reports & Test Certification & vendor Data Books

, Vendor Document Requirement List

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

By

8.5

Flue Gas Emission (NoX)

Codes & Std.

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–126

HVAC Equipment

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

Scope

list covers

This requirements for HVAC Equipment.

test and

inspection

1.1 Vendor approval

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders if any

3.4 Material test and certification

3.5 Manufacturing Drawings

3.6

Packing & preservation Procedure

3.7

3.8

3.9

(NDE)

Examination

Non-Destructive Procedures where applicable Weld Procedures Specification and Qualification Records where applicable Surface preparation, Painting/Coating Procedure

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Project Spec. P.O. Description, Standards,

Prod. Plan

QA Manual

Prod. Plan

P.O. Description approved Project Spec., project procedures, Drgs., Stds,

3.10

Inspection and Test Procedure

3.11 Leak Test

3.12 FAT Procedure

4. Production, Inspection & Testing

4.1 Air Cooled Chillers

4.1.1 Verification Of Purchased Product

4.1.2 Sheet Metal Fabrication

4.1.3 Powder Coating Of Sheet Metal Sheets

4.1.4 Production of Propeller Fan

4.1.5 Structural Steel Fabrication

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & Stds.

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–126 HVAC Equipment (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

4.1 Air Cooled Chillers (Cont’d)

4.1.6 Painting of Structural Steel frame

4.1.7 Insulation of Evaporator

4.1.8 Coil Manufacturing

4.1.9 Coil Leak Testing

4.1.10

Electrical Testing

components Assembly &

4.1.11 Unit Assembly

4.1.12 Production of Refrigerant Piping

4.1.13 Leak Test of Refrigerant Piping system

4.1.14 Evacuation & Charging

4.1.15 Operational Run Testing

4.1.16 Final Inspection

4.2 Air Handling Units

4.2.1 Verification of Purchased Product

4.2.2 Sheet Metal Fabrication

4.2.3 Powder Coating of Sheet Metal Sheets

4.2.4 Coil Manufacturing

4.2.5 Coil Leak Testing

4.2.6 Insulation of the Panel

4.2.7 Unit Assembly

4.2.8 Operational Run Testing

4.2.9 Motor Insulation Winding Test

4.2.10 Final Inspection

4.3 Fan Coil Units

4.3.1 Verification of Purchased Product

4.3.2 Sheet Metal Fabrication

4.3.3 Powder Coating of Sheet Metal Sheets

4.3.4 Coil Manufacturing

4.3.5 Coil Leak Testing

E C N E R E F E R

T N E M U C O D

P.O. Description, Project Spec. procedures,

Drgs,

International Codes & Stds.

P.O. Description, Project Spec. procedures,

Drgs,

International Codes & Stds.

P.O. Description, Project Spec. procedures,

Drgs,

International Codes & Stds.

Document No: AGES-SP-13-002

Rev. No: 01 Page 144 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–126

HVAC Equipment (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description, approved drawings, procedures, Codes & stds

Project Spec. P.O. Description, approved drawings, procedures, Codes & stds

SL. NO.

ACTIVITY

4.3.6

Insulation of the Panel

4.3.7 Unit Assembly

4.3.8

Final Inspection

4.4

Air Cooled Condensing Units

4.4.1 Verification of Purchased Product

4.4.2 Sheet Metal Fabrication

4.4.3 Powder Coating of Sheet Metal Sheets

4.4.4 Production of Propeller Fan Blade

4.4.5 Coil Manufacturing

4.4.6 Coil Leak Testing

4.4.7

Electrical Components Assembly & Testing

4.4.8 Unit Assembly

4.4.9 Production of Refrigerant Piping

4.4.10 Leak Test of Refrigerant Piping System

4.4.11 Final Assembly

4.4.12 Final Inspection

4.5 Air Cooled Packaged Units

4.5.1 Verification of Purchased Product

4.5.2 Sheet Metal Fabrication

4.5.3 Powder Coating of Sheet Metal Sheets

4.5.4 Production of Propeller Fan Blade

4.5.5 Structural Steel Fabrication

4.5.6 Painting of Structural Steel Frame

4.5.7 Coil Manufacturing

4.5.8 Coil Leak Testing

4.5.9

Electrical Components Assembly & Testing

4.5.10

Insulation of the Panel

4.5.11 Unit Assembly

4.5.12 Production of Refrigerant Piping

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–126

HVAC Equipment (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

4.5 Air Cooled Packaged Units

4.5.13 Leak Test of Refrigerant Piping System

4.5.14 Evacuation & Charging

4.5.15 Operational Run Testing

4.5.16 Final Inspection

Preparation for Dispatch

5.1

5.2

5.3

5.4

and

dimensional

Punch clearance inspection and Quality records review Visual checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

5.5 Manufacturing Record Book

Reports & Test Certificates

6.1

Vendor Data Report

6.2

6.3

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor (Wherever Applicable) Vendor Data Books, issue of release notes by TPA

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & Stds

approved Vendor Document Requirement List

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–201

132kV & above Power Transformers and Shunt Reactors

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Drawings

COMPANY Pre- qualification

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds &

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

SL. NO.

1

ACTIVITY

Scope This requirements transformers and Shunt Reactors

list covers for

test and 132kv

inspection Above

&

Vendor approval

Pre-production/Pre-inspection Meeting Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production & Internal Testing

4.1 Check of received material

4.2

4.3

4.4

4.5

4.6

Core stacking check:

• Critical dimensions
• Gluing time Foil winding check:
• Materials
• Dimensions
• Lightning Impulse-test Winding check:
• Materials
• Dimensions
• Structure and other critical issues according to design and instructions Winding assembly check:
• Drying
• Winding length
• Insulation test Tank cover and conservator manufacturing check: (2)
• Main dimensions
• Visual inspection of welding seams
• Leakage test with soap water or penetration liquid

Document No: AGES-SP-13-002

Rev. No: 01 Page 147 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–201 132kV & above Power Transformers and Shunt Reactors (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

4. Production & Internal Testing (cont’d)

4.7

Surface treatment check:

• Pre-treatment
• Painting conditions
• Painting thickness

4.8 Sample Test Panels for Coating

4.9

Surface treatment inspection (including welding visual)

4.10 Intermediate coating inspection

4.11 Final coating inspection

4.12

4.13

4.14

4.15

4.16

Electrical quality control measurements:

• Core earthing
• Voltage ratio
• CT ratio and polarity
• Winding resistances Active part review:
• Active part according to design and instructions Drying check:
• Drying method, time and temperature Vacuum treatment and oil filling:
• Pressure during oil filling
• Oil type Oil leakage test:
• Welding seams
• Gaskets
• Valves

4.17 Tank vacuum & pressure test

5. Routine Test

5.1 Measurement of winding resistance

5.2

Measurement of voltage ratio and check of voltage vector relationship Done as pre- tanking measurement

5.3

Measurement of impedance voltage (principal tapping), impedance and load loss

short-circuit

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Project Spec. IEC 60076-1 (2011-04) 11.1.2.1 a)

Project Spec. IEC 60076-1 (2011-04) 11.1.2.1 b)

Project Spec. IEC 60076-1 (2011-04) 11.1.2.1 c)

Document No: AGES-SP-13-002

Rev. No: 01 Page 148 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–201

132kV & above Power Transformers and Shunt Reactors (Cont’d)

SL. NO.

ACTIVITY

5. Routine Test (cont’d)

5.4 Measurement of no-load loss and current

5.5

routine

Dielectric Induced overvoltage withstand test with PD and separate-source voltage withstand test

tests:

5.6 Tests on on-load tap-changers

5.7

Insulation resistance measurement

5.8

Measurement of capacitances and dissipation factor

5.9

Measurement of dissolved gasses in dielectric liquid from each separate oil compartment except diverter switch compartment

5.10

Full wave lightnings impulse test for the line terminals

5.11

Operational test for control and protective devices. Insulation test of auxiliary wiring 2kV 50 Hz for 1 minute for auxiliary wiring and control equipment. Check of the ratio and polarity of built- incurrent transformers. Done as pre- tanking measurement.

Document No: AGES-SP-13-002

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description IEC 60076-1 (2011-04) 11.1.2.1 d), 11.1.2.2 e) Project Spec. P.O. Description IEC 60076-3 (2013-07) 11.1.2.1 e) IEC 60076-1 (2011-04) 11.1.2.1 f) Project Spec. P.O. Description IEC 60076-1 (2011-04) 11.1.2.1 j), 11.1.2.2 b) Project Spec. P.O. Description IEC 60076-1 (2011-04) 11.1.2.2 a), 11.1.2.2 c) Project Spec. P.O. Description IEC 60076-1 (2011-04) 11.1.2.2 d) Project Spec. P.O. Description IEC 60076-3 (2013-07) 7.2.1 Project Spec. P.O. Description IEC 60076-3 (2013-07)

IEC 60076-1, 11.1.2.1 i) (2011-04)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

Rev. No: 01 Page 149 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–201 132kV & above Power Transformers and Shunt Reactors (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

6. Type Test & Special Test

6.1 Type Test Certificates

Special test as per IEC & Specifications:

Vibration Test Lightning impulse test on line terminals full wave (LI) and test with chopped on tail (LIC) (HT and LT windings line terminals)

6.2

• Measurement of zero-sequence impedance
• Measurement of harmonics of the no-load

current Temperature-rise test Determination of sound level

• Measurement of power taken by the fan

and liquid pumps “if applicable”

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description IEC 60076

Project Spec. P.O. Description IEC 60076

6.3

Tests and inspection for ATEX AND/OR IECEX certification “if applicable”

ATEX AND/OR IECEX

6.4

Oil-filled transformer

• ECMS Control & Monitoring (IEC61850 & Modbus TCP)
• Electrical Asset Management System Monitoring Functions “if applicable”

7. Preparation for Dispatch

7.1

7.2

7.3

7.4

Punch clearance inspection and Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

7.5 Manufacturing Record Book

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Document No: AGES-SP-13-002

Rev. No: 01 Page 150 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–201 132kV & above Power Transformers and Shunt Reactors (Cont’d)

SL. NO.

ACTIVITY

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

E C N E R E F E R

T N E M U C O D

Approved Vendor Document Requirement List (VDRL)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

8.3

WIN/UTC/CMMS data completed applicable)

by

sheet

(to be (wherever

vendor

8.4

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–202

33kV & Below Oil Filled Power Transformers and Shunt Reactors

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

P.O. Project Spec. P.O. Description & Approved Drawings COMPANY Pre- qualification

Prod. Plan

QA Manual

Prod. Plan Project Spec. P.O. Description Codes, Stds &

P.O. Spec. & Approved procedures, Drawings,

International Codes & Standards

SL. NO.

1

ACTIVITY

Scope This inspection requirements for 33kv & below oil filled transformers and Shunt Reactors

list covers

test and

Vendor approval

Pre-production/Pre-inspection Meeting Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production & Internal Testing

4.1 Check of received material

4.2

4.3

4.4

4.5

4.6

Core stacking check:

• Critical dimensions
• Gluing time Foil winding check:
• Materials
• Dimensions
• Lightning Impulse-test Winding check:
• Materials
• Dimensions
• Structure and other critical issues according to design and instructions Winding assembly check:
• Drying
• Winding length
• Insulation test Tank cover and conservator manufacturing check: (2)
• Main dimensions
• Visual inspection of welding seams
• Leakage test with soap water or penetration liquid

Document No: AGES-SP-13-002

Rev. No: 01 Page 152 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–202 33kV & Below Oil Filled Power Transformers and Shunt Reactors (Cont’d)

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R O T C A R T N O C

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SL. NO.

4.7

ACTIVITY

Surface treatment check:

• Pre-treatment
• Painting conditions
• Painting thickness

4.8 Sample Test Panels for Coating

4.9

Surface treatment inspection (including welding visual)

4.10 Intermediate coating inspection

4.11 Final coating inspection

4.12

4.13

4.14

4.15

4.16

Electrical quality control measurements:

• Core earthing
• Voltage ratio
• CT ratio and polarity
• Winding resistances Active part review:
• Active part according to design and instructions Drying check:
• Drying method, time and temperature Vacuum treatment and oil filling:
• Pressure during oil filling
• Oil type Oil leakage test:
• Welding seams
• Gaskets
• Valves

4.17 Tank vacuum & pressure test

5. Routine Test

5.1 Measurement of winding resistance

5.2

Measurement of voltage ratio and check of voltage vector relationship Done as pre- tanking measurement

5.3

Measurement of impedance voltage tapping), (principal impedance and load loss

short-circuit

E C N E R E F E R

T N E M U C O D

P.O. Spec. & Approved procedures, Drawings,

International Codes & Standards

Project Spec. P.O. Description IEC 60076-1 (2011-04) 11.1.2.1 a) Project Spec. P.O. Description IEC 60076-1 (2011-04) 11.1.2.1 b) Project Spec. P.O. Description IEC 60076-1 (2011-04) 11.1.2.1 c)

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–202 33kV & Below Oil Filled Power Transformers and Shunt Reactors (Cont’d)

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R O D N E V

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R O T C A R T N O C

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Y N A P M O C

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SL. NO.

ACTIVITY

5.4 Measurement of no-load loss and current

5.5

routine

Dielectric Induced overvoltage withstand test with PD and separate-source voltage withstand test

tests:

5.6 Tests on on-load tap-changers

5.7

Insulation resistance measurement

5.8

Operational test for control and protective devices. Insulation test of auxiliary wiring 2kV 50 Hz for 1 minute for auxiliary wiring and control equipment. Check of the ratio and polarity of built- incurrent transformers. Done as pre- tanking measurement.

6. Type Test & Special Test

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description IEC 60076-1, (2011-04) 11.1.2.1 d), 11.1.2.2 e) Project Spec. P.O. Description IEC 60076-3 (2013-07) 11.1.2.1 e) Project Spec. P.O. Description IEC 60076-1 (2011-04) 11.1.2.1 f) Project Spec. P.O. Description IEC 60076-1 (2011-04) 11.1.2.1 j), 11.1.2.2 b) Project Spec. P.O. Description IEC 60076-3 (2013-07) IEC 60076-1, 11.1.2.1 i) (2011-04)

6.1 Type Test Certificates

IEC 60076

Special test as per IEC & Specifications:

Vibration Test Lightning impulse test on line terminals full wave (LI) and test with chopped on tail (LIC) (HT and LT windings line terminals)

6.2

• Measurement of zero-sequence impedance
• Measurement of harmonics of the no-load

current Temperature-rise test Determination of sound level

• Measurement of power taken by the fan

and liquid pumps “if applicable”

6.3

Tests and inspection for ATEX AND/OR IECEX certification “if applicable”

Project Spec. P.O. Description IEC 60076

ATEX AND/OR IECEX

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–202 33kV & Below Oil Filled Power Transformers and Shunt Reactors (Cont’d)

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L E V E L N O T N E V R E T N

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R O T C A R T N O C

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ACTIVITY

E C N E R E F E R

T N E M U C O D

Type Test & Special Test (Cont’d)

6.4

Oil-filled transformer

• ECMS Control & Monitoring (IEC61850 & Modbus TCP)
• Electrical Asset Management System Monitoring Functions “if applicable”

Project Specification , procedures, Data sheet

7. Preparation for Dispatch

7.1

7.2

7.3

7.4

Punch clearance inspection and Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

7.5 Manufacturing Record Book

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Vendor Wherever Completed Applicable) Vendor Data Books, issue of release notes by TPA

By

Approved Vendor Document Requirement List Project Spec. P.O. Description

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–203

Dry Type Power Transformers

SL. NO.

1

ACTIVITY

Scope

list covers

test and

for Dry

Type

inspection Power

This requirements transformers

Vendor approval

Pre-production/Pre-inspection Meeting Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production & Internal Testing

4.1 Check of received material

4.2 Resin Mixing Control - Gel Test

4.3 Control “Foil-Wire Winding”

4.4 Control “Active Part”

4.5 Control “Final Assembly”

4.6 Control “Ready for Test”

5. Routine Test

5.1

Verification of correct wiring of auxiliary circuits

5.2 Dielectric test on auxiliary circuits

5.3 Measurement of winding Resistance

5.4

5.5

5.6

Voltage ratio measurement and check of voltage vector relationship Measurement of impedance voltage, short circuit impedance and load losses Measurement of No-Load Losses and No- Load Current

5.7

Induced Overvoltage withstand Test

5.8 Separate-Source Voltage withstand Test

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R O T C A R T N O C

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E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Approved Drawings

COMPANY Pre- qualification

Prod. Plan

QA Manual

Prod. Plan

Project Spec. Codes, Stds &

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Stds.

Project Spec. P.O. Description & Approved Drawings, Codes & Standards IEC60076

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–203

Dry Type Power Transformers (Cont’d)

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards IEC60076

Project Spec. P.O. Description IEC 60076 ATEX AND/OR IECEX

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

As per Approved Vendor Document Requirement List (VDRL)

—

SL. NO.

ACTIVITY

5. Routine Test (cont’d)

5.9 Partial Discharge Test

5.10 Visual inspection

5.11 Temperature rise test

5.12 Noise level measurement test

5.13 Insulation resistance test

5.14 Harmonics of the no-load losses test

4.15 Zero-sequence impedance test

6. Type Test & Special Test

6.1 Type Test Certificates

6.2

Tests and inspection for ATEX AND/OR IECEX certification “if applicable”

7. Preparation for Dispatch

7.1

7.2

7.3

7.4

Punch clearance inspection and Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

7.5 Manufacturing Record Book

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

By

Document No: AGES-SP-13-002

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R O T C A R T N O C

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–204

132KV Gas Insulated Switchgear

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N O T A C F T R E C

I

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L E V E L N O T N E V R E T N

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R O T C A R T N O C

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E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description Std & Approved Drawings COMPANY Pre- qualification

SL. NO.

1

ACTIVITY

Scope

list covers

This requirements Switchgear

test and

inspection for 132KV Gas Insulated

Vendor approval

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production & Internal Testing

4.1 Check of received material/components

4.2

4.3

proper

connections,

Verification of visual dimensional check, earth terminal markings, completeness of labels, ratings and name plates Check of effectiveness of operating mechanism, inter-trips, interlocks, partitions and shrouds

4.4 Check electric assembly and wiring

4.5 Pressure tests for pressurized parts

5. Routine Test

5.1 Design and visual inspection

5.2

Mechanical operation test of all switching devices

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds &

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Project Spec. P.O. Description IEC 62271- 203 Project Spec. P.O. Description IEC 62271-100 IEC 62271-102

Document No: AGES-SP-13-002

Rev. No: 01 Page 158 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–204 132KV Gas Insulated Switchgear (Cont’d)

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description IEC 62271- 203 Project Spec. P.O. Description IEC 62271- 203 IEC 61869-2 Project Spec. P.O. Description IEC 62271- 200 Project Spec. P.O. Description IEC 62271- 203 Project Spec. P.O. Description IEC 62271- 203 IEC 61869-1

Project Spec. P.O. Description IEC 62271- 200

Project Spec. P.O. Description IEC 62271- 100

SL. NO.

ACTIVITY

5.3 Gas tightness test

5.4

Power frequency voltage test on main circuits (phase-to-earth, across open switching devices and between phases)

5.5 Dielectric test on auxiliary circuits

5.6

Measuring of resistance of the main circuits

5.7

Partial discharge measurement

5.8

Checking of phase layout/sequence of phases

5.9

Insulation resistance

5.10

5.11

5.12

test on auxiliary

Voltage withstand circuits Capacitive voltage indication during high voltage test Circuit breaker tests: -5 CLOSE operations at maximum operating pressure and maximum control voltage -5 OPEN operations at maximum operating pressure and maximum control voltage -5 CLOSE operations at minimum operating pressure and minimum control voltage -5 OPEN operations at minimum operating pressure and minimum control voltage -5 CLOSE-OPEN operations at rated operating pressure and rated control voltage -5 CLOSE-OPEN (O - t - C) operations at rated operating pressure and rated control voltage -Closing time at rated operating pressure and rated control voltage -Opening time at rated operating pressure and rated control voltage -measurement of recharging duration

Document No: AGES-SP-13-002

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R O T C A R T N O C

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–204

132KV Gas Insulated Switchgear (Cont’d)

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R O T C A R T N O C

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T N E M U C O D

Project Spec. P.O. Description IEC 62271- 102

Project Spec. P.O. Description IEC 62271- 102

SL. NO.

ACTIVITY

5. Routine Test (Cont’d)

5.12 Cont’d

-functional performance of pressure relief valve -measurement of the resistance of the control coils -hydraulic leakage test -dielectric test on auxiliary and control circuits

5.13

5.14

Disconnector and earthing switch tests:

• 5 CLOSE-OPEN operating cycles at minimum control voltage
• 5 CLOSE-OPEN operating cycles at maximum control voltage
• CLOSE operation at rated control voltage
• OPEN operation at rated control voltage
• CLOSE operation at minimum control voltage
• OPEN operation at minimum control voltage
• CLOSE operation at maximum control voltage
• OPEN operation at maximum control voltage
• 5 CLOSE-OPEN manual operations
• dielectric test on auxiliary and control circuits

Make-proof earthing switch tests:

• 5 CLOSE-OPEN operating cycles at minimum control voltage
• 5 CLOSE-OPEN operating cycles at maximum control voltage
• CLOSE operation at rated control voltage
• OPEN operation at rated control voltage
• CLOSE operation at minimum control voltage
• OPEN operation at minimum control voltage
• CLOSE operation at maximum control voltage
• OPEN operation at maximum control voltage
• 5 CLOSE-OPEN manual operations
• dielectric test on auxiliary and control circuits

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–204

132KV Gas Insulated Switchgear (Cont’d)

E C N E R E F E R

T N E M U C O D

SL. NO.

ACTIVITY

5. Routine Test (Cont’d)

Current transformer tests:

• verification of markings
• power frequency voltage withstands tests on secondary terminals
• power frequency withstand voltage test between sections
• inter-turn overvoltage test
• tests for accuracy:

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R O D N E V

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Y N A P M O C

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for ratio error and phase

-tests displacement -test for composite error (for class P and current transformers)

protective

PR

5.15

5.16

5.17

• determination of the instrument security factor of measuring current transformers
• determination of the secondary winding resistance
• recording of magnetization curves for all typical cores
• quantity and identification
• check of polarity
• check of rating plate and assignment to corresponding GIS bay

Voltage transformer test:

• operation of integrated isolation device (if applicable)
• power frequency voltage withstand test on primary terminals
• partial discharge measurement
• power frequency voltage withstands tests on secondary terminals
• tests for accuracy
• enclosure tightness test at ambient temperature
• quantity and identification
• check of rating plate

Surge arrester tests:

• measurement of reference voltage (Uref) at reference current (Iref)
• residual voltage test (Ures)
• internal partial discharge test
• gas leakage test
• rating plates

Project Spec. P.O. Description IEC 61869-1

Project Spec. P.O. Description IEC 61869-3

Project Spec. P.O. Description IEC 60099-4

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–204 132KV Gas Insulated Switchgear (Cont’d)

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R O T C A R T N O C

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T N E M U C O D

Project Spec. P.O. Description IEC 61439-1 IEC 62271- 203

SL. NO.

ACTIVITY

5.18

and

circuits

electrical

Local control cubicle tests:

• degree of protection of enclosures
• clearances and creepage distances
• protection against electric shock and integrity of protective circuits
• incorporation of built-in components

internal connections

• terminals for external conductors
• mechanical operation
• dielectric properties (2kV AC)
• wiring, operational performance and function
• functional test of individual switching devices

test of apparatus end positions

interlocking (between apparatus)

• alarm signals and blockings
• functional test of measuring and counting devices
• visual check of assembly, wiring and appearance
• visual check of preservation

test of complete bay

interlocking

functional

functional

in

5.19

Functional test of interface and primary injection of protective relays

6. Type Test & Special Test

6.1 Type Test Certificates

6.2 Special test as per IEC & Specifications

6.3

Tests and inspection for ATEX AND/OR IECEX certification “if applicable”

6.4

ECMS Control & Monitoring (IEC61850 & Modbus TCP)

6.5 EAMS Monitoring Functions

Project Spec. P.O. Description IEC 62271

ATEX AND/OR IECEX Project Spec. P.O. Description IEC 61850

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–204 132KV Gas Insulated Switchgear (Cont’d)

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R O T C A R T N O C

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I

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Approved Vendor Document Requirement List

SL. NO.

ACTIVITY

7. Preparation for Dispatch

7.1

Punch clearance inspection and Quality records review

7.2

Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks

7.3

Packing inspection and marking control of all goods, including spare parts

7.4

Inspection Release Note issuance Verification of Punch list clearance

7.5 Manufacturing Record Book

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

WIN / UTC / CMMS DATA Sheet (To Be Completed Vendor Wherever Applicable)

By

8.4

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–205

11KV & 6.6KV Air Insulated Switchgear

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description, Std.

COMPANY Pre- qualification

SL. NO.

1

ACTIVITY

Scope

list covers

This inspection requirements for 11KV & 6.6KV Air Insulated Switchgear

test and

Vendor approval

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production & Internal Testing

4.1

Internal factory testing

5. Routine Test

5.1 Visual inspection

5.2 Mechanical operation test

5.3 Functionality test

5.4

Power frequency voltage test on the main circuit

5.5 Dielectric test on auxiliary circuits

Document No: AGES-SP-13-002

Prod. Plan

QA Manual

Prod. Plan Project Spec. P.O. Description Codes, Stds &

Project Spec. P.O. Description IEC 62271- 200 IEC 62271-1

Project Spec. P.O. Description Project Spec. P.O. Description IEC 62271-200 Project Spec. P.O. Description IEC 62271- 200 IEC 62271-1 Project Spec. P.O. Description IEC 62271- 200 IEC 62271- 200 IEC 62271-1

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–205 11KV & 6.6KV Air Insulated Switchgear (Cont’d)

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R O T C A R T N O C

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L E V E L N O T N E V R E T N

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L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

5. Routine Test (Cont’d)

5.6

Measuring of resistance of the main circuits

5.7 Test of measuring and protection circuits

5.8 Painting examination

6. Type Test & Special Test

6.1 Type Test Certificates

6.2 Special test as per IEC & Specifications

6.3

Tests and inspection for ATEX AND/OR IECEX certification “if applicable”

6.4

ECMS Control & Monitoring (IEC61850 & Modbus TCP)

6.5 EAMS Monitoring Functions

7. Preparation for Dispatch

7.1

7.2

7.3

7.4

Punch clearance inspection and Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

7.5 Manufacturing Record Book

8. Reports & Test Certificates

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description IEC 62271- 200

Factory painting procedure

Project Spec. P.O. Description IEC 62271 ATEX AND/OR IECEX Project Spec. P.O. Description IEC 61850

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

8.1 Vendor Data Report

VDRL

8.2 Raw Material Test Certificates

8.3

WIN / UTC / CMMS DATA Sheet (To Be Completed Vendor Wherever Applicable)

By

8.4

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 165 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–206

415V SWGR

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

SL. NO.

1

ACTIVITY

Scope

list covers

This requirements for 415V switchgear

test and

inspection

Vendor approval

Pre-production/Pre-inspection Meeting Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production & Internal Testing

4.1 Material receiving and inspection

4.2

Verification of complete details of the assembly

4.3 Verification of all internal loops

4.4 Verification of electrical components

4.5 Functional testing

5. Routine Test

5.1 Visual inspection

5.2 Mechanical operation test

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description, Std.

COMPANY Pre- qualification

Prod. Plan

QA Manual

Prod. Plan

Project Spec. Codes, Stds &

Vendor procedures Proj. Spec. P.O. Description & App. Drgs. / Documents, International Codes & stds

5.3

test

(Power

frequency Functionality withstand test, Insulation resistance, ratio and polarity check of CTs & VTs, Dielectric routine tests, Interface and primary injection test of protective relays, Interlocking and Inter-tripping checks, Main circuit resistance measurements, Integrated FAT with ECMS applicable). EC Type Examination (ATEX AND/OR IECEX) Certificates (for hazardous area equipment)

(where

Project Spec. P.O. Description & App. Drawings Project Spec. P.O. Description IEC 61439

Document No: AGES-SP-13-002

Rev. No: 01 Page 166 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–206 415V SWGR (Cont’d)

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

5. Routine Test (Cont’d)

5.4 Dielectric test on auxiliary circuits

5.5

Measuring of resistance of the main circuits

5.6 Test of measuring and protection circuits

Project Spec. P.O. Description IEC 61439

5.7 Painting examination

Paint manual

6. Type Test & Special Test

6.1 Type Test Certificates

6.2 Special test as per IEC & Specifications

6.3

Tests and inspection for ATEX AND/OR IECEX certification “if applicable”

6.4

ECMS Control & Monitoring (IEC61850 & Modbus TCP)

6.5 EAMS Monitoring Functions

7. Preparation for Dispatch

7.1

7.2

7.3

7.4

Punch clearance inspection and Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

7.5 Manufacturing Record Book

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

By

Project Spec. P.O. Description IEC 61439 ATEX AND/OR IECEX Project Spec. P.O. Description IEC 61850

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Vendor Document Requirement List

Document No: AGES-SP-13-002

Rev. No: 01 Page 167 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–207

ECMS/PMS/EAMS

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

E V E L N O T N E V R E T N

R O D N E V

I

E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

E V E L N O T N E V R E T N

Y N A P M O C

I

E V E L N O T N E V R E T N

SL. NO.

1

ACTIVITY

Scope

list covers

This requirements for ECMS/PMS/EAMS

test and

inspection

Vendor approval

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production & Internal Testing

4.1 Check of received material

4.2

Assembly & production inspection of prototype cabinets: -Marshalling cabinet -IRP DCS cabinet -IRP ESD cabinet -FMS/SOE cabinet -Load shed RIO cabinet -Server cabinets

4.3 Cabinet hardware tests

4.4 Software tests

4.5 Functional testing

5. Routine Test

5.1 Visual inspection

5.2 System start-up test

5.3

I/O test

5.4 Verification of displays

5.5

ECMS, PMS & EAMS Graphics monitoring and control

5.6 Load shedding functions

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description, International Std. COMPANY Pre- qualification

Prod. Plan

QA Manual

Prod. Plan

Project Spec. Codes, Stds &

Project Spec. P.O. Description & Approved Drawings/Doc uments, International Codes and standards

Project Spec. P.O. Description & Approved Drawings

Document No: AGES-SP-13-002

Rev. No: 01 Page 168 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–207 ECMS/PMS/EAMS (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

5. Routine Test (cont’d)

5.7

System functions: -Cyber security -User authority & passwords -Diagnostics

5.8 System performance

5.9 ECMS & EAMS communication tests

5.10 MAC-MEES communication tests

5.11

ETAP real-time communication test, if applicable

6. Type Test & Special Test

6.1 Type Test Certificates

6.2 General performance requirements

6.3 Surge withstand capability test

6.4 Burst disturbance test

6.5 Electrostatic discharge test

6.6

Radiated electromagnetic field disturbance test

6.7 Dielectric impulse test

6.8

Immunity to external interference

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Drawings

Project Spec. P.O. Description IEC 61850 Project Spec. P.O. Description IEC 60255-6, Class 3 Project Spec. P.O. Description IEC 60255-4 Project Spec. P.O. Description IEC 60255- 22-1 Project Spec. P.O. Description IEC 60255- 22-2 Project Spec. P.O. Description IEC 60255- 22-3 Project Spec. P.O. Description IEC 60060 Project Spec. P.O. Description IEC 61000-4

Document No: AGES-SP-13-002

Rev. No: 01 Page 169 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–207

ECMS/PMS/EAMS (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

, Approved Vendor Document Requirement List

SL. NO.

ACTIVITY

7. Preparation for Dispatch

7.1

7.2

7.3

7.4

Punch clearance inspection and Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

7.5 Manufacturing Record Book

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

WIN / UTC / CMMS DATA Sheet (To Be Completed Vendor Wherever Applicable)

By

8.4

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 170 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–208

Neutral Earthing Resistor

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

SL. NO.

1

ACTIVITY

Scope

list covers

This requirements for Neutral Earthing Resistor

test and

inspection

Vendor approval

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production & Internal Testing

4.1 Check of received material

4.2

4.3

4.4

4.5

conservator

and

Tank cover manufacturing: -main dimensions -visual inspection of welding seams Surface treatment: -pre-treatment -painting conditions -visual inspection -paint thickness Vacuum treatment and oil filling: -process inspections Oil leakage test: -welding seams -gaskets valves

5. Routine Test

5.1 Measurement of resistance

5.2

Applied voltage test Test voltage: 70KV Test frequency: 50Hz Test time: 60s

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Prod. Plan

QA Manual

Prod. Plan

Project Spec. Codes, Stds &

Project Spec. P.O. Description & Approved Drawings/Doc uments, International Codes and standards

Project Spec. P.O. Description IEEE Std 32 10.1.4 IEEE Std 32 10.3

Document No: AGES-SP-13-002

Rev. No: 01 Page 171 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–208 Neutral Earthing Resistor (Cont’d)

SL. NO.

ACTIVITY

5. Routine Test (Cont’d)

5.3

Insulation test of auxiliary wiring 2 kV 50 Hz for 1 minute on control and supervisory equipment, 2.5 kV 50 Hz for 1 minute on CT’s

5.4

Checking of the functionality of transformer protective devices

5.5

Check of ratio and polarity of build-in current transformers

5.6 Leak testing

6. Type Test & Special Test

6.1 Type Test Certificates

6.2 Special test as per IEC & Specifications

Temperature-rise test KNAN At rated continuous current 10 A Guaranteed tank max. temp. rises 60 K Measurements:

• tank surface temperature rises with thermocouples
• Insulation liquid temperature rises with PT- 100
• Gas-in-oil analysis after temperature rise test Tests and inspection for ATEX AND/OR IECEX certification “if applicable”

6.3

6.4

7. Preparation for Dispatch

7.1

7.2

7.3

7.4

Punch clearance inspection and Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

7.5 Manufacturing Record Book

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description IEC 60076-3, 9

Project Spec. P.O. Description IEC 60076- 1,11.1.2.1 i Project Spec. P.O. Description IEC 60076-1, 11.8

Project Spec. P.O. Description IEC 60076

Project Spec. P.O. Description IEEE Std 32

ATEX AND/OR IECEX

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Document No: AGES-SP-13-002

Rev. No: 01 Page 172 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–208 Neutral Earthing Resistor (Cont’d)

E C N E R E F E R

T N E M U C O D

Vendor Document Requirement List (VDRL)

SL. NO.

ACTIVITY

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

By

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

Document No: AGES-SP-13-002

Rev. No: 01 Page 173 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

ITP–209

132KV Submarine Cable

SL. NO.

1

ACTIVITY

Scope This requirements for 132KV submarine cable

list covers

test and

inspection

Vendor approval

Pre-production/Pre-inspection Meeting Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre- production Meeting

3. General - Preliminary work

3.1 Data sheets

3.3 Vendor fabrication schedule

3.3 Vendor Q. P

3.4 Status of sub orders

3.5 Material test and certification

3.6 Manufacturing Specification

3.7 FAT Procedure review

3.8

3.9

Pre-Load out and Post Loadout Test Procedure Post installation and Site Acceptance Test Procedure

4. Production & Internal Testing

4.1

4.2

4.3

Material / component Traceability and Examination Measurement of Cu wire elongation and dimension outer Measurement diameter, and degree of filling water blocking material

conductor

of

E C N E R E F E R

T N E M U C O D

P.O. Project Spec.

COMPANY Pre- qualification

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds &

Vendor Data Book

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

4.4 Measurement of insulation concentricity

4.5

4.6

4.7

4.8

4.9

Recording of time/temperature while De- gassing Measurement of lead thickness and cable diameter after lead sheath extrusion Measurement of sheath thickness and cable diameter after: -core PE-sheath extrusion -Inner PE-sheath extrusion Visual inspection and X-ray conductor joints Measurement of cable diameter after armoring

Document No: AGES-SP-13-002

Rev. No: 01 Page 174 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–209 132KV Submarine Cable (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

5. Routine Test

5.1

Measurement of electrical resistance of conductor

5.2 Partial discharge test

5.3 Lightning impulse voltage test

5.4 High voltage AC test

5.5 Measurement of capacitance

5.6 Conductor examination

5.7 Electrical resistance of lead sheath

5.8 Thickness of insulation

5.9 Thickness of core sheath

5.10 Thickness of metallic sheath

5.11 Measurement of diameters

5.12 Hot set test for XLPE insulation

5.13 Volume resistivity

5. Routine Test (Cont’d)

5.14 Visual inspection of complete cable

5.15 Number of wires in each armor layer

5.16 Dimension of wires in each armor layer

5.17 Thickness of inner sheath measurement

5.18 Volume resistivity of inner sheath

5.19 Pitch length of armor

E C N E R E F E R

T N E M U C O D

Project Spec. IEC 60840 10.5 Project Spec. IEC 60840 9.2

Project Spec. IEC 60840 10.10 Project Spec. IEC 60840 10.4 Project Spec. IEC 68040 10.5 Project Spec. IEC 60840 10.4 Project Spec. IEC 60840 10.6 Project Spec. IEC 60840 10.7 Project Spec. IEC 60840 10.8 Project Spec. IEC 60840 10.9

Project Spec. IEC 60840 10.6

Document No: AGES-SP-13-002

Rev. No: 01 Page 175 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–209 132KV Submarine Cable (Cont’d)

I

N O T A C F T R E C

I

I

L E V E L

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project specification, procedures Data sheet

Project Spec. IEC 60502 Project Spec. IEC 60502

SL. NO.

ACTIVITY

5.20

Factory joints tests: -partial discharge test -high voltage AC test -lightning impulse voltage test -hot set test for XLPE insulation -tensile test

6. Type Test & Special Test

6.1 Type Test Certificates

6.2 High voltage AC test

6.3 Electrical resistance of conductor

6.4 TDR

6.5 OTDR

6.6

End to end attenuation measurement (power method)

6.7 Chromatic dispersion test

6.8 Polarization mode dispersion test

7. Preparation for Dispatch

7.1 Pre-Loadout inspection and Tests

7.2

7.3

7.4

7.5

clearance

inspection and

Punch Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing control of all goods, incl spare parts Inspection Release Note issuance Verification of Punch list clearance

inspection and marking

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

7.6 Manufacturing Record Book

8. Reports & Test Certificates

8.1 Vendor Data Report

VDRL

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 176 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–210

11KV Submarine Cable

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope This list covers test and inspection requirements for 11KV submarine cable

Project Spec. P.O. Description

I

N O T A C F T R E C

I

I

SL. NO.

1

COMPANY Pre- qualification

Prod. Plan

QA Manual

Prod. Plan

P.O. Description Project Specification , COMPANY STD Codes, Stds

Vendor Data Book

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Data sheets

3.2 Vendor fabrication schedule

3.3 Vendor Q.P

3.4 Status of sub orders

3.5 Material test and certification

3.6 Manufacturing Specification

3.7 FAT Procedure review

3.8

3.9

Pre-Load out and Post Loadout Test Procedure Post installation and Site Acceptance Test Procedure

4. Production & Internal Testing

4.1

4.2

4.3

4.4

4.5

4.6

4.7

Material / component Traceability and Examination Measurement of Cu wire elongation and dimension Measurement of conductor outer diameter, and degree of filling water blocking material Recording of time/temperature while De-gassing Measurement of lead thickness and cable diameter after lead sheath extrusion Measurement of sheath thickness and cable diameter after: -core PE-sheath extrusion -Inner PE-sheath extrusion -Outer PE-sheath extrusion Measurement of cable diameter after armoring

Document No: AGES-SP-13-002

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

Rev. No: 01 Page 177 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–210 11KV Submarine Cable (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

5. Routine Test

5.1

Measurement of electrical resistance of conductor

5.2 Partial discharge test

5.3 Lightning impulse voltage test

5.4 High voltage AC test

5.5 Measurement of capacitance

5.6 Conductor examination

5.7 Electrical resistance of lead sheath

5.8 Thickness of insulation

5.9 Thickness of core sheath

5.10 Thickness of metallic sheath

5.11 Measurement of diameters

5.12 Hot set test for XLPE insulation

5.13 Volume resistivity

5.14 Visual inspection of complete cable

5.15 Number of wires in each armor layer

5.16 Dimension of wires in each armor layer

5.17 Thickness of inner sheath measurement

5.18 Volume resistivity of inner sheath

5.19 Thickness of outer sheath measurement

5.20 Pitch length of armor

E C N E R E F E R

T N E M U C O D

Project Spec. IEC 60502-2 Project Spec. IEC 60502-2 Project Spec. IEC 60230

Project Spec. IEC 60502-2

Project Spec. IEC 60502-2 Project Spec. IEC 60502-2 Project Spec. IEC 60502-2

Project Spec. IEC 60502-2 Project Spec. IEC 60502-2

Project Spec. IEC 60502-2

Project Spec. IEC 60502-2

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–210 11KV Submarine Cable (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

6. Type Test & Special Test

6.1 Type Test Certificates

6.2 High voltage AC test

6.3 Electrical resistance of conductor

6.4 TDR

6.5 OTDR

6.6

End to end attenuation measurement (power method)

6.7 Chromatic dispersion test

6.8 Polarization mode dispersion test

7. Preparation for Dispatch

7.1 Pre-Loadout inspection and Tests

7.2

7.3

7.4

7.5

clearance

inspection and

Punch Quality records review checks, Visual and dimensional component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description IEC 60502 Project Spec. P.O. Description IEC 60502-2

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

7.6 Manufacturing Record Book

8. Reports & Test Certificates

8.1 Vendor Data Report

VDRL

8.2 Raw Material Test Certificates

8.3

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor Wherever Applicable)

8.4

Vendor Data Books endorsement, and issue of release note by TPA

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–211

Electrical Cables

SL. NO.

1

ACTIVITY

Scope This list covers test and inspection requirements for Electrical LV and HV Cables

Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production

4.1

Material / component Traceability and Examination

4.2 Sealing and Drumming

4.3

4.4

4.5

Laying up of conductors, insulation, armor, screening and inner & outer sheathing Inner and outer sheathing identification / color coding Hoisting, facilities of drums

transportability, pulling

5. Examination

Visual Check, Checking of proper identification of drums, completeness of quantities, sizes and voltage grades. Conductor and armor resistance, measurement of insulation thickness and high resistance Insulation voltage test (Dielectric routine tests)

5.1

5.2

5.3

5.4 Partial discharge test

5.5 Dimensional checks

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Prod. Plan

QA Manual

Prod. Plan

Project Spec. Codes

Vendor Data Book Project Spec. Standards Project Spec., std. & Approved Drawings Project Spec. Stds & Approved Drawings

Project Spec. Approved Drawings

Project Spec.

Project Spec.

Project Spec.

Project Spec. drawings & Standards

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–211 Electrical Cables (Cont’d)

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Project Spec. P.O. Description Project Spec. P.O. Description

Project Spec. P.O. Description, Project Spec. P.O. Description,

Vendor Document Requirement List

SL. NO.

ACTIVITY

6. Testing

6.1 Type tests (where appropriate)

6.2 Routine tests

6.3 Special tests (where appropriate)

7. Preparation for Dispatch

7.1 Marking, Tagging & Name plate

7.2 Protection for Shipment

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 181 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–212

AC UPS

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope This list covers test and inspection requirements for AC UPS

Project Spec. P.O. Description

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

COMPANY Pre- qualification

Prod. Plan

QA Manual

Prod. Plan

Project Spec. Codes, Stds &

Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production & Internal Testing

4.1

of

Check received material “Mechanical Components, Windings, Boards, & Electromechanical components, Batteries, BMS Cables”

electrical

4.2 Assembly & Dimensions check

4.3

4.4

Winding Marking with crimping, tightness Final Painting colour and Tagging check

ferrules,

4.5 Protective Circuit Continuity test

4.6

Insulation resistance test

Project Spec. P.O. Description & Approved Drawings/Do cuments, International Codes and standards

4.7 Dielectric test

4.8 Functional test

4.9 Heating test

4.10 Noise test

5. Routine Test

5.1 Battery Test Certificates- Review

5.2

Conformity checks- Dimensional checks, wiring checks, Accessibility & IP Rating, Continuity checking

Project Spec. P.O. Description

5.3 Insulation tests

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–212

AC UPS (Cont’d)

SL. NO.

ACTIVITY

5. Routine Test (Cont’d)

5.4 Load Duration tests

E C N E R E F E R

T N E M U C O D

test (constant

Functional tests a) Rectifier Load voltage) b) Rectifier Load current) Auxiliary equipment and control circuit tests

test (constant

5.5

5.6

5.7 Heating test

5.8 Noise test

5.9

5.10

5.11

5.12

5.13

5.14

Visual inspection EX-d Battery Protection Box and BMS (Battery Monitoring System) M-Sensors “if Applicable” Redundancy check 2x100% of each UPS Functional check for Online battery circuit monitoring facilities Operation and mechanical checks for all circuit breakers (MCCB, MCB, etc) Functional checks of auxiliary circuits (heaters, ventilation redundant blowers, internal lighting, etc.). Verification of name plate, Tag plate, identification, labeling, marking & ferruling

5.15 Checking of all outgoing feeders

5.16

5.17

5.18

5.19

5.20

Transient voltage response with step load changes up to 100% load Measurement of total transfer time, including failure detection period Check and record voltage and current wave shapes at no load and loadings Simulation of mains, inverter, and battery failure that would cause transfer of as per load from inverter output to bypass supply and return transfer tests Static switch transfers and permissive verification

Document No: AGES-SP-13-002

Project Spec. P.O. Description Project Spec. P.O. Description Project Spec. P.O. Description

Project Spec.

Project Spec.

Project Spec.

Project Spec.

Project Spec.

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–212 AC UPS (Cont’d)

SL. NO.

ACTIVITY

time

short

Overload test, to verify various loading overload requirements, capabilities until the unit current limits. Static switch transfer at current limit values shall also be verified. The test agreed / approved current limit and time values (125% of UPS rating for 1hr, 150% of UPS rating for 1 minute, and 400% of rated load for 1 second shall be verified during test Total harmonics distortion (THD) input current test, under rated linear load Conditions. Input source voltage shall be set to the nominal value and THD shall be in compliance with COMPANY STD Full load heat run test for 48 hours at 50%, 75% & 100% of full load rating of UPS system

5.21

5.22

5.23

5.24 Logic verification, scheme verification

5.25

Interface and communication test and check with PMS, DCS, etc. (including redundancy check)

5.26 Spare and space checks

E C N E R E F E R

T N E M U C O D

Project Spec.

5.27

5.28

5.29

Frequency out of limits test and synchronization test Full battery charge and discharge test (curves and submitted) Full functional test as per COMPANY STD

recorded

be

to

5.30 Verification of I/O list hard wired

5.31

5.32

One minute power frequency high voltage withstand (at 2kV) IR test before & after HV withstand test on Power, Control electronics, power electronics & auxiliary circuits

5.33

Soak test/unit under full load for 100hr

5.34

Demonstration a of minimum of 120 % of an estimated maximum load.

supplying

Project Spec.

Project Spec.

Document No: AGES-SP-13-002

Rev. No: 01 Page 184 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–212 AC UPS (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Desc.

Project Spec. P.O. Descrip.

ATEX AND/OR IECEX

Project Spec. P.O. Description & Approved Drawings/Do cuments, International Codes and standards

Vendor Document Requirement List

SL. NO.

ACTIVITY

5. Routine Test (Cont’d)

5.35

Demonstration of metering, alarms, and indications

5.36 Demonstration of protections

6. Type Test & Special Test

6.1 Type Test Certificates

6.2

Tests and AND/OR applicable”

inspection

for ATEX “if

certification

IECEX

7. Preparation for Dispatch

7.1

7.2

7.3

7.4

inspection and

Punch clearance Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

7.5 Manufacturing Record Book

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 185 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–213

DC UPS

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope This list covers test and inspection requirements for DC UPS

Project Spec. P.O. Description

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

COMPANY Pre- qualification Project Spec. P.O. Description

Prod. Plan

QA Manual

Prod. Plan

Project Spec. Codes, Stds &

Project Spec. P.O. Description & Approved Drawings/Do cuments, International Codes and standards

Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production & Internal Testing

4.1

Check of received material “Mechanical Components, Windings, Boards, electrical & components, Batteries, BMS Cables”

Electromechanical

4.2 Assembly & Dimensions check

4.3

4.4

Winding Marking with crimping, tightness Final Painting colour and Tagging check

ferrules,

4.5 Protective Circuit Continuity test

4.6

Insulation resistance test

4.7 Dielectric test

4.8 Functional test

4.9 Heating test

4.10 Noise test

5. Routine Test

5.1 Battery Test Certificates- Review

5.2

Conformity checks- Dimensional checks, Wiring checks, Accessibility & IP Rating, Continuity checking

5.3 Insulation tests

Project Spec. P.O. Description,

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–213 DC UPS (Cont’d)

SL. NO.

ACTIVITY

5.4 Load Duration tests

test (constant

Functional tests a) Rectifier Load voltage) b) Rectifier Load test (constant current) Auxiliary equipment and control circuit tests

5.5

5.6

5.7 Heating test

5.8 Noise test

5.9

5.10

5.11

5.12

5.13

5.14

Visual inspection EX-d Battery Protection Box And BMS (Battery Monitoring System) M-Sensors “if Applicable” Redundancy check 2x100% of each UPS Functional check for Online battery circuit monitoring facilities Operation and mechanical checks for all circuit breakers (MCCB, MCB, etc) Functional checks of auxiliary circuits (heaters, redundant ventilation blowers, internal lighting, etc.). Verification of name plate, Tag plate, identification, labeling, marking and ferruling

5.15 Checking of all outgoing feeders

5.16

Full load heat run test for 48 hours at 50% & 100% of full load rating of UPS system

5.17 Logic verification, scheme verification

5.18

Interface and communication test and check with PMS, DCS, etc. (including redundancy check)

5.19 Spare and space checks

5.20

5.21

Full battery charge and discharge test (curves to be recorded and submitted) Full functional test as per COMPANY STD

5.22 Verification of I/O list hard wired

E C N E R E F E R

T N E M U C O D

Project Spec.

Project Spec.

Project Spec.

Project Spec.

Project Spec.

Document No: AGES-SP-13-002

Rev. No: 01 Page 187 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–213 DC UPS (Cont’d)

ACTIVITY

E C N E R E F E R

T N E M U C O D

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

5.23

5.24

5.25

5.26

One-minute power frequency high voltage withstand (at 2kV) IR test before & after Power Frequency HV withstand test on Power, Control electronics, power electronics & auxiliary circuits a of Demonstration minimum of 120 % of an estimated maximum load. Demonstration of metering, alarms, and indications

supplying

5.27 Demonstration of protections

6. Type Test & Special Test

6.1 Type Test Certificates

6.2

Tests and AND/OR applicable”

inspection

for ATEX “if

certification

IECEX

7. Preparation for Dispatch

7.1

7.2

7.3

7.4

inspection and

Punch clearance Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

7.5 Manufacturing Record Book

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN/UTC/CMMS data sheet (to be completed by vendor (wherever applicable) Vendor Data Books endorsement, and issue of release note by TPA

Project Spec. P.O. Description

ATEX AND/OR IECEX

Project Spec. P.O. Description & Approved Drawings/Do cuments, International Codes and standards

Vendor Document Requirement List

Document No: AGES-SP-13-002

Rev. No: 01 Page 188 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–214

HV/MV Electric Motors

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope This list covers test and inspection requirements for HV/MV electric motors

Project Spec. P.O. Description

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

I

L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

SL. NO.

1

Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production & Internal Testing

4.1

4.2

4.3

Material / component Traceability and Examination Shaft forged rod heat analysis, mechanical properties and ultrasonic test Drawn rotor bars heat analysis, brinell hardness and dimensional and form check

4.4 Rotor balancing

4.5

4.6

4.7

Stator dielectric test -before coils connection -after coils connection -after impregnation S/C ring forgings heat analysis, brinell hardness, electrical conductivity, liquid penetrant inspection, ultrasonic test and dimensional inspection Sleeve bearings ultrasonic inspection of white metal adhesion and dimensional inspection

4.8 Sample coil test

COMPANY Pre- qualification

Project Spec. P.O. Description

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds

Vendor Data Book

Project Spec.

Project Spec.

EN 12163

Project Spec. P.O. Description & Approved Drawings

Project Spec.

Project Spec.

4.9

Dielectric loss angle test on sample coil

Project Spec.

4.10 Spray test

Document No: AGES-SP-13-002

Rev. No: 01 Page 189 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP-214 HV/MV Motors (Cont’d)

SL. NO.

ACTIVITY

5. Routine Test

5.1

Winding, heater and thermo-resistor (cold) resistance test

5.2 Insulation resistance measurement (cold)

5.3 Axial play check

5.4

No-load test (saturation test) and direction of rotation

5.5 No-load vibration test

5.6 Short circuit test with locked rotor

5.7

Insulation resistance measurement before and after high voltage test

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description Project Spec.

Drawing

Project Spec.

Project Spec. IEC 60034-14 Project Spec. IEEE 112 Project Spec. P.O. Description

5.8

High voltage test (windings, heaters and built-in temperature detectors)

IEC 60034-1 IEC 60060-1

5.9 Visual inspection

5.10

5.11

Functional test of PD coupler/detector (pulse phase analysis) Functional check of instruments (Vibration probe, PT100 RTDs and space heater)

6. Type Test & Special Test

6.1

Type Test Certificates

6.2

Insulation before and after temperature rise test

resistance measurement

6.3

Temperature rise test with double frequency method (frame and bearings winding resistance at warm)

temperatures,

6.4

Starting torque/current test with locked rotor

6.5 Shaft voltage test

Project Spec. P.O. Description & Approved Drawings

Project Spec. IEC 60034 Project Spec. IEEE 43 IEC 60204-1 Project Spec. IEC 60034-1 IEC 60034-29 Project Spec. IEEE 112 par. Project Spec. IEEE112 par.

Document No: AGES-SP-13-002

Rev. No: 01 Page 190 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–214

HV/MV Electric Motors (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

6. Type Test & Special Test (Cont’d)

6.6 Polarization index

6.7 Over speed test

6.8 Torque characteristic (f) RPM

6.9

Extrapolation of torque characteristic (f) RPM at 80% and 100% of rated voltage

6.10 Inertia moment test

6.11

No-load noise frequency by octave band analysis

test at nominal

6.12 Bearing insulation test

6.13

6.14

Efficiency, current, slip and power factor calculation with segregation of losses method (100-75-50% of load for ATEX Tests and inspection “if AND/OR applicable”

certification

IECEX

7. Preparation for Dispatch

7.1

7.2

7.3

7.4

inspection and

Punch clearance Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks inspection and marking Packing control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

7.5 Manufacturing Record Book

E C N E R E F E R

T N E M U C O D

Project Spec. IEEE 43 par. 5.4 Project Spec. IEC 60034-1 par. 9.7 Project Spec. IEEE 112 par. 7.3.2.2

Project Spec. IEC 60034-2-2 par. 7.2.5.1 Project Spec. ISO 3744 Project Spec. IEEE 112 par.8.4 Project Spec. IEC 60034-2

ATEX AND/OR IECEX

Project Spec. P.O. Description & Approved procedures, Drawings

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

Vendor Document Requirement List

Document No: AGES-SP-13-002

Rev. No: 01 Page 192 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–215

LV Electric Motors

I

N O T A C F T R E C

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

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L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification Project Spec. P.O.

Prod. Plan

QA Manual

Prod. Plan

Project Spec. Codes, Stds

Vendor Data Book

Project Spec. P.O. Description & Approved Drawings

SL. NO.

1

ACTIVITY

Scope This list covers test and inspection requirements for LV electric motors

Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production & Internal Testing

4.1

4.2

4.3

4.4

4.5

Material / component Traceability and Examination Shaft: -turning and grinding the shaft -Ex measuring document/shaft settings or random sample measurements -Ex measuring document/shaft routine measurement Rotor: -manufacturing rotors -correcting the shaft and turning the rotor core -balancing rotor Stator winding: -working instructions for winding -electrical during production -measuring the resistance of accessories -testing the winding with surge inspection Pressure test: -Routine pressure test of M3 Eexd- and Eexde-components Chapter “5 pressure test” -quality control pressure test of cast iron components

intermediate measurements

Document No: AGES-SP-13-002

Rev. No: 01 Page 193 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–215 LV Electric Motors (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

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R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Drawings

Project Spec. P.O. Description IEC 60034-1

Project Spec.

Project Spec.

Project Spec. Project Spec. Project Spec.

SL. NO.

ACTIVITY

5. Routine Test

5.1 Visual inspection

5.2 Withstand high voltage test

5.3

5.4

resistance measurement on

Insulation winding and heater Resistance measurement at the ambient temperature

5.5 Surge comparison test

5.6 Terminal markings and direction of rotation

5.7 No load point at 50 Hz

5.8 Locked rotor points at 50 Hz

5.9 Vibration level test

6. Type Test & Special Test

6.1 Type Test Certificates

6.2 No load test

6.3 Locked rotor test

6.4 Temperature rise test

6.5 Efficiency determination

6.6 Overload test

6.7 Starting current and torque

6.8 Torque – speed curve

6.9 Partial loads

6.10 Sound level test

7. Preparation for Dispatch

7.1

7.2

inspection and

Punch clearance Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks

Project Spec. P.O. Description & Approved Drawings

Document No: AGES-SP-13-002

Rev. No: 01 Page 194 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–215 LV Electric Motors (Cont’d)

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N O T A C F T R E C

I

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

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R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Vendor Document Requirement List

SL. NO.

ACTIVITY

7. Preparation for Dispatch (cont. ‘d)

7.3

7.4

Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

7.5 Manufacturing Record Book

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 195 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–216

Variable Speed Drives

SL. NO.

1

ACTIVITY

Scope

This list covers test and inspection requirements for VSD

Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

4. Production & Internal Testing

4.1 Check of received material

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Project Spec. P.O.

Prod. Plan

QA Manual

Prod. Plan

Project Spec. Codes, Stds

4.2 Dimensions check & Visual inspection

4.3

4.4

Winding Marking with crimping, tightness Final Painting colour and Tagging check

ferrules,

4.5 Check of electrical components

Project Spec. P.O. Description & Approved Drawings/ Documents

4.6 Mechanical construction

4.7 Clearance + Creeping Distances

5. Routine Test

5.1 Visual Check

5.2 Check Degree of Protection

5.3

5.4

Earthing

of Cubicles

Check Components of Cubicles Check Marking of Components Accordance with the Relevant Drawings

and

in

5.5 Check Rating Plate

5.6

Check Terminals and Wiring for Correct Marking and Diameters

5.7 Wiring Test

Project Spec. P.O. Description & Approved Drawings/ Documents

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–216

Variable Speed Drives (Cont’d)

E C N E R E F E R

T N E M U C O D

Project Spec. Approved procedures Drawings

Project Spec. P.O. Description Applicable for Water Cooled

Project Spec. P.O. Description Applicable for Air and Water Cooled

Project Spec. P.O. Description Applicable for Air Cooled

ATEX AND/OR IECEX

Project Spec. P.O. Description & Approved Drawings

SL. NO.

ACTIVITY

5.8

Insulation Test

5.9 High Voltage Test

5.10

Functional Test for Water Cooled VSD:

Hydraulic Test (with test field cooling unit) Check Pressure Difference Between Converter-in-/output at Rated Flow Rate Static Pressure Test

Functional Test for Air and Water Cooled VSD:

• check of APSM (AUX) (if applicable)
• check of terminal module
• check of motor modules in U/f Mode

5.11

(without load)

• check of CBM Braking Unit (if

applicable)

• check of LCM (if applicable)
• check of ALM/BLM/SLM (if applicable)
• generate routine test certificate Functional Test for Air Cooled VSD:
• starting up AOP/IOP
• Loading Firmware
• Check of ALM/BLM/SLM (if applicable)
• Check of Power Modules in U/f Mode

(without load)

5.12

6. Type Test & Special Test

6.1 Type Test Certificates

6.2

Tests and inspection for ATEX AND/OR IECEX certification “if applicable”

7. Preparation for Dispatch

7.1

7.2

7.3

7.4

dimensional

Punch clearance inspection and Quality records review Visual checks, and component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

7.5 Manufacturing Record Book

Document No: AGES-SP-13-002

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N O T A C F T R E C

I

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–216 Variable Speed Drives (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Vendor Document Requirement List

SL. NO.

ACTIVITY

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 198 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–217

Electrical Heat Tracing

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope This list covers test and inspection requirements for Electrical Heat Tracing

Project Spec. P.O.

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production & Internal Testing

4.2

4.1 Visual Inspection Dimensional Package Inspection equipment like (Control Panels, Junction box … etc.) Insulation Resistance Test for Heater Cable & for Package equipment like (Control Panels … etc.)

4.3

of

4.4 Dielectric Test for Heater Cable

4.5

Resistance of Metallic Braid (Sheath conductivity)

4.6 Thermal Output Test (Rated Output)

4.7 Start-Up Current Test

4.8 Maximum Sheath Temperature Test

4.9 Thermal Stability Test

4.10 Self-Regulating Index

5. Type Test & Special Test

5.1 Type Test Certificates

5.2

Tests and AND/OR applicable”

inspection

for ATEX “if

certification

IECEX

COMPANY Pre- qualification

Project Spec. P.O. Description

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds

Project Spec. P.O. Description & Approved Drawings/ Documents

ATEX AND/OR IECEX

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–217

Electrical Heat Tracing (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Drawings

Vendor Document Requirement List

SL. NO.

ACTIVITY

6. Preparation for Dispatch

6.1

6.2

6.3

6.4

inspection and

Punch clearance Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

6.5 Manufacturing Record Book

7. Reports & Test Certificates

7.1 Vendor Data Report

7.2 Raw Material Test Certificates

7.3

7.4

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 200 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–218

Navigational Aids

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

ACTIVITY

Scope This list covers test and inspection requirements for audible and visible navigational aids

Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description, IALA IEC & Other international Standards COMPANY Pre- qualification

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds

4.1

4.2

Material / component Traceability and Examination Mountings, orientation of installation & coverage

4.3 Power supply equipment

4.4

Terminals, Connectors, Cable glands & Enclosures

Vendor Data Book

Project Spec. P.O. Description & Approved Drawings

4.5 Hoisting facilities

5. Examination

5.1

Visual Check, Dimensional verification of each equipment in compliance with technical documentation

the

5.2

Weather proofing, protection)

I.P

(Ingress

5.3 Painting Examination

Project Spec. Approved Drawings

Project Spec. P.O. Description & Standards Approved PRO

Document No: AGES-SP-13-002

Rev. No: 01 Page 201 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–218 Navigational Aids (Cont’d)

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description Codes & Std

Project Spec. P.O. Description & Standards

Project Spec. P.O. Description, Std.

SL. NO.

ACTIVITY

6. Testing

6.1 PMI (Where applicable)

6.2

Insulation resistance tests, voltage tests, continuity of protective bonding circuit, protection against residual voltage, endurance test etc.

6.3 Routine tests

6.4 Performance & full functional test

6.5

Type and appropriate)

special

test

(where

6.6 Load Test (Where applicable)

7. Preparation for Dispatch

7.1 Marking, Tagging & Name plate

7.2 Protection for Shipment

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

Hazardous area classification (ATEX AND/OR IECEX approved notified bodies.)

Project Spec. P.O. Description & Standards

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor Wherever Applicable)

8.5

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 202 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–219

Solar Power Systems

SL. NO.

1

ACTIVITY

list covers

Scope This inspection requirements for equipment/items related to Solar Power Systems

test and

Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 FAT Procedure review

4. Production

4.1

4.2

4.3

4.4

4.5

Material / component Traceability and Examination Array module frame & array support structure Module JBs, isolators, CBs , Charge controller , interface box, distribution board, fittings and accessories Battery and Battery boxes & including battery CB Hoisting, transportability and assembling facilities

5. Examination

5.1

5.2

5.3

locking

Visual Dimensional Check, earth and cable connections, facilities completeness of the name plates, labels & rating plates Interchangeability and functional tests, insulation measurement and dielectric withstand test Measurement of SC current and open fault circuit voltage, verification of signaling circuit

5.4 Temperature Rise test

5.5 Painting Examination

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description P.O. Spec.

COMPANY Pre- qualification Project Spec. P.O. Description

Prod. Plan

QA Manual

Prod. Plan

Project Spec. Codes, Stds &

Vendor Data Book

Project Spec. P.O. Description & Approved Drawings

Project Spec. P.O. Description & Approved Drawings

/ Approved PRO

Document No: AGES-SP-13-002

Rev. No: 01 Page 203 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–219

Solar Power Systems (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

6. Testing

6.1 PMI (Where applicable)

6.2 Type tests (where appropriate)

6.3 Full load soak test

6.4

Full Functional Test & Factory Acceptance Test (FAT)

6.5 Special test (where appropriate)

7. Preparation for Dispatch

7.1 Marking, Tagging & Name plate

7.2 Protection for Shipment

8. Reports & Test Certificates

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description Codes & Std

Project Spec. P.O. Description & Standards

Project Spec. P.O. Description,

8.1 Vendor Data Report

VDRL

8.2 Raw Material Test Certificates

8.3

8.4

8.5

Hazardous area classification (ATEX AND/OR IECEX approved notified bodies.) WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor Wherever Applicable) Vendor Data Books endorsement, and issue of release note by TPA

P.O. Spec. & Standards

Document No: AGES-SP-13-002

Rev. No: 01 Page 204 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–220

Cathodic Protection System

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope This List covers Inspection of Cathodic Protection System

P.O, Project Spec. Codes & Stds.

1.1 Vendor approval

COMPANY PQ

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

3.1

Vendor’s commissioning schedule

CP

installation

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 Pre-Design Survey Procedure

and

Installation & commissionin g Plan

QA Manual

Prod. Plan

3.6

System

CP calculations

detailed

design

and

3.7 FAT Procedure review

Project Spec. P.O. Description Codes, Stds

Post Installation and Site Acceptance Test Procedure

Installation, Pre-Commissioning Testing and Inspection of CP System

3.8

4.1

4.2

4.3

4.4

Material / Component Traceability and examination Installation of CP on pipes, tanks, well casing Verify material correct and vendor data sheet where appropriate for installation Verify location of rectifier PDB test station associated equipment correct

4.5 Verify cable Route, Trench Size

4.6

4.7

Installation of anode loops and reference electrodes Installation of rectifiers test stations, PDB and associated equipment.

5. Verify Cables and cable terminations

5.1 Pin brazing

5.2 Coating Repair

5.3 Measure and record Soil resistivity

5.4

Electrical Bonding: Verify correct size bonding and continuity test

5.5 Steel to Soil Potential

Vendor Data Books

Project Spec. P.O. Description & Approved Drawings

Project Spec. P.O. Description & Approved Drawings

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–220

Cathodic Protection System (Cont’d)

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R E R U T C A F U N A M

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SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

5. Verify Cables and cable terminations (Cont’d)

5.6

Pre-Commissioning Inspection of CP System

Testing

and

5.7

Inspection Data

Vendor Book endorsement, and Issue of Release Note by TPA

Project Spec. P.O. Description Code & Stds

Document No: AGES-SP-13-002

Rev. No: 01 Page 206 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–221

GRP Cable Trays & Ladders

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N O T A C F T R E C

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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R O T C A R T N O C

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SL. NO.

ACTIVITY

Scope This list covers Inspection and testing of GRP Cable Trays & Ladders

1.1 Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Data sheet

3.2 Design/Drawing Approval

3.3 Vendor Manufacturing Schedule

3.4 Vendor QP

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description Code & Stds

COMPANY PQ

Project Spec. P.O. Description,

STD 107, Project specification Project Spec. Construction Drawing

Prod. Plan

QA Manual

3.5

Laminating procedures Approval and operator’s qualification

Project spec. Codes/stds

3.6 Status of sub orders

3.7 Material and Test Certificates/Compliance

3.8

FAT Procedure and manufacturer Technical specification review

Prod. Plan

Project Spec. Codes/Stds. &

4. In process inspection (Visual/ Dimensional/workmanship)

4.1

Raw material inspection: Glass Reinforced Polyester -Class 1 Type Flame Retardant and Non-Toxic Properties Flame-spread index Oxygen index Flame rating Class 1

4.2 Chemical resistance Test

4.3

Product sample test: –Minimum glass transition test (Tg)

4.4

Product sample test: Barcol hardness

Project Spec. Batch Certificate

Project Spec. ASTM C581

ISO 6721

Project Spec. ASTM D 2583

Document No: AGES-SP-13-002

Rev. No: 01 Page 207 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–221 GRP Cable Trays & Ladders (Cont’d)

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

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L E V E L N O T N E V R E T N

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R O T C A R T N O C

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L E V E L N O T N E V R E T N

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L E V E L N O T N E V R E T N

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4. In process inspection (Visual/ Dimensional/workmanship) – (Cont’d)

Product sample test: Glass content UV, Chemical and Water Resistance Properties Flame retardant & non-toxic, Anti- Static Property Water absorption test

4.5

Project Spec. P.O. Description ISO 1172

4.6 SWL Test using deflection meter

5. Final Inspection and Testing

5.1 Visual and dimensional inspection

5.2

Product marking, identification check and Quantity check Check Trays / Ladders and Accessories Catalogue Number

6. Preparation for Dispatch

6.1 Marking, Tagging & Name Plate

6.2 Protection for Shipment

7. Reports & Test Certificates

7.1 Vendor Data Report

7.2 Raw Material Test Certificates

7.3

Vendor Data Books endorsement, and issue of release note by TPA

Project Spec. Approved drawing and ASTM D 2563

Project Spec.

Project Spec. P.O. Description,

Project Spec. Code & Standards Project Spec. P.O. Description,

Document No: AGES-SP-13-002

Rev. No: 01 Page 208 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–222

Electric Traction Lift

E C N E R E F E R

T N E M U C O D

Codes & Stds. Project Spec. P.O. Description

COMPANY PQ

Project Spec. P.O. Description Manufacture r’s Catalogue

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds. &

Project Spec. P.O. Description , Codes & Std

SL. NO.

ACTIVITY

Scope This list covers Inspection and testing of Electric Traction Lift

1.1 Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Design/Model Approval

3.2 Vendor Manufacturing Schedule

3.3 Vendor QP

3.4 Status of sub orders

3.5 Material and Test Certificates/Compliance

3.6 FAT Procedure review

4. Final inspection and Testing

4.1

4.2

4.3

4.4

Visual/dimensional check, electrical rating inspection and workmanship Overhead guard and Hydraulic cylinders inspection Master assembly: Check for crack weld, bent areas and missing stop Lift chains, examination

rollers and Forks Tires

4.5 Examine the battery

4.6 Check the hydraulic fluid level

4.7

4.8

4.9

Check the gauges, Hour meter and Battery discharge indicator Test the standard equipment: Steering, Brakes, Front, tail, brake lights, Horn Check the operation of attachments

load-handling

4.10 Test the front, tail, and brake lights

4.11

Proof load and Safe working load testing

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

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R O T C A R T N O C

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ITP–222 Electric Traction Lift (Cont’d)

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description , Codes & Std Code & Standards

SL. NO.

ACTIVITY

5. Report & Test Certificates

5.1 Load test certificates

5.2 Vendor Data Reports

5.3 Raw Material Certificates

5.4 Instruction Manual

5.5

Book, Inspection Data Vendor Warranty certificate and Issue of Release Note by TPAA

6. Preparation for Dispatch

6.1 Marking, Tagging & Name Plate

6.2 Protection for Shipment

Project Spec. P.O. Description

Document No: AGES-SP-13-002

Rev. No: 01 Page 210 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–223

Pneumatic & Hydraulic Actuators

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope This List covers Inspection of (A) Pneumatic Actuators. (B) Hydraulic Actuators.

Project Spec., Codes & Stds. P.O.

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N O T A C F T R E C

I

I

SL. NO.

1

Vendor approval

2. Pre-production Meeting

3. General - Preliminary work

3.1 Data sheets and GA, Detailed drawings

3.2 Vendor Manufacturing Schedule

3.3 Vendor QP

3.4 Status of sub orders

3.5 Material and Test Certificates

3.6 Factory acceptance Test Procedure

4. Production

4.1

4.2

4.3

4.4

Construction

Material / Component Traceability and examination Base Frame, Yoke, Spring Cartridge, (Whichever Actuator applicable) Electrical Components, Electronic control circuits, Valve position Indicators, Flange Pipe pipe Enclosures, connections, Dynamic Actuator Seals, Pneumatic connections, Accessories Hoisting, Pulling, Transportability, Jacking Facility (If required)

connections,

Instrument

Threaded

5. Examination

5.1

Dimensional

Visual Proper mounting, Completeness of name plates, rating and diagram plates etc.

Check,

5.2 Painting Examination

6. Testing

6.1

NDE (PMI, Ultra Sonic, Dye Penetrant) (As applicable)

6.2 Actuator Thrust/Torque Test

6.3 Functional Test

Document No: AGES-SP-13-002

COMPANY Pre- qualification

Prod. Plan

QA Manual

Prod. Plan

Codes, Stds. & , Project Specification

Vendor Data Books

P.O. Spec & Approved Drawings

P.O. Spec & Approved Drawings

Codes & Std P.O. Spec , Code & Standards

R E R U T C A F U N A M

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R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–223 Pneumatic & Hydraulic Actuators (Cont’d)

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R O T C A R T N O C

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T N E M U C O D

P.O Spec.,

Vendor Document Requireme nt List

SL. NO.

ACTIVITY

6. Testing (Cont’d)

6.4 Fugitive Emission Test

6.5

Pressure Test (Hydro test & Seat Leakage Test)

7. Preparation for Dispatch

7.1 Marking, Tagging & Name Plate

7.2 Protection for Shipment

Inspection Release Note

8. Report & Test Certificates

8.1 Vendor Data Reports

8.2 Raw Material Certificates

8.3

8.4

8.5

Inspection Data

WIN/UTC/CMMS DATA Sheet (To be completed by Vendor wherever applicable Book Vendor endorsement, and Issue of Release Note by TPAA SIL Certificate for ESDV & for the whole assembly (valve, actuator & accessories)

Document No: AGES-SP-13-002

Rev. No: 01 Page 212 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–224

Motorized Actuators

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N O T A C F T R E C

I

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

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L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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SL. NO.

ACTIVITY

Scope This list covers Inspection and testing of Motorized Actuators

1.1 Vendor approval

2. Pre-production Meeting

3. General - Preliminary work

3.1 Data sheet, Design/Drawing Approval

3.2 Vendor Manufacturing Schedule

3.3 Vendor QP

3.4 Status of sub orders

3.5 Material and Test Certificates/Compliance

4. Production

E C N E R E F E R

T N E M U C O D

Codes & Stds. P.O.

COMPANY PQ

Design Data Sheet and Drawing

Prod. Plan

QA Manual

Prod. Plan

Codes, Stds. &

4.1

Material / Component Traceability and examination

Vendor Data Sheet

4.2 Wiring drawing verification

4.3

Electrical component or device in explosive atmosphere

4.4

Actuator compliance

construction and enclosure

4.5 Electronic control circuit test

4.6

Actuator opening/closing time

rated/peak/stall

torque and

Approved Design Drawing

UL/FM/CSA/ ATEX AND/OR IECEX

NEMA 4X and IP65

IEC 60255.22-3

P.O. Spec & Approved Data Sheet

4.7

Hand wheel, local control, control power supply, closing direction, all required inputs and outputs, operation of motor winding temperature detector, and operation position indication & LEDs.

P.O. Spec & Approved Design Drawing

4.8

Manufacturer or external Gear Box Model No.

Approved Data Sheet

Document No: AGES-SP-13-002

Rev. No: 01 Page 213 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

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N O T A C F T R E C

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R O D N E V

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L E V E L N O T N E V R E T N

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R O T C A R T N O C

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ITP–224 Motorized Actuators (Cont’d)

SL. NO.

ACTIVITY

5. Final inspection and Testing

5.1 PMI (Where applicable)

5.2 Functional Test

6. Preparation for Dispatch

6.1 Marking, Tagging & Name Plate

6.2 Protection for Shipment

Inspection Release Note

7. Report & Test Certificates

E C N E R E F E R

T N E M U C O D

Codes & Std

P.O. Spec , Code & Standards

P.O Spec., Std.&

P.O Spec.

7.1 Vendor Data Reports

Codes & Std

7.2 Raw Material Certificates

7.3

Instruction Manual

7.4

Vendor Inspection Data Book, Issue of Release Note by TPAA

Document No: AGES-SP-13-002

Rev. No: 01 Page 214 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–225

Analyzer System

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N O T A C F T R E C

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

I

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L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Y N A P M O C

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L E V E L N O T N E V R E T N

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SL. NO.

ACTIVITY

Scope This list covers test and inspection requirement for Analyzer Package (Sample Connection System)

1.1 Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5

3.6

Welding Procedure Qualification & Welder Qualification NDT Procedure & NDT Personnel Qualification

3.7 Leak Test Procedure

3.8 FAT Procedure review

3.9 Painting Procedure review

3.10 PMI Procedure review

4. Production & Testing

4.1 Check of received material

4.2 PMI

4.3 WELDING

4.4 NDE

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY PQ

Project Spec. P.O. Description

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds &

Project Spec. P.O. Description Codes, Stds.

Project Spec. Approved Drawings, Codes & Standards

Approved WPS Project Spec. P.O. Description & Approved Documents

Document No: AGES-SP-13-002

Rev. No: 01 Page 215 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–225 Analyzer System (Cont’d)

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N O T A C F T R E C

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

I

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R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Y N A P M O C

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L E V E L N O T N E V R E T N

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E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Documents & Std.

Project Spec. P.O. Description & Approved Documents & Std.

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Vendor Document Requirement List

SL. NO.

ACTIVITY

4. Production & Testing (Cont.’d)

4.5 Visual & dimensional Check

4.5.1 Sample Connection System

4.5.2 Name Plate

4.6 Leak Test

4.7 FAT

4.8 Painting Check

4.8.1 Visual Check

4.8.2 Coating Thickness

5. Preparation for Dispatch

5.1

5.2

5.3

5.4

inspection and

Punch clearance Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks inspection and marking Packing control of all goods, including spare parts Inspection Release Note Issuance Verification of Punch list clearance

5.5 Manufacturing Record Book

6. Report & Test Certificates

6.1 Vendor Data Reports

6.2 Raw Material Test Certificates

6.3

6.4

WIN/UTC/CMMS data sheet (to be (Wherever completed by vendor Applicable) Vendor Book endorsement, and Issue of Release Note by TPA

Inspection Data

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–226

Distribution Panel Board

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N O T A C F T R E C

I

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

I

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L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Y N A P M O C

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L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope This list covers test and inspection requirement for Distribution Panel Board

Project Spec. P.O. Description

1.1 Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 Manufacturing Drawings

3.6 Packing & Preservation Procedure

3.7 Painting Procedure

3.8 Inspection and Test Procedure

3.9 FAT Procedure

4. Production, Inspection & Testing

4.1 Check of received material

4.2 Dimensions of Boards

4.3 Size & Rating of Components

4.4 Texts & Sizes of Nameplates

4.5 Qty & Size of Cable Entries

4.6 Operation Physical Test

4.7 Temperature rise test

4.8 Check Wiring

4.9 Phase, earthing & continuity tests

COMPANY PQ

Project Spec. P.O. Description

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds &

Project Spec. P.O. Description Codes, Stds.

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Document No: AGES-SP-13-002

Rev. No: 01 Page 217 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–226

Distribution Panel Board (Cont’d)

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

4. Production, Inspection & Testing (Cont’d)

4.10 Insulation test (or impulse Test)

4.11 Dielectric Test

4.12

Functional electrical component check

Electrical

Test with

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I

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R O T C A R T N O C

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L E V E L N O T N E V R E T N

I

4.13 EC declaration of conformity

4.14 Hazardous conformity certificates

5. Preparation for Dispatch

5.1

5.2

5.3

5.4

inspection and

Punch clearance Quality records review checks, Visual and dimensional component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note Issuance Verification of Punch list clearance

5.5 Manufacturing Record Book

6. Report & Test Certificates

6.1 Vendor Data Reports

6.2

6.3

WIN/UTC/CMMS data sheet (to be completed by vendor (Wherever Applicable) Book Vendor endorsement, and Issue of Release Note by TPAA

Inspection Data

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Vendor Document Requirement List

Document No: AGES-SP-13-002

Rev. No: 01 Page 218 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–227

Flow meter

SL. NO.

ACTIVITY

Scope list covers This requirement for Flowmeter

test and

inspection

1.1 Vendor approval

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted and approved by COMPANY/Contractor prior to Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5

3.6

Welding Procedure Qualification & Welder Qualification where applicable NDT Procedure & NDT Qualification where applicable

Personnel

3.7 Inspection & Test Procedure review

3.8 Painting Procedure review

3.9 PMI Procedure review

4. Production, Inspection & Testing

4.1 Check of received /purchased material

4.2 PMI

4.3 WELDING where applicable

4.4 NDE where applicable

4.5 Pressure Test

4.6 Dimensional Inspection

4.7 Meter Proving (Function Test) (if required)

4.8 Review the Calibration Certificate

4.9 Visual Inspection (Assembly)

4.10 Painting Inspection

Document No: AGES-SP-13-002

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY PQ

Project Spec. P.O. Description

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds

Project Spec. P.O. Description Codes, Stds.

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards Approved WPS

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–227

Flowmeter (Cont.’d)

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N O T A C F T R E C

I

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

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R O T C A R T N O C

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T N E M U C O D

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Vendor Document Requirement List (VDRL)

SL. NO.

ACTIVITY

5. Preparation for Dispatch

5.1

5.2

5.3

5.4

inspection and

Punch clearance Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks inspection and marking Packing control of all goods, including spare parts Inspection Release Note Issuance Verification of Punch list clearance

5.5 Manufacturing Record Book

6. Report & Test Certificates

6.1 Vendor Data Reports

6.2 Raw Material Test Certificates

6.3

6.4

WIN/UTC/CMMS data sheet (to be completed by vendor (Wherever Applicable) Vendor Book endorsement, and Issue of Release Note by TPAA

Inspection Data

6.5 Calibration Test Certificate

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–228

Instrument Tubing (SMLS Tube)

SL. NO.

ACTIVITY

Scope

This list covers test and inspection requirement for Instrument Tubing (SMLS Tube)

1.1 Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 Packing & Preservation Procedure

3.6

Non-Destructive Examination (NDE) Procedures

3.7 PMI Procedure

3.8 Inspection and Test Procedure

4. Production, Inspection & Testing

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY PQ

Project Spec. P.O. Description

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes / Stds,

Project Spec. P.O. Description Codes, Stds.

4.1 Material Test

4.1.1 Mechanical

4.1.2 chemical

4.1.3 hardness test

4.2

4.3 Eddy Current Test

4.4 Hydro test

4.5 PMI Inspection

4.6 Visual & Dimensional Inspection

4.7 Marking

4.8 Final Inspection

Document No: AGES-SP-13-002

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R O T C A R T N O C

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–228

Instrument Tubing (SMLS Tube) (Cont’d)

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N O T A C F T R E C

I

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

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L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

I

Y N A P M O C

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L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Vendor Document Requirement List

SL. NO.

ACTIVITY

5. Preparation for Dispatch

5.1

5.2

5.3

5.4

inspection and

Punch clearance Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks inspection and marking Packing control of all goods, including spare parts Inspection Release Note Issuance Verification of Punch list clearance

5.5 Manufacturing Record Book

6. Report & Test Certificates

6.1 Vendor Data Reports

6.2

6.3

WIN/UTC/CMMS data sheet (to be completed by vendor (Wherever Applicable) Vendor Book endorsement, and Issue of Release Note by TPAA

Inspection Data

Document No: AGES-SP-13-002

Rev. No: 01 Page 222 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–229

Level Transmitter

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

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L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

I

SL. NO.

1

ACTIVITY

Scope

This list covers test and inspection requirement for Level Transmitter

Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5

3.6

Welding Procedure Qualification & Welder Qualification NDT Procedure & NDT Personnel Qualification

3.7 Inspection & Test Procedure

3.8 Preservation Procedure

3.9 Painting Procedure review

3.10 PMI Procedure review

3.11 Shipping & Handling Procedure

4. Production, Inspection & Testing

4.1 Check of received /purchased material

4.2 Visual / Dimension Inspection

4.3 Functional test

4.4 Pressure Test

4.5 PMI

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Project Spec. P.O. Description,

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds &

Project Spec. P.O. Description Codes, Stds.

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Document No: AGES-SP-13-002

Rev. No: 01 Page 223 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–229

Level Transmitter (Cont’d)

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R O T C A R T N O C

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I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

4. Production, Inspection & Testing (Cont’d)

Approved WPS Project Spec. P.O. Description & Approved Documents

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Vendor Document Requirement List

4.6 Welding (where applicable)

4.7 NDE

4.8

Final inspection & review of all documents including all certificate & report

5. Preparation for Dispatch

5.1

5.2

5.3

5.4

inspection and

Punch clearance Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note Issuance Verification of Punch list clearance

5.5 Manufacturing Record Book

6. Report & Test Certificates

6.1 Vendor Data Reports

6.2 Raw Material Test Certificates

6.3

6.4

WIN/UTC/CMMS data sheet (to be completed by vendor (Wherever Applicable) Vendor Book endorsement, and Issue of Release Note by TPAA

Inspection Data

6.5 Calibration Test Certificate

Document No: AGES-SP-13-002

Rev. No: 01 Page 224 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–230

Telecom System (LAN / WAN System)

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

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R O T C A R T N O C

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I

SL. NO.

ACTIVITY

Scope

This list covers test and inspection requirement for Telecom System (LAN / WAN System)

1.1

Vendor approval

Pre-production/Pre-inspection Meeting

Key Design Documents shall be submitted by COMPANY/Contractor prior to Pre- production Meeting

approved

and

General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 Manufacturing Drawings

3.6 Packing & Preservation Procedure

3.7 Painting & Coating Procedure

3.8

Inspection and Test Procedure

3.9

FAT & IFAT Procedure

4. Production, Inspection & Testing

4.1 Check of received material

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Project Spec. P.O. Description

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds &

Project Spec. P.O. Description Codes, Stds.

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Document No: AGES-SP-13-002

Rev. No: 01 Page 225 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–230 Telecom System (LAN / WAN System) (Cont’d)

SL. NO.

ACTIVITY

4.2

PRE-FAT Inspection (Internal)

E C N E R E F E R

T N E M U C O D

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I

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R O D N E V

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I

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R O T C A R T N O C

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L E V E L N O T N E V R E T N

Y N A P M O C

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L E V E L N O T N E V R E T N

4.2.1 Visual and Functional Inspection (internal) 4.2.1.1 Cabinets 4.2.1.2 Equipment 4.2.1.3 Tagging 4.2.1.4

Functional test

Project Spec. P.O. Description & Approved Drawings Codes & Standards

4.3

Factory Acceptance Testing

4.3.1

Verify equipment

Calibration

of

test

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

4.3.2 Visual and Dimensional Inspection

4.3.2.1 Cabinets

4.3.2.2 Equipment

4.3.2.3 Tagging

4.3.3 FAT - Main System

4.3.3.1 Equipment Assembly

4.3.3.2 Power supply/ Electrical test

4.3.3.3 Functional test

Project Spec. Approved Drawings/ Documents, International Codes & Standards

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

4.3.4

Integrated Factory Acceptance Test

4.3.4.1

IFAT

Document No: AGES-SP-13-002

Rev. No: 01 Page 226 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–230 Telecom System (LAN / WAN System) (Cont’d)

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R O D N E V

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L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Vendor Document Requirement List

SL. NO.

ACTIVITY

Preparation for Dispatch

5.1

5.2

5.3

5.4

Punch clearance inspection and Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Note Issuance Verification of Punch list clearance

Release

5.5

Manufacturing Record Book

Report & Test Certificates

6.1

Vendor Data Reports

6.2

6.3

WIN/UTC/CMMS data sheet (to be vendor by completed (Wherever Applicable) Vendor Inspection Data Book endorsement, and Issue of Release Note by TPAA

Document No: AGES-SP-13-002

Rev. No: 01 Page 227 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

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N O T A C F T R E C

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

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L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

Y N A P M O C

I

L E V E L N O T N E V R E T N

ITP–231 Wellhead Control Panels

SL. NO.

1

ACTIVITY

Scope

This list covers test and inspection requirement control panels

for Wellhead

Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4

Material test and certification including ATEX AND/OR IECEX & IP Certification where applicable

3.5

3.6

Welding Procedure Qualification & Welder Qualification where applicable NDT Procedure & NDT Personnel Qualification where applicable

3.7 Inspection & Test Procedure review

3.8 Painting Procedure review

3.9 PMI Procedure review

3.10 Drawings

3.11 Factory Acceptance Test Procedure

3.12 Site Acceptance Test Procedure

3.13 Commissioning Procedure

3.14 Pressure Testing Procedure

3.15 Leak Testing Procedure

3.16

Flushing of hydraulic equipment Procedure

4. Production, Inspection & Testing

4.1 Check of received /purchased material

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification Project Spec. P.O. Description,

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds &

Project Spec. P.O. Description Codes, Stds.

Project Spec. P.O. Description

Document No: AGES-SP-13-002

Rev. No: 01 Page 228 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–231 Wellhead Control Panels (Cont’d)

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N O T A C F T R E C

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R E R U T C A F U N A M

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R O D N E V

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L E V E L N O T N E V R E T N

I

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L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

4. Production, Inspection & Testing (Cont’d)

4.2 WHP Inspection from Sub-vendor

4.2.1 Dimensional check

4.2.2 Welding checks

4.2.3 Painting checks & Inspection

4.2.3.1 Surface Check before Painting

4.2.3.2 Salt contamination tests

4.2.3.3 Dry Film Thickness test

4.2.3.4 Visual Inspection of coating

4.2.3.5 Coating adhesion tests

4.2.3.6 Coating curing tests

4.3 Panel assembly

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

4.3.1 Well Control Module Assembly Inspection

4.3.1.1 Dimensional Check

4.3.1.2 Component check

4.3.1.3 Mechanical check

4.3.1.4 Electrical check

4.3.1.5 Flushing of Hydraulic System

4.3.1.6 Leak test

4.3.1.7 Pressure Test

4.3.2 ESD Module Assembly Inspection

4.3.2. 1 4.3.2. 2

4.3.2. 3

Dimensional Check

Component check

Electrical check

Project Spec. P.O. Description & Approved Drawings/ Documents

,

Internation al Codes & Standards

Project Spec. P.O. Description & Approved Drawings, procedures Codes & Standards

Document No: AGES-SP-13-002

Rev. No: 01 Page 229 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–231 Wellhead Control Panels (Cont’d)

I

N O T A C F T R E C

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R E R U T C A F U N A M

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R O D N E V

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L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Production, Inspection & Testing (Cont’d)

Project Spec. Approved Drawings, procedures Codes & Standards

Project Spec. Approved Drawings/ Documents, International Codes & Standards

4.3.3

Installation of Electrical and Instrumentation accessories

4.3.4 Internal Inspection of WHCP

4.3.4.1 Visual & Dimensional Check

4.3.4.2

Conformance drawings

to Schematic & GA

4.3.4.3 Component Tag and nameplate checks

4.3.4.4 Equipment Installation Inspection

4.3.4.5

4.3.4.6

E&I assembly checks Cable Testing & Inspection Correct Glands Installed Junction Box Inspection Termination as per drawing Correct Glands Installed Earthing as per requirements

4.3.4.7 Flushing of Hydraulic System

4.3.4.8 Leak Test

4.3.4.9 Pressure Test

4.3.5 Final Functional Testing (FAT & Loose Equipment Supply Inspection)

4.3.5.1 Factory Acceptance Test

4.3.5.2 Punch List Clearance

4.3.5.3

Inspection of Loose Supply Items & BOM verification

5.1

5.2

5.3

5.4

Preparation for Dispatch

and

dimensional

Punch clearance inspection and Quality records review Visual checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note Verification of Punch list clearance

Issuance

5.5 Manufacturing Record Book

Document No: AGES-SP-13-002

Project Spec. & Approved Drawings/ procedures Codes & Stds

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Rev. No: 01 Page 230 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–231 Wellhead Control Panels (Cont’d)

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N O T A C F T R E C

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

I

R O D N E V

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L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Vendor Document Requirement List

SL. NO.

ACTIVITY

6. Report & Test Certificates

6.1 Vendor Data Reports

6.2 Raw Material Test Certificates

6.3

6.4

WIN/UTC/CMMS data sheet (to be completed by vendor (Wherever Applicable) Vendor Book endorsement, and Issue of Release Note by TPAA

Inspection Data

Document No: AGES-SP-13-002

Rev. No: 01 Page 231 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

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I

R O D N E V

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L E V E L N O T N E V R E T N

I

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L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

I

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L E V E L N O T N E V R E T N

I

ITP–232

LV Diesel Driven Alternators

SL. NO.

ACTIVITY

Scope This List covers Inspection of LV diesel Driven Alternator

1.1 Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor Manufacturing Schedule

3.2 Vendor QP

3.3 Status of sub orders

3.4 Material and Test Certificates

3.5 FAT Procedure review

4. Production

E C N E R E F E R

T N E M U C O D

Codes & Stds. P.O.

COMPANY PQ

Prod. Plan

QA Manual

Prod. Plan

Project spec. Codes, Stds.

4.1

Material / Component Traceability and examination

Vendor Data Books

4.2 Base Frame and Core Construction

4.3

Voltage Regulator, Control Panel, Main Circuit Breaker, Battery and Battery Charger, Space Heaters and other ancillaries

4.4 Mounting

4.5

Hoisting, Pulling, Transportability, Jacking Facility

5. Examination

P.O. Spec & Approved Drawings

5.1

Visual Dimensional Check, earth connections, proper terminal marking, completeness of name plates, rating and diagram plates

P.O. Spec & Approved Drawings

5.2 Painting Examination

6. Testing

6.1 PMI (Where applicable)

Codes & Std

6.2 Standard Shop Test

6.3 Performance Test

6.4 Over speed Trip Test

Spec , Code & Standards

Document No: AGES-SP-13-002

Rev. No: 01 Page 232 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–232 LV Diesel Driven Alternators (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Spec , Code & Standards

P.O Spec., Std. &

Vendor Document Requirement List

SL. NO.

ACTIVITY

6. Testing (Cont’d)

6.5 Engine Starting Test

6.6 Generator Alarm and Shut Down Test

6.7 Generator circuit Breaker Test

6.8 Load Test (Where applicable)

7. Preparation for Dispatch

7.1 Marking, Tagging & Name Plate

7.2 Protection for Shipment

7.3 Inspection Release Note (IRN)

8. Report & Test Certificates

8.1 Vendor Data Reports

8.2 Raw Material Certificates

8.3

8.4

WIN/UTC/CMMS DATA Sheet (To be completed by Vendor wherever applicable

Inspection Data

Vendor Book endorsement, and Issue of Release Note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 233 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–233

MAC DCS, ESD & F&G Systems

SL. NO.

ACTIVITY

list covers

Scope inspection This requirement for MAC DCS, ESD & F&G Systems

test and

1.1 Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 Manufacturing Drawings

3.6 Packing & preservation Procedure

3.7

3.8

Examination

Non-Destructive Procedures where applicable Weld Procedures Qualification Records where applicable

Specification

(NDE)

and

3.9 Surface preparation and Painting Procedure

3.10 Inspection and Test Procedure

3.11 FAT Procedure

3.12 Integration Procedures

4. Production, Inspection & Testing

4.1 DCS In-Process Inspection

4.1.1

4.1.2

4.1.3

4.1.4

4.1.5

4.1.6

Visual and Dimensional Check of Cabinets including Cabinet painting Verification of Internal Components for Model No/Type within the Cabinets. Cabinets Internal Wiring Size / Color/ Type Check (Including Continuity & Isolation) Check of easy accessibility and removal of Individual components Check of terminal separation. Check of wiring separation for various level voltage steps

functional

strips

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY PQ

Project Spec. P.O. Description

Prod. Plan

QA Manual

Prod. Plan

Project Spec. Codes, Stds &

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Project Spec. P.O. Description & Approved Drgs, procedures, Codes & Strds

Document No: AGES-SP-13-002

Rev. No: 01 Page 234 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–233 MAC DCS, ESD & F&G Systems (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Production, Inspection & Testing (Cont’d)

4.1 DCS In-Process Inspection (Cont’d)

4.1.7 Check of filling of wire ducts

4.1.8 Visual Check for the future expansion

4.1.9 Cabinet Internal Grounding Circuit Check

4.1.10 Check of Internal Components labeling

4.1.11 Check of Internal Wire Marking

4.1.12

Check of Hardware assembly and Internal Wiring Workmanship

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

4.2

ICSS Prototype Hardware Inspection and Testing

4.2.1

Internal Prototype Test

Inspection of

ICSS System

Visual Cabinets including internal components, labeling & Painting Visual Inspection of ICSS Marshalling Cabinets & Server, Network Cabinets including internal components, labeling & Painting Visual Inspection of ICSS Marshalling Cabinets wiring check Visual Inspection of ICSS System & Marshalling Cabinets Spares check Visual Inspection of ICSS System & Marshalling Cabinets earthing check Visual Inspection of ICSS System & Marshalling Cabinets Alarm check

4.2.2

4.2.3

4.2.4

4.2.5

4.2.6

4.2.7

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

4.3 DCS Final Inspection and Testing

4.3.1

4.3.2

4.3.3

4.3.4

Review of Pre-Factory Acceptance Test Records (Pre-FAT) System Readiness Review and Overall System Configuration Check Visual Inspection of DCS System Cabinets including internal components, labeling & Painting Visual Inspection of DCS Marshalling Cabinets & Server, Network Cabinets including internal components, labeling & Painting

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Document No: AGES-SP-13-002

Rev. No: 01 Page 235 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–233 MAC DCS, ESD & F&G Systems (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Production, Inspection & Testing (Cont’d)

4.3 DCS Final Inspection and Testing (Cont’d)

4.3.5

4.3.6

4.3.7

Visual Inspection of Consoles including internal components, labeling & Painting Visual Inspection of HIS and Printers including labeling DCS Bill Of Material Checks (Including spares)

4.3.8 System Startup Check

4.3.9 CPU Redundancy Check

4.3.10 Communication Redundancy Check

4.3.11

4.3.12

Power Supply Module Redundancy Checks System Hardware Check. On-line removal and insertion under powered condition

4.3.13 Redundancy of I/O Modules Check

4.3.14

DCS- System loading and Resource Check

4.3.15 Printer Functional Check

4.3.16

4.3.17

4.3.18

4.3.19

4.3.20

4.3.21

4.3.22

4.3.23

4.3.24

4.3.25

4.3.26

Log Report

Application Check-Graphics Windows Check Application Check-Overview Windows Check Application Check – Tuning Windows Check Application Check – Trend Group Windows Check Application Check – Functional Check with time stamp Application Check- Historical Messages Report Check Application/ Logic Check for Field Control Station Functional Test of Fieldbus Configuration Check Functional Test of Fieldbus Components (only for Sample Components) Functional Test of – Fieldbus Loop Check Functions Functional Test of Fieldbus System- Alarms & Messages Check. (for sample device)

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Document No: AGES-SP-13-002

Rev. No: 01 Page 236 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–233 MAC DCS, ESD & F&G Systems (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Production, Inspection & Testing (Cont’d)

4.3 DCS Final Inspection and Testing (Cont’d)

4.3.27 DCS System – Loop Checking

4.3.28 DCS System – Spare I/O check

4.3.29 Screen Refresh rate check

4.3.30 Scan time Check

4.3.31 Bulk power supply redundancy check

4.3.32

Check of logics/ graphics (Including Change of Status) on consoles/HMI

4.3.33 Typical FF devices function check

4.3.34 Power UP / Power DOWN tests

4.3.35

Visual furniture

inspection of Control

room

4.3.36 Review of Hardware certificates

4.3.37 Review of Software licenses

4.4 ESD In-Process Inspection

4.4.1

4.4.2

Visual and Dimensional Check of Cabinets including Cabinet painting

Verification of Internal Components for Model No/Type within the Cabinets

4.4.3

Cabinets Internal Wiring size/Color/Type Check (including continuity & isolation)

4.4.4

4.4.5

4.4.6

Check of easy accessibility and removal of Individual components Check of separation Check of wiring separation for various level voltages

terminal strips

functional

4.4.7 Check of filling of wire ducts

4.4.8

Visual Check for the future spare/ expansion

4.4.9 Cabinet Internal Grounding Circuit Check

4.4.10 Check of Internal Components labeling

4.4.11 Check of Internal Wire Marking

4.4.12

Check of Hardware assembly and Internal Wiring Workmanship

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Document No: AGES-SP-13-002

Rev. No: 01 Page 237 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–233

MAC DCS, ESD & F&G Systems (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

SL. NO.

ACTIVITY

4.5 ESD Final Inspection and Testing

4.5.1 Review of Pre-FAT Records

4.5.2

4.5.3

4.5.4

System Readiness Review and Overall System Configuration Check. Visual Inspection of ESD System Cabinets including internal components & labeling Visual Inspection of ESD Marshalling Cabinets internal components & labeling

4.5.5 Nest Loading and I/O Assignments check.

4.5.6 Bill of Material Checks including spares

4.5.7 System Startup Check

4.5.8 ESD CPU Redundancy Check.

4.5.9 Communication Redundancy Check

4.5.10

4.5.11

Power Supply Module Redundancy Checks. System Hardware Check. On-line removal and insertion under powered condition.

4.5.12 SOE Functionality Check with timestamp.

4.5.13 Redundancy of I/O Modules Check.

4.5.14 ESD - System CPU loading Check.

4.5.15 Safety Control Station Application Check.

4.5.16

ESD Cabinets – Wiring Check including wire markers Check.

4.5.17 ESD Cabinets – Loop Checking.

4.5.18 ESD System-Spare I/O Checks

4.5.19 System Monitoring Check.

4.5.20 Alarm Summary

4.5.21 Historical Message Report

4.5.22 Operator Station Functional Check

4.5.23

ESD – Bulk power supply redundancy check

4.5.24

Check of logics/ graphics (Including Change of Status) on consoles/ HMI.

4.5.25 Power UP / Power DOWN tests

Document No: AGES-SP-13-002

Rev. No: 01 Page 238 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–233

MAC DCS, ESD & F&G Systems (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Production, Inspection & Testing (Cont’d)

4.5 ESD Final Inspection and Testing (Cont’d)

4.5.26 Diagnostic functions check

4.5.27 ESD cause and effect / logic check

4.5.28 Review of Hardware certificates

4.5.29 Review of software licenses

4.5.30 Integration of ESD signal with DCS check

4.5.31 ESD interlock check

4.5.32 ESD Functional check

4.6

F&G In-Process Inspection

4.6.1

4.6.2

4.6.3

4.6.4

4.6.5

4.6.6

Visual and Dimensional Check of Cabinets including Cabinet painting Verification of Internal Components for Model No/Type within the Cabinets Cabinets Internal Wiring size/Color/Type Check (including continuity & isolation) Check of easy accessibility and removal of Individual components Check of terminal strips separation Check of wiring separation for various level voltages

functional

4.6.7 Check of filling of wire ducts

4.6.8

Visual Check for the future spare/ expansion

4.6.9 Cabinet Internal Grounding Circuit Check

4.6.10 Check of Internal Components labeling

4.6.11 Check of Internal Wire Marking

4.6.12

Check of Hardware assembly and Internal Wiring Workmanship

4.7

F&G Final Inspection and Testing

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

4.7.1 Review of Pre-FAT Records

4.7.2

4.7.3

System Readiness Review and Overall System Configuration Check. Visual Inspection of F&G System Cabinets including internal components & labeling

Project Spec. Approved Drawings/ procedures

Codes & Stds

Document No: AGES-SP-13-002

Rev. No: 01 Page 239 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–233 MAC DCS, ESD & F&G Systems (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

4.0

4.7

4.7.4

4.7.5

Production, Inspection & Testing (Cont’d)

F&G Final Inspection and Testing (Cont’d)

Visual Inspection of F&G Marshalling Cabinets internal components & labeling Nest Loading and I/O Assignments check.

4.7.6 Bill of Material Checks including spares

4.7.7 System Startup Check

4.7.8 F&G CPU Redundancy Check.

4.7.10

4.7.9 Communication Redundancy Check Power Supply Module Redundancy Checks. System Hardware Check. On-line removal and insertion under powered condition. SOE timestamp.

Functionality

Check

with

4.7.12

4.7.11

4.7.14 Redundancy of I/O Modules Check.

4.7.15 F&G - System CPU loading Check.

4.7.17

4.7.16

Safety Control Station Application Check. F&G Cabinets – Wiring Check including wire markers Check. 4.7.18 F&G Cabinets – Loop Checking. 4.7.19 F&G System-Spare I/O Checks 4.7.20 System Monitoring Check. 4.7.21 Alarm Summary 4.7.22 Historical Message Report 4.7.23 Operator Station Functional Check

Project Spec. P.O. Description & Approved Drawings, procedures,

Codes & Standards

4.7.24

4.7.25

F&G – Bulk power supply redundancy check Check of logics/ graphics (Including Change of Status) on consoles/ HMI.

4.7.26 Power UP / Power DOWN tests 4.7.27 Diagnostic functions check

4.7.28 F&G cause and effect / logic check

4.7.29 Review of Hardware certificates

4.7.30 Review of software licenses

4.7.31 Integration of F&G signal with DCS check

Document No: AGES-SP-13-002

Rev. No: 01 Page 240 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–233 MAC DCS, ESD & F&G Systems (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

4.0 Production, Inspection & Testing (Cont’d)

4.7 F&G Final Inspection and Testing (Cont’d)

4.7.32

Integration of F&G signal with ESD check

4.7.33 F&G interlock check

4.7.34 F&G Functional check

4.8

Integration Test between DCS & Subsystems

Preparation for Dispatch

5.1

5.2

5.3

5.4

Punch clearance inspection and Quality records review Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note Issuance Verification of Punch list clearance

5.5 Manufacturing Record Book

Report & Test Certificates

6.1 Vendor Data Reports

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Vendor Document Requirement List

6.2

6.3

6.4

WIN/UTC/CMMS data sheet (to be completed by vendor (Wherever Applicable) Vendor Inspection Data Book endorsement, and Issue of Release Note by TPAA SIL Certificate systems (ESD/F&G)

the safety

for

Document No: AGES-SP-13-002

Rev. No: 01 Page 241 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–234

Remote Telemetry Unit (RTU)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

Scope This requirement for RTU

list covers

1.1 Vendor approval

test and

inspection

2. Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Vendor Documentation

3.5 Material test and certification

4. Production

4.1

4.2

Material / component Traceability and Examination Fabrication control Panel, and cabinet arrangement

4.3 Final Visual and Dimensional inspection

4.4 NDT (UT, MPI, RT – If Applicable)

4.5 PMI (If applicable)

4.6 ASSMEBY -RTU

5. Examination & FAT

5.1

5.2

5.3

5.4

including

Interconnection and Wiring Diagram arrangement Signals segregation, Tagging / Ferruling, Wires and Cable Characteristics and Color Verification of Equipment and Component Tags Internal component arrangement, JB installation, and termination Verification of IO via the HMI and SCADA Software, Integrated Test of Database, Tag Assignments and Addressing of Input/output Signals

glanding,

cable

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY PQ

Prod. Plan

QA Manual

Prod. Plan

Project Specification Codes & Stds

Vendor Data Book

P.O. Spec. & Approved Drawings

P.O. Spec. & Approved Drawing

5.5 Verification of spare requirements

5.6

CPU Health & Redundancy Tests, IO Module Failure Test

Document No: AGES-SP-13-002

Rev. No: 01 Page 242 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–234

Remote Telemetry Unit (RTU) (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

5. Examination & FAT (Cont’d)

5.7

5.8

5.9

Visual Dimensional and cabinet arrangement check Check of Mechanical Protection (IP rating area certification) and Operation accessibility checks

maintenance

Hazardous

and

5.10 Functional tests

5.11 Heat Soak Test

5.12

Fiber optic communication test (If applicable)

5.13 Grounding Circuit Check

5.14 Painting Examination

5.15 Marking / Name Plate

5.16 Closure of Punch points

5.17 Preservation, Packing and shipping

5.18

Vendor Data Book endorsement, and Issue of Release Note by TPIA

E C N E R E F E R

T N E M U C O D

P.O. Spec. & Approved Drawing / Procedure

/ Approved PRO P.O Spec., Std.&

P.O. Spec. & Approved Drawing

Document No: AGES-SP-13-002

Rev. No: 01 Page 243 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–235

Control and Instrumentation Cables

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

Scope This list covers test and inspection requirements and Instrumentation Cables

for Control

Project Spec. P.O. Description

Vendor approval

COMPANY PQ

Pre-production/Pre-inspection Meeting

General - Preliminary work

Vendor Manufacturing schedule

Prod. Plan

Vendor Q.P

Status of sub orders

1.1

3.1

3.2

3.3

3.4

Material test and certification

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds &

3.5

FAT Procedure review

4.1

Production

Material / component Traceability and Examination

Vendor Data Book

4.2

Sealing and Drumming

4.3

4.4

Laying up of conductors, insulation, armor, screening and inner & outer sheathing

Inner and outer sheathing identification / color coding

Project Spec. P.O. Description & Standards

Project Spec. P.O. Description, & std. Approved Drawings

Document No: AGES-SP-13-002

Rev. No: 01 Page 244 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–235 Control and Instrumentation Cables (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

Production (Cont’d)

4.5

Hoisting, transportability, pulling facilities of drums

Examination

Visual Check, Checking of proper identification drums, completeness of quantities, sizes and voltage grades.

of

Conductor and armor resistance, measurement insulation thickness

of

Insulation resistance and voltage test

5.1

5.2

5.3

5.4

Dimensional checks

Testing

6.1

Type tests (where appropriate)

6.2

Routine tests

6.3

Special tests (where appropriate)

Preparation for Dispatch

7.1

Marking, Tagging & Name plate

7.2

Protection for Shipment

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Stds & Approved Drawings

Project Spec. P.O. Description & Approved Drawings

Project Spec. P.O. Description &

Project Spec. P.O. Description &

Project Spec. P.O. Descriptio n

Project Spec. P.O. Description, Std.

Document No: AGES-SP-13-002

Rev. No: 01 Page 245 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–235 Control and Instrumentation Cables (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description, Std.&

Project Spec. P.O. Description, Std.&

Vendor Document Requiremen t List

SL. NO.

ACTIVITY

Preparation for Dispatch

7.1

Marking, Tagging & Name plate

7.2

Protection for Shipment

Reports & Test Certificates

8.1

Vendor Data Report

8.2

Raw Material Test Certificates

8.3

Vendor Data Books endorsement, and issue of Release Note by TPA

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–236

Control Valves

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N O T A C F T R E C

I

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

I

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R O T C A R T N O C

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I

SL. NO.

ACTIVITY

test and

list covers

Scope inspection This requirement of control valves (at vendor premises only). Nevertheless (if required), the test and inspection requirements of Pneumatic and Hydraulic Actuators are covered by ITP-213. And ITP-214 for Motorized Actuators

1.1 Vendor approval status

Pre-production/Pre-inspection Meeting

General - Preliminary work

3.1 Data sheet

3.2

COMPANY Material Specification Sheet. (If applicable)

3.3 Vendor’s Fabrication Schedule

3.4 Vendor QA Plan

3.5 Status of sub-orders

3.6 Material test and certification

3.7

Welding Procedure Qualification (WPS & PQR) and Welders Qualification

3.8 NDE Procedures

3.9

Hydrostatic and low-pressure pneumatic test procedure

3.10 PMI procedure

3.11 FAT Procedure

3.12

preparation

Surface Painting procedure, including PQT and production test panel

and

E C N E R E F E R

T N E M U C O D

Project Spec., P.O. Description BS 5793

COMPANY Pre- qualification

Project specification

Ref. Drawing

Production Plan

QA Manual

Production Plan Codes, Std &

Project Spec., P.O. Description Design Codes & Std

Project specification

4. Production

4.1

Material Traceability and chemical analysis, mechanical properties, of: Body, Bonnet, Trim /plug,

Vendor Data Book

4.2 Body & Bonnet

4.3

Trim / Plug

Standard

Standard

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–236 Control Valves (Cont’d)

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N O T A C F T R E C

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

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R O T C A R T N O C

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SL. NO.

ACTIVITY

4.4 Heat Treatments

4.5 Gasket surface

4.6

Flanges, Bolting, Gasket Packing, etc.

4.7

requirements

Actuators (if required), the test and inspection of Pneumatic and Hydraulic Actuators are covered by ITP-213. And ITP- 214 for Motorized Actuators., operators & control pressure fittings.

5. Examination

E C N E R E F E R

T N E M U C O D

Project Spec., P.O.

Project Spec., P.O. Description

Project Spec., P.O. Description

5.1 Visual and Dimensional Check

Project Spec.,

5.2 PMI (Where applicable)

Codes & Std

Testing

6.1

6.2

6.3

NDE Penetrant … etc) (As applicable)

Ultrasonic,

(PMI,

Dye

Hydrostatic Test (Body & Seat including low pressure air test)

Hardness Test including those on RTJ grooves

6.4

Fugitive Emission Test Prototype

6.5

Fugitive Emission test on Production

6.6

Ferrite Check on SS 316L overlay

6.7 Hysteresis & Dead band

6.8

Functional Test (stroke, linearity)

Project Spec., P.O. Description Codes & Std. Project Spec., P.O. Description BS 5793

Project Spec./P.O. Description Codes & Std

6.9

Load Test (Where applicable)

Approved Procedure,

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

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L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Y N A P M O C

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L E V E L N O T N E V R E T N

I

ITP–236 Control Valves (Cont’d)

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

7. Preparation for Dispatch

7.1

Surface Preparation and painting, Final DFT and colour code

7.2

Marking / Name Plate & Tagging, marking Flow direction and actuator orientation

7.3

Preparation Packing, preservation and storage

for Shipment and

Project Spec./P.O. Description &

7.4

CONTRACTOR Inspection Release Note (IRN)

Project specificatio n

8. Reports & Test Certificates & Vendor Data Books

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

WIN / UTC / CMMS DATA Sheet (To Be Completed by Vendor Wherever Applicable)

8.4

Vendor Data Books approval, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 249 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–237

AC Power Generators

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope This list covers test and inspection requirements for alternators driven by either gas turbines or diesel engines.

1.1

Sub-contractor / Vendor approval status Pre-production/Pre-inspection Meeting

3. General - Preliminary work

Project Spec. P.O. Description IEC 60034

COMPANY PQ

3.1 Data sheet and drawings

3.2 Vendor production schedule

3.3 Vendor Q.P

3.4 Status of sub orders

3.5 Material test and certification

3.6 Standard shop test procedures

3.7 Factory Acceptance test procedures

4. Production

4.1

4.2

Material / component Traceability and Examination bearings, Mounting, Stator frame, rotor, fan & coupling

lubrication,

4.3 Excitation system

4.4

Windings, Terminals, Connectors, Cable glands, Enclosures, Ventilation / Cooling & Heating equipment

4.5 Automatic Voltage Regulator

4.6

Instruments & Protective devices

4.7 Hoisting facilities

5. Examination

proper

Visual Dimensional Check, earth terminal connections, markings, completeness of the labels, rating & name plates Weather Proofing, protection)

(ingress

I.P

5.1

5.2

5.3 Painting Examination

Document No: AGES-SP-13-002

Prod. Plan

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds &

Vendor Data Book

Project Spec. P.O. Description & Approved Drawings

Project Spec. P.O. Description & Approved Drawings and procedure

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I

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R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–237 AC Power Generators (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

6. Testing

6.1 PMI (Where applicable)

Codes & Std

Project Spec. P.O. Description , & Standards

Approved PRO

Project Spec. P.O. Description , Std.

6.2

Dynamic balancing of rotor, Inter- turn electrical insulation & Hydro testing of air / water coolers

6.3 Standard Tests

6.4

6.5

Performance and complete including routine tests Abbreviated and special tests (where appropriate)

tests

6.6 Load Test (Where applicable)

7. Preparation for Dispatch

7.1 Marking, Tagging & Name plate

7.2

Protection for Shipment, preservation and storage

7.3

Inspection Release Note (IRN)

8. Reports & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor Wherever Applicable) Vendor Data Books approval and, issue of release notes by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 251 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP-238

Machine Monitoring System

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Project Spec. P.O. Description, Standards,

Prod. Plan

QA Manual

Prod. Plan

Project Spec.

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & Stds.

SL. NO.

ACTIVITY

Scope

This list covers test and inspection requirements for Machine Monitoring System.

1.1 Vendor approval

Pre-production/Pre-inspection Meeting Key Design Documents shall be by submitted COMPANY/Contractor prior to Pre- production Meeting

approved

and

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q. P

3.3 Status of sub orders if any

3.4 Material test and certification

3.5

Inspection & Test Procedure

3.6 Drawings where applicable

3.7 Packing & Preservation Procedure

3.8

FAT, IFAT Procedure review

4. Production, Inspection & Testing

4.1 In-Process Inspection

4.1.1 Material Verification

4.1.2 Visual Inspection

4.1.3 Dimensional Check

4.1.4 Component Check

4.1.5 Check wiring specifications

4.1.6 Check of wiring separation

4.1.7 Ventilation system check

4.1.8 Circuit Breakers Check

4.1.9 Grounding Circuit Check

4.1.10 Nameplates, labels, & ferrules check

Document No: AGES-SP-13-002

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R O D N E V

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L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Y N A P M O C

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L E V E L N O T N E V R E T N

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–238

Machine Monitoring System (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

E V E L N O T N E V R E T N

R O D N E V

I

E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

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E V E L N O T N E V R E T N

Y N A P M O C

I

E V E L N O T N E V R E T N

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

4.2 Pre-FAT (after building the cabinet)

4.2.1 Visual Inspection

4.2.2 Power Up Test

4.2.3 Signal Simulation Test for 3500 & System1

4.2.4 Pre-FAT Punch list review & close out

4.3 Factory Acceptance Test FAT

P.O. Description approved Project Spec., procedures, Drgs, Intl. Codes & stds

4.3.1 Visual Inspection

4.3.2 Power Up Test

4.3.3 Signal Simulation Test for 3500 & System1

4.3.4 Bill of Material Verification

4.3.5

Decision Support & Bently Performance - Configuration Verification

4.3.6 FAT Punch list review & Close Out

4.3.7 IFAT

5.1

5.2

5.3

5.4

Preparation for Dispatch

dimensional

Punch clearance inspection and Quality records review checks, and Visual component Marking, serial number, tag number and Name Plate checks Packing inspection and marking control of all goods, including spare parts Inspection Release Note issuance Verification of Punch list clearance

5.5 Manufacturing Record Book

Reports & Test Certificates

P.O. Description Approved Project Spec., procedures

Drgs

International Codes & stds

P.O. Description Project Spec. Approved

Drgs

Internation al Codes & Stds

6.1 Vendor Data Report

VDRL

6.2 Raw Material Test Certificates

6.3

WIN / UTC / CMMS DATA Sheet (To Be Completed (Wherever Applicable)

Vendor

By

& DST-003 Part 1

6.4

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–239

HVAC Control System

I

N O T A C F T R E C

I

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

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Y N A P M O C

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L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

Scope

This list covers test and inspection requirements for HVAC Control System.

1.1 Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders if any

3.4 Material test and certification

3.5 Manufacturing Drawings

3.6 Packing & preservation Procedure

3.7

3.8

3.9

Non-Destructive Examination (NDE) Procedures where applicable Weld Procedures Specification and Qualification where applicable Surface Painting/Coating Procedure

preparation,

Records

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification Project Spec. P.O. Description, Standards,

Prod. Plan

QA Manual

Prod. Plan

P.O. Description Project Spec., procedures, codes & Stds,

3.10

Inspection and Test Procedure

3.11 FAT Procedure

4. Production, Inspection & Testing

4.1 Receiving / Procured material inspection

4.1.1 PLC cabinets

4.1.2

HMI, Software package with media & license.

4.1.3 Field Devices

4.1.4 BMS System

4.1.5

Other procured/received material, equipment

4.2 Review and correlation of certificates

P.O. Description approved Project Spec. procedures, Drgs, codes & stds

Document No: AGES-SP-13-002

Rev. No: 01 Page 254 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–239 HVAC Control System (Cont’d)

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N O T A C F T R E C

I

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

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I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Approved Drgs/

Documents, International Codes & Stds.

Project Spec. procedures, Drgs, Codes & Stds.

Project Spec. procedures, Drgs, Codes & Stds.

P.O. Description, approved Project Spec. procedures, Drgs, Codes & Stds.

SL. NO.

ACTIVITY

4.3 In-process Inspection/Pre-FAT

4.3.1. 1

4.3.1. 2

Dimension Check

Panel Painting, color & thickness

4.3.2 Power Connection Check

4.3.2. 1 4.3.2. 2 4.3.2. 3

Incomer power supply check

Output Terminals Voltage check.

Redundancy Check

4.3.3 Components with wiring check

4.3.3. 1

Components part numbers

4.3.3. 2

wires & cable checks-size, type & ferruling

4.4 FAT

4.4.1 Check final assembly of the panel

4.4.2 Check cable terminations

4.4.3 Name plate detail check

4.4.4

Continuity test of control and power Cables

4.4.5 Field Devices

4.4.6 Module configuration check

4.4.7

IO check

4.4.8 Operation sequence check

4.4.9 System and graphics check

4.4.10 Communication check

4.4.11 Loop check for I/Os up to HMI

4.2.12 Operation sequence as per scheme

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–239

HVAC Control System (Cont’d)

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I

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

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L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

P.O. Description approved Project Spec. procedures , Drgs, Codes & Stds

SL. NO.

ACTIVITY

5. Preparation for Dispatch

5.1

5.2

5.3

Punch clearance Quality records review

inspection and

Visual and dimensional checks, component Marking, serial number, tag number and Name Plate checks

Packing inspection and marking control of all goods, including spare parts

5.4

Inspection Release Note issuance Verification of Punch list clearance

5.5 Manufacturing Record Book

5.6

Inspection Release Note (IRN)

6. Reports & Test Certificates

6.1 Vendor Data Report

VDRL

6.2

WIN / UTC / CMMS DATA Sheet (To Be Completed By Vendor (Wherever Applicable)

6.3

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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ITP–240

Temporary Refuge Room

SL. NO.

ACTIVITY

Scope This list covers test and inspection requirements for Temporary Refuge Room.

1.1 Vendor approval

2. Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders (if any)

3.4 Material test and certification

4. Production

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY Pre- qualification

Prod. Plan

QA Manual

Prod. Plan

Codes, standards &

4.1

4.2

Material / component Traceability and Examination (Including Tags and Labels)

Vendor Data Book

Shop prefabricated steel structural work

AWS D1.1

4.3 Shop prefabricated pipe work

4.4

Instrument installation, pressure gauge, Transmitter, Temperature gauge. etc.

4.5 PSV installation

Battery/UPS installation, electrical tests shall on the UPS/ DB:

• Conformity checks
• Insulation resistance test
• Load Duration test
• Heat run and temperature rise test
• Earth continuity test
• Polarity and continuity checks
• Operational checks of MCCB, MCB, meters, etc.
• Operation of earth fault monitors Control Panel, MCT installation etc.

and

JB

4.6

4.7

ANSI B31.3 .

P.O. project Spec., approved procedures, Standards Drawings

4.8

Lighting Installation

Document No: AGES-SP-13-002

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–240 Temporary Refuge Room (Cont’d)

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

I

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L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

4. Production (cont’d)

4.9

Fire and Gas Detector/Devises Installation

4.10 PAGA system Installation

4.11 Telecom Installation

4.12

Instrument and Electrical Cables & Cable Trays Installation

4.13 HVAC Installation

5. Examination

5.1

acceptance

Factory (for UPS/Battery, Control Panel, HVAC system, Rotating equipment)

Test

5.2

Painting Examination

5.3 Closure of Punch points

Inspection Release Note (IRN)

6. Preparation for Dispatch

6.1 Marking, Tagging & Name plate

6.2

Load Test of Container

6.3 Preservation, Packing and shipping

6.4

Vendor Data Book endorsement, and Issue of Release Note by TPIA

E C N E R E F E R

T N E M U C O D

P.O Spec. & Approved Drawings

/ App. PRO

P.O. Spec. & App. Drawing

P.O Spec., Std.&

P.O. Spec. & Approved Drawing

P.O. Spec. & Approved Drawing

P.O. Spec. & Approved Drawing

Document No: AGES-SP-13-002

Rev. No: 01 Page 258 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–301

Line Pipe

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

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L E V E L N O T N E V R E T N

I

1.1

3.1

3.2

3.3

3.4

Scope This list covers test and inspection requirements for Line pipes

Project Spec. P.O. Description

Vendor approval

Pre-production/Pre-inspection Meeting

COMPANY Pre- qualification

General - Preliminary work

Vendor Manufacturing schedule

Prod. Plan

Vendor Q.P

Status of sub orders

Review & Approval of MPS, QC-Plan, Test Procedures and NDT operator qualification

Production

4.1

MPQT

4.2

4.3

Steel making, slab making, heat analysis, slab condition check, reheating

Plate rolling, Plate Stack Cooling, plate marking ,test sampling, inspection of plate

4.4

UST, plate receving idenitification

QA Manual

Prod. Plan

Project Spec. P.O. Description Codes, Stds &

Vendor Data Book

Project Spec. P.O. Description & Standards

Project Spec. P.O. Description, & std. Approved Drawings

Document No: AGES-SP-13-002

Rev. No: 01 Page 259 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–301 Line Pipe (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Y N A P M O C

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L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

Production (Cont’d)

4.5

Pipe forming ,internal and external welding

Examination

NDI & Visual Inspection for Mill Control Purpose

5.1

Testing

6.1

Hydrostatic Testing

6.2

Auto UST of Welded Seam

6.3

Radiographic Inspection of Pipe Ends

Manual UST of Indication Detected by Auto UST

Auto UST and MPI of Pipe Ends

Final VDE

Production Mechanical Test

Preparation for Dispatch

7.1

Marking and End Protection

7.2

Protection for Shipment

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description & Stds & Approved Drawings

Project Spec. P.O. Description & Approved Drawings

Project Spec. P.O. Description

Project Spec.

Project Spec. P.O. Description, Std.

Document No: AGES-SP-13-002

Rev. No: 01 Page 260 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–301 Line Pipe (Cont’d)

SL. NO.

ACTIVITY

Reports & Test Certificates

8.1

Vendor Data Report/documentation

8.3

Vendor Data Books endorsement, and issue of Release Note by TPA

E C N E R E F E R

T N E M U C O D

Vendor Document Requiremen t List

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

Document No: AGES-SP-13-002

Rev. No: 01 Page 261 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–302

Hot Induction Bend

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope This list covers test and inspection requirement for Hot Induction Bend

Project Spec. P.O. Description

1.1 Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

COMPANY PQ

Project Spec. P.O. Description,

3.1 Data sheet

3.2 Vendor fabrication schedule

3.3 Vendor Q.P

3.4 Status of sub orders

3.5 Material test and certification

3.6 All related procedures

3.7

NDT Procedure & NDT Personnel Qualification

3.8

Hydrostatic Test Procedure

3.9 Manufacturing Drawings

3.10

Manufacturing specification Corrosion tests

Procedure including MPQT and

3.11 Heat Treatment Procedure

3.12 Weldability Test Procedure

3.13 Hardness Test Procedure

3.14 Painting Procedure review

4. Production, Inspection & Testing

4.1 Receipt inspection of Pipes

4.1.1

Verification of Mill Certificates and Tally Sheets

4.1.2 Verification of Traceability Markings

4.1.3

Inspection Condition/packing,

of

physical

4.1.4 Visual and Dimensional Checks,

Document No: AGES-SP-13-002

Prod. Plan

QA Manual

Prod. Plan

Project Spec.

Project Spec. P.O. Description Codes & Std

Project Spec. approved Drawings/ procedures,

Codes & Standards

I

N O T A C F T R E C

I

I

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I

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R O D N E V

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L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–302 Hot Induction Bend (Cont’d)

ACTIVITY

E C N E R E F E R

T N E M U C O D

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

Qualification Bend Forming Activity Cooling: air and water quenching during the hot induction bending for only bend portion Heat Treatment Stress Relieving of full length (seamless) qualification bends

SL. NO.

4.2

4.2.1

Project Spec. Approved Drawings, procedures Codes & Standards

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

4.2.2

Heat Treatment of Q&T R Welded Pipes qualification bends

4.2.3 Hydraulic Test

4.2.4 Visual and Dimensional

4.2.5 Wall Thickness by UT

4.2.6 Gauging Pig Dimensional Check

4.2.7 Gauging PIG Test

4.2.8 MPI bend body Ends and WELD

4.2.9 Residual Magnetism

4.2.1 0 4.2.1 1 4.2.1 2 4.2.1 3

4.2.1 4

Ultrasonic Test on bend ends and longitudinal weld

Weldability, Capsis and additional tests on mother

Sampling Tests (tangent, transition area, extrados, intrados, weld)

Mechanical Tests & Corrosion Tests

Simulation test cycle on MPQT Prior to additional Mechanical Tests (only for Min Wall Thick >31.8 mm)

4.3 Production Hot Induction Bends

4.3.1

4.3.2

quenching during the hot induction bends for only bend portion Heat Treatment of Stress-Relieving for seamless Bends

4.3.3 Heat Treatment

4.3.4 Hydraulic Test on all production bends

4.3.5 Visual and Dimensional (100% Bends)

4.3.6 Wall Thickness on bend W by UT

4.3.7 Gauging PIG Test (100% Bends)

Document No: AGES-SP-13-002

Rev. No: 01 Page 263 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–302

Hot Induction Bend (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

SL. NO.

ACTIVITY

4.3 Production Hot Induction Bends

4.3.8

4.3.9

4.3.1 0 4.3.1 1 4.3.1 2

M.P.I bend body and ends seam weld and ends (100% bends) Ultrasonic Test on bend ends and longitudinal weld

Residual Magnetism (100% Bends)

Surface External Hardness (HB)

Pipe Ends Visual and Dimensional

5.0 Preparation for Dispatch

Project Spec. P.O. Description & Approved Drawings/ Documents, International Codes & Standards

Vendor Document Requirement List

5.1

5.2

5.3

inspection and

Punch clearance Quality records review Visual and dimensional checks, component Marking, checks Packing control of all goods

inspection and marking

5.4

Inspection Release Note (IRN)

5.4 Manufacturing Record Book

6.0 Reports & Test Certificates

6.1 Vendor Data Reports

6.2 Raw Material Test Certificates

6.3

6.4

WIN/UTC/CMMS data sheet (to be completed by vendor (Wherever Applicable) Vendor Book endorsement, and Issue of Release Note by TPA

Inspection Data

Document No: AGES-SP-13-002

Rev. No: 01 Page 264 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–303

Barred Tee

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

Scope This requirement for Hot Induction Bend

list covers

test and

inspection

1.1 Vendor approval

Pre-production/Pre-inspection Meeting

3. General - Preliminary work

3.1 Data sheet

3.2 Vendor fabrication schedule

3.3 Vendor Q.P

3.4 Status of sub orders

3.5 Material test and certification

3.6 Welding procedures /WPQR

E C N E R E F E R

T N E M U C O D

Project Spec. P.O. Description

COMPANY PQ

Project Spec. P.O. Description,

Prod. Plan

QA Manual

Prod. Plan

Project Spec.

3.7

3.8

NDT Procedure & NDT Personnel Qualification

Hydrostatic Test Procedure

3.9 Manufacturing Drawings

3.10

Manufacturing Procedure specification including MPQT and Corrosion tests

Project Spec. P.O. Description Codes & Std

3.11 Heat Treatment Procedure

3.12 Hardness Test Procedure

3.13 Painting Procedure review

4. Production, Inspection & Testing

4.1 Receipt inspection of Pipes/ Plate for guide bar

4.1.1

Verification of Mill Certificates and Raw material cutting

4.1.2 Verification of Traceability Markings

4.1.3 Inspection of physical Condition/packing,

4.1.4 Visual and Dimensional Checks,

4.2.1 hot forming

4.2.2 Heat Treatment of Q&T including test ring

Project Spec. approved Drawings/ procedures,

Codes & Standards

Document No: AGES-SP-13-002

Rev. No: 01 Page 265 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–303

Barred Tee (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

SL. NO.

ACTIVITY

4.2 Hot forming and heat treatment

4.3 Welding

4.3.1 Welding guide bars

4.4 Final heat treatment

4.4.1

Final heat treatment stress reliving including test ring

4.5 Testing and examination

4.5.1 Surface hardness test

4.5.2

4.5.3

4.5.4

4.5.5

test on

for mechanical

sampling prolongation test ring Mechanical test ( tensile, Charpy V notch impact ) on tee and test ring Metallographic examination on Tee and test ring Hardness test through thickness on tee and test ring

4.5.6 Product analysis

4.5.7 Mech test only on Tee and guide bar

4.5.8. HIC test and SSCC test

4.5.9 Hydrotest

4.5.10 End bevel

4.5.11 Review of NDT operator qualification

4.5.12

4.5.13

100% Ultrasonic Test on tee body and beveled end bend ends and longitudinal weld 100% MPI on tee body and beveled end bend ends, fillet welds of bars

4.5.14 Residual magnetism

4.5.15

Visual and Dimensional (100% Tee) including pigging gauging test for Tee

4.5.16 Surface External Hardness (HB)

5.0 Preparation for Dispatch

5.1

Punch clearance inspection and Quality records review

Project Spec. Approved Drawings/ Documents,

Document No: AGES-SP-13-002

Rev. No: 01 Page 266 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–303 Barred Tee (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Vendor Document Requirement List

SL. NO.

ACTIVITY

5.2 External painting

5.3 Marking checks

5.4

Packing control of all goods

inspection and marking

5.5

Inspection Release Note (IRN)

5.6 Manufacturing Record Book

6.0 Reports & Test Certificates

6.1 Vendor Data Reports

6.2 Raw Material Test Certificates

6.3

6.4

WIN/UTC/CMMS data sheet (to be completed by vendor (Wherever Applicable) Vendor Inspection Data Book endorsement, and Issue of Release Note by TPAA

Document No: AGES-SP-13-002

Rev. No: 01 Page 267 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–401

Cranes Jib & Overhead

SL. NO.

ACTIVITY

Scope This requirement of Jib & Overhead cranes.

list covers

test and

inspection

1.1 Vendor approval

2. Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub orders

3.4 Material test and certification

3.5 Welding Procedure

3.6 List of qualified welders

3.7 Shop Test procedure

4. Production

4.1 Material Traceability and Examination

4.2 Fit-up, Size & Root run For Main members

4.3 Production Welding

4.4 Assembly of moving component

4.5 Hooks & Hoist wire system

4.6 Hydraulic & Electrical system

4.7

Personnel safety measure & devices

limiting

4.8

Instruments

5. Examination

5.1 Visual Dimensional Check

5.2 Non-Destructive Examination

5.3 Painting Examination

5.4 Noise level measurement

Document No: AGES-SP-13-002

E C N E R E F E R

T N E M U C O D

P.O. Spec & Standards

COMPANY PQ

Prod. Plan

QA Manual

Prod. Plan

Codes, Std &

Design codes, Stds & Drawings

Vendor Data Book Design codes, Specification & Assembly drawing Approved Drawings

P.O Spec & Std.

P.O Spec & Drawing

P.O Spec.

P.O Spec & Drawing

Codes & Std

Proj. Spec. & Std

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

Rev. No: 01 Page 268 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–401 Cranes Jib & Overhead (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Standards

Standard

P.O Spec. & Std. P.O Spec. & Std.

P.O Spec., Std.& P.O Spec., Std.&

Vendor Document Requirement List

PO SPEC. & STD

SL. NO.

ACTIVITY

6. Testing (FAT)

6.1 Static performance test

6.2 Dynamic performance test

6.3 Protection devices

6.4 Emergency operations

7. Preparation for Dispatch

7.1

Marking & name plate stamping / SWL indication

7.2 Protection for Shipment

8. Report & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

8.5

Lifting items, e.g. ropes, hooks, shackles, pulley blocks, …etc. WIN / UTC / CMMS Data Sheet (to be Completed by Vendor wherever applicable) Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 269 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–501

Marine Hoses

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope This list covers the inspection and test requirements for rubber reinforced, smooth- bore, suction and discharge submarine and floating hoses which are commonly used in offshore mooring installations.

Vendor approval

OCIMF ASTM A105

COMPANY Pre- qualification

SL. NO.

1

2. Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

Production Plan

3.2 Vendor Q.P

3.3 Status of sub-orders

3.4 Material test and certification

3.5 Approval of drawings

3.6 Approval of test procedures

3.7

Welding Specification (WPS&PQR) including Inconel 625 overlay

Procedure

3.8 Welder qualification

3.9 NDE Procedure

4. Production

4.1

Material Traceability and Examination Fittings: Visual, RT, MPI, PT reports Proof Load Test Report Compound: Traceability and, Mix and Test rubber and parameters, every batch Rheometer test

record mix

batched,

4.2 Welding of Fittings and Flanges

4.3

Hose manufacture: Hose body, Wire helixes & rubber reinforced textile body

5. Examination

5.1 Visual, Dimensional Check

5.2 Non-Destructive Examination

QA Manual

Production Plan

P.O Spec. Codes, Std &

Design codes, Standards

ASME V & Standards

Vendor Data Book

WPS and Assembly drawing OCIMF, procedures

OCIMF Std & Approved Drawings

Document No: AGES-SP-13-002

Rev. No: 01 Page 270 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ITP–501 Marine Hoses (Cont’d)

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

6. Testing

6.1

6.2

6.3

6.4

Type / Prototype test-if specified by Order Bend Test or Flexibility Test (MBR and stiffness) Hydro test & elongation check.

Adhesion test (on representative sample)

OCIMF Std. & Procedure

6.5 Kerosene Test (if order specifies)

6.6 Electrical Test

6.7 Vacuum Test

6.8 Proof Load Test (Where applicable)

Approved Procedure,

6.9 Calculate Buoyancy

6.10

Oil resistance test Floating Hydrostatic Test

7. Preparation for Dispatch

7.1 Marking (Ref: Clause-7 of OCIMF)

P.O Spec., Std.

7.2 Ends Protection

7.3

Packing / Palletizing & Preservation For shipping.

P.O Spec., Std

7.4 Supplier Certificate of Conformity

7.5

Inspection Release Note (IRN)

8. Report & Test Certificates

8.1 Vendor Data Report

8.2 Raw Material Test Certificates

8.3

8.4

WIN / UTC / CMMS Data Sheet (to be Completed by Vendor wherever applicable) Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 271 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–502 Mooring Buoys and PLEM

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope

This list covers the inspection and test requirements for Mooring Buoys and PLEM.

P.O Spec. OCIMF

1.1 Vendor approval

COMPANY PQ

2. Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub-orders

3.4

Material test and certification Piping components SS, DSS and CRA shall conform to ITP-122

3.5 Approval of drawings

3.6

3.7

Approval of NDE, and Test procedures, NDE personnel Welding Procedure specification (WPS & PQR)

3.8 Welder Qualification

3.9

FAT and SAT Procedure for associated components, as applicable

3.10 Baseline survey procedure

3.11 Manufacturing Procedure Specification

Prod. Plan

QA Manual

Prod. Plan

P.O Spec. Codes, Std &

Codes & Std

Codes & Std

Design codes & Standards

3.12

BUOY certification plan

and

PLEM

Inspection

and

3.13 Integrated FAT and SAT procedure

4. Production

4.1 Material Traceability and Examination

4.2 Plate forming & End preparation

4.3 Fit-up and Production Welding

4.4 Witness Stage NDE

4.5 PWHT

4.6

4.7

4.8

Trial Fit: BUOY Body assembly, Turret, Deck house Bearing installation and Rotational Torque test Weather tight door installation and leak testing

Document No: AGES-SP-13-002

Vendor Data Book

Design Code

WPS and Assembly drawing, OCIMF

Rev. No: 01 Page 272 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–502 Mooring Buoys and PLEM (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

5. Examination

5.1

Visual Dimensional Check-In and Outside Main Shell, End plates, Manhole & Cover, Fenders, Mooring Bar & Shackle Hole, Safety Chain Etc.

P.O spec, Std & Approved Drawings

5.2 Non-Destructive Examination

5.3

Surface preparation & Painting (including PQT and production test panel)

Codes & Std.

P.O Spec.

6. Testing

6.1 BUOY body compartment Leak Testing

BUOY Piping Hydrostatic leak Test

6.2 Bouncy Test/Trimming and Ballasting

Standards & Procedures OCIMF

6.3

Function Tests: Drainage Pipework fuction test Function test of valves Surge system test, as applicable Nav Aid Test Anode continuity Test Bilge Pump Chain stopper rotation test Chain Pull through Test Function test of winch PLEM Pigging Test PLEM Leak test PLEM Load Test of pad eye PLEM Sliding Test Weighing

Project specification, OCIMF

6.4 DFT- Coating (Inside & Outside)

P.O Spec.

6.5 Load Test (Where applicable)

6.6 Base line survey

7. Preparation for Dispatch/Load out

7.1

7.2

7.3

Inspection of Identification No. & Location

drawings

As-Built endorsement Packing / Palletizing & Preservation For shipping.

review

and

7.4

Inspection Release Note (IRN)

7.5 Mooring BUOY Load out

P.O Spec., OCIMF Std.

Project specification

Document No: AGES-SP-13-002

Rev. No: 01 Page 273 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–502 Mooring Buoys and PLEM (Cont’d)

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L E V E L N O T N E V R E T N

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R O T C A R T N O C

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E C N E R E F E R

T N E M U C O D

OCIMF

SL. NO.

ACTIVITY

8. Report & Test Certificates

8.1

8.2

8.3

Vendor Data Book including Test reports & As-built Drawings. Classification Society - Drawings approval Classification Society certification for Mooring BUOY and PLEM

8.4 Raw Material Test Certificates

8.5

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 274 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–503 Mooring Hawsers

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope

This list covers the inspection and test requirements for Mooring Hawser. (Double Braided Nylon Rope Assembly with Float).

OCIMF BS 7648 BS EN 919

1.1 Vendor approval

COMPANY PQ

2. Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub-orders

3.4 Material test and certification

3.5 Approval of drawings

4. Production

4.1 Material Traceability and Examination

4.2 Witness sample collection for test.

5. Examination

5.1 Weight Check of Sample Rope Section

5.2 Linear Density Check (Actual per 1Meter)

5.3

5.4

5.5

5.6

rope

Examination of Circumference under pre- load section sample Inspection of Construction, Wt. Ratio of Sheath / Core Etc. Visual & Dimensional Check of finished Mooring Hawser Inspection of Thimble Eye and Auxiliary Gear

6. Testing

6.1

Determination of The Breaking Strength of Rope. Realized Break Load

6.2 Melting Point of Core & Sheath Test

6.3 Acid Dissolve Test

6.4 Aqueous solution Boiling test

6.5 Burning Characteristics Test

Document No: AGES-SP-13-002

Prod. Plan

QA Manual

Prod. Plan

Spec. Codes, Std &

Codes & Std.

Vendor Data Book Design Spec. & Std.

Design Spec. & Std.

P.O Spec, Std & Approved Drawing.

BS 7648 & / or Approved Procedure OCIMF

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R O D N E V

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L E V E L N O T N E V R E T N

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L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

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N O T A C F T R E C

I

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

I

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L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Y N A P M O C

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L E V E L N O T N E V R E T N

I

ITP–503 Mooring Hawsers (Cont’d)

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

7. Preparation for Dispatch

7.1

Inspection of Marking / Tagging & Identification No. and Mark spare as applicable

7.2 Packing / Crating For shipping.

P.O Spec., OCIMF Std.

7.3

Inspection Release Note (IRN)

8. Report & Test Certificates

8.1 Vendor Data Book

8.2 Raw Material Test Certificates

OCIMF

8.3

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 276 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–504 Chains for Marine Services

SL. NO.

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope This list covers the inspection and test requirements for flash welded chain and forged kenter connecting links used for mooring of offshore floating vessels, pipe lay barges, derrick barges and storage tanks

API SPEC 2F, US Mil Spec.

1.1 Vendor approval

COMPANY PQ

2. Pre-production Meeting

3. General - Preliminary work

3.1 Vendor fabrication schedule

3.2 Vendor Q.P

3.3 Status of sub-orders

3.4 Material test and certification

3.5 Approval of drawings

3.6

Approval of NDE, Heat treatment and Test procedures

3.7 Welding Procedure

3.8 FAT Procedure

3.9 Painting Procedure

4. Production

4.1 Material Traceability and Examination

4.2 Welding

4.3 Heat treatment

4.4

Identification of test link

5. Examination

5.1 Visual Dimensional Check

5.2 Non-Destructive Examination

6. Testing

6.1 Break Test

6.2 Proof Test

6.3

Inspection Of Flash Weld After Proof Test

Document No: AGES-SP-13-002

Prod. Plan

QA Manual

Prod. Plan

P.O Spec. Codes, Std &

Codes & Std.

Codes & Std.

Design codes & Standards Project Specification

Vendor Data Book WPS and Assembly drawing

P.O Spec, Std & Approved Drawing.

PO SPEC & STD

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L E V E L N O T N E V R E T N

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L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Y N A P M O C

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L E V E L N O T N E V R E T N

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–504 Chains for Marine Services (Cont’d)

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N O T A C F T R E C

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

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L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Y N A P M O C

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L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

6. Testing (Cont’d)

6.4

6.5

6.6

6.7

Inspection of Length Over Five Links After Proof Test Inspection for Surface Defects After Proof Test Link Dimension and Measurements After Proof Test Mechanical Property Test of Finished Chain Link- One Link Per Each Length

6.8 Weight check

7. Preparation for Dispatch

7.1 Marking

7.2

Packing / Palletizing & Preservation For shipping.

7.3

Inspection Release Note (IRN)

8. Reports & Test Certificates

8.1 Vendor Data Book

8.2 Raw Material Test Certificates

8.3

Vendor Data Books endorsement, and issue of release note by TPA

E C N E R E F E R

T N E M U C O D

PO SPEC & STD

P.O Spec.,

P.O Spec.

Vendor Document Requirement List

Document No: AGES-SP-13-002

Rev. No: 01 Page 278 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–505 Rub strips and Fenders

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N O T A C F T R E C

I

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

ACTIVITY

Scope

This list covers test and inspection requirement for Rub strips for Well Head Fenders

Vendor approval

2. Pre-production Meeting

3. General - Preliminary work

3.1 Drawing & Specification

3.2

COMPANY Material Specification Sheet (If applicable)

3.3 Vendor Production Schedule

3.4 Vendor QA/Plan

3.5 Status of Sub Orders

3.6 Material Test & Certificates

3.7

3.8

Welding Procedure Qualification & Welder Qualification (if applicable) NDT Procedure & NDT Personnel Qualification (If applicable)

3.9 Test Procedures

4. Production

4.1 Material Traceability and examination

4.2 Steel Element

4.3 Rubber Element

4.4 Vulcanization

4.5 Surface Finish after Blasting

5. Examination

5.1 Visual

5.2 Dimension

5.3 Painting of Steel Surface

E C N E R E F E R

T N E M U C O D

Project Specification. P.O. Description BS 903 COMPANY Pre- qualification

Drawing & Specification Approved Drawing & Specification

Prod. Plan

QA Manual

Prod. Plan

Codes Standards &

Design Codes Specification , Codes & Standards

Vendor Data Book & Material Test Certificates Approved Drawing/ Specification

Specification

ISO 8501-1, SA 2.5

Approved Drg. Specification , procedures

Document No: AGES-SP-13-002

Rev. No: 01 Page 279 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–505 Rub strips and Fenders (Cont’d)

I

N O T A C F T R E C

I

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

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L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

ACTIVITY

6. Testing

6.1 Tensile Strength

6.2 Elongation at Break

6.3 Hardness

6.4 Tear Strength

E C N E R E F E R

T N E M U C O D

BS903- A2/ASTM D412 BS903- A2/ASTM D412

BS 903 A26

BS903- A2/ASTM D412

6.5 Compression Set (22 hours at 70o C)

BS 903-A6

6.6 Ozone Resistance

6.7 Hot Water Resistance

6.8 Abrasion Loss

6.9 Specific Gravity

6.10 Water Absorption

BS 903 A43

BS 903-A9

BS 903 A9

BS 903-A7

BS 903-A16

7. Preparation for Dispatch

7.1

Cleaning, Preservation & surface Treatment

Specification

7.2 Preparation for Shipment & Packing

Specification

Inspection Release Note (IRN)

8. Reports & Test Certificates

8.1 Vendor Data Book

8.2 Raw Material Test Certificates

8.3

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 280 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–506

Hydraulic Clamp

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N O T A C F T R E C

I

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R E R U T C A F U N A M

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L E V E L N O T N E V R E T N

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R O D N E V

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L E V E L N O T N E V R E T N

I

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L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

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Y N A P M O C

I

L E V E L N O T N E V R E T N

I

SL. NO.

1

ACTIVITY

Scope

This list covers test and inspection requirement for Hydro Clamp

Vendor approval

2. Pre-production Meeting

3. General - Preliminary work

3.1 Drawing & Specification

3.2

COMPANY Material Specification Sheet (If applicable)

3.3 Vendor Production Schedule

3.4 Vendor QA/Plan

3.5 Status of Sub Orders

3.6 Material Test & Certificates

3.7

3.8

Welding Procedure Qualification & Welder Qualification (if applicable) NDT Procedure & NDT Personnel Qualification (If applicable)

3.9 Coating Procedure

3.10 Test Procedures

4. Production

Manufacture

4.1

Identify Material & Certificates

check Mill

4.2 Machining of internal components

4.3 Rough Machining Body

4.4 Saw cut Rough machined Body

4.5 Mill Faces after saw cut

E C N E R E F E R

T N E M U C O D

Project Specification. P.O. Description

COMPANY Pre- qualification

Drawing & Spec. Approved Drawing & Spec.

Prod. Plan

QA Manual

Prod. Plan

Codes Standards & Design Codes & Standards

Codes & Standards

Spec., Codes & Standards

Approved Drg./Spec./Ce rtificates

Approved Spec., Drawings Certificates WPS

Document No: AGES-SP-13-002

Rev. No: 01 Page 281 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–506 Hydraulic Clamp (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

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L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Approved Drg., Spec., Certificates, WPS

Approved Drg, Spec., WPS

Specification, approved Procedure

Approved Coating Procedure

Specification, approved Drg, procedure

Spec. Approved, procedures Drawing

SL. NO.

4.6

4.7

4.8

ACTIVITY

Fit & Tack of two body halves together Final Machining of internal bores on Body Split Body Halves and finish all machining

4.9 Fabrication Fit up

4.10 Welding

4.11 Stress Relieving where applicable

4.12 Coating

4.13 Assemble of Clamp

5. Examination & Inspection

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

5.10

Receiving Inspection of Purchased Material Visual & Dimensional Inspection at rough machining Visual & Dimensional Inspection of rough machining Visual & Dimensional Inspection of saw cut Body Visual & Dimensional Inspection of milling Visual & Final Dimensional Inspection at Welding Completion Visual & Dimensional Inspection of Bores on Body Visual & Final Dimensional Inspection at Machining Completion Visual & Fabrication Dimensional Inspection at Fit up Stage Visual & Final Dimension at welding Completion

5.11 Final Surface NDE of Body Halves

5.12 Surface NDE after structural welding

Document No: AGES-SP-13-002

Rev. No: 01 Page 282 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–506 Hydraulic Clamp (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

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L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

E C N E R E F E R

T N E M U C O D

Approved procedure, Spec. Approved Coating Procedure

Project specification, approved Procedure, Drawing Specification, approved Test Procedure,

Spec., Drawing Spec./

Spec./

Vendor Document Requirement List

SL. NO.

ACTIVITY

5.13 Surface NDE after load test

5.14 Final Coating Inspection

6. Testing

6.1

Load test of welded pad eyes on the clamp at 1.5 times the clamp weight

6.2 FAT of Clamp assembly

7. Preparation for Dispatch

7.1 Marking

7.2 Cleaning, Preservation

7.3 Preparation for Shipment & Packing

8. Reports & Test Certificates

8.1 Vendor Data Book

8.2 Raw Material Test Certificates

8.3

Vendor Data Books endorsement, and issue of release note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 283 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–507

Connectors

ACTIVITY

E C N E R E F E R

T N E M U C O D

Scope This requirement for Connectors

list covers

test and

inspection

P.O, Project Specification.

SL. NO.

1.1 Vendor approval

COMPANY PQ

2. Pre-production Meeting

3. General - Preliminary work

3.1 Drawing & Specification

3.2

COMPANY Material Specification Sheet (If applicable)

3.3 Vendor Production Schedule

3.4 Vendor QA/Plan

3.5 Status of Sub Orders

3.6 Material Test & Certificates

3.7

3.8

Welding Procedure Qualification & Welder Qualification (if applicable) NDT Qualification (If applicable)

Procedure & NDT

Personnel

3.9 Coating Procedure

3.10 Test Procedures

4. Production

4.1 Identify Material & check Mill Certificates

4.2 Machining of internal components

4.3 Machining of Seal Housing Sections

4.4 Fit & Tack of Seal Housing sections

4.5 Welding of Seal Housing Section

4.6 Welding

4.7 Stress Relieving where applicable

4.8 Coating

4.9 Assembly

5. Examination & Inspection

5.1 Receiving Inspection of Purchased Material

5.2

Visual & Dimensional machining

Inspection at

Document No: AGES-SP-13-002

Approved Drawing. Approved Drawing & Spec.

Prod. Plan

QA Manual

Prod. Plan

Codes Standards &

Design Codes & Standards

Spec., Codes & Standards

Approved Spec., Approved Drawings Certificates WPS

Approved Proc/Spec Approved Procedure Approved Drawing

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I

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R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

R O D N E V

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L E V E L N O T N E V R E T N

I

L B A C L P P A E R E H W

R O T C A R T N O C

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L E V E L N O T N E V R E T N

Y N A P M O C

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Rev. No: 01 Page 284 of 285

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Procurement Inspection and Certification Requirement in Projects – APPENDIX A

ITP–507 Connectors (Cont’d)

I

N O T A C F T R E C

I

I

R E R U T C A F U N A M

I

L E V E L N O T N E V R E T N

I

R O D N E V

I

L E V E L N O T N E V R E T N

I

I

L B A C L P P A E R E H W

R O T C A R T N O C

I

L E V E L N O T N E V R E T N

I

Y N A P M O C

I

L E V E L N O T N E V R E T N

I

ACTIVITY

E C N E R E F E R

T N E M U C O D

Examination & Inspection (Cont’d)

Visual & Final Dimensional Inspection at Welding Completion Visual & Final Dimensional Inspection at Machining Completion Visual & Final Dimension at welding Completion Surface NDE of welds, RT, MT, PT as applicable

Project Specification approved procedures and Drawing

SL. NO.

5.3

5.4

5.5

5.6

5.7 Surface NDE after load test

5.8 Final Coating Inspection

Testing

6.1 Load test Lifting arrangement

6.2

Hydro Pressure Test/FAT of Clamp assembly

Approved Proc., Spec., Drawing

7. Preparation for Dispatch

7.1 Marking, cleaning, preservation

7.2 Preparation for Shipment & Packing

8. Reports & Test Certificates

Specification, Drawing

8.1 Vendor Data Report

VDRL

8.2 Raw Material Test Certificates

8.3

Vendor Data Book endorsement, and Issue of Release Note by TPA

Document No: AGES-SP-13-002

Rev. No: 01 Page 285 of 285

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Project: Q-32859 - NMDC - Ruwais Folder: RFQ Files