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1、 Inspection and Test Procedure for Construction of RPLC Project RPLC 项目检查和测试程序 DOC. No.: F074-PI-0310-0001 Revision Status: C18-07-13Issue for Approval B28-05-13Issue for Approval A17-04-13Issue for Approval Rev.DateDescription Prepared ByChecked ByApproved ByHYUNDAI-WISONClient Qin YongShi Xiangqua
2、nZhang Shouyue Table of Contents 1INTRODUCTION 简介简介.3 1.1 Purpose.3 1.2 Scope .3 1.3 Definitions and Abbreviations.3 2PROCESS .5 3GENERAL NOTICE .5 4OVERVIEW.7 5STEEL STRUCTURE.9 6PAINTING, BLASTING, GALVENIZING .14 7PIPING .17 8EQUIPMENT.27 9ELECTRICAL.29 10 INSTRUMENT.29 11 WEIGHTING.30 12 LOAD OU
3、T.30 13 DELIVERY .31 1INTRODUCTION 简介简介 This document presents the Wison (Nantong) Heavy Industry (BUILDER) Project Fabrication Inspection and Test Plan (ITP) for the module of RPLC Deep Conversion Project. 本程序介绍的是惠生重工 RPLC 项目的关于生产检查和试验计划。 The ITP is prepared and managed by the Project Quality Assur
4、ance Manager in accordance with the Project Specifications.本程序是项目质量保证经理根据项目的特殊说明而啊指定的。 1.1 Purpose 目的目的 To describe the inspection and test items during the project construction period and define the “Hold point”or “Witness point”or “Review Point”or “Surveillance Point” to ensure that the quality of
5、 each product item can meet the requirement of contract, specifications and drawings. This Inspection Test Plan (ITP) shall be issued for HIWIN (CONTRACTOR) and/or PDVSA (COMPANY) approval as required.本程序是在项目施工期间，为了描述检查和测试项 目以及定义“节点控制”或者“见证点” 、 “检查点” 、 “监测点”来确保产品质量满足合同需要， 满足图纸的说明。此 ITP 程序文件必须经过 HWIN
6、 和 PDVSA 的批准。 1.2 Scope 前景展望前景展望 This ITP covers all BUILDER Fabrication yard inspection and test items for the piperack module of RPLC Deep Conversion Project. The ITP must ensure compliance with the requirements of Production drawings, specifications, contract and relevant standards. 此 ITP 包含 RPLC
7、 项目部管廊模块所有预制厂房的检查和测试项目。此 ITP 必须确保遵守生产图纸， 说明以及合同相关标准的需要。 1.3 Definitions and Abbreviations 定义和缩写代码定义和缩写代码 1.3.1Definitions 定义 The following definitions apply to this Project Inspection and Test Plan:下面的定义适 用于此项目的检查和测试计划 COMPANYPetroles De Venezuela, S.A. (PDVSA) CONTRACTOR A consortium formed by HYUN
8、DAI ENGINEERING Ultrasonic examination extent UT performance Ultrasonic examination procedure F074-PI-0310 -0011 Client SPEC. ASME Section V 30506-01 Rev.2 HWSYY:YES 5.8NDT Radiographic Testing is applicable to butter welds only; Radiography inspection extent RT performance Identification of film Ra
9、diographic film evaluation Radiography procedure F074-PI-0310 -0012 Client SPEC. ASME Section V 30507-01 Rev.2 HRSYY:YES 5.9NDT Magnetic particle and Liquid penetration inspection is applicable to the weld surfaces of each type of joints; Magnetic particle inspection procedure F074-PI-0310 -0013 Liq
10、uid penetration procedure F074-PI-0310 -0014 Client SPEC. ASME Section V 30506-02 Rev.2 30505-01 Rev.1 HWSYY:YES 5.10Weld repair Approval of repair welding procedure Removal of defective welds Repair record , (if any NDT required after repair) Welding Repair Procedure F074-PI-0310 -0015 Client SPEC.
11、 ASME Section V ASME Section IX Approved PQR/WPS 30506-02 Rev.2 30507-01 Rev.2 30506-01 Rev.2 HWSYY:YES 5.11 Dimensional control Rolled tubular Nodes Panels Assembled blocks Completed jacket Piles and legs Flatness Erection dimensional Structure and Pipeline Dimensional Control Procedure F074-PI-031
12、0 -0016 Heat Straightening Procedure F074-PI-0310 -0017 Client SPEC. Inspection CriteriaTable F074- PI-0310-0055 30503-39 Rev.1 HWSYY:YES 5.12 Release check Before blasting: Overall visual / Dimension NDT/ Any tests required Delivery check Overall visual/ Dimension Painting NCR clearance Release Che
13、ck Procedure F074-PI-0310 -0018 Control of Non- conforming Procedure F074-PI-0310 -0019 Client SPEC.N/AHWSYY:YES 5.13 PWHT ( if applicable ) Equipment Performance Records Cleanliness: SSPC-SP3; Cleaning by solvent washing; Brush the specified paint. Galvanizing control procedure F074-PI-0310 -0024 C
14、lient SPEC. AASTM A 53/A 53M ASTM A 153/A 153M ASTM A 123/A123M 30583-01 Rev.1 HWSYY:YES 7.0 Piping 7.1 Material receiving SUPPLY BY CONTRACT OR Material ID/ marking Quantity Visual (surface , cut edge ) Material grade Size Heat No., Batch No. Material test certificate Materials and Equipments of cl
15、ient Inspection Procedure F074-PI-0310 -0025 Client SPEC ASME B31.3 N/AHWSYY:YES 7.2 Material identification Identify material size, marking (grade, heat No., vendor name) Ultrasonic examination extent UT performance Ultrasonic examination procedure F074-PI-0310 -0011 Client SPEC. ASME SEC. V 30506-
16、01 Rev.2 HWSYY:YES 7.9NDT Radiographic Testing is applicable to butter welds only; Radiography inspection extent RT performance Film Identification Radiography procedure F074-PI-0310 -0012 Client SPEC. Drawing Require ASME SEC. V 30507-01 Rev.2 HRSYY:YES Radiographic film evaluation 7.10NDT Magnetic
17、 particle and Liquid penetration inspection is applicable to the weld surfaces of each type of joints; Magnetic particle inspection procedure F074-PI-0310-0013 Liquid penetration procedureF074- PI-0310-0014 Client SPEC. Drawing Require NDT plan ASME SEC. V 30506-02 Rev.2 30505-01 Rev.1 HWSYY:YES 7.1
18、1Weld repair Approval of repair welding procedure Removal of defective welds Repair record , (if any NDT required after repair) Welding Repair Procedure F074-PI-0310-0015 Client SPEC. Approved PQR/WPS 30506-02 Rev.2 30507-01 Rev.2 30506-01 Rev.2 HWSYY:YES 7.12 Spool final inspection Review of the fo
19、llowing inspection results: M/I, Fit-up, Visual, NDT, PWHT, Hardness ISO drawing Spool drawing Spool physical condition Pipe Prefabrication, Installation and Inspection Procedure F074-PI-0310 -0026 Client SPEC. ASME B31.3 N/AH WS 7.13 PWHT ( if applicable ) Joint (spool ) number identification Heat
20、treatment time /temperature Loading/unloading temperature Holding time/temperature Calibration of PWHT equipments Post Weld Heat Treatment Procedure F074-PI-0310 -0020 Client SPEC. ASME B31.3 30503-13 Rev.2 HWSYY:YES 7.14 Hardness test ( if applicable ) Hardness check points Hardness value Welding C
21、ontrol Procedure F074-PI-0310 -0002 Client SPEC. ASME B31.3 30503-11 Rev.2 HWSYY:YES 7.15Installation Pipe support pre- fabrication Cleaning pipe inside & capping of open ends Lubrication rust prevention Fit-up/welding on erection joint NDT Pipe Prefabrication, Installation and Inspection Procedure
22、F074-PI-0310- 0026 Client SPEC. ASME B31.3 N/AWSS 7.16 Line inspection Line (hydro-package) identification Clearance between pipes Access for operation & interference of valves with other structures/ equipment protection of galvanic attack Isolation of hazardous fluid Bends/elbows/ Flanges/bolting /
23、gaskets/ Valves (type/orientation /stem/chain wheel/rating)/ Branch connections/ Pipe supports Pipe Prefabrication, Installation and Inspection Procedure F074-PI-0310- 0026 Client SPEC. 30503- 62Rev.1 HWWYY:YES 7.17 Pressure test HHWYY:YES 7.18 Piping system hydrostatic test Flushing fluid Flushing
24、velocity Removal of valve, instruments Calibration of pressure gauge & relief valve Vent & drain Test medium/temperature/pr essure/ holding time Temporary supports for hydro test Valve testing after pressure test Pressure Testing and Flushing Procedure of Pipework F074-PI-0310-0027 Client SPEC. ASME
25、 B31.3 30503-19 Rev.1 30503-15 Rev.1 HHWYY:YES 7.19Cleaning Chemical cleaning and Pickling Chemical cleaning and Pickling Procedure F074-PI-0310-0028 Client SPEC. ASME B31.3 N/AHWS 7.20 Reinstateme nt Drain/ dry of lines Removal of temporary attachments Pipe Prefabrication, Installation and Inspecti
26、on Procedure F074-PI-0310-0026 Client SPEC. ASME B31.3 N/AWWS 7.21 Final Line Check Before insulation Painting condition Completion of inspection of previous stage Pipe Prefabrication, Installation and Inspection Procedure F074-PI-0310-0026 Client SPEC. ASME B31.3 N/AHWW 7.22 Insulation fire proofin
27、g Extent of insulation Insulation thickness Insulation material Bands & sealer Insulation type(hot or cold) Insulation Procedure F074-PI- 0310-0040 Fire Proofing Inspection Procedure F074-PI-0310-0029 Client SPEC. 30503- 61Rev.1 HWSYY:YES 7.23 Surface preparation of welding joints Cleanliness : SSPC
28、-SP5 -SP6 SSPC-SP7 -SP10 SSPC-SP11 Blasting method: Dry blasting Blasting condition Surface Preparation and Painting Procedure F074-PI-0310 -0021 Client SPEC. ISO8501 SSPC -SP5/SP6 -SP7/SP10 -SP11 30517- 02 Rev.2 HWSYY:YES 7.24 Painting Inspection and Coating thickness (D.F.T) Applicable area Coat S
29、ystem Film Thickness (D.F.T) Defect repair Surface Preparation and Painting Procedure F074-PI-0310 -0021 Color coding Procedure F074-PI-0310 -0022 Client SPEC. SSPC-PA 2 30517- 02 Rev.2 HWSYY:YES 7.25 Painting Repair Damaged portion shall be thoroughly cleaned by blasting , power tools or sandpaper
30、Painting Repair Procedure F074-PI-0310 -0023 Client SPEC. 30517- 02 Rev.2 After repair, re-inspection HWSYY:YES 8.0 Equipment 8.1 Receiving Inspection of the equipments supplied by CONTRACTOR Size of the equipment Name plate identification Damages Loose and missing item Preservation of equipment Mat
31、erials and Equipments of client Inspection Procedure F074-PI-0310 -0025 Client SPEC. 30503-29 Rev.1 HWSYY:YES 8.2 Marking & Dimension for Location and election Mechanical Equipment Client SPEC.N/AHWS InstallationAnchor bolt location Installation and Inspection Procedure F074-PI-0310-0030 8.3 Base Su
32、pports Welding Base supports pads where applicable Welding Control Procedure F074-PI-0310-0002 Approved WPS AWS D1.1/1.8 Client SPEC. N/AHWS 8.4 Coating of Base Supports Coating condition Surface Preparation and Painting Inspecting Procedure F074-PI-0310-0021 Client SPEC.N/AHWS 8.5 Lifting & Setting
33、 Lifting lug & sling wire Locked shackle pin Setting location Level of equipment Bolt hole condition Cranes capacity Mechanical Equipment Installation & Inspection Procedure F074-PI-0310-0030 Client SPEC.N/AWSS 8.6 Installation/We lding Surface cleaning Alignment Root opening Welding consumable Weld
34、ing No. Mechanical Equipment Installation & Inspection Procedure F074-PI-0310-0030 Client SPEC. Approved procedures AWS D1.1 N/AHWS 8.7 Final Visual Inspection Width of bead Weld defect Arc strike Weld Profile Mechanical Equipment Installation & Inspection Procedure F074-PI-0310-0030 Client SPEC. AW
35、S D1.1 N/AHWW 8.8 Machinery Installation Contact condition Orientation Elevation Leveling Mechanical Equipment Installation & Inspection Procedure F074-PI-0310-0030 Client SPEC. 30503-17 Rev.2 HWS 8.9 Equipment Protection Protection Covering Protection control Procedure F074-PI-0310-0031 Client SPEC
36、.N/AWSS 9.0 Electrical 9.1 Installation Check of Electrical Support, Cable tray Electrical Support, Inspection Procedure F074-PI- 0310-0032 Client SPEC.N/AHWSYY:YES 10.0 Instrument 10.1 Installation Check of Instruments installation Check of Instruments Instrument Installation Inspection Procedure F
37、074-PI-0310-0033 Client SPEC. 30503-27 Rev.1 HWSYY:YES 11.0 Weighting 11.1Preparation Weighting procedure Qualification Weight control procedure F074-PI-0304 -0002 Project Spec.N/ARRR 11.2 Completion inspection Structure completeness Piping completeness Equipment completeness E&I completeness Others
38、 Weight control procedure F074-PI-0304 -0002 Project Spec.N/AHWS 11.3WeightingWeighting Weighting procedure F074-PI-0304 -0003 Project Spec. 30503-63 Rev.1 HHSYY:YES 12.0 Load out 12.1Lifting eyeNDT Load out Regulations Client SPEC. 30506- 02 Rev.2 HWS 12.2 steel wire rope & snap ring Tensile test D
39、imensional measure under tensile status Visual inspection Load out Regulations Client SPEC.N/AHWS 123 Export Parts and Components Export Parts and Components inspection Export Parts and Components Packing and Coding Procedure F074-PI-0304-0034 Client SPEC.N/AHWS 12.4Load out Package number check Fas
40、ten status Hoisting sling certification Load out Regulations Client SPEC. N/AHWS 13.0 Delivery 13.1 IRC As-built documents INSPECTION RELEASE CERTIFICATE As-built DWG. Inspection & test Reports Material certificates Procedures Project Delivery Regulations Client SPEC. As-built documents HHRYY:YES AT
41、TACHMENT-1 30510-02 Rev.2 Weld Procedure Specification Register(Structure/Pipework) ATTACHMENT-2 30512-03 Rev.1 Welder Qualification Register ATTACHMENT-3 30528-02 Rev.0 Project Nondestructive Inspector Qualification Register ATTACHMENT-4 30503-41 Rev.1 Welding Consumable Inspection Report ATTACHMENT-5 30503-47 Rev.0 Report of Painting Material Inspection ATTACHMENT-6 30516-02 Rev.3 Structure Material Inspection Record ATTACHMENT-7 30516-03 Rev.4 Pipe Material Inspection Report ATTACHMENT-8 30516-04 Rev.3 Inspection Report on Flange, Elbow, Unequal-diameter Joint Pipe Accessory ATTA