B-qac-pro-210-39162 -a

Ain Tsila Development Main EPC Contract A-CNT-CON-000-00282

Sub-contractor Name:

SARPI FLOWLINE & TRUNKLINE PIUL Approval Code/Name/Signature Name: Signature:

By ASHISH SHAH at 5:19 pm, Aug 20, 2020

CODE

DEFINITION

1

Accepted without comments

2

Accepted with comments

3

Not Accepted. Revise and Resubmit

4

For Information

5

Void-Cancelled / Superseded

Dimension Inspection and Weld Visual

Visual Inspection Test Procedure B-QAC-PRO-210-39162

A

Issued For Review & Comments

19/08/2020

Z. KALKIL

S. BRAHMI

A.TOUNSI

Rev

Purpose

Date

Prepared

Checked

Approved

Approved

This procedures is to be reviewed and approved by NDE Level-III. NDE Level-III to be certified in accordance to ASNT or ACCP or ISO 9712 or PCN

Visual Inspection Test Procedure Document No : B-QAC-PRO-210-39162 Revision A

Revision History Revision A

Changes Issued For Review & Comments

This revision checked and signed off by: Name

Function or Job Title

ZOUBIR KALKIL

SARPI QAQC Coordinator

SADEK BRAHMI

SARPI QA Responsible

ALLEL TOUNSI

SARPI Project Manager

Holds Hold No.

Location

Description

SARPI

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Visual Inspection Test Procedure Document No : B-QAC-PRO-210-39162 Revision A

Contents REVISION HISTORY

2

CONTENTS

3

ABBREVIATIONS

5

1

INTRODUCTION

6

2

PURPOSE OF THE DOCUMENT

6

3

SCOPE OF DOCUMENT

6

4

DEFINITIONS

7

5

REFERENCE DOCUMENTS

7

5.1 5.2 5.2.1 5.2.2

7 7 7 8

6

RESPONSIBILITY 6.1 6.2 6.3 6.4

7

Project Specifications Codes Algerian Codes and Standards International Codes and Standards

9

Construction representative: QA/QC Coordinator QC Engineer: NDT Welding Inspector

9 9 9 10

EXECUTION TECHNIQUE

10

7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.1.8 7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.3 7.3.1 7.3.2 7.3.3 7.3.4

10 10 10 10 11 11 11 11 11 11 11 12 12 12 12 12 12 13 13 13

Prior to Welding. Review Drawings and Specifications. Check Procedure and Performance Qualifications. Establish Hold Points. Establish Documentation Plan. Review Material Documentation. Examine Base Materials. Examine Joint Fit-Up and Alignment. Review Storage of Welding Consumables. During Welding. Check Preheat and Interpass Temperatures. Check Conformance with Welding Procedure Specification. Examine Weld Root Pass. Examine Weld Layers. Examine Second Side Prior to Welding. After Welding. Examine Weld Surface Quality. 7.3.2 Verify Weld Dimensions. Verify Dimensional Accuracy. Review Subsequent Requirements.

SARPI

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Visual Inspection Test Procedure Document No : B-QAC-PRO-210-39162 Revision A

7.4 7.5 1.0

8

Surface Condition Qualification of the personnel Acceptability criteria

LIST OF VERIFYING DOCUMENTS

13 13 14

14

.

SARPI

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Visual Inspection Test Procedure Document No : B-QAC-PRO-210-39162 Revision A

Abbreviations GIS

Groupement ISARENE

PIUL

Petrofac International (UAE) LLC

SC

Sub-Contractor

ITP

Inspection and Test Plan

QCP

Quality Control Procedure

ITR

Inspection Test Record

CR

Construction Representative

NDE

Non Destructive Examination

RT

Radiographic Examination

QCE

Quality Control Engineer

QCI

Quality Control Inspector

QA/QC

Quality Assurance/ Quality Control

ASME

American Society of Mechanical Engineers

SARPI

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Visual Inspection Test Procedure Document No : B-QAC-PRO-210-39162 Revision A

1

INTRODUCTION SARPI hereafter referred as Subcontractor will execute the (Gathering Pipelines, Wellheads & Manifolds MEI Works) Subcontract on behalf of PETROFAC referred hereafter as Contractor. Whereas the Groupement ISARENE, hereinafter collectively referred to as “client” or “COMPANY” have awarded Petrofac a Contract for EPCC of Ain Tsila Development (hereinafter referred to as the “Contract” or “Main Contract”).

2

PURPOSE OF THE DOCUMENT To develop and established quality control procedure reference for standards for Visual inspection testing as described in the contract, Sub-contract and standard procedure set by COMPANY / CONTRACTOR.

3

SCOPE OF DOCUMENT This document describes the procedure and acceptance standards for Visual inspection testing of welds in AinTsila Development project. In case of any conflict between this document and the Project Specification, drawings and applicable Codes, where Algerian regulations, codes and standards exist, their recommendations shall always take precedence. Such regulations shall therefore be deemed to supplement and/or amend the provisions of this specification. In the event of conflict between the requirements of this specification and other referenced documents, the CONTRACTOR shall request written clarification from COMPANY. The order of precedence will normally be: 

Statutory regulations



Referenced codes and standards



This specification



Other referenced project documents

Any deviations from these documents shall be agreed with COMPANY prior to implementation. However, adherence to them does not relieve the SUBCONTRACTOR of its obligation to apply good industry practices in the delivery of goods and services to the Development.

SARPI

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Visual Inspection Test Procedure Document No : B-QAC-PRO-210-39162 Revision A

4

DEFINITIONS The terms and definitions as used within this document are listed below. “COMPANY” means Groupement ISARÈNE (the operator of the Ain Tsila Development) “CONTRACTOR” Petrofac International UAE Limited, who is in charge for the execution of EPC project. “Sub-contractor” means any sub-supplier or subcontractor of any tier on whom the CONTRACTOR has directly or indirectly placed a Subcontract “shall” or “must” indicates that the specified action is mandatory (i.e. must be done by the specified action party) “should” Indicates that the specified action is recommended but not mandatory “will” indicates a commitment by others or a statement of fact

5 5.1

REFERENCE DOCUMENTS Project Specifications

A-PLE-SPE-200-30010 - Pipeline Construction Specification A-ENG-LST-000-00001 - List of Codes and Standards B-PLE-BOD-210-30001 - Gathering System Pipeline Basis of Design A-QAC-SPE-000-30002 - Specification for Pipeline Welding Requirements A-MTL-SPE-000-30004 - Specification for Wet Hydrogen Sulphide (H2S) Service A-QAC-SPE-000-30005 - Specification for Welding of Piping

5.2

Codes Current editions of the industry standards including all mandatory addenda in effect at the time of the order shall apply unless otherwise indicated

5.2.1 Algerian Codes and Standards Algerian Gas Pipeline Regulations

Règles de Security pour les Canalisations de Transport De gas Combustibles (Safety Regulations for theTransport by Pipeline of Combustible Gas)

Algerian Liquid Hydrocarbon Pipeline Regulations

Règles de Sécurité pour les Canalisations de Transport D’Hydrocarbures Liquides (Safety Regulations for the Transport by Pipeline of Liquid Hydrocarbons)

Algerian LPG Pipeline Regulations

Règles de Sécurité pour les Canalisations de Transport D’Hydrocarbures Liquides liquéfies sous pression (Safety Regulations for the Transport by Pipeline of Hydrocarbons Liquefied Under Pressure)

SARPI

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Visual Inspection Test Procedure Document No : B-QAC-PRO-210-39162 Revision A

P-CTE-1

Procédure de traitement des dossiers techniques et modalités d'exécution des contrôles et essais règlementaires. Note: French and English side-by-side translation issued as project document A-PMT-PRO-000-00005.

Decree No. 88-35, 1988

Définissant la nature des canalisations et ouvrages annexes relatifs à la production et au transport d’hydrocarbures ainsi que les procédures applicables a leur réalisation

5.2.2 International Codes and Standards

ASME B31.4,2016

Pipeline Transportation Systems for Liquid and Slurries

ASME B31.8 ,2018

Gas Transmission and Distribution Piping Systems

ASME B31.3,2018

Process Piping

API 1104

Welding of Pipeline and Related Facilities

API 5L, 46th Edition

Specification for Line Pipe

API 6D

Specification for Pipeline and Piping Valves

ASME V, 2019

Non-destructive Examination

ASME BPVC

EN 473

Qualification and certification of NDT operators

ASNT RP SNT-TC-1A

Recommended Practice and Standard Topical Outlines for Qualification Nondestructive Testing personnel

ISO 17637

Non Destructive Examination of Fusion Welds – Visual examination

SARPI

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Visual Inspection Test Procedure Document No : B-QAC-PRO-210-39162 Revision A

6

RESPONSIBILITY Responsibilities of project personnel related to this procedure are described as below.

6.1

Construction representative: The Construction representative (CR) shall be responsible for the following:

6.2



To ensure construction is carried out in accordance with the Project Specifications approved drawings, ITP’s and QCP’s.



To ensure that all necessary resources like Manpower, machineries, equipment’s, Tools & tackles are arranged at site to perform the site activities



To ensure the required work permits are obtained prior to work start of.



Personnel to be deployed in the field shall be trained about project documentation and Client’s requirements

QA/QC Coordinator Responsible for the implementation of the quality control process in accordance with project procedures. Insuring adequate QC monitoring in accordance with the ITP a QC support where necessary:

6.3



Ensuring that all NDT activity in accordance with Quality Plants and Procedure.

  

Ensuring that all construction activities are carried out to schedule and in accordance with quality and safety requirement. NDT activity carried out to relevant Procedure. Assurance of weld numbering system.



Ensuring record of accepted and rejected welds are maintained and traceable.



Establish & maintain QC system for early diagnosis & avoidance of weld defects to minimize repair rate. Liaise with Weld Supervisor to ensure corrective action.

QC Engineer: The Quality Control Engineer shall be responsible for the following: 



Review all relevant documentations, test reports, calibration certificates issued by parties involved such as surveyor, QC inspectors and submit the records to the Contractor/COMPANY as required. Review all material certificate with Project Requirements

 

Organize and allocate inspection works to the Quality Control Inspectors. Accompany Contractor & COMPANY representative if required, carrying out inspections and release hold points.



Sign and obtain signatures from Contractor & COMPANY on the various forms and verifying documents as required.



Coordination with construction representatives.

 

Ensure as built information is recorded in ITR. NCR’s if any Non-conformance observed and to follow up with Construction representative to provide timely and appropriate root cause, Correction, and corrective action. Review / monitor non-conformance reports and track disposition and close out.



SARPI

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Visual Inspection Test Procedure Document No : B-QAC-PRO-210-39162 Revision A

6.4

NDT Welding Inspector 

Implementing Procedure and NDT Procedure.



Interpretation of NDT results



Supervising personnel involved in NDT activity and ensuring their competence



Ensuring NDT equipment is maintained in good order.



Monitor defect type, location, frequency to apply prompt corrective action & avoid repairs. Liaise with QC to maintain records & review trends. Ensuring that correct weld numbering is adhered to and clearly visible.

  

7

NDT personnel management The risk assement and all safety instruction shall be respected all the time and during the work.

EXECUTION TECHNIQUE The Visual Examination shall be performed during process welding to ensure that welded joints are carried out in compliance with WPS and codes applicable. Unless otherwise prescribed by the QCP, the examination shall be carried out on 100% of the welded joints. The check shall be made when access is sufficient to place the eye within 600 mm from the surface to be examined and an angle not less than 30° to the surface to be examined. Mirrors or other devices may be used to improve the angle vision. Weld gauges may be used if necessary. The Visual Examination shall include the following checks:

7.1

Prior to Welding. Prior to welding, some typical action items requiring attention by the visual inspector should include the following:

7.1.1 Review Drawings and Specifications. The inspector should either have copies of the drawings and specifications, or have access to them, and should review them periodically. Information to be gained includes: weld details, material requirements, inspection requirements, dimensions, and qualification requirements.

7.1.2 Check Procedure and Performance Qualifications. The inspector should review welding procedures and welder qualification records to assure the qualifications meet the requirements of the job specification.

7.1.3 Establish Hold Points. Consideration should be given to the establishment of hold points or check points where an examination is to occur prior to the accomplishment of any further fabrication. Hold points should be established for inspection of work which will become inaccessible for

SARPI

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Visual Inspection Test Procedure Document No : B-QAC-PRO-210-39162 Revision A

inspection because it will be covered by subsequent work.

7.1.4 Establish Documentation Plan. It may be necessary to record some inspection results. This documentation will provide data needed for final acceptance.

7.1.5 Review Material Documentation. The inspector should verify that the correct material was ordered, received, and used during fabrication.

7.1.6 Examine Base Materials. Prior to welding, the base materials should be examined for unacceptable discontinuities.

7.1.7 Examine Joint Fit-Up and Alignment. Joint fit-up and alignment are critical to the production of a sound weld. Items that may be considered prior to welding include: (1) Groove angle (2) Root openings (3) Joint alignment (4) Backing (5) Consumable insert (6) Joint cleanliness (7) Tack welds (8) Preheat (when required) All of these factors could have a direct bearing on the resultant weld quality. If the fit-up is poor, it should be corrected prior to welding. Extra care taken during the joint assembly can greatly improve welding effectiveness.

7.1.8 Review Storage of Welding Consumables. Welding consumables should be stored in accordance with the manufacturer’s recommendations, applicable codes, and contract requirements.

7.2

During Welding. During welding, some typical action items requiring attention by those responsible for weld quality should include the following:

7.2.1 Check Preheat and Interpass Temperatures. When required by the reference code, contract documents, or the Welding Procedure Specification, preheat and interpass temperatures should be verified by the inspector.

SARPI

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Visual Inspection Test Procedure Document No : B-QAC-PRO-210-39162 Revision A

7.2.2 Check Conformance with Welding Procedure Specification. Verify that the welding operation is in compliance with the Welding Procedure Specification. Such variables as consumables, wire feed speed, joint design, electrical characteristics, and technique among others should be verified.

7.2.3 Examine Weld Root Pass. A great many defects that are discovered in a weld are associated with the weld root bead. Good visual examination following the application of the weld root bead should expose the problem for correction.

7.2.4 Examine Weld Layers. To evaluate the weld as work progresses, it is wise to visually examine each layer. This also provides a check to determine if adequate cleaning is being accomplished between passes. This may help to alleviate the occurrence of slag inclusions in the final weld.

7.2.5 Examine Second Side Prior to Welding. Critical joint root conditions may exist on the second side of a double-welded joint. This area should be examined after removal of slag and other irregularities. This is to assure that all discontinuities have been removed and that the contour of the excavation provides access for subsequent welding.

7.3

After Welding. Following welding, some typical action items requiring attention by the visual inspector should include the following:

7.3.1 Examine Weld Surface Quality. Visually examine weld surface and verify that the weld contour concavity and convexity meet acceptance criteria required by the contract documents. Workmanship standards may address such items as surface roughness, weld spatter, and arc strikes. Most codes and specifications describe the type and size of discontinuities that are acceptable. Many of these discontinuities can be found by visual examination of the completed weld. The following are typical discontinuities found at the surface of welds: (1) Porosity (2) Incomplete fusion (3) Incomplete joint penetration (4) Undercut (5) Underfill (6) Overlap (7) Cracks (8) Metallic and nonmetallic inclusions

SARPI

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Visual Inspection Test Procedure Document No : B-QAC-PRO-210-39162 Revision A

(9) Excessive reinforcement

7.3.2 7.3.2 Verify Weld Dimensions. To determine if compliance has been obtained, the inspector should check to see if all welds meet drawing requirements for size, length, and location. Fillet weld sizes can be determined by using one of several types of weld gauges. Groove welds should be filled to the full cross section of the joint, or as specified, and the weld reinforcement should not be excessive. Some conditions may require the use of special weld gauges to verify these dimensions.

7.3.3 Verify Dimensional Accuracy. Final inspection of a fabricated weldment should verify that the dimensions are in accordance with the drawing.

7.3.4 Review Subsequent Requirements. Review the specification to determine if additional procedures are required. Such procedures may include postweld heat treatment, nondestructive examination, proof testing, and others. The welding inspector when responsible for final acceptance should verify that each of these subsequent operations was performed.

7.4 Surface Condition

Add : Surface irregularities, including cap welds, inhibiting accurate interpretation of the specified method of NDE shall be ground smooth

Acceptance Criteria as per ASME B31.3

The surface for visual examination shall be clean. Any possible surface imperfection or dirtiness that might impede the interpretation or result shall be removed by a suitable means (i.e. scraping, wire brushing, etc.) until the desired cleanliness is achieved. The means of cleaning shall not be detrimental to the surface under inspection. Artificial/natural lighting shall be of an intensity and quality that illuminate the area under examination without surface glares. Minimum illumination of the surface shall be 350 lx. 1076 lux Where lighting is insufficient shall be used a suitable method of artificial illumination such as a torch.

7.5 Qualification of the personnel

Add : Weld Visual inspection to be performed by AWS CWI Certified personnel with10 years experience

The personnel carrying out the visual examination shall have adequate knowledge of the fabrication process and the operating functions of the part under examination. Moreover, according to ISO 17637 and ASME Section V, Art 9, the personnel must: a) Know the applicable standards, rules and specifications standard b) Know the WPS to be used c) Have a good visual acuity as required. A visual test should be performed to ensure proper vision even with the corrective means.

SARPI

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Personnel shall have an annual vision test to assure natural or corrected near distance acuity such that they are capable of reading standard J-1 letters on standard Jaeger test type charts for near vision. Equivalent near vision tests are acceptable.

Visual Inspection Test Procedure Document No : B-QAC-PRO-210-39162 Revision A

1.0 Acceptability criteria Acceptance criteria shall be in accordance with documentations applicable at the project and more exactly at Standard and Code; Where there are doubts about presence of unacceptable surface defects, may be requested Dye Penetrant Examination or Magnetic Particle Examination to supplement the Visual Examination. The rejected joint shall be repaired as required until it conforms to the required specification and shall be re-inspected.

8

LIST OF VERIFYING DOCUMENTS

No.

ITR Number

Project ITR Number

Description

1

ITR-W-0103X

2045-ITR-020

DAILY WELDING CONTROL SHEET (SHOP / FIELD)

Sub contractor to add following ASME BPVC SEC V - Article 9 requirements after Para 7.4 of this procedure : 1) T-952 DIRECT VISUAL EXAMINATION Direct visual examination may usually be made when access is sufficient to place the eye within 24 in. (600 mm) of the surface to be examined and at an angle not less than 30 deg to the surface to be examined. Mirrors may be used to improve the angle of vision, and aids such as a magnifying lens may be used to assist examinations. Illumination (natural or supplemental white light) of the examination surface is required for the specific part, component, vessel, or section thereof being examined. The minimum light intensity shall be 100 fc (1 076 lx). 2) T-953 REMOTE VISUAL EXAMINATION In some cases, remote visual examination may have to be substituted for direct examination. Remote visual examination may use visual aids such as mirrors, telescopes, borescopes, fiber optics, cameras, or other suitable instruments. Such systems shall have a resolution capability at least equivalent to that obtainable by direct visual observation. General appearance, workmanship and fit-up shall be acceptable in accordance with ASME B31.3. Weld surfaces shall show a smooth contour.

Sub contractor to add following requirements under Para 7.4 of this procedure : 1) All pressure retaining components and welds shall be subjected to 100% visual inspection examination for poor workmanship, surface breaking flaws, fabrication damage and clealiness after all welding and heat treatment (wherever applicable) but prior to pressure testing and application of protective coatings or insulation. 2) Each joint shall be throughly cleaned using power driven wire brushes and hand tools (for SS, DSS, SDSS, carbon steel wire brushes and hand tools are forbidden to avoid contaminant) following welding and before inspection. Spatter and extraneous material shall be removed. Surface irregularities, including cap welds, inhibiting accurate interpretation of the specified method of NDE shall be ground smooth. Cleaned zone shall be a minimum of 25 mm (1 in) on each side of weld. To avoid hot cracking, the area adjacent to the weld preparation shall be clean. S, Pb, Sb, Cd and Zn are detrimental impurities, which may be present in grease or paint. Acetone and equivalent solvents are to be used for cleaning. 3) Visual examination shall be carried out in accordance with ASME Section V Article 9. Internal bead profile shall be visually examined wherever accessible. Areas not easily accessible shall be examined by use of optical instruments such as mirrors or boroscope wherever feasible. Sufficient illumination (more than 1076 lux) shall be provided to enable proper inspection.

SARPI

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