Itp For Insulation

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UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 INSPECTION AND TEST PLAN FOR INSULATION WORK Doc. No. P7512-04-001-YS-ITP-0002

Page: 1 of 13

Rev. C

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 CONTRACT No. : CT750 UZ110110 PETROFAC JOB No.: PE-103 INSPECTION AND TEST PLAN FOR INSULATION WORK DES-1358‐ITP‐012 

SUBCON. Document. No. 

Document Rev. 



SUBCON. No. 

SUBCON. NAME 

SUBCONTRACT TITLE 

04‐001 

Descon Engineering 

STR,  Mechanical  &  Piping  Works  for  all  Islands  

REVIEW CODE 











Legend: 1. Approved; 2. Approved With Comments; 3. Reviewed With Comments, Correct & Re-Submit; 4. Information Only, Review Not Required; 5. Rejected Name:  

Signature:

Date: 

By R. Nakkeeran at 10:38 am, Oct 11, 2016

C

02-Oct-2016

ISSUED FOR APPROVAL

MAB

NA

NA

B

10-AUG-2016

COMMENTS INCORPORATED

MAB

NA

SH

A

19-JUL-2016

ISSUED FOR REVIEW

MAB

NA

SH

REV.

DATE

DESCRIPTION

PRPD

CHKD

APPD

PROJ. APPD

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 INSPECTION AND TEST PLAN FOR INSULATION WORK Doc. No. P7512-04-001-YS-ITP-0002

Rev. C

Page: 2 of 13

TABULATION OF REVISED SECTIONS / PAGES REV

PAGE

DESCRIPTION

A

Initial Review

B

Comments Incorporated

C

Issued for approval

TABULATION OF HOLDS PAGE / SECTION

DESCRIPTION OF HOLD

None

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 INSPECTION AND TEST PLAN FOR INSULATION WORK Doc. No. P7512-04-001-YS-ITP-0002

Rev. C

Page: 3 of 13

TABLE OF CONTENTS 

1.

LIST OF VERIFYING DOCUMENTS ……………………………………………………………………………………. 4 

2.

DEFINITIONS ………………………………………………………………………………………………………………….. 4 

3.

ABBREVIATIONS …………………………………………………………………………………………………………….. 4 

4.

REFERENCE DOCUMENTS ………………………………………………………………………………………………. 5 

5.

EXECUTION STEP ……………………………………………………………………………………………………………. 6 

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 INSPECTION AND TEST PLAN FOR INSULATION WORK Doc. No. P7512-04-001-YS-ITP-0002

Rev. C

Page: 4 of 13

1. LIST OF VERIFYING DOCUMENTS (ITRS) P7512-V-0301-X-I

Hot Insulation Application Report

P7512-V-0302A-I

Final Insulation Inspection Report

ITR Copy not attached

2. DEFINITIONS PROJECT

:

UZ 750 Upper Zakum Islands Surface Facilities (EPC - 2)

COMPANY

:

Zakum Development Company (ZADCO)

CONTRACTOR

:

Petrofac Emirates & DSME

SUB-CONTRACTOR

:

Descon Engineering

3. ABBREVATIONS

GA

:

General Arrangement

CRA

:

Corrosion resistance alloy

MIR

:

Material Inspection Report

IFC

:

Issued For Construction

ITP

:

Inspection and Test Plan

MOM

:

Minutes of Meeting

MTC

:

Material Test Certificate

NCR

:

Non Conformance Report

NDT

:

Non Destructive Testing

PO

:

Purchase Order

QA

:

Quality Assurance

QC

:

Quality Control

RFI

:

Request for Inspection

TPIA

:

Third Party Inspection Agency

FEDC

:

Field Engineering & Document Control

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 INSPECTION AND TEST PLAN FOR INSULATION WORK Doc. No. P7512-04-001-YS-ITP-0002

Rev. C

Page: 5 of 13

4. REFERENCE DOCUMENTS The following documents are used as source of reference and may be read in conjunction with the procedure.

P7512-TS-2000-Y-0003 P7512-TS-2000-W-0002

Repeated 2 times?

P7512-TS-2000-Y-0003 P7512-PD-2000-Q-0038 P7512-04-001-YS-MTS-0001

Coating and Lining Specification Thermal and Acoustical Insulation specifications PED Coating and Lining Specifications PED Inspection and Test Plan for Hot Insulation MS for Surface preparation, painting, and Holiday test

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 INSPECTION AND TEST PLAN FOR INSULATION WORK Doc. No. P7512-04-001-YS-ITP-0002

Page: 6 of 13

Rev. C

P1358 for UZ750? DESCON Document No: P1358-ITP-012

Revision: C

Date:02-Oct-2016

Project Title:Upper Zakum-Islands Surface Facilities Project-EPC-2 Project / Order No:P7512 Sub-order / Sub-contract No:TBA Activity / Item Covered: INSPECTION AND TEST PLAN FOR INSULATION WORK

Requisition No:TBA Tag No(s):TBA

Vendor / Contractor name:Consortium of Petrofac Emirates LLC and Daewoo Shipbuilding and Marine Engineering (*) QC SURVEILLANCE POINTS

Co. Ltd.

Sub- Vendor / Sub-Contractor name:Descon Engineering Vendor / Contractor QA/QC Manager:Nadir Abbas QC Responsible on the implementation of this ITP: QC Team

H

: Hold Point

W

: Witness Inspection

S

: Operation Surveillance

A

: Approval Required

R

: Review of Documentation

EXECUTION STEP

Item

1

Quality Control

Reference

Characteristics to be verified/

Activity

document

frequency

Project  Specifications  P7512‐TS‐2000‐ W‐0002,  

Review & Verification   of  validity of Calibration Certificate  with reference to instrument  serial number / identification  number. 

Control  of  Inspection test   and  measuring  equipment 

clause 18.4 Manufacturer’s  data sheet

Verify Condition of test  equipment 

Acceptance Criteria

Contractor QC Procedure

In accordance with  approved calibration of  measurement and  test  equipment procedure 

MS For Insulation Work P7512-04-001YS-MTS-0002

SURVEILLANCE POINTS (*)

Verifying

Person

document/

responsible for

Record

the inspection

DES

PED

 Valid calibration  certificate   Good  working condition

Insulation  Supervisor  Piping/Insulation  Inspector 

H

A

Accept ance

TPIA

Remove TPI column if not applicable (Typ)

ZADCO

R

Status

Comment (s)

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 INSPECTION AND TEST PLAN FOR INSULATION WORK Doc. No. P7512-04-001-YS-ITP-0002

Item

Quality Control

Reference

Characteristics to be verified/

Activity

document

frequency

Page: 7 of 13

Rev. C

Acceptance Criteria

Contractor QC

Verifying

Procedure

document/Record

Person

SURVEILLANCE POINTS (*)

responsible for the inspection

ance DES

PED

TPIA

ZADCO

H

A

R

H

A

A

 Company  specification 

 Approved 

Z0‐TS‐Y‐03010 

2

Approval  of  documents 

& Z0‐TS‐Y‐

 Insulation Drawings. 

03020  

 Manufacturer's Compatibility 

 Project 

QCP/Hot, Cold &   Documents shall be  

Certificates and Application 

approved for 

Specifications 

Procedure from 

construction or 

P7512‐TS‐

Manufacturer 

implementation 

2000‐W‐0002,    Insulation 

clause 18.2

Manufacturer’ s Documents 

Insulation Applicator Qualification Records

PP Insulation  application  manual   MS For Insulation  Work 

 Document  control and  approval 

 Piping/Insulati on Inspector 

procedure 

 P7512‐04‐001‐ YS‐MTS‐0002 

 Company  specification  Z0‐TS‐Y‐03010  & Z0‐TS‐Y‐

3

Approval of  Insulation Material 

03020    Project 

 Correct Type and Brand  Name.   Density as Specified.   Product Batch number. 

Specifications 

 Material Certificate. 

P7512‐TS‐

 Shelf Life. 

2000‐W‐0002,    Manufacturer’ s data sheet 

 MS For Insulation   Conformance to  Requirements 

Work   P7512‐04‐001‐ YS‐MTS‐0002 

 MAR for  Insulation  Material. 

 Piping/Insulati on Inspector 

Accept Status

Comment (s)

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 INSPECTION AND TEST PLAN FOR INSULATION WORK Doc. No. P7512-04-001-YS-ITP-0002

Item

Quality Control

Reference

Characteristics to be verified/

Activity

document

frequency

Page: 8 of 13

Rev. C

Acceptance Criteria

Contractor QC

Verifying

Person

Procedure

document/Record

responsible for the inspection

3.1

Material Receiving  Inspection 

 Comply with 

 MAR for  Insulation 

 Material Test Certificates 

material 

Manufacturer’s Data  Sheet and Project  Specifications 

 MS for insulation  work and P7512‐ TS‐2000‐W‐0002 

4

Storage of  Insulation Material 

 Product Data  Sheet.   MSDS 

manufacturer's Data 

Implemented 

sheet and Project 

to avoid moisture and dust 

Specifications P7512‐ TS‐2000‐W‐0002 

 MS For Insulation  Work   P7512‐04‐001‐ YS‐MTS‐0002 

 House keeping 

 Company  specification  Z0‐TS‐Y‐03010  & Z0‐TS‐Y‐ 5

Tools and  Equipment 

03020     Project  Specifications  P7512‐TS‐ 2000‐W‐0002,  

on Inspector 

PED

H

W

TPIA

ZADCO

S

W

 Company   Comply with 

Material Manufacture is   Covered with plastic sheets 

certificate 

 Piping/Insulati

DES

clause 18.1.1

 Storage Condition as  Stipulated by the Insulation 

 Material test 

SURVEILLANCE POINTS (*)

Product Data Sheet must contain a minimum mositure content and that maximum figure should be used to define whether Availability of Tools    N/A  excess moisure is present.

specification 

 Insulation 

Z0‐TS‐Y‐03010 

Supervisor 

& Z0‐TS‐Y‐

Piping/Insulati on Inspector 

03020  

W

W

S

H

S

S

 Manufacturer’s  Data Sheet 

clause 19.1 & 19.2  Approved  QCP/Hot, Cold &  PP Insulation  application  manual   MS For Insulation  Work   P7512‐04‐001‐ YS‐MTS‐0002 

 Visual 

Insulation  Supervisor  Piping/Insulation  Inspector 

Accept

Comment

ance

(s)

Status

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 INSPECTION AND TEST PLAN FOR INSULATION WORK Doc. No. P7512-04-001-YS-ITP-0002

Item

Quality Control

Reference

Characteristics to be verified/

Activity

document

frequency

Page: 9 of 13

Rev. C

Acceptance Criteria

Contractor QC

Verifying

Person

Procedure

document/Record

responsible for the inspection

SURVEILLANCE POINTS (*) DES

PED

TPIA

ZADCO



W



W

W

R/S 

R/S 

 Company   Approved 

specification 

6

Damage to  Surfaces Prior to  Installation of  Insulation 

Z0‐TS‐Y‐03010 

QCP/Hot, Cold & 

& Z0‐TS‐Y‐

PP Insulation  application 

03020    Visual Inspection 

 No damage   Smooth surfaces 

 Project 

manual 

 Release Note 

 MS For Insulation  Work 

Specifications 

Insulation  Supervisor  Piping/Insulation  Inspector 

 P7512‐04‐001‐

P7512‐TS‐ 2000‐W‐0002,  

YS‐MTS‐0002 

 Company   Approved 

specification 

QCP/Hot, Cold & 

Z0‐TS‐Y‐03010 

7

Release of Piping /  Equipment to  Commence  Insulation 

& Z0‐TS‐Y‐ 03020    Project 

PP Insulation 

 Release Note by Piping and  Painting Disciplines    Surface Clean, Dry and Free 

Specifications  P7512‐TS‐ 2000‐W‐0002,  

clause 18.1.2

from Moisture 

 Spool Release Note 

 Insulation 

application  manual   MS For Insulation  Work   P7512‐04‐001‐ YS‐MTS‐0002 

  Release Note 

Supervisor  Piping/Insulati on Inspector  



Accept

Comment

ance

(s)

Status

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 INSPECTION AND TEST PLAN FOR INSULATION WORK Doc. No. P7512-04-001-YS-ITP-0002

Item

Quality Control

Reference

Characteristics to be verified/

Activity

document

frequency

Page: 10 of 13

Rev. C

Acceptance Criteria

Contractor QC

Verifying

Procedure

document/Record

Person

SURVEILLANCE POINTS (*)

responsible for the inspection

ance DES

PED



W

TPIA

ZADCO

 Insulation / PP Support Rings   Expansion Joints at Specified 

8

1‐ Installation of   Insulation plus  fixing (Hot ,Cold &  Acoustic service)  2‐Joint Sealant  Application (in  Cold Service)  3‐Vapor Barrier  and Scrim Cloth  Application (In  Cold Service)  4‐Support Ring and  Mesh Installation  (PP Insulation) 

Intervals.  Company  specification  Z0‐TS‐Y‐03010 

 Correct type Thickness, Size, 

& Z0‐TS‐Y‐

Correct and Correctly Spaced 

03020 

out. 

 Project  Specifications  P7512‐TS‐ 2000‐W‐ 0002sheet 

 Approved 

Condition and shape.   Banding and Fastening is 

 Insulation Layering  Staggering is Correct.   Joint Sealant applied properly  in Cold Insulation.   Vapor Barrier and Scrim Cloth  Applied Properly in Cold  Insulation.   PP Mesh Installed Properly 

clause 17 & 18

QCP/Hot, Cold &   Conformity to  Specified  Requirements 

PP Insulation 

 Insulation 

application  manual   MS For Insulation  Work   P7512‐04‐001‐ YS‐MTS‐0002 

 ITR‐V‐0301X‐I 

Supervisor  Piping/Insulati on Inspector  

Accept



Status

Comment (s)

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 INSPECTION AND TEST PLAN FOR INSULATION WORK Doc. No. P7512-04-001-YS-ITP-0002

Item

Quality Control

Reference

Characteristics to be verified/

Activity

document

frequency

Page: 11 of 13

Rev. C

Acceptance Criteria

Contractor QC

Verifying

Person

Procedure

document/Record

responsible for the inspection

SURVEILLANCE POINTS (*) DES

PED

H

W

TPIA

ZADCO

 Installed Insulation Layer is  dry and free from Moisture.   Correct Cladding Material is  used.   Correct Thickness and Profile.   Joint Overlap and  Terminations are Correct and  Company  specification  Z0‐TS‐Y‐03010  & Z0‐TS‐Y‐ Installation of 

9

Cladding and  Banding 

03020   Project  Specifications  P7512‐TS‐ 2000‐W‐ 0002sheet 

Fixed Securely.   Longitudinal and  circumferential seams at  correct distance. (For piping  and Equipment as applicable)   Approved sealant applied.   Banding over Cladding is of  Correct and spaced at  required Intervals.   Screws and Rivets are of  Correct Type and Material    Any metal cladding applied  does not make contact with  clad item and min. clearance  and overlap to be ensure.   Sufficient bolt clearance at  valve & Flanges. Min.  clearance is equal to the Stud  bolt +25mm or as per Spec. 

 Conformity to  Specified  Requirements 

 Insulation 

 MS For Insulation  Work   P7512‐04‐001‐ YS‐MTS‐0002 

Supervisor   ITR‐V‐0301X‐I 

Piping/Insulati on Inspector 

S

Accept

Comment

ance

(s)

Status

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 INSPECTION AND TEST PLAN FOR INSULATION WORK Doc. No. P7512-04-001-YS-ITP-0002

Item

Quality Control Activity

Reference document

Characteristics to be verified/ frequency

Page: 12 of 13

Rev. C

Acceptance Criteria

Contractor QC Procedure

Verifying document/Record

Person

Accept

SURVEILLANCE POINTS (*)

responsible for the inspection

ance DES

PED

TPIA

ZADCO

Company  specification  Z0‐TS‐Y‐03010 

10

Repair of  Insulation and  Cladding 

& Z0‐TS‐Y‐ 03020 

 Insulation shall be Repaired  Prior to Cladding   Repairs or Rework Shall be  noted and Carried out in 

 Project 

Accordance With the 

Specifications 

Manufacturer’s Approved 

P7512‐TS‐ 2000‐W‐ 0002sheet 

 Conformity to  Specified  Requirements 

 Insulation 

 MS For Insulation  Work   P7512‐04‐001‐

Supervisor   ITR‐V‐0301X‐I 

Piping/Insulati

H

H

W

H

H

H

on Inspector 

YS‐MTS‐0002 

Procedure.  

clause 18.6 Company  specification  Z0‐TS‐Y‐03010  & Z0‐TS‐Y‐ 03020 

Activities

 Project 

11

Final Visual  Inspection 

Specifications  P7512‐TS‐ 2000‐W‐

 All Activates Completed and  Documented 

0002sheet   Manufacturer’ s Data Sheet 

clause 18.5 & 18.7

 Conformity to  Specified  Requirements 

 Insulation 

 MS For Insulation  Work   P7512‐04‐001‐ YS‐MTS‐0002 

Supervisor   ITR‐V‐0302A‐I 

Piping/Insulati on Inspector 

Status

Comment (s)

UPPER ZAKUM 750 ISLANDS SURFACE FACILITIES PROJECT – EPC2 PROJECT No. P7512 INSPECTION AND TEST PLAN FOR INSULATION WORK Doc. No. P7512-04-001-YS-ITP-0002

PREPARED BY

APPROVED BY

Title

Name

Title

Name

QA Engineer

M.A.Bilal

DQCM

Nadir Abbas

Signature

Date

Signature

Date

02-Oct-2016

Attach applicable ITR formats

Page: 13 of 13

Rev. C

02-Oct-2016

CERTIFIED COMPLETED

COMPLETION ENDORSEMENT

Title

Name

Title

Name

Signature

Date

Signature

Date

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