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ENI - IRAQ ZUBAYR OIL FIELD DEVELOPMENT PROJECT QUALITY CONTROL SPECIFICATION FOR WELDING/PIPING/TANKS/VESSELS/ STEEL STRUCTURE

00 CD-FE Validity Rev. Status number Revision Index

21/07/10 Date

Final Issue Description

Pasqualato Prepared by

Ditommaso Checked by

Chiorrini Approved by

exploration & Pproduction division


Contractor logo and business name

Project name ZUBAYR OIL FIELD DEVELOPMENT PROJECT

Company Document ID

00250600BBQB09623
Job N. Contractor Document ID

2506-ZA-E-09623
Vendor logo and business name Contract N. Vendor Document ID Order N. Scale n.a.

Facility Name ZUBAYR FIELD GENERAL Document Title

Location ONSHORE

Sheet of Sheets 1 of 31

Supersedes N. Superseded by N. Plant Area n.a.

LOGISTIC SUPPORT BASE QUALITY CONTROL SPECIFICATION FOR WELDING/PIPING/TANKS/VESSELS/STEEL STRUCTURE


Software: Microsoft Word 97-2003

Plant Unit n.a.

File No. 00250600BBQB09623_CDFE00_32.d

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00

REVISION HISTORY

Rev. CD-FE 00

Date 21/07/2010

Nr. of sheets 32

Description Final Issue

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INDEX

3 4

GENERAL .............................................................................................................................................................4 1.1 Scope and Objective........................................................................................................................................4 1.2 Terms and definitions ......................................................................................................................................4 QUALITY CONTROL PLANNING........................................................................................................................5 2.1 Information Related to this Document .............................................................................................................5 2.2 Issuing of QCP and ITP(s)...............................................................................................................................5 2.3 Construction Contractor responsibility.............................................................................................................6 2.4 Local Regulations ............................................................................................................................................6 APPLICABLE DOCUMENTATION ......................................................................................................................6 3.1 Specifications Codes and Standards ..............................................................................................................6 SITE QUALITY ACTIVITIES.................................................................................................................................6 4.1 Site welding activities.......................................................................................................................................6 4.2 Inspection on welding resources .....................................................................................................................7 4.3 Welding inspection checklists........................................................................................................................10 ATTACHMENTS .................................................................................................................................................13 5.1 ITP (s) ............................................................................................................................................................13 5.2 Forms List ......................................................................................................................................................13

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1.1 1.1.1 1.1.2

00

GENERAL
Scope and Objective This specification defines the quality control requirements for Construction Contractor for the execution of welding of Piping / Tank /Vessel / Structural Steel related works to be performed during construction of logistic support base. This document is additional to specification n 2506-ZA-E-09610 already delivered to Construction Contractor and with all other applicable contractual documentation. Terms and definitions PROJECT COMPANY ZUBAYR OIL FIELD DEVELOPMENT PROJECT Eni S.p.A. Exploration & Production Division

1.2

1.2.1

The following terms and definitions are applicable to this document: Construction Contractor(s) Company TPI Organisation(s), including its sub-contractors to whom any part of the Works has been subcontracted by Client; Is the party, which requests contract activities/service and pays for them Third Party Inspection: any organization, authority, person or persons, to which Construction Contractor has subcontracted the execution of inspection and or laboratory testing related activities. Means the facilities constituting the Project, including all the construction services, materials and equipment to be provided by Client to satisfy its obligations pursuant to the Contract undertaken with the Client. Quality Management System: part of the organizations management system that focuses on achievement of results, in relation to the quality objectives, to satisfy the needs, expectations and requirements of Client and of any other interested parties, as appropriate. Quality Control Specification: Company specification for quality control requirements. Quality Control Plan: Construction Contractor plan contain all quality control requirements. This plan complements and compiles all applicable ITP(s). Inspection and Test Plan: Construction Contractor plan of inspection and tests required by engineering and vendors documents or elsewhere specified. ITP(s) shall provide references to applicable procedures, acceptance criteria, documentation, quality records and inspection attendance to be performed, in chronological order, from initial inspection, throughout final inspections and mechanical completion. ITP(s) and relevant forms shall be issued as QCP enclosures. Inspection report Form, attached to the ITP. They shall be used during checks and inspections /tests and signed by the involved parties, as per relevant QC code. Request for Inspection: Written notification to be issued by Construction Contractor in order to allow all parties involved to perform their inspection and test witness as planned in the applicable ITP; Quality Assurance: Part of quality management focused on providing confidence that quality requirements will be fulfilled;
This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

Works

QMS

QCS QCP

ITP

MDT

RFI

QA

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QC NCR Non Conformity Special Process

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Quality Control: Part of quality management focused on fulfilling quality requirements; Non Conformity Report: Document recording a non-fulfilment of a requirement; The non-fulfilment of specified requirements; A process, the results of which are highly dependent on the control of the process or the skill of the operator and in which the specified quality cannot be readily determined by inspection or test on the product; Comparison of a measurement and test equipment with a reference standard or with another one provided with better tolerance in order to detect or to measure possible inaccuracies and to document or eliminate them.

Calibration

1.2.2

Any other terms related to quality and not listed above shall conform to section 3 Term and Definition of ISO 9000:2005 Quality Management System Fundamentals and vocabulary.

2
2.1 2.1.1 2.1.2

QUALITY CONTROL PLANNING


Information Related to this Document This document includes the ITP(s) and forms, listed under paragraph 5.1 and 5.2, for performing as minimum the inspection, tests and certification during site activities related to welding. The ITPs are separated in two following groups: 1. General ITP(s) include the initial necessary checks and verification to be performed but not limited to documentation, personnel and equipment, material receiving, climatic conditions, etc.. Specific ITP(s) include inspection and tests directly related to construction items and or part of the Works that can be identified and tracked through engineering drawings.

2.

2.2 2.2.1

Issuing of QCP and ITP(s) Construction Contractor shall endorse and reissue this document Quality Control Specification (QCS) as Quality Control Plan (QCP), improving the enclosed ITPs in accordance to the scope of work, project requirements and completing the information requested on clause 3.1 and the ITPs columns Reference document & Acceptance Criteria Construction Contractor will number the QCP in accordance to the project numbering system provided by Company. If during Works Construction Contractor will need additional ITP/ ITP phase for further test and checks with the relevant QC Codes, the same shall be numbered adding an alphanumeric suffix to the preceding available QC Code. New QC Codes shall be submitted and approved by Company. Construction Contractor during the execution of the Works shall revise and update, as and when required, the QCP(s) and relevant ITP(s) to incorporate any other pertinent requirements set forth in engineering specifications, standards, design codes, recommended practices, safety design, referred hereafter or included elsewhere in the contractual and vendors documents. Before starting of Works, the QCP containing the ITPs applicable for the project items and works, shall be submitted by the Construction Contractor for Company review and approval.

2.2.2

2.2.3

2.2.4

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2.3.1

00

Construction Contractor responsibility


Construction Contractor in order to meet all the contractual requirements will prepare and update any other necessary QCP(s) and ITP(s), and quality procedures which include all inspections, examinations and tests required to verify the quality of the Works. The above documents shall be timely submitted to Company for review and approval in order to ensure their availability in approved status prior to starting of the welding works. Construction Contractor will perform and record all inspections, examinations and tests required and shall carry out all the works necessary for the preparation of inspections, examinations and tests, including adequate scaffolding for safely witnessing the inspection. Construction Contractor will provide, for the execution of testing, inspection and measurements all necessary equipment, tools and shall make available the applicable international Standards and Codes. Construction Contractor will issue inspections, examinations and tests reports immediately after the completion of each inspection activity. All reports shall be approved and signed off by Construction Contractor authorized personnel prior to submission to Company for review or approval, as appropriate. Company or other Parties signature on inspection, examination and test reports does not release the Construction Contractor from his responsibilities. Construction contractor shall have at his own charge the filing of the relevant QCP form certificate on dedicated Dossiers, at the time required, the Construction Contractor will deliver to Company hard copies and PDF file of the dossiers. Local Regulations Inspections and tests required by local law and regulation shall be strictly adhered to, documented by Construction Contractor and shall take precedence over this specification When local law and local regulations are different from the applicable design codes, Construction Contractor shall inform COMPANY for the necessary actions.

2.3.2 2.3.3 2.3.4

2.3.5 2.3.6

2.4 2.4.1 2.4.2

3
3.1 3.1.1 3.1.2 3.1.3

APPLICABLE DOCUMENTATION
Specifications Codes and Standards Contractual Specification: Project Specifications: TO BE UPDATE BY EPC CONTRACTOR Codes and Standards: Applicable Codes and Standards are those referred in the above specification and in engineering documentation. API 650 for TANK AWS D1.1 for Steel structures ASME B31.3 ASME V ASME IX ASME II Part C

4
4.1 4.1.1

SITE QUALITY ACTIVITIES


Site welding activities Table 1 outlines welding related activities which are required to be carried out by Construction Contractor in a controlled manner:
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TABLE 1

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Welding documents control (Welding summary list/Weld map / WPS / WPQR / Work Instructions) PWHT procedure control Welding personnel Inspection, testing and examination personnel Welding and allied process equipment Welding consumables Materials (base metals and consumables) identification and traceability Welding execution Post weld heat treatment execution Welding related inspection and testing Quality records

4.2 4.2.1

Inspection on welding resources Construction Contractor will provide resources such as: working facilities, welding equipment tools, consumables, weather protection and any other special equipments suitable to the specific work to be performed. Welding resources and welding activities are outlined in Table 2 TABLE 2
Tools Equipment (2) Construction Contractor action (1)

Reference

Welding quality control - Check on that warehouse shall be dry, clean and protected by weather condition. - Check on different working areas for storage, working tools, welding consumables, working and welding activities according to parent material (carbon steel, stainless steel, nonferrous material, etc). - Check on identification of non destructive examination area. - Check on identification of scrap area.

Working facilities

Construction Contractor procedure

Visual inspection

Handling equipment and cranes Equipment for identification and traceability

Manufacturer data sheet Manufacturer recommendation / certification

Visual inspection

- Check on efficiency and safety system - Check on availability - Check on certificates

Visual inspection

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Tools Equipment (2) Reference Construction Contractor action (1)

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Welding quality control - Check on the availability of welding machine, cables, amperometer, voltmeter, etc. - Check on calibration of all parameters that can affect production quality - Check on certificates - Check on availability, efficiency and cleaning of purging and trailing gas system - Check on cylinder identification/marking - Check on efficiency, calibration and cleaning of gas flow meter, gas hoses, etc. - Check on certificates - Check on availability of cutting tools, cutting torch and similar. - Calking tool efficiency - Test efficiency - Check on availability of yokes, jigs, pipe couplers, connecting spacers, etc - Check on presence of different area in warehouse for fit-up equipment in terms of: pipe base metal chemical composition, etc. - Check on certificates - Check on identification and marking

Welding power source and other machines

Manufacturer recommendations / certification

Visual inspection and test

Welding, cutting gas and allied system

Manufacturer recommendations / certification Visual inspection

Equipment for joint preparation, cutting and gouging

Manufacturer recommendations / certification

Visual inspection and test

Fit-up equipment (jigs and fixtures)

Project specification

Visual inspection

Welding consumables (electrodes, filler wires and fluxes)

Manufacturer recommendations / certification /

Visual inspection

- Check on that Welding consumables warehouse is dry, clean and protected by weather condition. - Check on presence of different area in warehouse for consumables in terms of: storage, conditioning and scrap; type, size and classification. - Check on batch/lot certificates - Check on filler metal marking - Check on implementation of manufacturer recommendations for storage, drying, reconditioning and handling

Warehouse and portable ovens

Manufacturer recommendations / certification

Visual inspection and test

- Check on the availability of ovens. - Check on certificates, marking - Test temperature calibration - Check on availability of brushing, grinding tools, etc. - Check on presence of different area in warehouse for tools in terms of: type / material - Check on identification and marking

Welding machining and handle tools

Manufacturer recommendations / certification

Visual inspection

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Tools Equipment (2) Reference Construction Contractor action (1)

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Welding quality control - Check on availability of proper protection for the part to be welded and for welders/ operators function of weather conditions and welding process/ consumables - Check on availability of gauges, calliper, magnifier lens, mirror, borescopes, artificial lighting, etc. - Check on certificates and calibration - Test efficiency - Check on availability of X-ray machines, -ray sources, radiographic film, intensifying screens, wire IQI, hole IQI, densitometer, etc. - Check on certificates and calibration - Test efficiency - Check on availability of pulse-echo instrument, TOFD, probes, couplant, calibration blocks, etc - Check on certificates and calibration - Test efficiency - Check on the availability and efficiency of penetrant, emulsifiers, solvents and cleaning agents, etc. - Check on certificates - Test efficiency - Check on availability of electromagnet or similar, magnetic particles, lighting equipment. - Check on certificates and calibration - Test efficiency - Check on availability of instruments - Check on certificates, calibration and marking - Test efficiency - Check on availability of instruments - Test efficiency -Check on certificates, calibration and marking - Check on the availability of thermocouples, heating elements, electrical generator, temperature indicating-crayons, insulation and cables. - Availability check of oven - Check on certificates, calibration and marking - Test efficiency - Check on availability and efficiency

Weather protection

Project specification

Visual inspection

Equipment for visual examination

Manufacturer recommendation / certification

Visual inspection and test

Equipment for radiographic examination

Manufacturer recommendation / certification

Visual inspection and test

Equipment for ultrasonic examination

Manufacturer recommendation / certification

Visual inspection and test

Equipment for liquid penetrant examination Equipment for magnetic particle examination Equipment for hardness checks, Positive material identification, Ferrite measurements Special equipments (like Eddy current equipment, Oxygen meter, etc) Equipment for preheating, post heating and postweld heat treatment

Manufacturer recommendation / certification Manufacturer recommendation / certification Manufacturer recommendation / certification PMI specification Manufacturer recommendation / certification

Visual inspection and test

Visual inspection and test

Visual inspection and test (if required)

Visual inspection and test (if required)

Manufacturer recommendation / certification

Visual inspection and test

Personnel protective equipment

Manufacturer recommendations / certification

Visual inspection

Notes:
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1. Construction Contractor will issued and submit to Company Welding Supervisor for approval written procedures detailing welding material and equipment receiving, storage, handling, preservation and maintenance. All procedures will be in accordance with the manufacturers recommendations (if any). 2. All item will be tested or monitored at specified intervals during progress of work as required by ASME B31.3 & ASME V and by accepted procedure. Relevant testing and measurement records will be maintained at site by Construction Contractor and be made available at all time to Company upon request. Construction Contractor shall demonstrate at all time all applicable and approved welding procedures has been followed as well as proper sequence of inspection or testing and shall ensure identification and traceability of material and equipment from receiving throughout all installation. 4.3 4.3.1 Welding inspection checklists Table 3 lists minimum welding inspection checklists to be developed implemented by Construction Contractor in accordance with the enclosed ITP(s)

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TABLE 3
WORK PHASE Pre-Welding Inspection -

00

DESCRIPTION OF INSPECTION/CHECKS Check presence of approved WPS Check removal of protective coating from bevel end. Check conformity of base materials in compliance with the WPS Check materials identification and transfer of material ID. All materials must be marked as to its material composition before starting of welding operations. Verify joint preparation (angle, gap, landing, etc.) and tack welds (presence, correctness). Verify consumables materials per WPS (type, size, etc.) and Brand/Manufacturer (if required). Check handling, storage & re-conditioning of electrodes Check calibration of welding machines (only for automatic machine) Verify correct alignment in reference to the specification Verify if weather conditions are acceptable for welding Verify NDT performed on cut fittings or for cut bevel pipe prior to welding Check segregation of SS materials and relevant tools from carbon steel materials and alloyed materials Check that consumables are reconditioned conforming to supplier recommendation. Check wind barriers as required Check remote current control utilized Check proper grounding and polarity Check protection of external coating Check removal internal clamp after completition 100% of the root pass Check removal external clamp after the execution 60% of the root pass Check removal of tack welds (if required) Check and verify pre-heating as per standard requirements (WPS procedure, applications, temperature diagrams, etc) Check fulfilment of WPS variables Check heat input/run out of length (if required) Check monitoring of interpass temperature Check grinders for SS materials not contamined with CS material Verify weave not exceeding 3X diameter electrode (as required by WPS) Verify correct application of shielding and internal purging gas (if required) Visual inspection of each pass Check back-gouging (if applicable): method, surface appearance and NDT application. Verify consumables and rod ovens Verify quivers and rod ovens are in use and at temperature Verify rebake ovens are properly set and used

In-Process Welding Inspection

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Post-Welding Inspection -

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Visual Inspection (weld profile, size, reinforcement, visual defects, etc) Verify weld and welder ID markings Check Postheat (when required) Check PWHT (when required) Check Hardness testing (when required) Check NDT Verify welding/quality records, weld table/map and daily weld summary sheet PMI of alloy welds

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5.1 5.1.1 5.1.2

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ATTACHMENTS
ITP (s) General ITP for Initial Inspection: ITP N WL-0001 Document review and material receiving Specific ITP for construction: ITP N WL - 0101 Welding of: piping components, saddles and supports- pressure vessel storage tank Steel Structure Forms List Inspection and test report forms: MDT.WL.CDQ.0132 Positive material identification report MDT.WL.CDQ.0133 Register sheet of approved WPS/WPQR MDT.WL.CDQ.0134 Register sheet of approved Welders and Welding Operators MDT.WL.CDQ.0135 Register sheet of approved NDE Operators MDT.WL.CDQ.0136 Register sheet of approved Welding Procedures MDT.WL.CDQ.0141 Radiographic examination report MDT.WL.CDQ.0142 Liquid penetrant examination Daily report MDT.WL.CDQ.0143 Ultrasonic examination Daily report MDT.WL.CDQ.0144 Ultrasonic examination Daily report for lamination MDT.WL.CDQ.0145 Summary of Welds - Ndt (Weekly Report) MDT.WL.CDQ.0150 Alignment and welding visual inspection daily report MDT.WL.CDQ.0160 Welding summary list MDT.DT.CDQ.0610 Golden weld

5.2 5.2.1

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ITP N WL-0001 Title: DOCUMENT REVIEW AND MATERIAL CONSUMABLE RECEIVING QC CODE
WL 0001 01

00

DISCIPLINE CIVIL GENERAL Reference Document


Project SPC..

Description
Before commencement the Project works review and approval of following documents: -Welding Summary List -WPS/PQR

Acceptance Criteria -API 650 for TANK - AWS D1.1 for Steel structures
ASME IX ASME B31.3 ASME IX ASME B31.3

Quality Records/ Document Register list of WPS and PQR used in Project MDT.WL.CDQ.0 133 Register List MDT.WL.CDQ.0 134

Involvement Notes CC
P

QC
H

SP
R

TP

CO

CL
Issue WPS, Welding Table, Weld Map (for Equipment) according to Piping class / Construction drawings (for Equiment) for SP-WES approval. Register in dedicated list for each welders/operators project qualified under SP-WES supervision.

-API 650 for TANK - AWS D1.1 for Steel structures

WL

0001

02

Welder and Welding operator certifications WPQR

Project SPC..

-API 650 for TANK - AWS D1.1 for Steel structures


Project SPC..

WL

0001

03

NDEs personnel qualifications:


1. 2. 3. 4. 5.

Magnetic particle Test Penetrant Test Radiographic Test Ultrasonic Test Visual Test

-API 650 for TANK - AWS D1.1 for Steel structures

ASME IX ASME B31.3 ASME V

Register List MDT.WL.CDQ.0 135

Register in dedicated list each NDE operators project qualified under SP-WES supervision.

WL

0001

04

PWHT working station verification-

Project SPC..

ASME B31.3

-API 650 for TANK - AWS D1.1 for Steel structures

Qualification/ certification

CC Construction Contractor QC QC Construction Contractor SP Company Supervision

ORGANIZATION CODE CO Company Commissioning TP Laboratory/Third party CL Client


This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

INVOLVEMENT CODE P Perform/Submit W Witness (minimum 20% inspection rate) S Surveillance H Hold Point (100% inspection rate) R Review M- Monitoring

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ITP N WL-0001 Title: DOCUMENT REVIEW AND MATERIAL CONSUMABLE RECEIVING QC CODE
WL 0001 05

00

DISCIPLINE CIVIL GENERAL Reference Document


Project SPC..

Description Procedures review: 1. Procedure for Storage, Drying, Reconditioning, Handling and Scrapping of Welding Consumables. 2. Procedure for Weld Identification and Weld Traceability (original, modified and repaired welds) 3. Weld Repair Method 4. Production Weld Hardness Testing Procedure* 5. Post Weld Heat Treatment Procedure* 6. Positive Material Identification Procedure* 7. Procedure for Control of Welding Consumables 8. Penetrant Test 9. Magnetic Particle Test 10. Radiographic Test 11. Ultrasonic Test 12. Visual Test 13. Ferrite Test*
Receiving inspection and verification of welding consumables and theirs certificates

Acceptance Criteria
ASME IX ASME B31.3 ASME V

Quality Records/ Document MDT.WL.CDQ.0 136 Files

Involvement Notes CC
P

QC
H

SP
R

TP

CO

CL
SP-WES to file copy of approved procedures

-API 650 for TANK - AWS D1.1 for Steel structures

* if required by Client
Specification

WL

0001

06

Project SPC..

ASME II Part C -API 650 for ASME B31.3 TANK - AWS D1.1 for Steel structures

Register of consumable received, Manufacture Certificates

Warehouse Recording Verify compliance of filler metals

CC Construction Contractor QC QC Construction Contractor SP Company Supervision

ORGANIZATION CODE CO Company Commissioning TP Laboratory/Third party CL Client


This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

INVOLVEMENT CODE P Perform/Submit W Witness (minimum 20% inspection rate) S Surveillance H Hold Point (100% inspection rate) R Review M- Monitoring

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Company Document Identification


00250600BBQB09623

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ITP N WL-0001 Title: DOCUMENT REVIEW AND MATERIAL CONSUMABLE RECEIVING QC CODE
WL 0001 07

00

DISCIPLINE CIVIL GENERAL Reference Document


Project SPC ISO 10012

Description
Welding measurement devices: Calibration, Verification

Acceptance Criteria
Manufacturer Recommendation ASME B31.3 ASME V

Quality Records/ Document


Calib.Certificates Register list

Involvement Notes CC
P

QC
H

SP
W

TP

CO

CL
Welding measurement devices Register

WL

0001

08

Weekly reporting of NDT

Project SPC..

-API 650 for TANK - AWS D1.1 for Steel structures

As per contractor instruction ASME B31.3 ASME V

MDT.WL.CDQ. 0145

Weekly report from Sucontrctor to contractor

CC Construction Contractor QC QC Construction Contractor SP Company Supervision

ORGANIZATION CODE CO Company Commissioning TP Laboratory/Third party CL Client


This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

INVOLVEMENT CODE P Perform/Submit W Witness (minimum 20% inspection rate) S Surveillance H Hold Point (100% inspection rate) R Review M- Monitoring

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00250600BBQB09623

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ITP N WL-0101 Title: WELDING OF: PIPING COMPONENTS, SADDLES AND SUPPORTS- PRESSURE VESSEL STORAGE TANK Steel Structure QC CODE
WL 0101 01

DISCIPLINE CIVIL Reference Document


Project SPC..

Description
Alignment and welding visual inspection report

Acceptance Criteria
Approved WPSs ASME B31.3

Quality Records/ Document


MDT.WL.CDQ. 0150

Involvement Notes CC
P

QC
H

SP
W

TP

CO

CL
CC shall maintain Quality Records in a register at QC/CC office to submit to SP-WES.

-API 650 for TANK - AWS D1.1 for Steel structures


Project SPC Approved WPSs

WL

0101

02

Golden Weld

ASME B31.3 Approved WPSs

MDT.WL.CDQ. 0610

CC shall maintain Quality Records in a register at QC/CC office to submit to SP-WES.

WL

0101

03

- Selection of Weld seams position (Tank) - Control of Welded Joints, selection for NDE (a) - In-Process NDE Inspection (b)

Project SPC..

-API 650 for TANK - AWS D1.1 for Steel structures

-API 650 for WSL TANK MDT.WL.CDQ.0160 - AWS D1.1 for Steel structure - ASME B31.3
- ASME V

(a) 100% witness: WI / WS shall participate in the selection of weld seams position (tank) , weld to be tested (b) CC shall maintain Quality Records in a register at QC/CC office to submit to SP-WES. P only If CC NDE Operators and Equipment are not approved by Client 100% RX reading, daily inspection on ongoing construction works due by SP no Notification is require

WL

0101

04

Non-Destructive Examination Evaluation: results evaluation

Project SPC..

- ASME V

-API 650 for TANK - AWS D1.1 for Steel structures

MDT.WL.CDQ.0141 and/or MDT.WL.CDQ.0142 and/or MDT.WL.CDQ.0143 MDT.WL.CDQ.0144

CC Construction Contractor QC QC Construction Contractor SP Company Supervision

ORGANIZATION CODE CO Company Commissioning TP Laboratory/Third party CL Client


This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

INVOLVEMENT CODE P Perform/Submit W Witness (minimum 20% inspection rate) S Surveillance H Hold Point (100% inspection rate) R Review M- Monitoring

Logo and business name of Document owner

Company Document Identification


00250600BBQB09623

Owner Document Identification


002506-ZA-E-09623

Revision Index Validity Status CD-FE Rev.

Sheet of Sheets 18 / 31

e & p division
ITP N WL-0101 Title: WELDING OF: PIPING COMPONENTS, SADDLES AND SUPPORTS- PRESSURE VESSEL STORAGE TANK Steel Structure QC CODE
WL 0101 05

00

DISCIPLINE CIVIL Reference Document


Project SPC..

Description
Application of Post Weld Heat Treatment Hardness Testing Application and Results

Acceptance Criteria - ASME B31.3


- ASTM E 92

Quality Records/ Document


WSL MDT.WL.CDQ.0160 Certification Test result

Involvement Notes CC
P

QC
W

SP
W

TP
P

CO

CL
As defined in WPS laboratory test result

-API 650 for TANK - AWS D1.1 for Steel structures


Project SPC 00GA-E-60901

WL

0101

06

Positive Material Identification (PMI) of deposited weld for alloyed materials (where applicable)

- ASME B31.3

MDT.WL.CDQ. .0132

only If CC Operators and Equipment are not approved by Client

WL

0101

07

Final Welding Inspection: Check Welding Summary Report, Weld Map and all quality records (NDT, PMI, FERRITE, PWHT, HARDNESS, REPAIR).

Project SPC..

-API 650 for TANK - AWS D1.1 for Steel structures

- ASME B31.3 - AWS D1.1 - API 650

WSL MDT.WL.CDQ.0160

CC Construction Contractor QC QC Construction Contractor SP Company Supervision

ORGANIZATION CODE CO Company Commissioning TP Laboratory/Third party CL Client


This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

INVOLVEMENT CODE P Perform/Submit W Witness (minimum 20% inspection rate) S Surveillance H Hold Point (100% inspection rate) R Review M- Monitoring

CLIENT

JOB

UNIT

e & p division
Construction Contractor

PLANT LOCATION

QC CODE

ONSHORE
PROJECT TITLE
REPORT N

ZUBAYR OIL FIELD DEVELOPMENT

POSITIVE MATERIAL IDENTIFICATION (PMI) REPORT


DOCUMENT/SPECIFICATION: PAGE OF

INSPECTION
Line number Spool number Heat number Pmi Elements Acceptable Yes Not


NOTES:

INSPECTION NOTIFICATION REFERENCE

RFI N

QC CONSTRUCT. CONTRACTOR
NAME NAME

SP
NAME

TP
NAME

CLIENT

SIGNATURE

SIGNATURE

SIGNATURE

SIGNATURE

Date

Date

Date

Date

Form code: MDT.WL.CDQ.0132

This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

CLIENT

JOB

UNIT

e & p division
Construction Contractor

PLANT LOCATION

QC CODE

ONSHORE
PROJECT TITLE
REPORT N

ZUBAYR OIL FIELD DEVELOPMENT

REGISTER SHEET OF APPROVED WPS/WPQR


REFERENCE TO CODE: PAGE OF

WPS N

WPQR N

QUALIFICATION RANGE

APPROVED DATE

NOTES:

INSPECTION NOTIFICATION REFERENCE

RFI N

QC CONSTRUCT. CONTRACTOR
NAME NAME

SP
NAME NAME

CLIENT

SIGNATURE

SIGNATURE

SIGNATURE

SIGNATURE

Date

Date

Date

Date

Form code: MDT.WL.CDQ.0133


This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

CLIENT

JOB

UNIT

e & p division
Construction Contractor

PLANT LOCATION

QC CODE

ONSHORE
PROJECT TITLE
REPORT N

ZUBAYR OIL FIELD DEVELOPMENT

REGISTER SHEET OF APPROVED WELDERS AND WELDING OPERATORS


DOCUMENT/SPECIFICATION: PAGE WELDER NAME WELDER STAMP APPROVED RANGE OF APPROVED DATE

NOTES:

INSPECTION NOTIFICATION REFERENCE

RFI N

QC CONSTRUCT. CONTRACTOR
NAME NAME

SP
NAME NAME

CLIENT

SIGNATURE

SIGNATURE

SIGNATURE

SIGNATURE

Date

Date

Date

Date

Form code: MDT.WL.CDQ.0134

This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

CLIENT

JOB

UNIT

e & p division
Construction Contractor

PLANT LOCATION

QC CODE

ONSHORE
PROJECT TITLE
REPORT N

ZUBAYR OIL FIELD DEVELOPMENT

REGISTER SHEET OF APPROVED NDE OPERATORS


DOCUMENT/SPECIFICATION: PAGE OPERATOR NAME QUALIFIED FOR QUALIFICATION NUMBER APPROVED DATE OF

NOTES:

INSPECTION NOTIFICATION REFERENCE

RFI N

QC CONSTRUCT. CONTRACTOR
NAME NAME

SP
NAME NAME

CLIENT

SIGNATURE

SIGNATURE

SIGNATURE

SIGNATURE

Date

Date

Date

Date

Form code: MDT.WL.CDQ.0135

This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

CLIENT

JOB

UNIT

e & p division
Construction Contractor

PLANT LOCATION

QC CODE

ONSHORE
PROJECT TITLE
REPORT N

ZUBAYR OIL FIELD DEVELOPMENT

REGISTER SHEET OF APPROVED QC PROCEDURES


TAG/ITEM or ISO DWG.: PAGE OF

PROCEDURES
1.

CHECK AVAILABILITY OF QC PROCEDURES YES NO N/A

2.

Procedure for Storage, Drying, Reconditioning, Handling and Scrapping of Welding Consumables Procedure for Weld Identification and Weld Traceability (original, modified and repaired welds) Weld Repair Method Production Weld Hardness Testing Procedure Post Weld Heat Treatment Procedure Positive Material Identification Procedure Procedure for Control of Welding Consumables Penetrant Test Magnetic Particle Test Radiographic Test Ultrasonic Test Visual Test Ferrite Test Welding Procedures

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.


RFI N

NOTES: N/A = NOT ACCEPTABLE

INSPECTION NOTIFICATION REFERENCE

QC CONSTRUCT. CONTRACTOR
NAME NAME

SP
NAME NAME

CLIENT

SIGNATURE

SIGNATURE

SIGNATURE

SIGNATURE

Date

Date

Date

Date

Form code: MDT.WL.CDQ.0136


This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

CLIENT

JOB

UNIT

e & p division
Construction Contractor

PLANT LOCATION

QC CODE

ONSHORE
PROJECT TITLE
REPORT N

ZUBAYR OIL FIELD DEVELOPMENT

RADIOGRAPHIC EXAMINATION REPORT


DOCUMENT/SPECIFICATION:

PAGE
FILM PROGR. N WELD N FILM LOCATION DRW/ ISO/SPOOL N DIAM. [] THICK. [mm] WELDER STAMP

OF
JUDGEMENT (1)

TAG / LINE NUMBER

MATERIAL

NX NR RX NT EX

(1) A = ACCEPTABLE; NX = UNACCEPTABLE RADIOGRAPHY; NR = TO BE REPAIRED; RX = RADIOGRAPHY TO BE REPEATED; NT = TO BE CUT; EX = EXAMINATION TO BE EXTENDED NOTES: INSPECTION NOTIFICATION REFERENCE

RFI N

QC CONSTRUCT. CONTRACTOR
NAME NAME

SP
NAME

TP
NAME

CLIENT

SIGNATURE

SIGNATURE

SIGNATURE

SIGNATURE

Date

Date

Date

Date

Form code: MDT.WL.CDQ.0141

This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

CLIENT

JOB

UNIT

e & p division
Construction Contractor

PLANT LOCATION

QC CODE

ONSHORE
PROJECT TITLE
REPORT N

ZUBAYR OIL FIELD DEVELOPMENT

LIQUID PENETRANT EXAMINATION DAILY REPORT


DOCUMENT/SPECIFICATION: PAGE OF

SURFACE CONDITION

As welded Ground

As rolled Brushed

As Forged Machined

As cast As bent

Conformance to processes of :CLEANING, PENETRANT APPLICATION / REMOVAL, DRYING, DEVELOPER APPLICATION , PENETRATION TIME

TAG/LINE NUMBER

DRW/ISO/SPOOL

WELD NUMBER

MATERIAL A

JUDGEMENT (1)

;
EX

NR

RX

NT

(1) A = ACCEPTABLE; NR = TO BE REPAIRED; RX = TO BE REPEATED; NT = TO BE CUT; EX = EXAMINATION TO BE EXTENDED NOTES: Attach list of welds examinated INSPECTION NOTIFICATION REFERENCE

RFI N

QC CONSTRUCT. CONTRACTOR
NAME NAME

SP
NAME

TP
NAME

CLIENT

SIGNATURE

SIGNATURE

SIGNATURE

SIGNATURE

Date

Date

Date

Date

Form code: MDT.WL.CDQ.0142

This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

CLIENT

JOB

UNIT

e & p division
Construction Contractor

PLANT LOCATION

QC CODE

ONSHORE
PROJECT TITLE
REPORT N

ZUBAYR OIL FIELD DEVELOPMENT

ULTRASONIC EXAMINATION DAILY REPORT


DOCUMENT/SPECIFICATION: PAGE
TAG / LINE / SPOOL N WELD N DIAM.

OF
MATERIAL JUDGEMENT (1) A NA EX

[]

THICK.SS [mm]

A = ACCEPTABLE; NA = NOT ACCEPTABLE EX = EXAMINATION TO BE EXTENDED NOTES:

INSPECTION NOTIFICATION REFERENCE

RFI N
QC CONSTRUCT. CONTRACTOR
NAME NAME

SP
SIGNATURE

TP
SIGNATURE

CLIENT

SIGNATURE

SIGNATURE

Date

Date

Date

Date

Form code: MDT.WL.CDQ.0143

This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

CLIENT

JOB

UNIT

e & p division
Construction Contractor

PLANT LOCATION

QC CODE

ONSHORE
PROJECT TITLE
REPORT N

ZUBAYR OIL FIELD DEVELOPMENT

ULTRASONIC EXAMINATION DAILY REPORT FOR LAMINATION


DOCUMENT/SPECIFICATION: PAGE OF

Progres. number

Weld number

Pipe Number

Material

Wall thk. (mm)

Location of indication (mm)

Type of indication

Evaluation (1)

A NR NC A NR NC A NR NC A NR NC A NR NC A NR NC A NR NC A NR NC A NR NC A NR NC A NR NC
NDE procedure: Legend: (1) A= Acceptable
NOTES:

Code/Standard:

Drawing:

NR= Not acceptable (to be repaired)

NC= Not acceptable (to be cut out)


INSPECTION NOTIFICATION REFERENCE

RFI N

QC CONSTRUCT. CONTRACTOR
NAME NAME

SP
NAME

TP
NAME

CLIENT

SIGNATURE

SIGNATURE

SIGNATURE

SIGNATURE

Date

Date

Date

Date

Form code: MDT.WL.CDQ.0144

This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

CLIENT

JOB

UNIT

e & p division
Construction Contractor

PLANT LOCATION

QC CODE

ONSHORE
PROJECT TITLE
REPORT N

ZUBAYR OIL FIELD DEVELOPMENT

SUMMARY OF WELDS - NDT (WEEKLY REPORT )


DOCUMENT/SPECIFICATION: PAGE
WELDING PROCESS:

OF

Actual week

Total previous

WITH RT
EXISTING WELDS EXECUTED WELDS n. CHECKED ACCEPTED REPAIRS CUT RT REFUSED DEFECT TO REPAIR n. n: n. n. n. n.

WITH UT

RT + UT

WITH RT

WITH UT

RT + UT

n. n. n. n. n. n. n. n. n. n. n. n. n. n. n. n. n. n. n. n. n. n. n.

Lack of penetration Lack of fusion (in root) Root concavity Overlap Porosity cluster Undercut Undercut (in root) Slag inclusion Wormholes Cold lap Crack Crater crack Gas inclusion Excess weld metal Excessive penetration Poor restart
DEFECT TO CUT

Crack Stray flash or arc strike Summary defect Welds not accepted by RT Welds not accepted by UT

THE LAST FOUR POSITIONS REFER EXCLUSIVELY TO THE WELDS CHECKED USING BOTH METHODS (RT+UT)
NOTES: INSPECTION NOTIFICATION REFERENCE

RFI N
QC CONSTRUCT. CONTRACTOR
NAME NAME

SP
NAME NAME

CLIENT

SIGNATURE

SIGNATURE

SIGNATURE

SIGNATURE

Date

Date

Date

Date

Form code: MDT.WL.CDQ.0145


This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

CLIENT

JOB

UNIT 100

e & p division
Construction Contractor

PLANT LOCATION

QC CODE

ONSHORE
PROJECT TITLE
REPORT N

ZUBAYR OIL FIELD DEVELOPMENT

ALLIGNAMENT AND WELDING VISUAL INSPECTION REPORT


DOCUMENT/SPECIFICATION:
TAG NUMBER (FOR TANK / VESSEL/ STEEL STRUCTURE):

PAGE

OF

REPORT
FOR TANK /VESSEL
PLATE TO PLATE N NOZZLE N

STEEL STRUCTURE
TAG / ELEMENT

FOR PIPING.
WELD N. LINE NUMBER SPOOL NUMBER

ALIIGNEMENT: - PIPE To PIPE -/PIPE to FLANGE - PLATE to -PLATE -BEAM To BEAM -NOZZLE

VISUAL WELD STATUS

A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT A NR NT
A = ACCEPTABLE; NR = TO BE REPAIRED; NT = TO BE CUT NOTES: INSPECTION NOTIFICATION REFERENCE

RFI N
QC CONSTRUCT. CONTRACTOR
NAME NAME SIGNATURE SIGNATURE Date Date Form code: MDT.WL.CDQ.0150 Date Date SIGNATURE SIGNATURE

SP
NAME NAME

CLIENT

This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

CLIENT

JOB

UNIT 100

e & p division
Construction Contractor

PLANT LOCATION

QC CODE

ONSHORE
PROJECT TITLE
REPORT N

ZUBAYR OIL FIELD DEVELOPMENT

WELDING SUMMARY LIST


LINE No. SPOOL No. TANK/VESSEL/STEEL STRUCTURE TAG: PAGE OF

Weld
Weld No
Welder Stamp NPS

MATERIAL
Result Result
WPS

Control NDT
Result Result Result Result Mark Item Piece No Heat No
VT PT / MT RT 1 RT 2 UT 1 UT 2 Preheating PWHT

Other Information
HB Test
Golden Weld

inch

Thick mm

Test Pack

Description

Type of Material

Manufacturer

Date

Form code: MDT.WL.CDQ.0160

To be done in excel sheet

This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

CLIENT

JOB

UNIT 100

e & p division
Construction Contractor

PLANT LOCATION

QC CODE

ONSHORE
PROJECT TITLE
REPORT N

ZUBAYR OIL FIELD DEVELOPMENT


GOLDEN - WELD DOCUMENT/SPECIFICATION: PAGE Connection progressive: Reference document: Section: Date: PIPELINE CHARACTERISTICS Nominal pipe Size NPS Wall-thickness (mm) Type of Base-metal Type of coating TIE-IN CHECK Check of welding temperature Check of Lamination bevel ends Check of alignment of sections to be connected Check of min/max temperature Check of joint coating CHECK OF MECHANICAL INFORMATIONS REPORTED ON PIPE BOOK Joint N: Welders Stamp: NDT Inspection VT Date: RT Date: UT Date: NDT Repair Inspection VT Date: RT Date: UT Date: Types of Components: Straight Pipe / Straight Pipe Straight Pipe / Field Bend Field Bend / Field Bend Fitting Hot formed Bend / Straight pipe Fitting Hot formed Bend / Field Bend Pup piece length (if welded) NOTES: WPS: Type of Fillermetal: Report N Time: Time: Time: Repair Date: Time: Time: Time: INSPECTION NOTIFICATION REFERENCE RFI N QC CONSTRUCT. CONTRACTOR NAME SIGNATURE Date Form code: MDT.WL.CDQ.0610 NAME SIGNATURE Date SP NAME SIGNATURE Date NAME SIGNATURE Date CLIENT h h h h h h Piece N Describt. Acceptable Acceptable Acceptable Repair WPS: Not acceptable Not acceptable Not acceptable Not acceptable Not acceptable Not acceptable Describt. Type of Weld: Buttweld Filletweld Acceptable Acceptable Acceptable Acceptable Acceptable Not acceptable Not acceptable Not acceptable Not acceptable Not acceptable Start: h Finish: h Km Drawing Plant OF

Acceptable Acceptable Acceptable Piece N

This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.