MNT-INTG-2007OP - Maintenance Welding Inspection

Shell Eastern Petroleum - Pulau Bukom Oil Refinery - Refinery Management System
MNT_INTG-2007OP Welding Inspection August 2018

Revision: 10
1. Purpose
This procedure describes the activities for the execution and reporting of the inspection of welding
of pressure static equipment and piping.
2. Scope
This procedure applies to Quality Assurance (QA) and Quality Control (QC) for welding works
associated with pressure static equipment and piping
3. References
3.1 MNT_INTG-2005OP - Compliance with Workplace Safety and Health Act
Requirements.
3.2 MNT_INTG-2009OP - NDT Services by Site Based Contractor
3.3 ASTM B.31.3 - Process Piping
3.4 ASTM B.31.1 - Power Piping
3.5 ASME IX - Welding and Brazing Qualification
3.6 DEP 31.10.60.18 - Welding of Metals (additional to API RP 582)
3.7 DEP 31.22.20.31 - Unfired Pressure Vessels
3.8 DEP 31.38.01.31 - Shop and Field Fabrication of Piping
3.9 API 577 - Welding Inspection and Metallurgy
4. Definitions
4.1 DEP Design and Engineering Practice.
4.2 NDT/NDE Non-Destructive Testing.
4.3 PRIMOS Process Industries Skills Management System.
4.4 W-IMS Web-Integrity Management System
4.5 WPS Welding procedure specifications.
4.6 PQR Procedure qualification records.
4.7 PMI Positive Material Identification
4.8 ASME American Society of Mechanical Engineers
4.9 PWHT Post Weld Heat Treatment
4.10 HFA Hydrofluoric Alkylation (plant)
4.11 NACE National Association of Corrosion Engineers
5. Responsibility
The Asset Integrity Manager and the designated Inspection Engineers shall be responsible to
implement this procedure.
Document Status APPROVED
Page 1 of 43 The controlled copy of this document is in electronic format on the Shell Singapore Web. Issued by: Dept QSC
This hardcopy is uncontrolled and was printed on 19 January 202023 April 201913 August Approved by: DMA/122
2018
Revision: 10
6. Procedure
6.1 INSPECTION ROLE
The role of the Inspection Engineer is to:
 To attend pre-fabrication – refer to appendix 1a/b for typical agenda of meeting.
 Review all Welding, NDE and PWHT procedures, where necessary in consultation with the
Senior Materials/Corrosion Engineer.
 Verify welders’ qualifications are current and qualified in the processes of the weld procedures
used.
 Review and approve work/quality plans, including QA / QC and Inspection and Test Plans
(ITP) to ensure that Company requirements (e.g. DEPs) are incorporated and that the
contractor carrying out the work has a approved quality plan for the work to be conducted;
 Where statutory equipment is involved, to liaise with Ministry of Manpower (MOM) (refer to
MNT_INTG-2005OP, Compliance with Workplace Safety and Health Act Requirements.);
 Conduct inspection of welds;
 Arrange for and review NDT results, where necessary – see section 6.8
 Witness hydrostatic testing where applicable.
 Retain all the appropriate documents, which are provided by the contractor or Maintenance
Section, and file into individual equipment record.
6.2 Welders Qualifications

All welders shall be qualified in the appropriate processes being applied in accordance to the
requirements of ASME IX and be certified by an approved test centre/authority, such as PRIMOS,
or equivalent.
6.3 Documentations
The Contractor shall submit the following documents to the Inspection Engineer for review prior to
execution of work. Any documents or procedures not complying with company requirements shall
be returned to the contractor for revision.
 Documents containing details of;
 Contract No. / Title,
 Welder Qualifications and ID No., plus PRIMOS qualification/certification
 Weld Map and Joint No.,
 Welding Procedure Specification No. plus revision and appropriate PQR.
 Test Loops
 Contractor’s quality and test plans, including an Inspection Test Plan, for approval by the
Inspection Engineer.

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Revision: 10
Note:
NDT, PMI, when necessary, and hydrostatic testing requirements are recorded by the
Inspection Engineer in the Inspection Test Plan
 Shell approved sketches or isometrics/drawings
 Materials mill certificates
 Contract specifications, where applicable
 Welders Procedure Qualification, where applicable
Where statutory equipment is involved, refer to MNT_INTG-2005OP, Compliance with Workplace
Safety and Health Act Requirements.
6.3.1 Bukom Based Contractors

Welding procedures that have been approved for previous work need not be resubmitted for
approval, however the contractor shall indicate the WPS number to be used.
For piping work, Contractor to specified the WPS’s numbers in the Quality Plan.
A copy of the Integrity Department approved WPS together with the respective PQR are kept in
Integrity Department archives for reference. A content sheet/register of all WPS/PQR to be included
plus document revision. Welding focal point to review the register on a yearly basis.
In cases where Integrity Department approved WPS for the specific job is not available, the
Inspection Engineer is responsible to obtain and provide the appropriate WPS for the job. If this is
not possible, the Asset Integrity Manager shall be consulted.
Welders who have been approved for previous work on Bukom and who are registered in the
PRIMOS Common Welders Qualification scheme need not have their test certificates resubmitted,
however their names and Bukom pass numbers shall be indicated for internal control purposes.
Monthly Welders and Welders’ Performance Return submitted by Contractors are to be stored in
Integrity Web page. Rejection rate capped at 2% based on length. Welders whose rejection rate
hits 1%, shall be investigated and appropriate actions, approved by Shell’s Focal Point, to be taken
by the contractor. A report by the Contractor QC of his action to be submitted together with the
Monthly Welders Performance return.
During work fabrication, the contractor shall submit any requests for inspection as indicated in the
job specification and quality plan.
6.3.2 Piping Work

In addition to the above, the contractor shall prepare test packages and submit to the Inspection
Engineer when requesting for inspection services. The test package should consist of the following
where applicable.
 Isometric drawings or Shell approved sketches indicating the weld joint numbers,
 Test Loops,
 Hydrostatic pressure test control sheet, etc.
The contractor shall enter information such as the welds and welder’s identification into their Welder
Menu before requesting for inspection from the Inspection Engineer. The Inspection Engineer shall
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Revision: 10
then proceed with inspection and arrange for NDT and PMI, if necessary, to be carried out. For
weld joints that are subjected to Radiographic Test, the Contractor shall input the test results into
their Welder Menu so that the performance of welders is being tracked. All NDT reports shall then
be incorporated in the test package, to be retained by the Inspection Engineer, for records.
6.3.3 Fabrication outside Bukom

In cases where the fabrication work is being carried out at contractor premises outside Bukom, the
Inspection Engineer shall visit the contractor premises, if it is called for in the contract specification
or scope of work, for the following purposes:
 To attend pre-fabrication – refer to appendix 1a/b for typical agenda of meeting.
 To conduct shop inspection for the assessment of quality and technical acceptability of
fabrication work based on Inspection Test Plan
 To conduct final acceptance inspection.
 To align expectation for document compilation such as piping fabrication records & test
package, equipment manufacture/fabrication data records booklet(MDR) and if any, propriety
equipment manual.
For Quality Assurance or Statutory requirement, approved 3rd Party Inspector may be engaged.
6.4 Welding Process

For Piping, weld root passes shall be made with Gas Tungsten Arc Welding (GTAW) weld
process with the exception that SMAW can be used for Hot Tapping.
6.5 Material:
For material colour coding, to refer to MNT_INTG-2013OP - Inward Goods Inspection Procedure.
The heat numbers shall be reflected onto the relevant shop fabrication isometric/weld map and
the Welding Inspection Results and Report sheet. The heat number shall be transferred by low
stress hard stamp or suitable permanent marker before materials are cut.
6.5.1 Consumables
i) Contractors shall have system to verify and demonstrate effective control of correct
consumables meeting specifications are used throughout the fabrication process. For filler
rods, sampling PMI to be done per box/tube
ii) Consumables requirement shall follow :
a) The relevant as built construction code for pressure static equipment or piping.
b) For HFA services - Alloy 400 welding,
i) Weld metal iron content shall be less than 5 wt%.
ii) Weld electrode titanium content should be less than 2.2 wt%.

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Revision: 10
6.6 Hydrogen Degassing and PWHT requirements :

6.6.1 Hydrogen Degassing Requirements prior to Repair Welding
a. This sub section applies to repairs of in-service equipment/piping exposed to hydrogen, high
severity sour service and HF service and constructed in carbon steel/low alloy steel
metallurgy.
b. Hydrogen degassing shall be carried out prior to any welding or grinding for repair.
c. The area to be repaired shall be heated as per the following details:
i) Wall Thickness range: ¼” – 1” (no degassing is required for thickness < ¼”.
ii) Holding temperature: 315 deg.C (min.)
iii) Holding time: 2 hours
d. For wall thickness > 1”, Materials and Corrosion Engineer shall be consulted to review and
finalise the holding time for degassing.
e. Steels exposed to HF may become saturated with hydrogen. In order to avoid potential
issues with thermal decomposition of iron fluoride, such as hydrogen charging of the base
metal as well as personnel exposure to HF fumes, any scale on the internal surfaces of
equipment in the area that is subjected to degassing or PWHT should be removed and the
surfaces fully cleaned.
6.6.2 PWHT requirement shall follow:

a) Code requirement
i) The relevant as built construction code for the pressure static equipment or piping , eg,
Pressure static equipment as built to ASME VIII shall conform to PWHT requirement of
ASME VIII.
ii) The relevant Shell DEP, DEP 30.10.60.18-Gen – Welding of Metals (Amendments
/Supplements to API RP 582)
b) Service requirement
i) For wet hydrogen sulfide service
- DEP 31.22.20.31-Gen Pressure Vessels (Based on ASME Section VIII) Annex IX
Additional Requirements for Carbon Steel Pressure
Vessels in wet hydrogen sulfide service.
- DEP 31.38.01.11-Gen Piping – General Requirements, Appendix 10 Additional
Requirement for specific services.
- NACE MR0175 as referenced in - DEP 31.22.20.31 Annex IX.3
- NACE MR0103 as referenced in - DEP 31.22.20.31 Annex IX.3
ii) For caustic services
- DEP General Requirements, Appendix 10 Additional Requirement for specific services
- NACE RP0403 Avoiding Caustic Stress Corrosion Cracking of Carbon Steel Refinery
Equipment and Piping

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Revision: 10
iii) For Pressure Vessel constructed from Cr-Mo Steels,

- DEP 31.22.20.31-Gen Pressure Vessels (Based on ASME Section VIII) Annex X
Additional Requirements for Pressure Vessels Constructed from Cr-Mo Steels.
iv) For HFA services
- DSM-5000010-SP-01 Hydrofluoric (HF) Alkylation Technical Specification
- Carbon steel and Alloy 400 in HF acid (i.e. main, dilute, trace) service shall be PWHT
during original fabrication and subsequent repairs.
- Carbon steel shall be PWHT 635ºC +/- 15ºC (1175ºF +/- 27ºF) for one hour per inch
of thickness.
- Alloy 400 shall be 610ºC +/- 10ºC (1130ºF +/- 20ºF) for one hour per inch of thickness.
-Where hardness control is recommended for carbon steel, PWHT shall be conducted.
-Carbon steel and Alloy 400 equipment shall be stress relieved during fabrication.
- All welds forming part of the pressure envelope shall have 100% crack detection by an
appropriate method after stress relief or PWHT procedure.
6.7 Hardness
a) The extent of hardness testing shall follow DEP 31.38.01.31-Gen; Appendix 4
b) The acceptance criteria for hardness limit shall meet the appropriate code requirement as
outlined in
i) DEP 31.22.00.31-Gen UNFIRED PRESSURE VESSELS
ii) All weld procedures shall meet the hardness testing criteria and hardness limits for
carbon steel piping as outlined in DEP 31.38.01.31-Gen. “Shop and Field Fabrication of
Piping.”
6.8 NDT:
a) NDE procedures and technician competency are to be reviewed and approved by Inspection
Engineer.
b) For Extent of NDT, DEP 31.38.01.31-Gen; Appendix 4 shall be used plus the following
additional:
c) 100% PMI shall be done on each component including welds for all alloy steel. This shall
include valves body and all fittings. Writing PMI-OK beside the tested point is required.
i) For HF services - Low Temp Carbon Steel and Monel require PMI. For
acceptance criteria :
Low Temp Carbon steel -
For 0.18wt% <C <0.23wt%
Cu+Ni < 0.15wt%
For C< 0.18wt%
Cr+Cu+Ni <0.15%.
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Revision: 10
Alloy 400 welding, Weld metal iron content shall be less than 5 wt% and Ti
<2.2%
d) For all tie-ins, the following additional requirement is required for all Hydrocarbon service
pipes:
i) Penetrant Test (PT) or Magnetic Particle Test (MT) of existing pipe tie-in weld
preparation
ii) Spot Ultrasonic Thickness Gauging (UTG) on existing pipe; adjacent to the weld
preparation in the following breakdown:
 Diameter <4” = 2 points
 Diameter 4 to 12” = 4 points
 Diameter >12” = 8 points
iii) 100% Radiography Test (RT) of tie-in.
Note; Ultrasonic Test (UT) maybe use inplace of RT for branch connections if RT is not
possible.
e) HFA services NDT requirement shall follow “Severe Cyclic Conditions” as indicated in
Appendix 2
f) Acceptance criteria
i) Acceptance criteria for the NDT shall follow the relevant original construction code for
the pressure static equipment or piping.
ii) For HFA services, the acceptance criteria for the Piping shall meet the weld acceptance
criteria for “Severe Cyclic Conditions” as outlined in ASME B31.3 “Process Piping.”
6.9 Pressure Testing:

Refer MNT_INTG_2009WI
7.0 Deviations :
Deviations from the requirements of this procedure shall be approved by the Asset Integrity
Manager, the deviation request form in Appendix 5 is to be used.
8. Records and related documents
Ref No. Title Storage Retention

Custodian Period
- Approved Contractor’s WPS/PQR Inspection Validity
Engineer
- Equipment or pipe repairs, parts replacement or Inspection Equipment’s
modifications carried out recorded in IDMS .Engineer; Plan life

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Revision: 10
- QA/QC record Inspection 5 yrs

Engineer; Plant
9. Custodian and review panel
The custodian of this procedure: Dept Quality System Coordinator

This procedure was reviewed by: DMA122, DMA/1221, DMA/122, DMA/1223,
DMA/12271, DMA/122142, DMA/122121
Last formal review date: Aug 2018
10. Change history
date section of doc. Summary of change

March 1. Purpose Added; static equipment and piping. Where applicable, it may also
2005 apply to work done in contractor’s fabrication shops outside Bukom.
March 3. References Added; MNT_INTG-2005OP, Compliance with Factories Act
2005 Pressure Vessel Requirements.
March 4. Definitions Added; 4.8- PMI & 4.9- CIF
2005
March 5. Responsibility Replaced; “head of EISD” with “Integrity Manager”
2005
March 6.1 INSPECTION Added; New clauses, for requirements on; 1) statutory equipment and
2005 ROLE 2) PMI.
6.2 INSPECTION
SERVICES
March 6.2 INSPECTION Added; New clauses, for requirement on Inspection Test Plans.
2005 SERVICES
March 6.2.4 Piping Work Added; “PMI, if necessary,” to Inspection Engineer’s role.
2005
March Appendix 2 Added; New Appendix 2, for PMI Requirements.
2005
March Entire doc. Amended; “Inspector” with “Inspection Engineer.”
2005
March Title Amended; to “Maintenance Welding Inspection” for clarity.
2007
March 1. & 2. Amended; to better reflect current practice and procedure.
2007

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Revision: 10
March 3. Amended; correct references name.

2007
March 4. Added; definition for MDR.
2007
March 5. Amended; existing paragraph with new to reflect current practice and
2007 procedure.
March 6.1 Delete; 1st line (non relevant)
2007 Amended; minor words changes to better reflect current practice and
procedure.
March 6.2.1, 6.2.3 & 6.2.4 Amended; minor words and terminology changes to better reflect
2007 current practice and procedure.
March 6.3 Amended; 2nd bullet point to better reflect current practice and
2007 procedure.
Delete; 2nd last statement (non relevant)
March 7 Delete; welders record, etc, (non relevant)
2007
March 10 Added; references to appendices 1 & 2.
2007
March Appendix I Amended; references to Inspection Engineer.

2007
Jan General Changed: word “PACER-I” to “IDMS”

2008
Dec General Added 6.4, Appendix 2 and 3.
2008 Remove Appendix 2 - for PMI Requirements
Mar General Item 6.5; Remove Appendix and made it a referral to MNT_INTG-
2010 2013OP - Inward Goods Inspection Procedure; RMS procedure
Revised Appendix 1.
Mar 6.4 (d) Added new section 6.4 (d) Acceptance criteria
2010
Mar 6.5.1 Added new section 6.5.1 Consumable
2010
Mar 6.6 Added new section 6.6 PWHT requirement
2010
Mar 6.7 Added new section 6.7 Hardness Requirement
2010
Mar 6.8 Added new section 6.8 Welding Process
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2010
Jan 3. References Delete; MNT_INTG-2004OP and DEPs on Standard Vertical Tanks
2012 (non relevant)
Jan 4. Definitions Delete; Commissioner and MDR (non relevant)
2012 Added; ASME, PWHT, HFA, NACE
Jan 6.1 Inspection Added; Review welding and PWHT Procedures, Verify welders
2012 Role qualifications
Amended; included, QA/QC and ITPs and Review NDT Results.
Jan New 6.2 Added; Welder Qualifications as new requirements.
2012
Jan New 6.3 Amended; change heading.
2012 Added; Welder Qualifications and ID
Jan New 6.3.1 Added; new header - 6.3.1 Bukom Based Contractors
2012 Amended; actions for welders with 1% rejection rate.
Jan 6.4 to 6.8 Amended; re-arranged sections for clarity.
2012
Jan 6.5.1 Added; new section on controls of consumables
2012
Amended; To reflect current practice .
Nov Header Title
2012 Amended; to reflect current practice and procedure.Sep 2012
Nov
2012 1. To 3 Added; To attend pre-fabrication.To review NDE procedure
Nov
2012 Added; Weld Map.
Nov 6.1
2012 Added; To align expectation for document compilation.
Nov
6.3 Added; To align expectation for document compilation.
2012
Added; Statutory requirement for 3rd party Inspector.
6.3.
Nov 6.5.1 Added; Filler rods control

2012
Nov 6.8 Added; NDE and technician competency review
2012
Nov 6.9 Added; new section on pressure testing.
2012
Nov 10 Added; Appendix 1b for equipment pre inspection meeting
2012
Amended; Appendix 2 to current DEP 31.38.01.31-GEN Appendix 4.
Nov 6.8 Added; in a section on NDT requirements for HFA
2012 A

2018
Revision: 10
Nov 6.5.1 to 6.8 Monel PMI requirement from Consumable section to PMI section. HF
2012 service
Nov Appendix 3 Added

2012 Appendix 3 ITP for HFA welding
Appendix 4 Work flow of PMI for Non CS Welding.
Nov Appendix 2 Revised Appendix 2 from Extent of Inspection table to ITP for non CS
2012 welding
Feb Section 7 Added Deviation clause.

2014
References Added API 577
Section 6.5.1 ii) Added the word Code
Section 11 Updated list of 5 Appendix
Dec Deleted 6.8.1 Consumables

2014
Paint color coding at both ends of each filler rod. (see
MNT_INTG 2013OP appendix 2 and 3).
Aug Section 4.4 Updated: W-IMS superseded IDMS
2018
Section 6.4 Amended with exception.
Section 6.5 Added requirements for shop fabrication practice.
Section 6.6, 6.6.1 Added degassing requirement
Section 6.8, a), i) Amended requirements for Low Temp Carbon Steel.
Appendix 2, 6 Added baseline UTG
Appendix 3, 1.1 Amended requirements for Carbon Steel in Remark column.

and 5.3.3.1
Section 3 Updated references to current.
11. APPENDICES
Appendix 1a/b: Typical agenda cum Minute-of-Meeting of pre-fabrication meeting

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Appendix 2: Inspection Classes for Piping (Amendment to DEP 31.38.01.31-Gen;

Appendix 4)
Appendix 3 : ITP for HF Service.
Appendix 4: Work Flow, PMI for NON CS Welding
Appendix 5 : Deviation Request Form

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Appendix 1a
PIPING FABRICATION/CONSTRUCTION MOM No. SEPL-PIM-
MINUTES OF PRE-INSPECTION MEETING Date :
Project :
Project Description :
Job No. :
Purchase Order No. :
Vendor Name :
Manufacturer :
Meeting Location :
Meeting Date :
Attendance:
Company Name Department Name Signature

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Distribution:
SEPL Team SEPL Project Mrgr

2018
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No. ITEMS ACTION DUE

BY DATE
1. PURCHASE ORDER DOCUMENTS:
1.1 Requisition No. (revision):
1.2 Completion Date:
i) PO date:
ii) Planned and agreed date:
2. PREPARATION:
2.1 Scope of Work:

Equipment =
Pipe =
Valves =
Relief Valves =
Structural =
2.2 Statutory requirement?

Who is the AE?
MOM informed?

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2.3 Sub Contractors:
NDT contractor =
= Contractor managed
PWHT contractor =
Painting =
Contractor doing wrapping of underground pipes =

Others……………….
* A copy of latest Sub-Vendors List – see attachment 1

2.4 Shell inspector in-charge:
Name and Contact no:

Email address:

Email address:

Email address:
3. FABRICATION AND INSPECTION SCHEDULE:

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3.1 Who handle the scheduling?
Confirmed to issue weekly status report starting from
Comments:
All schedule shall be forwarded to …….
All delay by Operations has to be recorded by MS Project Engineer and forward

to …….
* A copy of latest schedule – see attachment 2
4 REVIEW OF MATERIAL:
Supplier of material:
Electrodes = supplied by SEPL.
Pipes/Fittings =
Structural material =
Comments:
a) Mill certificate (Original or certified True-copy) to be made available for
inclusion into test packages.
5. INSPECTION DOCUMENT FLOW:

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5.1 Application for Inspection
Confirm Application Format via Email and verbal contact
Confirm one (1) days advance notice to on Witness/Hold Points
Attention to:
Attention :
Tel No. :
E-mail :
Attention :
Tel No. :
E-mail :
Courtesy Copy to inspection engineer:

Attention :
Tel No. :
E-mail :

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5.2 Test Packages

Review the contents:
ITP (to be approved by SEPL)
WPS [* New PQR (new qualification test) if is necessary]
1) Will be using AWS 6013 (3.2mm) electrodes. Initial order of

100kg to be placed by MFBP42. Whatever electrode used, all
welders shall be familiar. For quality, and if performance of
welder is unclear, production test to be taken.
2) TIG ER70sg (2.4mm) for root pass
Overall Welder map
Separate Repair log sheet
Drawings
Marked-up PEFS indicating test package
Relevant procedure
Repair procedure
Baseline readings (UTG)
Overall marked-up PEFS showing all test package plus register
Confirm control of test packages
6. FINAL DOCUMENT SUBMISSION:

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6.1 Test packages (all original record)

Film
To be submitted within 2 weeks after completion of painting
7. COMMUNICATION CHANNELS:
7.1 Shell Project Team, Singapore

Attention:
(Construction Engineer)
Tel No. :
Fax No. :
e-mail :
CC:
Tel No.:
Fax No. :
e-mail :

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7.2 Shell Inspection Dept (Quality/Inspection Issues Only)

Attention :
e-mail :
Attention :
e-mail :
CC :
e-mail :
All Technical, Cost and schedules issues to be communicated to Construction

Engineer.
7.3 Vendor
For Project and Engineering matter : :
Attention :
Tel. :
E-mail :
CC :
Tel No. :
E-mail :
For Quality matter:

Attention :
Tel No. :
E-mail :
8. QUALITY ASSURANCE (QA) SYSTEM:

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8.1 Organization
Is QC department independent from fabrication department?
Yes No
8.2 Document Control

Confirmed doc control to maintain the latest documents/drawings are
available in a fabrication shop?
Comments:
Old drawing will be collected back by Doc controller.
8.3 Control of Non-conformance Issue

Review samples of NCR format including the Internal Procedure and
Logging
Material segregation method
Confirm NCR Work flow and definition of NCR
* A copy of Vendor’s NCR sample format to be attached.
9. SHOP TOUR:
Shop tour is carried out during PIM Yes No

Material marking, marking transfer
Material storage condition
Calibration of inspection tools and equipment
Welding material control
Comments;
10. OTHERS:
10.1 Presentation of fabrication process:

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10.2 Confirmation of Inspection and Test Plan (ITP) in line with 10.1 above.
Review ITP and incorporating Witness and HOLD points.
Incorporated MOM inspection point.
Comments:
1) Total of --- test packages ITP to be review during submission.
2) To submit all golden welds for approval before work start
NDT scope
a) Branch connection = UTG on run pipe (Run pipe = 6” 4spots >8” 12
spots). To be perform by SEPL on request by MS. PT of branch pipe’s
weld preparation. RT (5%)
b) Butt weld to existing = UTG of old pipe (Run pipe = 6” 4spots >8” 12
spots). To be perform by SEPL on request by MS. PT of branch pipe’s
weld preparation. 100% RT.
c) The rest of NDE will be based on Bukom’s Practice.
Dis-similar weld
a) Provide a calibration block of actual weld profile and welding
10.3 Special Remarks:

Monthly/weekly* Welder performance report (frequency depend on
project). Starting from dd/mm/yy to SEPL welding inspector.
Weekly NDT status report to SEPL Welding Inspector
Contractor QC to submit welding daily log to SEPL Welding Inspector
Contractor QC to request for UTG of pipe for OSI monitoring to SEPL

Welding Inspector; during workshop fabrication.
All site isometrics for erection shall be issued via official transmittal.
Revision to be indicated. Such document has to be approved by
Construction Engineer.
Asbestos insulation is expected to be on old pipes. Shall be managed by

HSSE procedure.
All pipes shall be provided with wear plate for location that sits on
support/sleepers. Round bars to be provided. To incorporated into
contractor sketches.
TFA compliance
Cleanliness compliance

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Appendix 1b
EQUIPMENT FABRICATION MOM No. PIＭ-
MINUTES OF PRE-INSPECTION MEETING Date :
Project :
Job No. :
Purchase Order No. :
Vendor Name :
Manufacturer :
Order Description :
Meeting Location :
Meeting Date :
Attendance:
Company Name Department Name Signature
Distribution:
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SEPL Team SEPL Project Mrgr
Fabricator Team

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No. ITEMS ACTION DUE

BY DATE
1. Purchase Order Documents
1.1 Requisition No. (revision):
1.2 Ordered Item and Quantity:
1.3 Delivery Date:
1.4 Delivery Point:

Main Equipment:
1.5 QC Instructions:
To conform to drawings, Shell standard drawings and DEP requirement.
Review TPI CV/resume if any (Attached resume of inspector)
MOM required
Comments;- SEPL to have direct access to TPI and fabrication vendor and sub-vendors.
1.6 Revision status of applicable Purchase Order documents
Confirmed based on PO
The following documents are not with Vendor
2. Fabrication and Inspection Schedule
Confirmed to issue 2 weekly status report starting from

…………….(dd/mm/yy)
Comments:
1.Detailed Production Schedules are required
2.Photos reporting required.
3. Review of Sub-Vendors (including material suppliers)

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(Name of sub-vendor) :
Type of sub-order :
Location :
Contact point :
QA system :
Comments:
 A copy of latest Sub-Vendors List to be attached.
4. Inspection Document Flow
4.1 Application for Inspection:

Confirm Application Format
Confirm two (2) weeks advance notice to Purchaser’s Witness/Hold Points
Attention to ：(SEPL Inspector)
Attention to ： (TPI)
Courtesy Copy to: (Inspection Engineer)
4.2 Monthly Inspection Schedule

Confirm Schedule Format
Confirm schedule to be submitted together with fabrication schedule; starting from

PIM date
Confirm schedule to indicate the confirmed inspection dates of next two (2) weeks
Attention to: (Project Engineer)
Courtesy Copy to: (Inspection Engineer)
Courtesy Copy to: TPI

2018
Revision: 10
4.3 Manufacturers’ Data Report (MDR)

Confirm the contents and compilation method of MDR
MDR to be reviewed by “ Shell Inspector ” before submission
Confirm required number Copy of MDR to be submitted within 1 weeks after

shipment
Attention to: (Project Engineer)
4.4 Inspection Completion Notice (ICN) & Inspection Release Notice (IRN)
Confirm Format
5. Communication Channel
5.1 Shell Project Design Engineering Team, Singapore
Attention : (Project Engineer)
Tel No. :
E-mail :
CC : (Inspection Engineer)
Tel No. :
E-mail :
5.2 Shell Project Construction/Fabrication Inspection Team, Singapore

Attention : (SEPL Inspector)
E-mail :
CC : (Inspection Engineer)
Tel No. :
E-mail :

2018
Revision: 10
5.3 Vendor Project Design Engineering Team :

Attention :
Tel. :
E-mail :
Vendor Project Construction/Fabrication Inspection Team :

Attention :
Tel. :
E-mail :
TPI Project Construction/Fabrication Inspection Team :

Attention :
Tel. :
E-mail :
6 Presentation of fabrication process:

a. Check material before cut-out.
b. Etc……..
7. Review of Vendor Documents

Make reference to vendor document list
Attachment : Document list plus revision.

2018
Revision: 10
7.1 WPS & PQR with Weld Map

Approved by Purchaser (status “A”): rev.[ ]
Commented by Purchaser to proceed (status “B”): rev. [ ]
Commented by Purchaser to hold (status “C”): rev.[ ]
Submitted to Purchaser on “YY/MM/DD”: rev.[ ]
To be submitted by “YY/MM/DD”: rev. [ ]
Comments:
* New PQR (new qualification test) is necessary

No
Yes, for “ “
7.2 Inspection Procedure

Approved by Purchaser (status “A”): rev. [ ]
Commented by Purchaser to proceed (status “B”): rev.[ [
To be submitted by “YY/MM/DD”: rev.[ ]
Comments:

2018
Revision: 10
7.3 Inspection and Test Plan (ITP/MIT)

Comments:
7.4 Heat Treatment Procedure (PWHT Procedure)

Comments:
7.5 NDE Procedure with NDE Map

Comments:

2018
Revision: 10
7.6 Others ;- _____________

Approved by Purchaser (status “A”)
Commented by Purchaser to proceed (status “B”)
Commented by Purchaser to hold (status “C”)
Submitted to Purchaser on “YY/MM/DD”
To be submitted by “YY/MM/DD”
Comments:
8. Quality Assurance (QA) System
8.1 Vendor’s Quality System

ISO 9001 ISO 9002 In-house QA Manual
Others “ ”
a
8.2 Organization
Is QC department independent from fabrication department?
Yes No
8.3 Document Control

To confirms how to maintain the latest documents/drawings are available in a fabrication
shop?
Confirmed
8.4 Control of Non-conformance Issue

Review samples of NCR format including the Internal Procedure and Logging
Material segregation method
Confirm NCR Work flow and definition of NCR
* A copy of Vendor’s NCR sample format to be attached.
8.5 QA Audit
Vendor to accept that Purchaser may perform “QA audit” at Purchaser’s option.
Accepted by Vendor

2018
Revision: 10
9. Confirmation of Inspection and Test Plan (ITP)
9.1 Purchaser’s Witness/Hold Points
Comments:
9.2 TPI(3rd party) Witness/Hold Points:
Comments:
10. Shop Tour
Shop tour is carried out during PIM Yes No

: Material marking, marking transfer
: Material storage condition
: Calibration of inspection tools and equipment
: Welding material control
Comments;
11. Others
11.1 Review ITP in line with 6 above
(Attached ITP)

2018
Revision: 10
11.2 Special Remarks: & Action Items

Dis-similar weld
a) Provide a calibration block of actual weld profile and welding
Total Flange Assurance:

a)
b)
Cleanliness Check
a)
Others
b)
c)

2018
Revision: 10
Appendix 2 -
INSPECTION TEST PLAN FOR NON CS Welding
Work No :
This ITP is applicable for non CS Welding Job No :
TEST PACKAGE NO :
Dwg. / Line no :
CONTRACTOR SEPL
S/N ITEM Completion Remark(s)
Disposition Initial / Date Disposition
Initial / Date
1 Material Verification (PMI) H R/W Raw material
1.1 Verify mill cert. H R/W
1.2 For filler rods, sampling PMI to

H R/W
be done per box/tube.
2 WPS / PQR H R
3 Welder Qualification H R
Electrode Storage /
4 M R
Baking Condition
5 FABRICATION
5.1 Edge-Prep / Fit-up / Dimension H M
5.2 Visual Inspection H R/W
5.3 NDE
R/W R/W
5.3.1 RT
R/W R/W
5.3.2 PT/MT
R/W R/W
5.3.3 PMI 100%
R/W R/W
5.4 PWHT / HARDNESS
R/W R/W
e. Air-Leak Test H R/W
f. Hydrostatic Test H H/R
6 INSTALLATION

2018
Revision: 10
6.1. Edge-Prep / Fit-up / Dimension H M
6.2. Visual Inspection H R/W

6.3 NDE
R/W R/W
6.3.1 RT
R/W R/W
6.3.2 PT/MT
R/W R/W
6.3.3 PMI 100% Field Weld
and Modification R/W R/W
6.4. PWHT / HARDNESS H R/W
6.5 Baseline UTG H R/W
6.6. Air-Leak Test H R/W
6.7. Hydrostatic Test H H/R
6.8 Service Test H R
6.9. Reinstatement H R
6.10. Punch list H R

6.11 Painting
By Other
6.12.Insulation
By Other
Proposed Disposition Approved Disposition endorsed

Legend: endorsed by Contractor by SEPL
M=
H = Hold Point ( Mandatory Inspection ) Monitoring R = Review of Document
P = Prepare Document /
W = Witness ( Can Proceed without Inspection ) N/A = Not Applicable Report
Remarks:

2018
Revision: 10
APPENDIX 3
Work No :
INSPECTION TEST PLAN ( HFA PIPING )
This ITP only applicable for Piping Class 31310, 31311, 36081 Job No :
TEST PACKAGE NO :
Dwg. / Line no :
CONTRACTOR SEPL
S/N ITEM Completion Remark(s)
Disposition Initial / Date Disposition
Initial / Date
1 Material Verification (PMI) H R/W Raw material
Verify mill cert:
For 0.18wt% <C

<0.23wt%,
Cu+Ni <0.15wt%
1.1 Carbon Steel H R/W
For C< 0.18wt%,

Cr+Cu+Ni<0.15%.
1.2 Monel H R/W
If Monel 60 electrode
1.3 Electrode Monel 60 only H R/W is used
Ti <2.2 wt%
CS PEC-TD-WPS-
0034
2 WPS / PQR H R MONEL PEC-TD-
WPS-4020
3 Welder Qualification H R
Electrode Storage /
4 M R
Baking Condition
5 FABRICATION
5.1 Edge-Prep / Fit-up / Dimension H M
5.2 Visual Inspection H R/W
5.3 NDE
R/W R/W

2018
Revision: 10
5.3.1 RT 100% Before and After

R/W R/W
PWHT
5.3.2 PT/MT 100%
R/W R/W
5.3.3 PMI 100%
R/W R/W
5.3.3.1 Carbon Steel For 0.18wt% <C
<0.23wt%,
Cu+Ni <0.15wt%
R/W R/W
For C< 0.18wt%,

Cr+Cu+Ni<0.15%.
5.3.3.2 Monel As per monel and

R/W R/W Fe < 5wt%,
Ti < 2.2wt%
5.4 PWHT / HARDNESS 100%
R/W R/W
e. Air-Leak Test H R/W
f. Hydrostatic Test H H/R
6 INSTALLATION
6.1. Edge-Prep / Fit-up / Dimension H M
6.2. Visual Inspection H R/W

6.3 NDE
R/W R/W
6.3.1 RT 100% Before and After
R/W R/W
PWHT
6.3.2 PT/MT 100%
R/W R/W
6.3.3 PMI 100%
R/W R/W
6.4. PWHT / HARDNESS H R/W
6.5 Baseline UTG H R/W
6.5. Air-Leak Test H R/W
6.6. Hydrostatic Test H H/R
6.7 Service Test H R
6.8. Reinstatement H R
6.9. Punch list H R

2018
Revision: 10
6.10 Painting
By Other
6.11.Insulation
By Other
Proposed Disposition Approved Disposition endorsed by

Legend: endorsed by PEC SEPL
M=
H = Hold Point ( Mandatory Inspection ) Monitoring R = Review of Document
P = Prepare Document /
W = Witness ( Can Proceed without Inspection ) N/A = Not Applicable Report
Remarks: Piping Class 31310, 31311, 36081equivalent to old DEP piping class 3131 and 3608

2018
Revision: 10
APPENDIX 4 – WORK FLOW, PMI FOR NON CS WELDING
Material
Issued
from
Warehous
e
To
Review PMI documentation to
Uncontrolled
ascertain material meet
Material Flow REJECTED specification prior to start of
(Point 2)
welding.
Inward Goods
For filler rods, sampling PMI to
Inspection
be done per box/tube.
Procedure
ACCEPTED
Start Welding
After fabrication perform PMI

(100% component PMI)
REJECTED Review PMI documentation to
Cut weldment
ascertain material meet
specification prior to proceed
for hydrotest.
ACCEPTED
Proceed for Hydrotest

2018
Revision: 10
APPENDIX 5 – Deviation Request forms.
Deviation Request Form
1 Deviation Requestor
2 Date :
Deviation Procedure
number (This is
3
referencing Inspection
Procedure)
4 Deviation Details
(Include attachments if applicable)
5 Deviation Justification
Risk Assessment
Demonstrating that
6 Process Safety Risks
are Managed to
ALARP.
Mitigation Proposal
7
(Operations/
Maintenance Manager Indicator :

8
Comment/Support Date :
Senior Inspection
Indicator :
9 Engineer
Date :
Comment/Support
PUM Indicator :
10
Comment/Support Date :
Asset Integrity Indicator :

11
Manager Approval Date :

2018

MNT-INTG-2007OP - Maintenance Welding Inspection

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Shell Eastern Petroleum - Pulau Bukom Oil Refinery - Refinery Management System

MNT_INTG-2007OP Welding Inspection August 2018

6.2 Welders Qualifications

Document Status APPROVED

6.3.1 Bukom Based Contractors

6.3.2 Piping Work

6.3.3 Fabrication outside Bukom

6.4 Welding Process

Document Status APPROVED

6.6 Hydrogen Degassing and PWHT requirements :

6.6.2 PWHT requirement shall follow:

Document Status APPROVED

iii) For Pressure Vessel constructed from Cr-Mo Steels,

6.9 Pressure Testing:

Ref No. Title Storage Retention

Document Status APPROVED

- QA/QC record Inspection 5 yrs

9. Custodian and review panel

The custodian of this procedure: Dept Quality System Coordinator

10. Change history

date section of doc. Summary of change

Document Status APPROVED

March 3. Amended; correct references name.

March Appendix I Amended; references to Inspection Engineer.

Jan General Changed: word “PACER-I” to “IDMS”

Nov 6.5.1 Added; Filler rods control

Document Status APPROVED

Nov Appendix 3 Added

Feb Section 7 Added Deviation clause.

References Added API 577

Section 6.5.1 ii) Added the word Code

Section 11 Updated list of 5 Appendix

Dec Deleted 6.8.1 Consumables

Section 6.5 Added requirements for shop fabrication practice.

Section 6.6, 6.6.1 Added degassing requirement

Appendix 2, 6 Added baseline UTG

Appendix 3, 1.1 Amended requirements for Carbon Steel in Remark column.

Document Status APPROVED

Appendix 2: Inspection Classes for Piping (Amendment to DEP 31.38.01.31-Gen;

Document Status APPROVED

PIPING FABRICATION/CONSTRUCTION MOM No. SEPL-PIM-

MINUTES OF PRE-INSPECTION MEETING Date :

Purchase Order No. :

Document Status APPROVED

Document Status APPROVED

Document Status APPROVED

No. ITEMS ACTION DUE

1. PURCHASE ORDER DOCUMENTS:

1.1 Requisition No. (revision):

1.2 Completion Date:

ii) Planned and agreed date:

2.1 Scope of Work:

2.2 Statutory requirement?

Document Status APPROVED

2.3 Sub Contractors:

Contractor doing wrapping of underground pipes =

* A copy of latest Sub-Vendors List – see attachment 1

Name and Contact no:

Name and Contact no:

Name and Contact no:

3. FABRICATION AND INSPECTION SCHEDULE:

Document Status APPROVED

3.1 Who handle the scheduling?