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Petrokemya GES-025-01 Inspection

Rev. 4

December, 1998 Page 2 of 8

CONTENTS SECTION PAGE

1. SCOPE.......................................................................................................................................................................................... 3

2. DEFINITIONS.............................................................................................................................................................................. 3

3. CODE INSPECTION.................................................................................................................................................................. 3

3.1 DETERMINATION OF CODE REQUIREMENTS.........................................................................................................................3 3.2 PERSONAL QUALIFICATIONS ....................................................................................................................................................3

4. NON-CODE INSPECTION........................................................................................................................................................ 4

4.1 GENERAL ......................................................................................................................................................................................4

5. OWNER PARTICIPATION ...................................................................................................................................................... 5

5.1 PARTIAL PARTICIPATION .........................................................................................................................................................5 5.2 COMPLETE PARTICIPATION.....................................................................................................................................................5 5.3 CODE OR THIRD PARTY INSPECTION ......................................................................................................................................6

6. GENERAL INSPECTION REQUIREMENTS ......................................................................................................................... 6


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1. SCOPE This specification covers the general requirements for inspection of materials and equipment in a Vendor shop, or at the jobsite for field fabricated equipment erected by the equipment Vendor.

2. DEFINITIONS 1. In applying the various codes, this specification defines the following two types of inspection:

a) Code Inspection - Functions performed by an authorized inspector, his delegates,

government agencies, or other independent third-party inspectors to verify compliance with the applicable codes, government regulations, and, when specified, the engineering design.

b) Non-Code Inspection - Functions performed by OWNER and/or its authorized agent to:

1) Review, monitor, and conduct surveillance of the Vendors Quality Control Program

and its implementation. 2) Perform quality control functions required by OWNER standards or specifications that

are in addition to any code requirements.

2. Vendor, Sub-vendor, Sublet, Subsupplier - Any person or firm contracted to manufacture, fabricate or supply an item; or to provide services incidental to the design, construction, operation, or testing of any item or facility. However, the Vendor shall have the total responsibility for the performance of his Sub-vendor(s), Sublets(s), and Sub-supplier(s).

3. Audit - An activity to determine through investigation the adequacy of, and adherence to,

required procedures and the effectiveness of their implementation.

3. CODE INSPECTION

3.1 Determination of Code Requirements 1. All equipment or materials purchased or specified in accordance with a code or government

regulation shall be inspected as required by that code regulation. 2. The codes, laws, or regulations of record applicable to a project, together with any additional

requirements, shall be those referenced in the Project Design Data.

3.2 Personal Qualifications 1. Inspections and examinations required by all codes, laws or government regulations

applicable to the project shall be made by inspectors and other personnel who are


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officially qualified in accordance with those applicable code, laws, or government regulations, and have a minimum of 5 years of relevant experience.

2. Welders, non-destructive examination personnel, and other construction specialists

required to be tested or certified by the applicable code, law, or government regulation shall be verified as having satisfied these requirements.

3. In no case shall the OWNER inspector or inspection representative be construed as the

authorized code or independent third-party inspector.

4. NON-CODE INSPECTION

4.1 General 1. The inspection of a Vendor by OWNER or its inspection representative shall include, but is

not limited to, the complete or partial performance of the following:

a) Verification of the use of qualified welders and qualified welding procedures including pre and post weld heat treatment.

b) Checks on materials, dimensions, and finishes. c) Review of non-destructive examinations, including alloy verifications if required.

Ensuring that personnel are qualified to perform these examinations. d) Witnessing of pressure test and equipment mechanical and performance tests. e) Review of documentation. f) Audit of the Vendors quality control program, including document control and

disposition of non-conforming work. Shop audits shall be conducted at the Vendor shop. Audits of field fabricated items shall take place at the jobsite.

g) Verify paint and coating (type, thickness, etc.)

2. The extent of inspection to be performed by each Vendor over and above the specified requirements shall be determined by considering the Vendors quality control program and previous experience of OWNER with the Vendor.

3. OWNER or a designated representative of OWNER shall perform inspection in addition to

or exceeding code requirements in order to meet quality standards specified by OWNER. This shall also be applicable to materials requiring code stamped and/or National Board Certificates.

4. All materials, packaging, equipment, and fabricated items shall be subject to non-code

inspection during all stages of fabrication, testing, transportation, storage, and erection.


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5. OWNER PARTICIPATION

5.1 Partial Participation 1. Partial participation is defined as limited OWNER participation in the inspection program;

i.e. when a contractor has the primary inspection responsibility. 2. The contractors inspector shall act as the official spokesman in all discussions with Vendors

and will issue all criticisms, acceptances, and rejections. The OWNER inspector shall submit all comments and criticisms to the contractors inspector.

3. When OWNERs inspector is to accompany the contractors inspector, the contractor shall

notify OWNER at least three (3) calendar weeks prior to the date of the inspection. Failure of OWNER to be present at the appointed time will serve as OWNERs waiver of that particular inspection.

4. In the event the contractors inspector is not present when the OWNER inspector

encounters an unacceptable condition which may cause a delay in shipment, the OWNER inspector shall immediately sent complete information regarding the condition, proposed corrective measures and estimated delay through the established channels for Contractor/OWNER communication for contractor action.

5.2 Complete Participation 1. Complete participation is defined as when OWNER wishes to inspect materials and

equipment which will not be inspected by a contractor, or when OWNER desires to conduct all Vendor inspections.

2. Prior to start of purchasing, OWNER will provide the contractor a list of all materials and

equipment which OWNER wishes to inspect or audit the inspection thereof. 3. All inspections shall be conducted in the Vendors shop, except that inspections shall be

conducted at the jobsite for items field fabricated by the Vendor. 4. OWNER inspection reports, criticisms, acceptances, and rejections shall be transmitted to

the Vendor through the contractor. When unacceptable conditions are encountered, the contractor will be informed of the proposed corrective measures and the estimated delay.

5. OWNERs inspector shall coordinate the examinations so as not to restrict the Vendor in

meeting the delivery dates specified in the Purchase Orders. 6. The imposition by OWNERs inspector of conditions more stringent that those specified in

the contractors Purchase Order shall not necessarily be a cause for rejection of an item.


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5.3 Code or Third Party Inspection Unless the governing code or authority requires OWNER to assume the responsibility for the authorized code inspection, the contractor shall make the necessary arrangement with the Vendor for all required code or third-party inspection, and shall collect the Authorized Inspectors Reports and the Manufacturers Data Reports. In the absence of a contractor, OWNER will assume this responsibility.

6. GENERAL INSPECTION REQUIREMENTS 1. All parts are subject to inspection to ensure adequacy of the Vendors product quality. All

materials and equipment requiring alloy verification are subject to inspection. 2. Vendor shall be required to present an inspection plan for the total supply at the inquiry stage

to be in line with Appendix 1 as a minimum and shall solicit the approval for the same from OWNER.


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APPENDIX 1 Page 1 of 2

MINIMUM REQUIREMENTS FOR OWNER INVOLVEMENT

FOR ASME PRESSURE CONTAINING EQUIPMENT Stages and extent to which OWNER or their assigned contractor shall be involved as a minimum EXTENT OF INVOLVEMENT

STAGES OF INSPECTION CATEGORY 1

CATEGORY 2

CATEGORY 3

MATERIAL Pre-inspection H H H Material Test Certificates R R R Identification of material and transfer of

marking W I/R R

Supplementary mechanical properties R R R Sub-orders R R R QUALIFICATIONS Welders/operators qualifications W/R W/R R Welding procedure specifications R R R WPS + repair procedures H/R H/R R Welding procedure qualifications R R R PQR records R R R NDT operator qualifications R R R NDT procedures R R R Manufacturing procedures R R R NON-DESTRUCTIVE TESTING

Dye penetrant/magnetic particle Ultrasound

W/R W/R

I/R I/R

I/R I/R

Radiographic I/R I/R I/R Hardness W/R I/R I/R Alloy verification H/R H/R H/R DESTRUCTIVE TESTING Production TEST COUPONS W I R FABRICATION Corrective actions for non-conformities Bevel preparation/tacking I I I Back gauging I I I Weld parameters/operation + repairs I I I Forming I R R PWHT I/R R R Dimensional/visual H/W/ H/I H/I Hydro/pneumatic test H/W/R/ H/W/R/ H/W/R Tightness test H/W H/W --- PREPARATION FOR SHIPMENT

Sandblasting/painting Drying/preservation Packing/marking

I/R W

W/R

I/R I

W/R

I I I

VENDOR DOCUMENTATION

Manufacturing reports H/R H/R H/R

1) LEGEND: W=Witness I=Random inspection H=Hold point R=Document review and approval 2) Category 1, 2, and 3 are defined on next page


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APPENDIX 1 Page 2 of 2

CATEGORIES FOR THE EXTENT OF INVOLVEMENT

CATEGORY 1 Vessels, exchangers, columns having material of construction of alloy, high alloy and stainless steel

OR Vessels, exchangers, columns to be designed and

manufactured in accordance to ASME Section VIII, Division 2 OR Vessels, exchangers, columns having shell thickness of 50mm

and above. OR Vessels, exchangers, columns having weight of 50MT and

above. OR Exchangers having channel diameter of 1500mm and above.

CATEGORY 2 Vessels, exchangers, columns having material of construction of carbon steel.

OR Vessels, exchangers, columns having weight of 20 MT above

and up to 50 MT. OR Exchangers having channel diameter less than 1500mm.

CATEGORY 3 All other items not covered under CATEGORY 1 & 2 above.

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