Inspection Test Plan (Itp) Rev.00: DOC - NO. OPR08-01 REV. No: 00

DOCUMENT NO:
GSCC-ZS-PV-ITP-005-2014
REV.01
ITEM DESCRIPTION
PRESSURE VESSELS
ITEM NO / DRAWING NO:
PED-0246 & 0242 REV.1
PROJECT
RABIGH II REFINIG & PETROCHEMICALS

(CP3 & CP4)
JOB NO: GSCC-MD-2014-356
INSPECTION TEST PLAN (ITP) REV.00
Revised to incorporate client and PIM comments
QA/QC ENGG
GSCC
QA/QC
MANAGER
GSCC
ZS
AI
GS E&C
SA
For Approval
QA/QC ENGG
GSCC
QA/QC
MANAGER
GSCC
ZS
AI
GS E&C
SA
ISSUENCE
PREPARED By
REVIEWED
By
ACCEPTED
By
ACCEPTED
By
REV:
DATE:
DOC.NO. OPR08-01
REV. No: 00
PAGE 1
APPROVED BY CLIENT
GULF SKY CRANES & CONT. CO. LTD

INSPECTION TEST PLAN ( ITP) No:
CLIENT : ZAMIL STEEL CO.LTD.
DATE: 29/10/2014
DRAWING No: PED-0242-05-001
P.O No: 101652 REV.0
PROJECT TITLE : RABIGH II REFINING AND PETROCHEMICAL PROJECT

DESCRIPTION : PRESSURE VESSEL FABRICATION
ITE
WORK PROCESESS
M
ACTIVITY
No:
Pre-Inspection Meeting
DOCUMENTS
1.1
Weld Map, WPS, PQR,

Weld Repair Procedure,
Welding Control &
Consumable Procedure
1.2
Welder Qualification
Record Review
1.3
NDE Personnel
Qualification and Procedure
Review
Receiving Inspection
CHARECTERISTIC
TO BE CHECKED
Review of Weld Map, WPS,

Fabrication Drawings, & Applicable
Codes & Specifications
Review of Welder Qualification Records
Review of NDE (RT, UT, MT,

PT) Procedures & Codes &
Spec.
EQUIPMENT NAME : BYPRO OIL DRUM

REFERENCE
DOCUMENTS/
ACCEPTANCE
CRETERIA.
2.1
Review of MTC/ Material Specification

DOC No: OPR08-01
GSCC
ZS
CLIENT
AI
GS E&C
Res Sign Res Sign Res Sign Res

H
SA
Sign Res
Approved GSCC
WPS & PQR and
& Approved
Procedures
As per ASME Sec. IX
Approved 3rd Party

WQT Records
AMES Sec. V
Approved 3rd Party

Procedures
Mill Test
Certificates
As per Drawings
ASME Sec. VIII
Div.1
ASME Sec. II Part A

Identification Marking Heat Number
against MTC / Material
Specification
INSPECTION STAGES
INSPECTION
FORM &
RECORD
Approved Fabrication
Drawings,
ASME Sec. IX,
ASME Sec. VIII. Div 1
Visual Inspection, Dimension Checking

As Per Specification
Shell, Dishes, Forgings,
Pipe & Fittings, Nozzles
VESEEL TAG No: P 210-D-1126
MTC & Material
Specification
Incoming Material
Inspection Report,
Doc. No:
OPR08-40
REV.NO: 02
PAGE 2
Sign

DATE: 29/10/2014
P.O No: 101652 REV.0

ITE
WORK PROCESESS
M
ACTIVITY
No:
2.2
Welding Consumables
Material Traceability
of Pressure Parts,
Attachment to
Pressure Parts
4.1
CHARECTERISTIC
TO BE CHECKED

REFERENCE
DOCUMENTS/
ACCEPTANCE
CRETERIA.
Verification against the Requirement

of the Consumable MTC
As per ASME Sec. II

Part C
INSPECTION STAGES
INSPECTION
FORM &
RECORD
GSCC
ZS
AI
CLIENT
GS E&C
SA
Sign Res
Raw Material
Inspection
Report.Doc. OPR08-04
Traceability Verification As per MTC

And approved Fabrication Drawings.
Drawings, marking
on Plates & Pipes
ASME Sec. VIII
Div.1
Approved
Fabrication
Drawings,
Incoming Material
Inspection Reports
Doc.OPR08-40
Fit-Up Alignment check, Tack Welds,

Surveillance of welding parameters
against the applicable WPS
Fabrication Drawings,
applicable WPS and
Weld Map
Inspection Report, DOC.

OPR08-64
WFirst,
RRest
IW
IW
PT on back gouged Surface
ASME Sec. V
3rd PARTY Procedure

AIS QP-7.5.1D
Visual Inspection of welds 100%
ASME Sec. VIII

Div. 1
Inspection Report, DCO.OPR08H

07
In-Process Inspection
Long Seam & Cir.

Seam Fit-Up,
Welding to the Shell
to Head
Carry out MT (100%)
Carry out RT
(Head to Shell Circular Seam-Full
RT, Shell Long Seam-Spot RT )
DOC. No: OPR08-01
ASME Sec. V &

ASME Sec
VIII,Div.1
3rd PARTY,
AIS QP-7.5.1C
ASME Sec. V &

ASME Sec
3rd PARTY,
AIS QP-7.5.1A
VIII,Div.1
REV.NO: 02
PAGE 3
Sign

DATE: 29/10/2014
P.O No: 101652 REV.0

4.2
Rolled Nozzle Neck
4.3
4.4
4.5
Nozzle layout
Marking on shell and head

INSPECTION STAGES
REFERENCE
DOCUMENTS/
ACCEPTANCE
CRETERIA.
INSPECTION
FORM &
RECORD
Fit-up alignment check, Tack Welds,

Surveillance of welding
p a r a m e t e r s against the applicable
WPS.
applicable WPS & ASME
Sec VIII. Div.1
Inspection Reports,
DOC. OPR08-64
PT on the back gouged surfaces

& 100% Visual Inspection, 100 % RT for
Nozzle butt welds, 100 % MT
ASME Sec .V
3rd Party Procedure

AIS QP-7.5.1A AIS-QP 7.5 1C
Nozzle Orientation conformity and
As Per Fabrication
Inspection Reports,
Drawings.
DOC. OPR08-67
Fit-Up Tack weld visual

check, Surveillance of
welding parameters
against applicable
WPS, weld Visual 100%
Applicable WPS/ Weld

Map,
Reports
Inspection Report
OPR08-64 OPR08-07
H
Verify fit-up tolerance,100 % PT & Full

RT
ASME Sec .V
3rd Party Procedure

AIS QP-7.5.1A AIS-QP 7.5 1D
Fit-Up Tack weld visual

check, Surveillance of
welding parameters
against applicable
WPS
Applicable WPS/ Weld

Map,
Reports
Inspection Report
OPR08-64 OPR08-07
H
ITE
WORK PROCESESS
M
ACTIVITY
No:
Nozzle Fabrication
CHARECTERISTIC
TO BE CHECKED
verification of weld edge

preparation
10" above joints pipe to

pipe, pipe to elbow, pipe to
flange, pipe to Tee etc..
10" below joints pipe to

pipe, pipe to elbow, pipe to
flange, pipe to Tee etc.
Verify fit-up tolerance,100 % Weld visual

& PT
DOC. No:
ASME Sec .V
GSCC
ZS
AI
CLIENT
GS E&C
Sign Res
3rd Party Procedure

AIS QP-7.5.1A AIS-QP 7.5 1D
REV.NO: 00
SA
PAGE 4
Sign

DATE: 29/10/2014
P.O No: 101652 REV.0

Nozzle Neck to shell &

head fit-up & welding
Fit-Up Tack weld visual check,

against applicable WPS, weld Visual
100%
Applicable WPS / Weld

Main Drawings ASME
Sec V
Inspection Reports Doc.

OPR08-64
WFirst,
RRest
IW /S
IW
PT on back gouged Surface
ASME Sec V
3rd PARTY,
AIS QP-7.5.1D
UT on Nozzle Neck to head & shell weld
ASME Sec VIII Div-1,

PED-246-UT
PED -QC-07,Rev-0
MT on Nozzle Neck to shell and head

weld
ASME Sec V
3rd PARTY,
AIS QP-7.5.1C
Inspection Report
DOC. OPR08-07
IW/S
External attachment
Fit-Up & Welding on
the vessels including
leg support and Lifting lugs MT on Leg supports to Shell
Attachment welds
MT on all External attachment welds &
temporary support removed area & Arc
strikes removed area.
4.8
All the Internal

Fit-Up and Welding
on the Vessel
INSPECTION STAGES
INSPECTION
FORM &
RECORD
CHARECTERISTIC
TO BE CHECKED
Welding parameters, surveillance

against applicable WPS, Verification of
location Inspection of weld
4.7

REFERENCE
DOCUMENTS/
ACCEPTANCE
CRETERIA.
ITE
WORK PROCESESS
M
ACTIVITY
No:
4.6
Fit-Up Tack weld visual check,

against applicable WPS, weld
Visual
100%
Verify Fit-Up tolerance
DOC .No:
Fabrication
Drawings,
Applicable WPS.
3rd Party MT Procedure
AIS-7.5.1C
3rd PARTY,
AIS QP-7.5.1C
3rd Party MT Procedure

AIS-7.5.1C
3rd PARTY,
AIS QP-7.5.1C
Applicable WPS/
Approved Drawings.
Inspection Reports.
Inspection Report
WPS, DOC.
OPR08-07
REV.NO: 00
GSCC
ZS
AI
CLIENT
GS E&C
SA
Sign Res
PAGE 5
Sign

DATE: 29/10/2014
P.O No: 101652 REV.0

ITE
WORK PROCESESS
M
ACTIVITY
No:
4.9
4.10
4.11
4.12
4.13
Internal Inspection of
Vessel (Before
closing the Head)
Final Dimension &

Visual checking of Vessel
RF Pads leak Test
CHARECTERISTIC
TO BE CHECKED

REFERENCE
DOCUMENTS/
ACCEPTANCE
CRETERIA.
INSPECTION STAGES
INSPECTION
FORM &
RECORD
ASME Sec. VIII. Div.1

Approved Drawings,
MT on Internal attachment welds
ASME Sec .V
3rd PARTY
AIS QP-7.5.1C
Inspection Reports.
APPROVED DWG,
Inspection Reports. DOC.
Fabrication Tolerance
OPR08-08
Approved Procedures
QP PPT-08 Rev.0
Pneumatic Test of Pads at 5 PSIG
Certification of Equipment Applicable ASME Certification Mark in

& PDR
Equipment with PART STAMP
Documents Review and

Equipment Release
Dossier Review (IRB)
DOC.No:
ZS
AI
CLIENT
GS E&C
Visual Inspection of Internal surface

and verification of nozzle internal sharp
corners rounding off.
Verification of dimension (Over all

dimensions, Nozzles and
attachments) and Final Visual
Inspection
GSCC
Inspection Report
DOC. OPR08-07,
SA
Sign Res
Inspection Report OPR08-12
Drawings
Certification rub off / Photo
ASME Sec. VIII , Div.1
Approved Formats
REV.NO: 00
PAGE 6
Sign

DATE: 29/10/2014
P.O No: 101652 REV.0

ITE
WORK PROCESESS
M
ACTIVITY
No:
LEGEND:
DOC.No:
CHARECTERISTIC
TO BE CHECKED

REFERENCE
DOCUMENTS/
ACCEPTANCE
CRETERIA.
INSPECTION STAGES
INSPECTION
FORM &
RECORD
GSCC
ZS
CLIENT
AI
GS E&C
Sign Res
IW- Initial Witness , H- Hold Points , W- Witness Points , S- Surveillance , R- Review of Records
REV.NO: 00
PAGE 7
SA
Sign

Inspection Test Plan (Itp) Rev.00: DOC - NO. OPR08-01 REV. No: 00

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Inspection Test Plan (Itp) Rev.00: DOC - NO. OPR08-01 REV. No: 00

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DOCUMENT NO:

ITEM NO / DRAWING NO:

PED-0246 & 0242 REV.1

RABIGH II REFINIG & PETROCHEMICALS

JOB NO: GSCC-MD-2014-356

INSPECTION TEST PLAN (ITP) REV.00

Revised to incorporate client and PIM comments

GULF SKY CRANES & CONT. CO. LTD

CLIENT : ZAMIL STEEL CO.LTD.

P.O No: 101652 REV.0

PROJECT TITLE : RABIGH II REFINING AND PETROCHEMICAL PROJECT

Weld Map, WPS, PQR,

Review of Weld Map, WPS,

Review of Welder Qualification Records

Review of NDE (RT, UT, MT,

EQUIPMENT NAME : BYPRO OIL DRUM

Review of MTC/ Material Specification

Res Sign Res Sign Res Sign Res

As per ASME Sec. IX

Approved 3rd Party

Approved 3rd Party

ASME Sec. II Part A

Visual Inspection, Dimension Checking

VESEEL TAG No: P 210-D-1126

MTC & Material

GULF SKY CRANES & CONT. CO. LTD

CLIENT : ZAMIL STEEL CO.LTD.

P.O No: 101652 REV.0

PROJECT TITLE : RABIGH II REFINING AND PETROCHEMICAL PROJECT

VESEEL TAG No: P 210-D-1126

EQUIPMENT NAME : BYPRO OIL DRUM

Verification against the Requirement

As per ASME Sec. II

Res Sign Res Sign Res Sign Res

Traceability Verification As per MTC

Fit-Up Alignment check, Tack Welds,

Inspection Report, DOC.

PT on back gouged Surface

3rd PARTY Procedure

Visual Inspection of welds 100%

ASME Sec. VIII

Inspection Report, DCO.OPR08H

Long Seam & Cir.

Carry out MT (100%)

DOC. No: OPR08-01

ASME Sec. V &

ASME Sec. V &

GULF SKY CRANES & CONT. CO. LTD

CLIENT : ZAMIL STEEL CO.LTD.

P.O No: 101652 REV.0

PROJECT TITLE : RABIGH II REFINING AND PETROCHEMICAL PROJECT

Rolled Nozzle Neck

Marking on shell and head

EQUIPMENT NAME : BYPRO OIL DRUM

Fit-up alignment check, Tack Welds,

PT on the back gouged surfaces

3rd Party Procedure

Nozzle Orientation conformity and

Fit-Up Tack weld visual

Applicable WPS/ Weld

Verify fit-up tolerance,100 % PT & Full

3rd Party Procedure

Fit-Up Tack weld visual