PIPING REPLACEMENT (CARBON STEEL)

INSPECTION TEST PLAN ITP NO: REV:1.0 DATE:

CLIENTS : ABBREVIATIONS
PROJECT : M : MONITOR W : WITNESS
BY : STS EDAC PLANT SERVICES SDN BHD R : REVIEW AP : APPROVAL
DESCRIPTIONS : GENERIC ITP FOR PIPING REPLACEMENT (CARBON STEEL) RD : RANDOM H : HOLD
NA : NOT APPLICABLE

RESPONSIBILITY INSP. STATUS

ITEM
PROCESS DESCRIPTION QC ACTIVITY SPEC / ACCEPTANCE CRITERIA VERIFYING RECORD THIRD THIRD REMARK
NO STS EDAC CLIENT STS EDAC CLIENT
PARTY PARTY

1 QA/QC Document Submission & Approval

1.1 Drawing
Receive Dwgs from CLIENT Review against Dwg Masterlist NA Transmittals QA/QC NA MECH R NA AP
Approval drawing NA Transmittals QA/QC NA MECH M NA AP
1.2 PQR & WPS
Qualification of PQR/WPS Perform Procedure Qualification Test ASME -IX, July 2015 Procedure Qualification Record (PQR) QC Inspector Inspector CLIENT INSP W/AP R/AP R
Visual Inspection ASME -IX, July 2015 Procedure Qualification Record (PQR) QC Inspector Inspector CLIENT INSP W/AP AP R
Non-destructive Testing(NDT) ASME -V / IX, July 2015 RT Report QC Inspector Inspector CLIENT INSP W/R AP R
Mechanical Testing ( if required ) ASME -IX, July 2015 Lab. Report ( if required ) QC Inspector Inspector CLIENT INSP W/AP R R
Compile WPS ASME -IX, July 2015 Welding procedure spec.record(WPS) QC Inspector Inspector CLIENT INSP W/AP R R
1.3 Welder Qualification Testing (WQT)
Qualification of Welders Perform Welder Qualification Test ASME -IX, July 2015 Welder Qualification Test Record QC Inspector Inspector CLIENT INSP W/R AP/W R
Visual Inspection ASME -IX, July 2015 Welder Qualification Test Record QC Inspector Inspector CLIENT INSP W/M AP/W R
Non-destructive Testing(NDT) ASME -V / IX, July 2015 RT Report QC Inspector Inspector CLIENT INSP W/R AP R
Issue welder certificate. ASME -IX, July 2015 Welder certificate QC Inspector Inspector CLIENT INSP R AP R

2 Material Receiving
2.1 Material receiving inspection Check material against purchasing docs API 573/API 650 Delivery Note Matl Contl NA CLIENT INSP R/AP NA H
Check material certificates (mill cert) Material Receiving Inspection Report QC inspector Inspector CLIENT INSP M/R H H
Mill Cert

2.2 Storage of Material Ensure all material adequately protected NA NA Supervisor NA CLIENT INSP M NA RD

2.3 Handling of materials Ensure all material carefully handled NA NA Supervisor NA CLIENT INSP M NA RD

2.4 Material Traceability NA NA Traceability / Mill cert Supervisor / Inspector CLIENT INSP M/R R/RD M
QC inspector

3 Production Welding & Consumable

3.1 Welding Pipe Amps, volts, weave width, heat input WPS NA QAQC Supv Inspector CLIENT INSP M RD R/RD
Check correct consumable WPS NA QAQC Supv Inspector CLIENT INSP M RD R

3.2 Consumables received. Check manufacturer's certificate Retain all manufacturer's certificates M/Controller Inspector CLIENT INSP M/W R R
Storage Ensure stored dry and sealed NA QAQC Supv NA CLIENT INSP M/W NA R
Baking / Holding Bake and hold electrodes activity Baking/Holding record QAQC Supv Inspector CLIENT INSP M/W RD R
Issuing Record weight and type of electrodes Consumable Issue record QAQC Supv Inspector CLIENT INSP M R RD
issued/return

4 Shop Fabrication
4.1 Storage of Material/Handling of Materials Ensure all material adequately protected NA NA Supervisor NA CLIENT INSP M NA RD

4.2 Site Verification & Measurement Confirm with verified the defect area Inspection report QC inspector Inspector CLIENT INSP M/W H W/AP
Client Acceptance
Ensure the located area Inspection report QC inspector Inspector CLIENT INSP M/W H W/AP

4.3 Marking / cutting / edge prep Visual Inspection Approved Drawing , Inspection Report NA Supervisor Inspector CLIENT INSP M W RD

4.4 Fit-up Fit-up Inspection ASME VIII DIV.1, July 2015 - Division1 / UW-33 Fit-up inspection report QC Supervisor Inspector CLIENT INSP W/M H H
i)Dimensional check Approved Drawing
WPS/PQR

4.5 Fit-up Inspection ASME B31.3, 2014 ASME B31.3, 2014 - para 328.4 Fit-up Inspection Report QC Supervisor Inspector CLIENT INSP W/M H H

4.6 Welding (GTAW/SMAW Process) Amps, volts, weave width , heat imput Refer WPS/PQR IPC Static Sumamry QC Supervisor Inspector CLIENT INSP W/M H M/W
Check correct consumable Refer WPS/PQR Welder Pass

4.7 Visual Inspection To verify that all completed joints ASME V, July 2015 - Article 9 - Visual Examination Visual Inspection Report QC Supervisor Inspector CLIENT INSP M R H
Comply with the acceptance standard ASME V, July 2015 - Article. 2
 PIPING REPLACEMENT (CARBON STEEL)
INSPECTION TEST PLAN ITP NO: REV:1.0 DATE:

CLIENTS : ABBREVIATIONS
PROJECT : M : MONITOR W : WITNESS
BY : STS EDAC PLANT SERVICES SDN BHD R : REVIEW AP : APPROVAL
DESCRIPTIONS : GENERIC ITP FOR PIPING REPLACEMENT (CARBON STEEL) RD : RANDOM H : HOLD
NA : NOT APPLICABLE

RESPONSIBILITY INSP. STATUS

ITEM
PROCESS DESCRIPTION QC ACTIVITY SPEC / ACCEPTANCE CRITERIA VERIFYING RECORD THIRD THIRD REMARK
NO STS EDAC CLIENT STS EDAC CLIENT
PARTY PARTY

4.8 Non-Destructive Test (NDT) Evaluate Welding Quality Non-Destructive Examination NDT Report QC Inspector NDT Tech CLIENT INSP M R R/AP
4.8.1 Dye Penetrant Test (DPT) ASME V, July 2015-Article 6 - Liquid Penetrant examination

4.8.2 100% Radiographic Test (Butt Joint) before PWHT Evaluate Welding Quality ASME V, July 2015 - Article II - Radiographic examination / UW-51 RT Report QC Inspector NDT Tech CLIENT INSP M R R/AP
ASME B31.3 Ed 2014 - Table 341.3.2

4.8.3 Post Heat Treatment (PWHT), If required To ensure temperature within range of WPS & PQR ASME B31.3 Ed 2014 - Table 330.1.1 PWHT Report QC Inspector Inspector CLIENT INSP M R R/AP *PWHT temperature shall be
follow WPS/PQR & Code and
ASME VIII DIV.1, 2015 - Table UCS-56 standard

4.8.4 100% Radiographic Test (Butt Joint) after PWHT Evaluate Welding Quality ASME V, July 2015 - Article II - Radiographic examination / UW-51 RT Report QC Inspector NDT Tech CLIENT INSP M R R/AP *After 24 hours
ASME B31.3 Ed 2014 - Table 341.3.2

4.8.5 Hardness test (after PWHT) To ensure the test using correct tools ASME B31.3, 2014 - Table 331.1.1 (Brinell Hardness) Hardness Test Report QC Inspector Inspector CLIENT INSP M R R/AP
PTS 15.12.01 – Welding of Chemical, Oil, and Gas Industries

5 Site Execution/Installation
5.1 Marking / cutting / edge prep Visual Inspection Approved Drawing , Inspection Report NA Supervisor Inspector CLIENT INSP M W RD

5.2 *Surface Preparation Visual Inspection Client Acceptance N/A QC Supervisor Inspector CLIENT INSP W/M H RD/AP
-Cleaning area

5.3 Perform DPT on surface preparation (existing bevel) Request NDT ASME V, July 2015 - Article 6 NDT Request QC Inspector NDT Tech CLIENT INSP M R R/AP
/ASME VIII Design Code & Standard
5.4 Fit-up Fit-up Inspection ASME VIII DIV.1, July 2015 - Division1 / UW-33 Fit-up inspection report QC Supervisor Inspector CLIENT INSP W/M H H
i)Dimensional check Approved Drawing
WPS/PQR

5.5 Dehydrogenation on existing pipe (if required) Ensure the works follow procedure approved N/A QC Supervisor Inspector CLIENT INSP W/M R R/AP

5.6 Fit-up Inspection ASME B31.3, 2014 ASME B31.3, 2014 - para 328.4 Fit-up Inspection Report QC Supervisor Inspector CLIENT INSP W/M H H

5.7 Welding (GTAW/SMAW Process) Amps, volts, weave width , heat imput Refer WPS/PQR IPC Static Sumamry QC Supervisor Inspector CLIENT INSP W/M H M/W
Check correct consumable Refer WPS/PQR Welder Pass

5.8 Visual Inspection To verify that all completed joints ASME V, July 2015 - Article 9 - Visual Examination Visual Inspection Report QC Supervisor Inspector CLIENT INSP M R H
Comply with the acceptance standard ASME V, July 2015 - Article. 2

5.9 Non-Destructive Test (NDT) Evaluate Welding Quality Non-Destructive Examination NDT Report QC Inspector NDT Tech CLIENT INSP M R R/AP
5.9.1 Dye Penetrant Test (DPT) ASME V, July 2015-Article 6 - Liquid Penetrant examination

5.9.2 100% Radiographic Test (Butt Joint) before PWHT Evaluate Welding Quality ASME V, July 2015 - Article II - Radiographic examination / UW-51 RT Report QC Inspector NDT Tech CLIENT INSP M R R/AP
ASME B31.3 Ed 2014 - Table 341.3.2

5.9.3 Post Heat Treatment (PWHT), if required To ensure temp within range of WPS & PQR ASME B31.3 Ed 2014 - Table 330.1.1 PWHT Report QC Inspector Inspector CLIENT INSP M R R/AP *PWHT temperature shall be
follow WPS/PQR & Code and
ASME VIII DIV.1, 2015 - Table UCS-56 standard

5.9.4 100% Radiographic Test (Butt Joint) after PWHT Evaluate Welding Quality ASME V, July 2015 - Article II - Radiographic examination / UW-51 RT Report QC Inspector NDT Tech CLIENT INSP M R R/AP *After 24 hours
ASME B31.3 Ed 2014 - Table 341.3.2

5.9.5 Hardness test (after PWHT) To ensure the test using correct tools ASME B31.3, 2014 - Table 331.1.1 (Brinell Hardness) Hardness Test Report QC Inspector Inspector CLIENT INSP M R R/AP
PTS 15.12.01 – Welding of Chemical, Oil, and Gas Industries
 PIPING REPLACEMENT (CARBON STEEL)
INSPECTION TEST PLAN ITP NO: REV:1.0 DATE:

CLIENTS : ABBREVIATIONS
PROJECT : M : MONITOR W : WITNESS
BY : STS EDAC PLANT SERVICES SDN BHD R : REVIEW AP : APPROVAL
DESCRIPTIONS : GENERIC ITP FOR PIPING REPLACEMENT (CARBON STEEL) RD : RANDOM H : HOLD
NA : NOT APPLICABLE

RESPONSIBILITY INSP. STATUS

ITEM
PROCESS DESCRIPTION QC ACTIVITY SPEC / ACCEPTANCE CRITERIA VERIFYING RECORD THIRD THIRD REMARK
NO STS EDAC CLIENT STS EDAC CLIENT
PARTY PARTY

6 Welding Repairs (If Applicable)

6.1 Remove Defect Ensure defect has fully removed ASME VIII DIV.1, July 2015 - Division1 / UW-33 NA QC Inspector Inspector CLIENT INSP M R R
Perform weld repair WPS/PQR

6.2 Welding Amps, volts, weave width , heat imput Refer WPS/PQR IPC Static Sumamry QC Supervisor Inspector CLIENT INSP W/M H H
Check correct consumable Refer WPS/PQR Welder Pass

6.3 Visual Inspection To verify that all completed joints ASME V, July 2015 - Article 9 - Visual Examination Visual Inspection Report QC Supervisor Inspector CLIENT INSP W/M H H
Comply with the acceptance standard ASME V, July 2015 - Article. 2

6.4 Non-Destructive Test (NDT) Evaluate Welding Quality Non-Destructive Examination NDT Report QC Inspector NDT Tech CLIENT INSP M R R/AP
6.4.1 Dye Penetrant Test (DPT) ASME V, July 2015-Article 6 - Liquid Penetrant examination

6.4.2 100% Radiographic Test (Butt Joint) before PWHT Evaluate Welding Quality ASME V, July 2015 - Article II - Radiographic examination / UW-51 RT Report QC Inspector NDT Tech CLIENT INSP M R R/AP
ASME B31.3 Ed 2014 - Table 341.3.2

6.4.3 Post Heat Treatment (PWHT), if required To ensure temp within range of WPS & PQR ASME B31.3 Ed 2014 - Table 330.1.1 PWHT Report QC Inspector Inspector CLIENT INSP M R R/AP *PWHT temperature shall be
follow WPS/PQR & Code and
ASME VIII DIV.1, 2015 - Table UCS-56 standard

6.4.4 100% Radiographic Test (Butt Joint) after PWHT Evaluate Welding Quality ASME V, July 2015 - Article II - Radiographic examination / UW-51 RT Report QC Inspector NDT Tech CLIENT INSP M R R/AP *After 24 hours
ASME B31.3 Ed 2014 - Table 341.3.2

6.4.5 Hardness test (after PWHT) To ensure the test using correct tools ASME B31.3, 2014 - Table 331.1.1 (Brinell Hardness) Hardness Test Report QC Inspector Inspector CLIENT INSP M R R/AP
PTS 15.12.01 – Welding of Chemical, Oil, and Gas Industries

7 Hydrostatic Test Check calibration of pressure gauges ASME VIII DIV.1 1 Ed 2015 -UG 102 (Test Gages) Calibration Certificates QAQC Supv Inspector CLIENT INSP H R H
7.1 Piping /chart recorder Valid Calibration Certificate
7.2 Valve Check test pressure & Test Duration PSM-MI-20408 - Para 5.1 (Determine Test Pressure IRP Record & Approved Drawing QAQC Supv Inspector CLIENT INSP H W/R H
and Method) Hydrotest Certificate Form QAQC Supv Inspector CLIENT INSP H
Visual Inspection of leaks ASME PCC-2 -Part 5 (Examination and Testing) NA QAQC Supv Inspector CLIENT INSP M H H
General Arrangement (GA) Drawing

8 Blasting and Painting

8.1 Surface Preparation Grade of surface preparation Blasting & Painting Report QAQC Supv Inspector CLIENT INSP H W H
i- Salt Test (if required) PTS 30.48.00.31 SEPT 2012

8.2 Painting works - Correct paint material Blasting & Painting Report QAQC Supv Inspector CLIENT INSP M W W/M
- Correct application method PTS 30.48.00.31 SEPT 2012

8.3 Painting Inspection Ensure that the dry film thickness meet the Blasting & Painting Report QAQC Supv Inspector CLIENT INSP M H H
requirement
PTS 30.48.00.31 SEPT 2012

8.4 Holiday Test (If required) Ensure the painting is no defect ASTM D5162-01, Edition Jan 1, 2016 Holiday Test Report QAQC Supv Painting Inspector CLIENT INSP M H R/AP

9 Insulation
9.1 Insulation works - Correct insulation material as per spec. Insulation Record QAQC Supv Inspector CLIENT MECH R W W/M
- Correct material thickness
CLIENT INSP &
9.2 Insulation Inspection Visually inspect completed of work Insulation Record QAQC Supv Inspector R W RD
MECH

10 Documentation Review all Quality report and compile N/A Final Documentation ( Quality ) QC Inspector Inspector CLIENT INSP M/R R AP
all Quality document

PREPARED BY : REVIEWED BY : REVIEWED BY : APPROVED BY : APPROVED BY :

NAME NAME : NAME : NAME :

DATE DATE : DATE : DATE :