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193602CSQROP034

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REVISION LIST

00 Issue For Approval

HOLD RECORD

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TABLE OF CONTENTS

1.0  INTRODUCTION................................................................................................................................................... 5 

2.0  DEFINITIONS AND ABBREVIATIONS ........................................................................................................... 5 

2.1  Definitions............................................................................................................................................................ 5 
2.2  Abbreviations ...................................................................................................................................................... 6 

3.0  LIST OF REFERENCED DOCUMENTS ........................................................................................................... 7 

3.1  COMPANY Documents ..................................................................................................................................... 7 


3.2  CONTRACTOR Documents ............................................................................................................................. 7 
3.3  Industry Codes & Standards............................................................................................................................. 7 

4.0  PURPOSE OF THE DOCUMENT ....................................................................................................................... 8 

5.0  EXTENT OF MANUAL ULTRASONIC TESTING ......................................................................................... 9 

5.1  Qualification stage .............................................................................................................................................. 9 


5.2  Production stage ................................................................................................................................................. 9 

6.0  PERSONNEL REQUIREMENTS ...................................................................................................................... 10 

7.0  SAFETY ................................................................................................................................................................. 10 

8.0  TEST METHOD ................................................................................................................................................... 10 

9.0  EQUIPMENT AND CONSUMABLES .............................................................................................................. 11 

9.1  Ultrasonic flaw detector ................................................................................................................................... 11 


9.2  Probes................................................................................................................................................................. 11 
9.3  Coupling mean .................................................................................................................................................. 11 
9.4  Calibration blocks ............................................................................................................................................ 11 
9.4.1  IIW block type V1.......................................................................................................................................... 11 
9.4.2  IIW block type V2.......................................................................................................................................... 11 
9.4.3  DAC calibration blocks ................................................................................................................................. 11 

ULTRASONIC EQUIPMENT VERIFICATION .......................................................................................................... 13 

9.5  Flaw detector calibration ................................................................................................................................. 13 


9.5.1  Calibration certificate..................................................................................................................................... 13 
9.5.2  Calibration verification .................................................................................................................................. 13 
9.6  Probes verification ............................................................................................................................................ 13 
9.6.1  Probe index point verification ....................................................................................................................... 13 
9.6.2  Probe beam angle verification ....................................................................................................................... 13 
9.7  Physical state and external aspects ................................................................................................................. 13 

10.0  SENSITIVITY CALIBRATION......................................................................................................................... 14 


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10.1  Inspection of girth weld ................................................................................................................................... 14 


10.2  Transfer correction .......................................................................................................................................... 15 

11.0  TEST EXECUTION ............................................................................................................................................. 16 

11.1  Surface conditions ............................................................................................................................................ 16 


11.2  Inspection of girth weld ................................................................................................................................... 16 
11.3  Lamination check ............................................................................................................................................. 17 
11.4  Wall thickness check ........................................................................................................................................ 18 

12.0  EVALUATION OF INDICATIONS .................................................................................................................. 19 

12.1  Inspection of girth weld ................................................................................................................................... 19 


12.2  Lamination check ............................................................................................................................................. 19 

13.0  ACCEPTANCE CRITERIA ............................................................................................................................... 20 

13.1  Acceptance criteria for weld inspection ......................................................................................................... 20 


13.2  Acceptance criteria for lamination check ...................................................................................................... 21 
13.3  Acceptance criteria for wall thickness check ................................................................................................ 21 

14.0  REPORTING ........................................................................................................................................................ 22 

ATTACHMENT 1 – MUT REPORT FORM ................................................................................................................. 23 

ATTACHMENT 2 – PROCEDURE APPROVER CERTIFICATE ........................................................................... 24 

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1.0 INTRODUCTION
This document describes the methods, techniques, equipment, personnel requirements and all other details
to carry out manual ultrasonic testing on carbon steel girth welds for Baltim South West Development
Project. This procedure is applicable during welding procedure qualification testing and production stages of
the project.

2.0 DEFINITIONS AND ABBREVIATIONS

2.1 Definitions
COMPANY shall mean Belayim Petroleum Company, a company having its head office at 5 El-
Mokhayem El-Dayem Street, Nasr City, Cairo, Egypt (A.R.E)

CONTRACTOR shall mean PETROLEUM MARINE SERVICES Co., a corporation existing under the
laws of Egypt and having its registered place of business at Anwar El Mofty St., Dev.
& Housing Bank - Buildings B. Right Block Nasr City, Cairo

SAIPEM MISR FOR PETROLEUM SERVICES (S.A.E.) Free Zone, a company


NOMINATED whose administrative office is situated at 2 C. El Morshedy St. from El Laselky St.
SUBCONTRACTOR New Maadi Cairo, 11431 Egypt (A.R.E.)

CONTRACT The contract signed between CONTRACTOR and NOMINATED


SUBCONTRACTOR created by the execution of the CONTRACT DOCUMENTS for
carrying out the activities for the PROJECT and any amendments, supplements and
alterations thereto in writing signed by the PARTIES.
CONTRACT Means the FORM OF AGREEMENT and documents listed therein as forming the
DOCUMENTS CONTRACT and any amendments, supplements and alterations thereto.
PROJECT Baltim South West Development

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2.2 Abbreviations

CS Carbon Steel

ID Inner Diameter

ITP Inspection and Test Plan

MPI / MT Magnetic Particle Testing / Magnetic Testing

MUT Manual Ultrasonic Testing

NDT Non-Destructive Testing

OD Outer Diameter

UT Ultrasonic Testing

VT Visual Testing

WPQT Welding Procedure Qualification Test

WT (or t) Wall Thickness

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3.0 LIST OF REFERENCED DOCUMENTS

3.1 COMPANY Documents

Ref CPY Document No. Rev. Document Title


Specification for Onshore/Offshore Carbon Steel
[1] 193116BXST00933 00
Pipelines Welding
[2] 20413.SLI.OFF.FUN 04 Welding of Offshore Pipelines

3.2 CONTRACTOR Documents

Ref CTR Document No. CPY Document No. Rev. Document Title
Last
[3] 277497-SAI-NDT-PRO-031 193602CS-QR-OP-031 PMS12 – Baltim – VT procedure
rev.
Last
[4] 277497-SAI-NDT-PRO-034 193602CS-QR-OP-032 PMS12 – Baltim – MT procedure
rev.
Last PMS12 – Baltim – Automated
[5] 277497-SAI-NDT-PRO-033 193602CS-QR-OP-033
rev. UT procedure
Calibration of non-destructive
[6] WI-SPA-ENG-WELD-024-E NA 01
testing equipment
Site manual ultrasonic
[7] WI-SPA-WELD-023-E NA 01
equipment verification procedure

3.3 Industry Codes & Standards

Ref Document No. Rev. Document Title


[8] DNV OS-F101 2013 Submarine Pipeline System

[9] DNV Classification Notes no.7 2012 Non destructive Testing

Petroleum and natural gas industries -


[10] ISO 3183 2012 Steel pipe for pipeline transportation
systems
Non-destructive testing-qualification and certification of
[11] EN ISO 9712 2012
NDT personnel- general principles
Non-destructive testing of welds - Ultrasonic testing –
[12] ISO 17640 2010
Techniques, testing levels, and assessment
Non-destructive testing - Ultrasonic testing -
[13] ISO 2400 2012 Specification for calibration block No. 1
Non-destructive testing - Ultrasonic testing -
[14] ISO 7963 2006 Specification for calibration block No. 2

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4.0 PURPOSE OF THE DOCUMENT


This document describes the methods, techniques, equipment, personnel requirements and all other details
to carry out manual ultrasonic testing on girth welds for Baltim project. This procedure is applicable during
welding procedure qualification testing and production stages of the project.

When required, manual ultrasonic testing is performed on girth welds related to the following applications:

Table 1 - MUT CS pipeline Scope of Work

Application Steel Grade OD (in.) WT (mm)

26” line Carbon Steel 26 17.5

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5.0 EXTENT OF MANUAL ULTRASONIC TESTING


5.1 Qualification stage
Extent of MUT during qualification stage is recalled below:

 Inspection of welds for onshore prefabrication WPQT (automatic welds between pipe and forged
materials): 100% of the weld circumference.
 Inspection of repaired welds for all WPQT for CS pipeline scope fo work.
 If AUT calibration block is not ready, MUT may be carried on WPQT welds instead of AUT
(automatic and manual welds): 100% of the weld circumference.

5.2 Production stage


Extent of MUT during production stage is recalled below:

 Repaired welds:
MUT shall be performed on repaired weld, when a new indication is detected by AUT (TOFD) (after
excavation and repair activity) and over the repaired area only. Any detected flaw in the repaired
area shall be sentenced by MUT acceptance criteria.
 Lamination check:
In case of cut-out of pipe exceeding 100mm (including re-bevelling), lamination check shall be
performed over 100mm from the new bevel.
 Wall thickness check:
After grinding of pipe body, wall thickness check of ground area shall be performed.

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6.0 PERSONNEL REQUIREMENTS


Manual Ultrasonic Testing shall be performed and results evaluated by personnel qualified and certified at
least level II in UT in accordance with EN ISO 9712.

This procedure is reviewed and approved by personnel qualified level 3 in UT according to ISO 9712.
Certificate of the level 3 approver is given in attachment 2.

7.0 SAFETY
Work shall be carried out using safe working practices in accordance with statutory and local requirements
and Company’s applicable safety standards.

8.0 TEST METHOD


Manual ultrasonic testing described in this document is based on the methodology given in ISO 17640 (Ref.
[12]), DNV classification notes no.7 (Ref. [9]) and considering additional requirements of DNV-OS-F101 (Ref.
[8]) / Appendix D / section B.300.

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9.0 EQUIPMENT AND CONSUMABLES


9.1 Ultrasonic flaw detector
Ultrasonic Testing shall be performed using a digital ultrasonic pulse echo system, using an A-Scan
presentation and capable of operations at frequencies between 1 to 6 MHz. It shall have a calibrated gain
regulator with maximum 2 dB per step over a range of at least 60 dB. The flaw detector shall be able to
clearly distinguish echoes with amplitudes of 5% of FSH.

9.2 Probes
Characteristics of the probes to be used are given below.

 Longitudinal Wave Straight Beam Probes


 0° incidence angle (LW) single or twin crystal
 Typical diameter between 6 and 12 mm
 Nominal frequency between 2 and 5 MHz

 Shear Wave Angle Beam Probes


 One of each nominal angle 45°, 60° and 70° (SW) – to be chosen as per section 11.2.
 Nominal frequency between 2 and 5 MHz
 Oscillating element shall be square in shape with dimensions between 6 and 12 mm.

9.3 Coupling mean


A couplant shall be used between the transducer (search unit) and the material under inspection in order to
have a good ultrasonic “penetration”. This couplant shall be either ultrasonic coupling gel or a solution of
water and cellulosic paste.

The same couplant shall be used during calibration and inspection.

9.4 Calibration blocks


9.4.1 IIW block type V1
IIW block V1 (or calibration block No. 1 according to ISO 2400) shall be used to verify the emission point of
the ultrasonic beam, the probe angle, beam spread and equipment linearity. This block can also be used for
time base calibration.

9.4.2 IIW block type V2


IIW block V2 (or calibration block No. 2 according to ISO 7963) shall be used to verify the emission point of
the ultrasonic beam and for time base calibration. It is used at site when IIW V1 block cannot be used
because of its weight and bulk.

9.4.3 DAC calibration blocks


DAC blocks shall be used for sensitivity calibration for the inspection of weld.

DAC blocks are manufactured from project materials (pipe or forgings), in order to cover all MUT scope of
work given in Erreur ! Source du renvoi introuvable.. They contain 3 (three) 3.0 mm SDHs located at ¼ ,
½ and ¾ of the block WT (as required in section B.315 and Table D-1 of DNV-OS-F101 / Appendix D).

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For each application from the MUT scope of work, drawing of the specific DAC blocks are prepared.

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ULTRASONIC EQUIPMENT VERIFICATION


9.5 Flaw detector calibration
9.5.1 Calibration certificate
The equipment shall have valid calibration certificate according to a recognized standard (EN 12268 or
ASME V), dating from less than 12 months.

9.5.2 Calibration verification


Verification of Screen Height Linearity and Amplitude Linearity shall be performed in compliance to WI-SPA-
WELD-023-E rev.01 (ref. [7]) at the beginning of each period of extended use (or every 3 months).

If any of the above verification fails, the instrument shall be sent to the manufacturer or to a qualified lab for
corrective action.

9.6 Probes verification


9.6.1 Probe index point verification
Verification of the index point of angle beam probes shall be performed at least every 8 hours of use.

The probe examined shall be positioned on the V1 block and shall project its beam towards the curve
R = 100 mm of the calibration block. The position of the probe corresponding to the maximum echo
displayed on the screen shall be the index point (beam emission point) for the probe.

9.6.2 Probe beam angle verification


Verification of the beam angle of angle beam probes shall be performed at least every 8 hours of use.

The response from the convex surface of the 50 mm diameter cut-out in the V1 block shall be obtained and
the signal shall be maximized. The angle marked on the block coinciding with the beam emission point
marked on the probe shall be the probe angle for the selected probe.

The deviation from the nominal angle shall be within ± 2°.

9.7 Physical state and external aspects


The ultrasonic instruments, probes, cables and calibration blocks which show visual damages or defects that
may cause variations in signals shall be replaced. Carrying out the inspection using damaged components is
not allowed.

Equipment shall be checked every day it is used.

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10.0 SENSITIVITY CALIBRATION

10.1 Inspection of girth weld

For the inspection of girth weld, sensitivity calibration is performed by drawing a DAC curve using the
relevant DAC block (see section 9.4.3). DAC curve (Distance Amplitude Correction curve) is constructed to
compensate the decreasing signal amplitude received from a reflector when its distance from the probe
increases.

The DAC is based on the construction of a 3 points reference level derived from the responses of 3 reflectors
(SDH of 3.0 mm diameter).

The echo reflected from the first SDH in the reference block is maximised and the gain control regulated so
that the echo amplitude is 80% FSH. This gain setting is called the primary gain and is to be noted. Without
altering the primary gain, the probe is positioned in order to maximize the echo from the second and, then,
the third SDH. The respective echo amplitudes are marked on the screen. A line drawn through these peaks
represents the amplitude expected from a reflector of the same size at any distance from the probe.

Curves representing 33% (DAC -10dB) and 50% (DAC -6dB) of the reference sensitivity DAC curve have
also to be constructed.

Figure 1 - DAC curve

Range scale shall be adjusted to cover the specific acoustic path defined in the DAC curve settings.

DAC shall be verified once per shift using the relevant DAC block.

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If deviation is found above 2% of range scale or above 4dB of primary gain setting the examinations carried
out with the equipment over the previous period shall be repeated

10.2 Transfer correction

Any possible difference in attenuation and surface condition between the reference block and the area to be
tested shall be checked by the transfer correction . Two angle probes of the same type as those to be
employed during the testing are to be utilized . One of the probes is to be worked as transmitter, whilst the
other acts as receiver. The first echo is maximised and it is adjusted to reach DAC curve with the aid of the
gain control. Without altering the gain setting the probes are moved to the reference block and the echo is
adjusted to reach DAC curve.

If the differences of the two gain settings are less than 2dB, correction is not required. If differences are
greater than 2dB, but smaller than 12 dB, the transfer correction shall be compensated. If transfer losses
exceed 12 dB, the reason shall be investigated and further preparation of the scanning surfaces shall be
carried out (if applicable).

Figure 2 - Transfer Correction – Direction and Extent of scanning

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11.0 TEST EXECUTION

11.1 Surface conditions

The surface to be examined shall be clean, dry, and free of rust, paint and other coating, oil, grease, water,
welding flux or any other impediments that could cause an improper scanning of the probe or a bad contact
between the probe and the material under examination.

11.2 Inspection of girth weld

When required as per section 5.0, inspection of girth weld shall be performed according to ISO 17640, with
testing level B, and Appendix D / section B.300 of DNV-OS-F101.

The whole volume of the weld and heat affected zones shall be scanned.

Weld inspection will be performed using at least 2 probe angles. The following angle probes are
recommended to be employed :

 45° and 60° or 70° for WT > 15 mm

Sensitivity calibration shall be performed according to section 10.1. Inspection for longitudinal indication shall
be performed positioning the probes in positions A or B as per Figure 3. Inspection for transverse indication
shall be performed positioning the probes in positions (X and Y) or (W and Z) as per Figure 3.

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Figure 3 - Weld examination

During the scanning the primary gain will be increased by 6 dB in order to increase the sensitivity to flaws
with a difficult orientation. However, the gain shall be reduced to the primary reference level when the flaw
evaluation is carried out.

The examination shall be carried out by moving the search unit over the examination surface so as to scan
the entire volume of the weld. Each pass of the search unit shall overlap a minimum of 10% of the transducer
dimension perpendicular to the direction of the scan. Maximum probe velocity shall not exceed 150mm/sec.

11.3 Lamination check

As per section 5.0, if more than 100mm, including re-bevelling, is removed from pipe end, a lamination check
has to be done. In this case, lamination check shall be performed over 100mm from the new pipe end.

The inspection shall be performed using straight beam probe, calibrated on the backwall echo of the DAC
block. Each pass of the search unit shall overlap a minimum of 10% of the transducer dimension
perpendicular to the direction of the scan. Maximum probe velocity shall not exceed 150mm/sec.

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11.4 Wall thickness check

After grinding, wall thickness check shall be performed to verify that the thickness of the ground area
remains above the minimum acceptable value.

Wall Thickness shall be measured between two back wall echoes.

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12.0 EVALUATION OF INDICATIONS

12.1 Inspection of girth weld

Evaluation of indication shall be performed at primary gain.

All indications having signal amplitude more than 33% of the DAC shall be investigated to find the nature and
orientation of the discontinuity. This can be assessed by the responses of the reflector to the sound beam
using different probe angles and also by the lateral and transverse manipulation of the probe. It will be
permissible to use a higher amplification level (dB) for this investigation.

This procedure classifies discontinuities detected by ultrasonic testing into three groups, namely, linear,
volumetric and transverse discontinuities. Linear discontinuities are incomplete fusion/penetration, elongated
slag inclusion, copper inclusion, cracks, undercutting adjacent to cover pass or root pass and hollow bead
porosity. Volumetric discontinuities are voids, pores, single or multiple inclusions, internal concavity and
cluster porosity. A transverse discontinuity has its greater dimension across the weld. It will be adequate to
classify and record the discontinuities as linear, volumetric or transverse.

For all indications having signal amplitude more than 33% of the DAC, the length of the indication (in the
circumferential direction of the pipe/forging) shall be evaluated between the points where the echo exceeds
33% of the DAC.

Then, indications shall be confronted to the acceptance criteria based on their nature, their maximum echo
amplitude and their length (if applicable).

In the report, the length of acceptable indications with amplitude exceeding 50% of the reference curve shall
be included.

12.2 Lamination check

Any discontinuities causing a reflection exceeding 50% of the reference level and accompanied by a 50%
loss in amplitude of the back wall echo shall be evaluated.

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13.0 ACCEPTANCE CRITERIA

13.1 Acceptance criteria for weld inspection


Acceptance Criteria for inspection of welds, both during qualification and production stages, shall be in
accordance with Table D-6 of DNV-OS-F101 (Ref.[8]). They are reported in Table 2 here-below:

Table 2 - Acceptance criteria for weld inspection

Base Material Thickness 15 mm ≤ WT ≤ 150 mm

Max. echo amplitude Corresponding acceptable indication length, L (mm)

DAC + 4 dB L ≤ 0.5 WT (but max. 12.5 mm)


DAC - 2 dB 0.5 WT < L ≤ WT (but max. 25 mm)
DAC - 6 dB L > WT (but max. 25 mm in both outer t/3)
DAC - 6 dB L > WT (but max. 50 mm in middle t/3)

Cracks are not permitted

Transverse indications: Indications shall be considered transverse if the echo amplitude


transversely exceeds the echo amplitude from the same indication longitudinally with more than
2 dB. Transverse indications are unacceptable unless proven not to be planar, in which case
the acceptance criteria for longitudinal indications apply.

The total length of acceptable indications with echo amplitude of DAC – 2 dB and above shall
not exceed 3 t, maximum 100 mm in any weld length of 300 mm, not more than 12% of weld
length. Any accumulation of defects in any cross section of weld that may constitute a leak path
or reduce the effective thickness of weld more than t/3 is not acceptable.

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13.2 Acceptance criteria for lamination check


Acceptance criteria for lamination check at pipe ends, both during qualification and production stages, shall
be in accordance with specification ISO 3183 (Ref. [10]) annex K, section K.2.1.1. They are reported here-
below:

No indications longer than 6.4 mm in the circumferential direction and having an area greater than 100 mm²
are permitted.

13.3 Acceptance criteria for wall thickness check


Acceptance criteria for wall thicknesses variation for each application given in Erreur ! Source du renvoi
introuvable. are specified in the documentation relevant to each application.

Table 3 summarizes the minimum and maximum allowable wall thicknesses for each application.

Table 3 - Wall thickness tolerances

Minimum Maximum
WT nominal
Application Tolerance criteria allowable allowable WT
(mm)
WT (mm) (mm)
As per Table J.4 of ref.[10]:
26” line 17.5 16.5 18.5
±1mm

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14.0 REPORTING
MUT reports that clearly identify the work areas tested and their location shall be submitted by the operator
at the time of inspection. These reports (together with any relevant sketches and/or drawings for clarification
where needed) shall be submitted to include the following information:

 Name of the company and operator carrying out the testing including certification of the operator
 Object and drawing references
 Place and date of testing
 Material type and dimensions
 Post weld heat treatment, if required
 Location of examined areas, type of joint
 Welding process used
 Surface conditions
 Temperature of the object
 Number of repairs if specific area repaired twice or more
 Contract requirements e.g. order no., specifications, special agreements etc.
 Sketch showing location and information regarding detected defects
 Extent of testing
 Test equipment used
 Description of the parameters used for each method
 Description and location of all recordable indications
 Testing results with reference to acceptance level
 Other information related to the specific method may be listed under each method

MUT report form is given in ATTACHMENT 1 – MUT REPORT FORM.

This document is property of Petrobel.


It shall neither be shown to Third Parties nor used for purposes other than those for which it has been sent.
Internal 277497-SAI-NDT-PRO-034
Document Number:

Client
PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034

Revision: 00 Status :

Contractor Project : 277497 - BALTIM PROJECT Page 23 of 24

ATTACHMENT 1 – MUT REPORT FORM

This document is property of Petrobel.


It shall neither be shown to Third Parties nor used for purposes other than those for which it has been sent.
Internal 277497-SAI-NDT-PRO-034
Document Number:

Client
PMS12 – BALTIM – MANUAL UT PROCEDURE Document Number
193602CSQROP034

Revision: 00 Status :

Contractor Project : 277497 - BALTIM PROJECT Page 24 of 24

ATTACHMENT 2 – PROCEDURE APPROVER CERTIFICATE

This document is property of Petrobel.


It shall neither be shown to Third Parties nor used for purposes other than those for which it has been sent.

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