TECHNIQUE INSPECTION & CONTROLE s.a.

Quality Control Plan

Applicable Standards:
ASME VIII: Division 1, Rules for Construction of Pressure Vessels API 571 Damage Mechanisms Affecting Fixed Equipment in the Refining Industry API 572 Inspection of Pressure Vessels API 576 Inspection of Pressure-Relieving Devices API 577 Welding Inspection and Metallurgy API 578 Material Verification Program for New and Existing Alloy Piping Systems API 579 Fitness-For-Service API 580 Risk-Based Inspection API 510 Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair, and Alteration ASME V: Non Destructive Examination ASME IX: Welding and Brazing Qualifications API 661: Air-Cooled Heat Exchangers for General Refinery Service API 1104 Welding of Pipelines and Related Facilities ASME B31 Process Piping. API 6 D Specification for Pipeline Valves 3-2006 ISO 3183-3 Petroleum and natural gas industries Steel pipe for pipelines-Technical delivery conditions

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API 510: Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair, and Alteration. API 570: Piping Inspection Code: Inspection, Repair, Alteration, and Rerating of In-service Piping Systems. ASME B31-3: Process Piping. IEC 947 (1 to 4) : For electrical equipment IEEE Std C37.20.2-1993 for Metal-Clad and Station-Type Cubicle Switchgear ANSI/IEEE 576-1989: IEEE Recommended Practice for Installation, Termination, and Testing of Insulated Power Cable as Used in the Petroleum and Chemical Industry IEEE Std 1159-1995 Recommended Practice for Monitoring Electric Power Quality IEEE C62.92.2 IEEE Guide for the Application of Neutral Grounding in Electrical Utility Systems Part IIGrounding of Synchronous Generator Systems IEEE Std C62.92.1 IEEE Guide for the Application of Neutral Grounding in Electrical Utility SystemsPart I: Introduction IEEE Std C62.92.3 IEEE Guide for the Application of Neutral Grounding in Electrical Utility Systems, Part IIIGenerator Auxiliary Systems IEEE C62.92.4 IEEE Guide for the Application of Neutral Grounding in Electrical Utility Systems, Part IVDistribution IEEE Std C62.92.5 : IEEE Guide for the Application of Neutral Grounding in Electrical Utility Systems, Part VTransmission Systems and Sub transmission Systems LOLER 98 BS EN 12077-2 Cranes safety-Requirements for health and safety-Part 2: Limiting and indicating devices BS EN 12644 Crane - Information for use and testing-Part 2: Marking BS IS0 5057 Industrial trucks Inspection and repair of fork arms in service on fork-lift trucks
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TECHNIQUE INSPECTION & CONTROLE s.a.
BS4278: Eyebolts for lifting purposes BS 6994:1988 : Specification for Steel shackles for lifting and general engineering purposes: grade M(4) BS EN13411-1:2002 : Terminations for steel wire ropes Safety Part 1: Thimbles for steel wire rope slings BS EN 13411-2:2001: Terminations for steel wire ropes Safety Part 2: Splicing of eyes for wire rope slings BS EN 13411-4:2002: Terminations for steel wire ropes Safety Part 4: Metal and resin Socketing BS 6570: 1986: The selection, care and maintenance of steel wire ropes BS7035:1989: Socketing of stranded steel wire ropes

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TECHNIQUE INSPECTION & CONTROLE s.a.

I- Pressure vessels in factory :

N Activity Inspection / Test Applicable standards Qualification Equipment Procedure Records

Review and approve the technical calculation, data sheets, drawings and design data. Review Material List and certificates to pressure vessel drawings. Review manufacturer Welding Procedure Specifications (W.P.S.) and Procedure Qualification Record (P.Q.R.) for the materials of construction. Review manufacturer proposed level and extent of Non Destructive Examination (N.D.E.) Review manufacturer procedure for post weld heat treatment (if applicable). Review manufacturer pressure test procedure.
Design code

Document Review and

An engineer

NA

approve

PQ/CRSAPP/02 AG

FQ/CRS-APP/02 AG

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Activity Inspection / Test Applicable standards Qualification Equipment Procedure
Manufacture rs

Records

Visual inspection according to approved and as built drawings. Dimensional check Internal and external inspection
Design code A qualified inspector

Preliminary inspections

Meter, clamps meter & Depth gauge

procedures RQ/CRS-APP/04 PQ/RSCCV/01AG

PQ/RSCCV/01 AG

Manufacture s procedure PQ/CRSAPG/01 AG

Attend and witness the test pressure: Make sure that the equipment withstands the

PQ/CRSEHV/01 AG Design code An authorised pressure vessel inspector Calibrated manometer RQ/CRS-APP/04 CE/CRS-APP/04

Pressure Test:

hydrostatic test without leakage through the weld seam or the vessel body.

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Activity Inspection / Test Applicable standards Qualification Equipment Procedure Records

Ensure that each pressure vessel has a permanently attached nameplate showing at least:

The name of the manufacturer The manufacturers location

4 Die stamping and marking:

The manufacturer's serial number

identifying the vessel

Manufactures procedure Design code

The year built The internal volume The hydraulic test pressure; The date of test; Any statutory marking required
Affix the T.I.C. stamp on the accepted vessel

An authorised pressure vessel inspector

T.I.C Stamp..

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TECHNIQUE INSPECTION & CONTROLE s.a.
II- Pressure vessels on site :
N Activity Inspection / Test Applicable standards Qualification Equipment Procedure Records

Review and approve the technical calculation, data sheets, drawings and design data. Review Material List and certificates to pressure vessel drawings. Review manufacturer Welding Procedure Specifications (W.P.S.) and Procedure Qualification Record (P.Q.R.) for the materials

Document

of construction. Review manufacturer proposed level and extent of Non Destructive Examination (N.D.E.) Review manufacturer procedure for post weld heat treatment (if applicable). Review manufacturer pressure test procedure Review of the maintenance record book / Review of previous inspection reports Design code An engineer

Review and approve

NA

PQ/CRSAPP/02 AG

FQ/CRSAPP/02 AG

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Applicable standards

Activity

Inspection / Test

Qualification

Equipment

Procedure

Records

Visual inspection

Visual inspection according to approved and as built drawings. API 510

A qualified inspector

Manufacturers

NA

procedures PQ/RSCCV/01AG Manufacturers

RQ/RSC-IV/01

Dimensional check

Dimensional check of each pressure vessel according to approved and as built drawings. Check the condition of the outside surface of the vessel, insulation systems, painting and coating systems, supports, and associated structure

Design code

A qualified inspector

Meter

procedures

External inspection

API 510 & API allowance for expansion and the general 571 alignment of the vessel on its supports

Check for leakage, hot spots, vibration, the

A qualified inspector

Meter, clamps meter & Depth gauge

PQ/CRSAPG/02 AG

PQ/CRS-APG/02 AG

Particular attention should be given to welds used to attach components (e.g. reinforcement plates, and clips) for cracking or other defects.
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Applicable standards

Activity

Inspection / Test

Qualification

Equipment

Procedure

Records

Thorough check of internal pressure boundary surfaces for damage Specific N.D.E. techniques may be required by

Internal Inspection

the inspector to find damage specific to the vessel or service conditions. For equipment not designed for entrance by personnel, Boroscope check techniques may aid the check of these equipment internal surfaces. They are taken to verify the thickness of vessel
components. This data is used to determine the corrosion rates and remaining life of the vessel. The inspector should consult with a corrosion specialist when the short term corrosion rate changes significantly from the previous identified rate to determine the cause. Appropriate responses to accelerated corrosion rates may include, additional thickness readings, U.T. scans in suspect areas, corrosion/process monitoring, and revisions to the vessels inspection plan.

API 510 & API 571

Qualified inspector

meter, clamps meter, Depth gauge, Gas detector & Borescope

PQ/RSC-CV/01 AG PQ/CRS-APG/02 AG

RQ/RSC-IV/01

Wall Thickness measurement

API 510

Qualified inspector UT inspector Level II

Wall thickness measurement apparatus

PQ/RSC-ME/01 AG PQ/NDT-UT/01

RQ/RSC-ME/01 AG RQ/CND-UT/01

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Applicable standards

Activity

Inspection / Test

Qualification

Equipment

Procedure

Records

Pressure Test:

Attend and witness the pressure test . Ensure that each pressure vessel has a permanently attached nameplate showing at least:

API 510 Design code

An API510 pressure vessel inspector

Calibrated manometer

PQ/CRS-APG/01 AG PQ/CRS-EHV/01 AG

RQ/CRSAPP/04

The name of the manufacturer The manufacturers location 8

D ie stamping

The manufacturer's serial number

identifying the vessel

and marking:

The year built The internal volume The hydraulic test pressure; The date of test; Any statutory marking required
Affix the T.I.C. stamp on the accepted vessel

Manufactures procedure Design code

An API 510 pressure vessel inspector

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TECHNIQUE INSPECTION & CONTROLE s.a.
IIIN

Tubular elements in factory control :

Inspection / Test Applicable standards Qualification Equipment Procedure Records

Activity

Review and approve the technical calculation, data sheets, drawings and design data. Review Material List and certificates to pressure vessel drawings. Review manufacturer (W.P.S.) Welding and Procedure Procedure
PQ/CRS-APP/02 AG FQ/CRSAPP/02 AG

Document

Specifications

1 Review and approve

The code to Authorized Piping Inspector which the construction. tubular Review manufacturer proposed level and extent of elements were built Non Destructive Examination (N.D.E.) Qualification Record (P.Q.R.) for the materials of Review manufacturer procedure for post weld heat treatment (if applicable). Review manufacturer pressure test procedure.

NA

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Inspection / Test Applicable standards

Activity

Qualification

Equipment

Procedure

Records
RQ/CRS-CUT /

Quality control of tubular element steel

The quality control of steel used for tubes is conducted by means of samples taken from tubes, after completion of manufacturing process likely to Confirm all operations have been done as per internal mill practices and procedures Design code, client requirements

Tools inspection and PQ/CRS-CUT / Authorized Piping instrumentation 01 AG Inspector should PQ/CRS-CUT / provided by the 02 AG manufacturer

01 AG or

RQ/CRS-CUT / 02 AG

Quality control of tubular elements welding

RQ/CRS-CUT /

modify the metals properties. Values measured elongation, traction resistance and elasticity limits must fulfil provisions of the design code and be at least equal to the minimal specified values selected for the calculation of tubular elements. They must be measured on samples taken for the basic metal.

Tools Design code, inspection and PQ/CRS-CUT / Authorized Piping instrumentation 01 AG client Inspector should PQ/CRS-CUT / requirements provided by the 02 AG manufacturer

01 AG or

RQ/CRS-CUT / 02 AG

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Applicable standards

Activity

Inspection / Test

Qualification

Equipment

Procedure

Records

Each pipe shall be visually inspected to detect

Visual inspection

surface defects: Such inspection shall be over the entire external surface and shall cover as much of the internal surface as is practical. Tests pertaining to the quality of steel shall be performed on samples taken at the end of tubes

Design code, client requirements A qualified inspector

Manufacturers procedures PQ/RSCCV/01AG RQ/RSC-IV/01

RQ/CRS-CUT /

Destructive

randomly chosen by the T.I.C. from each lot of tubes made up of elements of the same characteristics, produced by the same melt Destructive Examinations related to the quality of longitudinal or spiral welds shall be performed on samples randomly chosen at the end of tubes

Examinatio n

Design code, client requirements

A qualified inspector

Tools inspection and PQ/CRS-CUT / instrumentation 01 AG should PQ/CRS-CUT / provided by the 02 AG manufacturer

01 AG or

RQ/CRS-CUT / 02 AG

Non Destructive

Design code, Inspection of pipe to reveal imperfections, using radiographic, ultrasonic or other methods that do not involve disturbance, stressing or breaking of the materials client requirements

RQ/CRS-CUT /

6 Examinatio
n

Tools inspection and PQ/CRS-CUT / A qualified instrumentation 01 AG inspector level should PQ/CRS-CUT / II provided by the 02 AG manufacturer

01 AG or RQ/CRS-CUT / 02 AG

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Applicable standards

Activity

Inspection / Test

Qualification

Equipment

Procedure

Records
RQ/CRS-CUT / 01 AG

Hydraulic test

The pipe shall withstand the hydrostatic test without Design code, leakage through the weld seam or the pipe body. client requirements

An Authorized Piping Inspector

Tools inspection and instrumentation should provided by the manufacturer Tools inspection and instrumentation should provided by the manufacturer Tools inspection and instrumentation should provided by the manufacturer Tools inspection and instrumentation should provided by the manufacturer

PQ/CRS-CUT / 01 AG PQ/CRS-CUT / 02 AG

CE/CRS-CUT / 01 AG RQ/CRS-CUT / 02 AG CE/CRS-CUT/02 AG

Control

related

to Any fitting equipment must be subject to an

individual hydraulic test

Design code, client requirements Design code, client requirements

An Authorized Piping Inspector

PQ/CRS-CUT / 01 AGor 01 AG

RQ/CRS-CUT /

the fittings Control

PQ/CRS-CUT / RQ/CRS-CUT / 02 AG 02 AG PQ/CRS-CUT / 01 AGor 01 AG

RQ/CRS-CUT /

related accessory devices Hydraulic

to

Accessory devices must be subject of in factory hydraulic tests under the same conditions of tubular elements The accessory equipment shall withstand the

An Authorized Piping Inspector

PQ/CRS-CUT / RQ/CRS-CUT / 02 AG 02 AG
RQ/CRS-CUT /

10

test accessory equipment

of hydrostatic test without leakage through the weld

seam or the body.

Design code, client requirements

Authorized Piping Inspector

PQ/CRS-CUT / 01 AGor 01 AG PQ/CRS-CUT / 02 AG 02 AG

RQ/CRS-CUT /

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Applicable standards

Activity

Inspection / Test

Qualification

Equipment

Procedure

Records

Ensure that the pipe markings includes the following information, as applicable:

Pipe markings
11 and

Name or mark of the manufacturer of the pipe Specified outside diameter; Specified wall thickness; Pipe steel grade (steel name) Product specification level designation; Type of pipe Mark of the customer's representative, if applicable; Design and code client
An Authorized Piping Inspector
PQ/CRS-CUT / 01 AG

d ie

stamping:

inspection requirements

PQ/CRS-CUT / 02 AG

An identification number, which permits the correlation of the product or delivery unit (e.g bundled pipe) with the related inspection document, if applicable.

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Applicable standards

Activity

Inspection / Test

Qualification

Equipment

Procedure

Records

Coating
12 inspection :

The pipe coating inspector shall check, the following points, but not limited to: Material coating The identification of each tube Visual inspection shall be investigated for surface imperfections, Pipe end inspection Heat treatment Control of the pipe roughness surface Control of the coating thickness Pipe final marking Coating / Painting Inspector
PQ/CRS-CUT /

specification requirements

Tools 01 AG inspection and instrumentation PQ/CRS-CUT / 02 AG should provided by the manufacturer PQ/RSCCP/01AG

RQ/RSCCP/01

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IVN

Pipeline on site :
Inspection / Test Applicable standards Qualification Equipment Procedure Records

Activity

Review and approve the technical calculation, data sheets, drawings and design data. Review Material List and certificates to pressure vessel drawings. Review manufacturer (W.P.S.) Welding and Procedure Procedure
An Authorized Piping Inspector

Document

Specifications construction.

1 Review and approve

Qualification Record (P.Q.R.) for the materials of Review manufacturer proposed level and extent of Non Destructive Examination (N.D.E.) Review manufacturer procedure for post weld heat treatment (if applicable). Review manufacturer pressure test procedure. The code to which the vessel was built

NA

PQ/CRSAPP/02 AG

FQ/CRSAPP/02 AG

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Applicable standards

Activity

Inspection / Test

Qualification

Equipment

Procedure

Records

The pipeline shall withstand a pressure test without failure, leakage, distress, or distortion other than elastic distortion at a pressure equal to the test pressure of the system in which it is installed, either before installation or during the system test.

Calibrated manometer
PQ/CRS-EHG /

Dead weight tester with accessories

01 AG PQ/CRS-EOL / 01 AG

RQ/CRSEHG/01 AG CE/CRS-EHG / 01 AG RQ/CRS-EOL / 01 AG CE/CRS-EOL / 01 AG

Pipeline hydro test

API 570

An Authorized Piping Inspector

Pressure recorder, Temperature gauge.

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V- Electrical equipments:
N Activity Inspection / Test Applicable standards Qualification Equipment Procedure Records

Visual & general checks Insulation Measurement. Bonding Measurement Earth connection Measurement Infrared testing ANSI/IEEE Standards listed above
A qualified inspector

Electrical tester Megohmmeter Voltage detector Clip-on ammeter Infrared Camera

PQ/CRS-IE/01 AG PQ/CRS-IE/02 AG PQ/RSC-TIT/01 AG

Safety inspection &

testing of electrical equipments

RQ/CRSIE/01 RQ/CRS-IE /02

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VIN

Lifting devices:
Inspection / Test Applicable standards Qualification Equipment Procedure Records

Activity

Visual inspection of the characteristics of the different equipments, and determination of their conformities with specified requirements where applicable, and based on professional judgement where general requirements apply

Safety inspection &

Dimensional check to show that the equipment has

Dynamometer Magnetic
PQ/CRS-LE/01 PQ/CRS-LE/02 PQ/CRS-LE/03 PQ/CRS-LE/04 RQ/CRS-LE/01 RQ/CRS-LE/02 RQ/CRS-LE/03 RQ/CRS-LE/04

1 testing lifting

of

LOLER & British abnormality that would render it incapable of standards listed being used safely for its designed purpose. above
which should be examined by Magnetic Particle Inspection (M.P.I.) Functional tests related to the safety organs Functional tests an d overload tests

neither

permanent

deformation,

nor

Qualified inspector

indicator Magnetic yoke

equipments Non-destructive examination of lifting equipment

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