Rf.

PERU LNG EXPORT PROJECT

MARINE FACILITIES EPC CONTRACT

Date:

03-Mar-08

INSPECTION AND TESTING PLAN

Rev.:

05

F12254

CDB

W03

QUA

ITP

60053

Job code

Origin

Unit Code

Discipline

Doc Type

Sequential

Page: 1/7

A SCOPE
ISSUER:
(CONTRACTOR,SUBCONTRACTOR)

PROJECT :
WORKPACKAGE:

CDB Melchorita

Purchase Order or
Subcontract Numb:

N/A

Peru LNG Export Project

Marine Facilities EPC Contract

Works Designation:

Piles Prefabrication-Welding

Works Start Date:

15 May 2007 (Estimated)

W03 Trestle & Associated Works

Mechanical Completion
Date:
Disciplines Concerned:

Dec 2008 (Estimated)

WEL - WELDING

B INSPECTION CODING SYSTEM

ITP Standard Coding System are defined in appendix B of the F12254-CDB-W01-QUA-PLA-00205 Project Construction Quality Control Plan
It recalled here in footer of each page

C VALIDATION

02

Approved for Construction - Modifying Attendance on Hold for

Joint Fit-up of welds.
Approved for Construction Including Owners comments and
ITRs
Approved for Construction - Modifying Attendance on Hold for
Joint Fit-up of welds.
Approved for Construction-Including specific straightness
requirements on fabricated piles and a new ITR for straightness
report. It also includes an explanatory graphic for welding repairs
location.
Approved for Construction

18-Jul-07

01

23-Apr-07

0A

Date

Rv.

03-Mar-08

06

12-Dec-07

05

27-Nov-07

04

23-Oct-07

03

06-Sep-07

N/A

VJU

PCO

TBA

PLNG

N/A

VJU

PCO

TBA

PLNG

N/A

VJU

PCO

TBA

PLNG

N/A

VJU

PCO

TBA

PLNG

N/A

VJU

PCO

TBA

PLNG

Approved for Construction

N/A

VJU

PCO

TBA

PLNG

Issue for review

N/A

VJU

PCO

TBA

PLNG

SUB CRT

CONS - CDB

QC - CDB

TPart

OWN

Revision

Rf.

PERU LNG EXPORT PROJECT

MARINE FACILITIES EPC CONTRACT

Date:

03-Mar-08

INSPECTION AND TESTING PLAN

Rev.:

05

F12254

CDB

W03

QUA

ITP

60053

Job code

Origin

Unit Code

Discipline

Doc Type

Sequential

Page: 2/7

D APPLICABLES CODES, STANDARDS, SPECIFICATIONS

OWNER Specfications:
o CONTRACT LNG-P/05-0005 Peru LNG Export Project / Marine Facilities EPC Contract

Applicables Codes
o AWS D1.1/D1.1 M : 2006 Structural Welding Code Steel
o ASTM E709-01 Standard Guide for Magnetic Particle Examination
o ASTM E165-02 Standard Test Method for Liquid Penetrant Examination
o API RP 2A-WSD Recommended Practice for Planning, Designing and Constructing Fixed Offshore Platforms-Working Stress Design

CONTRACTOR Method Statements, Specifications and procedures

o F12254-CDB-W03-MET-MST-20032 Piles Prefabrication Method Statement
o F12254-CDB-W01-QUA-PRO-10048 Site Welding Procedure
o F12254-CDB-W01-QUA-PRO-00220 Welding Visual Inspection
o F12254-CDB-W01-QUA-PRO-00221 Magnetic Particle Examination
o F12254-CDB-W01-QUA-PRO-00222 Liquid Penetrant Examination
o F12254-CDB-W01-QUA-PRO-00224 Ultrasonic Examination
o F12254-CDB-W01-QUA-PRO-00225 Qualification of NDT personnel
o F12254-CDB-W01-QUA-PRO-00226 Control of Inspection, Measuring & testing Equipment
o F12254-CDB-W01-WEL-PRO-10053 Welding book for Piles Prefabrication

Rf.

PROCESS

PERU LNG EXPORT PROJECT

MARINE FACILITIES EPC CONTRACT

Date:

03-Mar-08

INSPECTION AND TESTING PLAN

Rev.:

05

F12254

CDB

W03

QUA

ITP

60053

Job code

Origin

Unit Code

Discipline

Doc Type

Sequential

INSPECTION, CHECK AND TEST

Page: 3/7

RECORDS

RESPONSIBILITIES (ii)
EXE

Activities

Subject

Means or procedure (i)

(i)

Pre-conditions
Approval of Documents

o Welding Book for Piles Prefabrication

Job Safety Analysis

NDT Procedures

to be proposed by EXE and approved by CTR unless otherwise specified

As per
F12254-CDB-W01-DCO-PRO-00004
Document Control Procedure
As per
F12254-CDB-W01-DCO-PRO-00004
Document Control Procedure
Job Safety sent to OWNER
As per
F12254-CDB-W01-DCO-PRO-00004
Document Control Procedure

o Piles Prefabrication Method Statement

Acceptance criteria (i)

Document Status :
Approved for Construction (AFC)
Document Status :
Approved for Construction (AFC)
Approved by OWNER
Document Status :
Approved for Construction (AFC)

Or type of document to supply

(ii)

SUB
CTR

CONS
CDB

QC
CDB

Thd
PART

OWN

according to the Quality Control Construction Plan.

F12254-CDB-W03-MET-MST-20032

F12254-CDB-W01-WEL-PRO-10053
Job Safety Analysis
F12254-CDB-W01-QUA-PRO-00220
F12254-CDB-W01-QUA-PRO-00221
F12254-CDB-W01-QUA-PRO-00224

Check the qualification of personnel

o Qualifications of welders and welding operators

Document verification

o Qualifications of NDT personnel

Document verification

As per F12254-CDB-W01-WEL-PRO10053- Welding book for Piles

Prefabrication
As per
F12254-CDB-W01-QUA-PRO-00225
Qualification NDT personnel

Welding Performance Qualification

Records
NDT Personnel Qualification Records

Calibration Certificates

Calibration Certificates

Calibration Certificates

Calibration Certificates

Equipment and tools check:

o Visual welding inspection gauges

Document verification

o Liquid penetrant examination Equipments , accessories and

consumables

Document verification

o Magnetic particle examination Equipments , accessories and

consumables

Document verification

o Ultrasonic examination Equipments , accessories and consumables

Document verification

As per
F12254-CDB-W01-QUA-PRO-00226
Control of Inspection, Measuring &
Testing Equipment
As per
F12254-CDB-W01-QUA-PRO-00226
Control of Inspection, Measuring &
Testing Equipment
As per
F12254-CDB-W01-QUA-PRO-00226
Control of Inspection, Measuring &
Testing Equipment
As per
F12254-CDB-W01-QUA-PRO-00226
Control of Inspection, Measuring &
Testing Equipment

Safety
Involvement code
E
R
S
A
W
H

Name

Execution
Review
Surveillance
Acceptance
Witnessing
Validation (Hold point)
Other mentions :

Implementation to the organization involved in the case of documents

Implementation to the organization involved in the case of works

The organization involved issues the document.

The organization involved performs the inspection or checks and issues the relevant ITRs.
The organization involved performs and formalizes a review of relevant documents and/or quality records.
N/A
N/A
The organization involved watches (supervise) the inspection, control or test.
Formal acceptance in writing of the inspection(s) or test(s) performed is required.
N/A
Witnessing organization must be notified within the contractually agreed time scale; its non attendance shall not delay the inspection or check being carried out by the performing organization.
The organization involved must approve the document, prior to the execution of the corresponding works.
Operations are not allowed to proceed beyond this point until inspected and approved without non-conformities
(*) means through survey or through sampling
EXE is in charge of performing works and controls. It can be SCT, VDR or CTR (refer to CQCP)

Rf.

PROCESS

PERU LNG EXPORT PROJECT

MARINE FACILITIES EPC CONTRACT

Date:

03-Mar-08

INSPECTION AND TESTING PLAN

Rev.:

05

F12254

CDB

W03

QUA

ITP

60053

Job code

Origin

Unit Code

Discipline

Doc Type

Sequential

INSPECTION, CHECK AND TEST

Page: 4/7

RECORDS

RESPONSIBILITIES (ii)
EXE

Activities

Subject

HSE Training

Safety Task Analysis Risk Reduction Talk

Means or procedure (i)

HSE Training performed
STARRT performed

Material
Site material verification
o Material Certificate and Heat Number
o Pipe identification, Verify pipe serial number and dimension (length,
diameter and thickness)
o Verify proper supplies and quantity

Acceptance criteria (i)

As per
F12254-CDB-W01-HSE-PLA-00131
As per
F12254-CDB-W01-HSE-PRO-00134

Visual Inspection

o Welding consumables (wire for FCAW-G , wire and flux for SAW )
batch number, monitoring, storage conditions and cleanliness

Visual Inspection

o Welding shielding gas (for FCAW-G) batch number and storage

conditions.

Visual Inspection

As per F12254-CDB-W01-WEL-PRO10053- Welding book for Piles

Prefabrication
As per F12254-CDB-W01-WEL-PRO10053 - Welding book for Piles
Prefabrication

Or type of document to supply

SUB
CTR

CONS
CDB

QC
CDB

Thd
PART

OWN

Attendees Sheet

Start form

Piles Prefabrication Butt weld report

ITR
F12254-CDB-W03-QUA-ITP-60053 //
003
Welding Consumables Report ITR
F12254-CDB-W03-QUA-ITP-60053 //
002
Welding Consumables report ITR
F12254-CDB-W03-QUA-ITP-60053 //
002

Works
PIPE PRIOR TO WELDING
o Pipe thermal cutting for beveling ( Verify angle and edge alignment )

Visual Inspection

AWS D1.1/D1.1 M Structural Welding

Code Steel 5.15.4.3

o Cleanliness of pipe: internal & external inspection

Visual Inspection

As per F12254-CDB-W01-WEL-PRO10053 - Welding book for Piles

Prefabrication

o Pipe orientation marking (To keep the vertical reference)

Visual Inspection

o Bevel surface inspection

Visual Inspection

As per F12254-CDB-W01-WEL-PRO10053- Welding book for Piles

Prefabrication &
AWS D1.1/D1.1 M Structural Welding
Code Steel 5.15

Piles Prefabrication Butt weld report

ITR
F12254-CDB-W03-QUA-ITP-60053 //
003
Piles Prefabrication Butt weld report
ITR
F12254-CDB-W03-QUA-ITP-60053 //
003
Piles Prefabrication Butt weld report
ITR
F12254-CDB-W03-QUA-ITP-60053 //
003
Piles Prefabrication Butt weld report
ITR
F12254-CDB-W03-QUA-ITP-60053 //
003

WELDING OF PIPE
Involvement code
E
R
S
A
W
H

Name

Execution
Review
Surveillance
Acceptance
Witnessing
Validation (Hold point)
Other mentions :

Implementation to the organization involved in the case of documents

Implementation to the organization involved in the case of works

The organization involved issues the document.

The organization involved performs the inspection or checks and issues the relevant ITRs.
The organization involved performs and formalizes a review of relevant documents and/or quality records.
N/A
N/A
The organization involved watches (supervise) the inspection, control or test.
Formal acceptance in writing of the inspection(s) or test(s) performed is required.
N/A
Witnessing organization must be notified within the contractually agreed time scale; its non attendance shall not delay the inspection or check being carried out by the performing organization.
The organization involved must approve the document, prior to the execution of the corresponding works.
Operations are not allowed to proceed beyond this point until inspected and approved without non-conformities
(*) means through survey or through sampling
EXE is in charge of performing works and controls. It can be SCT, VDR or CTR (refer to CQCP)

Rf.

PROCESS

PERU LNG EXPORT PROJECT

MARINE FACILITIES EPC CONTRACT

Date:

03-Mar-08

INSPECTION AND TESTING PLAN

Rev.:

05

F12254

CDB

W03

QUA

ITP

60053

Job code

Origin

Unit Code

Discipline

Doc Type

Sequential

INSPECTION, CHECK AND TEST

Page: 5/7

RECORDS

RESPONSIBILITIES (ii)
EXE

Activities

Subject

Means or procedure (i)

Acceptance criteria (i)

o Backing ring internal tack welding

Visual Inspection

As per F12254-CDB-W01-WEL-PRO10053- Welding book for Piles

Prefabrication

o Fit-up pipe ( root opening)

Visual Inspection

As per F12254-CDB-W01-WEL-PRO10053- Welding book for Piles

Prefabrication

o Backing ring external welding (inside the groove)

Visual Inspection

As per F12254-CDB-W01-WEL-PRO10053- Welding book for Piles

Prefabrication

o Welding of pipe

Visual Inspection

As per F12254-CDB-W01-WEL-PRO10053- Welding book for Piles

Prefabrication

o Visual inspection (Verify Preheating and Interpass temperature

control)

o Magnetic Particle Examination

o Ultrasonic Examination

o IF REQUIRED: Repair welding

Involvement code
E
R
S
A
W
H

Name

Execution
Review
Surveillance
Acceptance
Witnessing
Validation (Hold point)
Other mentions :

F12254-CDB-W01-QUA-PRO-00220
Welding Visual Inspection

F12254-CDB-W01-QUA-PRO-00221
Magnetic Particle Examination
and ASTM E 709

F12254-CDB-W01-QUA-PRO-00224
Ultrasonic Examination

Visual Inspection
Implementation to the organization involved in the case of documents

As per F12254-CDB-W01-QUA-PRO00220 Welding Visual Inspection

& AWS D1.1/D1.1 M Structural
Welding Code Steel Table 6.1
As per F12254-CDB-W01-QUA-PRO00221 Magnetic Particle
Examination
&
AWS D1.1/D1.1 M Structural Welding
Code Steel 6.10
As per F12254-CDB-W01-QUAPRO-00224 Ultrasonic
Examination & AWS D1.1/D1.1 M
Structural Welding Code Steel
6.13
&
API RP 2A-WSD Recommended
Practice for Planning, Designing
and Constructing Fixed Offshore
Platforms-Working Stress Design
As per F12254-CDB-W01-WEL-PRO-

Or type of document to supply

Piles Prefabrication Butt weld report
ITR
F12254-CDB-W03-QUA-ITP-60053 //
003
Piles Prefabrication Butt weld report
ITR
F12254-CDB-W03-QUA-ITP-60053 //
003
Piles Prefabrication Butt weld report
ITR
F12254-CDB-W03-QUA-ITP-60053 //
003
Piles Prefabrication Butt weld report
ITR
F12254-CDB-W03-QUA-ITP-60053 //
003
As per F12254-CDB-W01-QUA-PRO00220 - Welding Visual Inspection

SUB
CTR

CONS
CDB

QC
CDB

OWN

As per F12254-CDB-W01-QUA-PRO00221 Magnetic Particle

Examination

As per F12254-CDB-W01-QUA-PRO00224 Ultrasonic Examination

Piles fabrication Repair Weld

Thd
PART

Implementation to the organization involved in the case of works

The organization involved issues the document.

The organization involved performs the inspection or checks and issues the relevant ITRs.
The organization involved performs and formalizes a review of relevant documents and/or quality records.
N/A
N/A
The organization involved watches (supervise) the inspection, control or test.
Formal acceptance in writing of the inspection(s) or test(s) performed is required.
N/A
Witnessing organization must be notified within the contractually agreed time scale; its non attendance shall not delay the inspection or check being carried out by the performing organization.
The organization involved must approve the document, prior to the execution of the corresponding works.
Operations are not allowed to proceed beyond this point until inspected and approved without non-conformities
(*) means through survey or through sampling
EXE is in charge of performing works and controls. It can be SCT, VDR or CTR (refer to CQCP)

Rf.

PROCESS

PERU LNG EXPORT PROJECT

MARINE FACILITIES EPC CONTRACT

Date:

03-Mar-08

INSPECTION AND TESTING PLAN

Rev.:

05

F12254

CDB

W03

QUA

ITP

60053

Job code

Origin

Unit Code

Discipline

Doc Type

Sequential

INSPECTION, CHECK AND TEST

Page: 6/7

RECORDS

RESPONSIBILITIES (ii)
EXE

Activities

Subject

Means or procedure (i)

F12254-CDB-W01-QUA-PRO-00220
Welding Visual Inspection
&

o IF REQUIRED: Visual and NDT control after repair

F12254-CDB-W01-QUA-PRO-00221
Magnetic Particle Examination
and ASTM E 709
or
F12254-CDB-W01-QUA-PRO-00222
Liquid Penetrant Examination
&
F12254-CDB-W01-QUA-PRO-00224
Ultrasonic Examination

Acceptance criteria (i)

Or type of document to supply

10053- Welding book for Piles

Prefabrication
As per F12254-CDB-W01-QUA-PRO00220 Welding Visual Inspection
& AWS D1.1/D1.1 M Structural
Welding Code Steel Table 6.1
&
As per F12254-CDB-W01-QUA-PRO00221 Magnetic Particle
Examination
or
F12254-CDB-W01-QUA-PRO-00222
Liquid Penetrant Examination &
&
AWS D1.1/D1.1 M Structural Welding
Code Steel 6.10
&
F12254-CDB-W01-QUA-PRO-00224
Ultrasonic Examination

Report ITR F12254-CDB-W03-QUAITP-60053 // 004

SUB
CTR

CONS
CDB

QC
CDB

Thd
PART

OWN

As per F12254-CDB-W01-QUA-PRO00220 Welding Visual Inspection

&
As per F12254-CDB-W01-QUA-PRO00221 Magnetic Particle
Examination
or
F12254-CDB-W01-QUA-PRO-00222
Liquid Penetrant Examination &
&
F12254-CDB-W01-QUA-PRO-00224
Ultrasonic Examination

&
AWS D1.1/D1.1 M Structural Welding
Code Steel 6.13

o Pile, Dimensional check

o IF REQUIRED: Cutting over length

o IF REQUIRED: Ultrasonic Examination after cutting

Involvement code
E
R
S
A
W
H

Name

Execution
Review
Surveillance
Acceptance
Witnessing
Validation (Hold point)
Other mentions :

Visual Inspection & taut wire along

the length of the pile repeated at a
minimum of three radial points

As per drawings & AWS D1.1

5.23.1

Visual Inspection

As per drawings

F12254-CDB-W01-QUA-PRO-00224
Ultrasonic Examination

As per F12254-CDB-W01-QUA-PRO00224 Ultrasonic Examination

Implementation to the organization involved in the case of documents

Piles Prefabrication Butt weld report

ITR
F12254-CDB-W03-QUA-ITP-60053 //
003
&
Piles Prefabrication Piles
straightness report ITR F12254-CDBW03-QUA-ITP-60053// 005
Piles Prefabrication Butt weld report
ITR
F12254-CDB-W03-QUA-ITP-60053 //
003
As per F12254-CDB-W01-QUA-PRO00224 Ultrasonic Examination

Implementation to the organization involved in the case of works

The organization involved issues the document.

The organization involved performs the inspection or checks and issues the relevant ITRs.
The organization involved performs and formalizes a review of relevant documents and/or quality records.
N/A
N/A
The organization involved watches (supervise) the inspection, control or test.
Formal acceptance in writing of the inspection(s) or test(s) performed is required.
N/A
Witnessing organization must be notified within the contractually agreed time scale; its non attendance shall not delay the inspection or check being carried out by the performing organization.
The organization involved must approve the document, prior to the execution of the corresponding works.
Operations are not allowed to proceed beyond this point until inspected and approved without non-conformities
(*) means through survey or through sampling
EXE is in charge of performing works and controls. It can be SCT, VDR or CTR (refer to CQCP)

Rf.

PROCESS

PERU LNG EXPORT PROJECT

MARINE FACILITIES EPC CONTRACT

Date:

03-Mar-08

INSPECTION AND TESTING PLAN

Rev.:

05

F12254

CDB

W03

QUA

ITP

60053

Job code

Origin

Unit Code

Discipline

Doc Type

Sequential

INSPECTION, CHECK AND TEST

Page: 7/7

RECORDS

RESPONSIBILITIES (ii)
EXE

Activities

Subject

QC
CDB

Thd
PART

Means or procedure (i)

Acceptance criteria (i)

Or type of document to supply

As per
F12254-CDB-W01-QUA-PRO-00205
Mechanical Completion

By CONTRACTOR QA/QC Manager

& OWNER Representative

Mechanical Completion Certificate

All ITR & Mechanical Completion

Certificates

SUB
CTR

CONS
CDB

OWN

Mechanical completion
Mechanical Completion
Final Dossier
Compilation of all QC records (according to final dossier procedure)

Involvement code
E
R
S
A
W
H

Name

Execution
Review
Surveillance
Acceptance
Witnessing
Validation (Hold point)
Other mentions :

Implementation to the organization involved in the case of documents

Implementation to the organization involved in the case of works

The organization involved issues the document.

The organization involved performs the inspection or checks and issues the relevant ITRs.
The organization involved performs and formalizes a review of relevant documents and/or quality records.
N/A
N/A
The organization involved watches (supervise) the inspection, control or test.
Formal acceptance in writing of the inspection(s) or test(s) performed is required.
N/A
Witnessing organization must be notified within the contractually agreed time scale; its non attendance shall not delay the inspection or check being carried out by the performing organization.
The organization involved must approve the document, prior to the execution of the corresponding works.
Operations are not allowed to proceed beyond this point until inspected and approved without non-conformities
(*) means through survey or through sampling
EXE is in charge of performing works and controls. It can be SCT, VDR or CTR (refer to CQCP)