SPHERETECH ENGINEERING SDN. BHD.

PLO Lot 494, Jalan Keluli 7, Pasir Gudang Industrial Estate

81700, Pasir Gudang, Johor, Malaysia.
TEL : 607-2511860 Fax : 607-2514493
E Mail Address : [email protected] / [email protected]

Document Number SP-A595-SITP-001

MANUFACTURER'S PROJECT DOCUMENT Revision Number 0

Date of Issue 21 07 08
SHOP INSPECTION AND TEST PLAN Number of Pages 13
Approved By Approved By Approved By

Client OPTIMAL OLEFINS ( M ) SDN. BHD.

EQUIPMENT NO. C - 3837

EQUIPMENT 5575 M³ ETHANE SPHERICAL TANK Client's Main Contractor's Third Party
QA / QC Manager QA / QC Manager Inspector
Owner OPTIMAL OLEFINS ( M ) SDN. BHD. Approved By Approved By Approved By

Main Contractor
Hexagon Tower Sdn. Bhd. / Spheretech Engineering Sdn Bhd
- Joint Operation
SESB's Job No. A 595
Manufacturing No. SP / PV / 509 SESB's
Project Manager
SESB's
Engineering Manager
SESB's
QA / QC Manager
Page Description of Revision Date Rev. No. Prepared By Checked By Approved By
 Submission for Acceptance 21 / 07 / 08 0 Muthu TSMok TSMok
Client Chiyoda Malaysia Sdn Bhd. Document No. SP-A595-SITP-001
Project M3204 - No. 4 BD Tank Project Revision No. 0
SHOP INSPECTION AND TEST PLAN Spheretech Job No. TK - 512 Date 21 07 08
Manufacturing No. SP / PV / 509 Total No. of pages 2 of 13
AR Approval Required SW Spot Witness C/P Control Point H Hold point - To Be Release prior to Next Production Stage
Legends
R Document Review FW Full Witness M Monitoring T/C Document / Procedures / Test Certificate / Report required
UDS User's Design Specification ARD Approved Reference Drawings AEP Accepted Examination Procedure ASMEII ASME Section II - Same Ed as Code
MDR Manufacturer's Design Report AFC Approved Construction Drawings ATP Accepted Test Procedure ASMEV ASME Section V - Same Ed as Code
Code ASME Sect VIII Div 2 07 Ed. AFCC Approved Code Construction Drawings AAP Approved Application Procedure ASMEIX ASME Section IX - Same Ed as Code
Abbr.
QCM Spheretech's QC Manual - Ed. 3 PO Purchase Order MCP Material Cutting Plan
RPE Registered Professional Engineer DIR Dimensional Inspection Report WTR Welding Traceability Report
SCOPE OF INSPECTION
MTR Materail Traceability Report MPS Material Purchasing Specification
ACTIVITY QUALITY RELATED REFERENCE CHARACTERISTIC ACCEPTANCE SESB A. I. Optimal
T /C
NO ACTIVITY DOCUMENT TO BE VERIFIED CRITERIA C/P SIGN C/P SIGN C/P SIGN

Section A Kick Off / Pre-Production Meeting Section 2.0 - 2.25 and 2.26 of SESB's QC Manual
1 Purchasing Conditions Purchase Order Terms and Conditions Accepted Purchase Order
2 Client's Project Specifications Project Specifications Document Title, Recorded in SESB's Document -
H NA NA H T/C
3 Client's Project Procedures Project Procedures Document Number Client's Incoming Project
4 Client's Project instructions Project instructions and Latest Revision No. Document Master List

Section B Engineering Drawing, Design Calculation and Specification Section 2.0 of SESB's QC Manual
Manufacturer's Design Report
R.P.E's Acceptance
1 Design Calculation PS / ARD / UDS UDS's Compliance
2 Design Drawings A. I's Acceptance AR R R T/C
3 Nozzle Stress Analysis
CODE CODE Rules' Compliance DOSH Acceptance
4 Vessel Supports
5 Platform and ladders PS PS Compliance Client's Approval AR NA NA R T/C
6 Water Drenching System PS NFPA Bomba Regulation Compliance PE / Bomba Approval AR NA NA R T/C

Section C Project Document Furnished by SESB Section 2.0 of SESB's QC Manual

1. Inspection And Test Plan AR R R T/C
2. Weld map AR R R T/C
Full Compliance with
3. Welding Procedure Specification UDS ASMEIX CODE AR R R T/C
4. Procedure Qualification Record AR R R T/C
5. Welder/Welding Operator List / WPQ PS / CODE Compliance AR R R T/C
6. NDT Procedures AR R R T/C
7. PWHT Procedures UDS ASMEIX ASMEV CODE AR R R T/C
AFCC ASMEV QCM
8. Air Leak Testing Procedure NA NA NA NA NA NA NA
9. Hydrostatic Procedure AR R R T/C
 10. External Blasting and Painting Procedure AR NA NA R T/C
PS PS Compliance Acceptance by Client
11. External Insulation Procedure AR NA NA R T/C

Document No. SP-A595-SITP-001

Revision No. 0
SHOP INSPECTION AND TEST PLAN Date 21 07 08
Page Number 3 of 13
AR Approval Required SW Spot Witness C/P Control Point H Hold point - To Be Release prior to Next Production Stage
Legends
R Document Review FW Full Witness M Monitoring T/C Document / Procedures / Test Certificate / Report required
UDS User's Design Specification ARD Approved Reference Drawings AEP Accepted Examination Procedure ASMEII ASME Section II - Same Ed as Code
MDR Manufacturer's Design Report AFC Approved Construction Drawings ATP Accepted Test Procedure ASMEV ASME Section V - Same Ed as Code
Code ASME Sect VIII Div 2 07 Ed. AFCC Approved Code Construction Drawings AAP Approved Application Procedure ASMEIX ASME Section IX - Same Ed as Code
Abbr.
QCM Spheretech's QC Manual - Ed. 3 PO Purchase Order MCP Material Cutting Plan
RPE Registered Professional Engineer DIR Dimensional Inspection Report WTR Welding Traceability Report
SCOPE OF INSPECTION
MTR Materail Traceability Report MPS Material Purchasing Specification
ACTIVITY QUALITY RELATED REFERENCE CHARACTERISTIC ACCEPTANCE SESB A. I. Optimal
T /C
NO ACTIVITY DOCUMENT TO BE VERIFIED CRITERIA C/P SIGN C/P SIGN C/P SIGN

Section D Material Procurement Section 5.0 of SESB's QC Manual

1. Material Thickness and Dimensions
UDS Material Specification Material Test Report
2. Material Specifications
3. Control of Material Specifications Material
ASME II and Grade Compliance furnishing
4. Carbon Content Limitations
5. Carbon Equivalent Value Material Mandatory /
QCM Material Specification and Grade
6. Type of Material Test Report Supplementary Test Test
Supplementary Test Requirement Compliance H R R
Part 3 Mechanical Test Acceptable
7. Heat treatment Material NDE
8. Vacuum Treatment Examination Report
CODE Numerical Results
9. Additional or Special Tension Test Compliance
20. Impact Testing and Test Result Material Test Report NDE Examination Result
11. Non - Destructive Examination MDR and Certification
Manufacturer's Certification
12. Material Manufacturer's Certification Compliance

Section E Material Test Report ( Mill Certificate ) Review Section 5.0 of SESB's QC Manual
Purchase / Storck Materials Type of Material Test Material
Material Purchasing
1 Type of Material Test Report Report Compliance Material Receiving
2 Datas Furnished in the Report Material Specification Inspection
Specifications - PRS
Material Heat Number and Grade Compliance Report
Material Specifications, Chemical Analysis Material Chemical Test Certificate
Mechanical properties Composition Compliance Report
ASME II
Carbon Content Limitations Material Carbon Type
Carbon Equivalent Value Equivalent Compliance Compliance H R R Material
Mandatory / Supplementary Test and Material Mandatory Test Test

CODE - Part 3
 H R R

Numerical Test Result Requirement Compliance Report

CODE - Part 3 Manufacturer's
Heat treatment, Vacuum Treatment Material Supplementary Numerical
Additional or Special Tension Test Requirement Compliance Test
Certification
Impact Testing and Test Result Material Test Numerical
Non - Destructive Examination QCM Test Result Compliance Result
on the Report
11 Manufactuer's Certification of Test Performed Manufacturer's Certification
Document No. SP-A595-SITP-001
Revision No. 0
SHOP INSPECTION AND TEST PLAN Date 21 07 08
Page Number 4 of 13
AR Approval Required SW Spot Witness C/P Control Point H Hold point - To Be Release prior to Next Production Stage
Legends
R Document Review FW Full Witness M Monitoring T/C Document / Procedures / Test Certificate / Report required
UDS User's Design Specification ARD Approved Reference Drawings AEP Accepted Examination Procedure ASMEII ASME Section II - Same Ed as Code
MDR Manufacturer's Design Report AFC Approved Construction Drawings ATP Accepted Test Procedure ASMEV ASME Section V - Same Ed as Code
Code ASME Sect VIII Div 2 07 Ed. AFCC Approved Code Construction Drawings AAP Approved Application Procedure ASMEIX ASME Section IX - Same Ed as Code
Abbr.
QCM Spheretech's QC Manual - Ed. 3 PO Purchase Order MCP Material Cutting Plan
RPE Registered Professional Engineer DIR Dimensional Inspection Report WTR Welding Traceability Report
SCOPE OF INSPECTION
MTR Materail Traceability Report MPS Material Purchasing Specification

Section F Material Verification Inspection and Verification Inspection Report Section 5.0 of SESB's QC Manual
Incoming / Stock Material Material Thickness, Material Thickness, Material
PO
Inspection for Steel Plates, Forgings, Width and Length within Width and Length within Receiving
Forgings, Pipes, Pipe Fittings, etc. Tolerance Limit Tolerance Limit Compliance Inspection
MCP
1 Material Thickness and Dimensions Pipe, Fitting and Forging - Pipe, Fitting and Forging - Report
Inspection and Measurement NB, Schedule Marking NB, Schedule Marking Compliance
MPS
2 Visual Inspection of Material Surfaces Material Specification Material Specification Report
for Surface Imperfection and Grade Marking and Grade Marking Compliance Type
ASME II - H R R
3. Material Markings on the Material Material Heat Number Material Heat Number Marking Material
Material Specifications and Grade Marking Identification Identification with Mtl. Test Report Test
SA 6 / SA 20
Pipe Schedule and Diameter Material Manufacturer's Material Manufacturer's Report
Material Heat Number Company Name Marking Company Name Marking Numerical
CODE - Part 3
Marking for Heat Treatment Material Heat Material Heat Treatment Test
Specific Material Component Marking Treatment Marking Marking Identified Result
QCM
4. Material quantity Counting Material Quantity Correct Material quantity

Incoming / Stock Material Inspection

PO Qty order / Received Correct Ordered Qty.
for Welding Consumable
1 Welding Filler Metal Specification Welding Filler Metal
ASME II - Part C Correct Ordered Size
F - Number ( Table QW - 432 ) Diameter Marking Batch
A - Number ( Table QW - 442 ) Manufacturer's Product Cert
Specification Number - SFA ASME IX Name Marking Correct Specification
H R R
AWS Classification Name of Manufacturer
2. Diameter of Welding Filler Metal Marking
3. Welding Filler Metal Material Test Report AWS Classification Marking
QCM
 H R R

Marking
4. Material Batch Certificate QCM Marking
Type of Covering
5. Condition of Welding Electrode Packing Packing Not Damaged
Marking

Document No. SP-A595-SITP-001

Revision No. 0
SHOP INSPECTION AND TEST PLAN Date 21 07 08
Page Number 5 of 13
AR Approval Required SW Spot Witness C/P Control Point H Hold point - To Be Release prior to Next Production Stage
Legends
R Document Review FW Full Witness M Monitoring T/C Document / Procedures / Test Certificate / Report required
UDS User's Design Specification ARD Approved Reference Drawings AEP Accepted Examination Procedure ASMEII ASME Section II - Same Ed as Code
MDR Manufacturer's Design Report AFC Approved Construction Drawings ATP Accepted Test Procedure ASMEV ASME Section V - Same Ed as Code
Code ASME Sect VIII Div 2 07 Ed. AFCC Approved Code Construction Drawings AAP Approved Application Procedure ASMEIX ASME Section IX - Same Ed as Code
Abbr.
QCM Spheretech's QC Manual - Ed. 3 PO Purchase Order MCP Material Cutting Plan
RPE Registered Professional Engineer DIR Dimensional Inspection Report WTR Welding Traceability Report
SCOPE OF INSPECTION
MTR Materail Traceability Report MPS Material Purchasing Specification
ACTIVITY QUALITY RELATED REFERENCE CHARACTERISTIC ACCEPTANCE SESB A. I. Optimal
T /C
NO ACTIVITY DOCUMENT TO BE VERIFIED CRITERIA C/P SIGN C/P SIGN C/P SIGN

Section F Fabrication and Fabrication Inspection Activities Section 6.0, 7.0, 8.0, 9.0 10.0 of SESB's QC Manual
F1 Shell Plate Forming, Cutting and Bevelling
Fabrication of Gauge plate for Curvature Correctness Acceptance by
1
Inspection AFCC Drawing Roundness of Quality
1.1 Inspection of Gauge Plate Gauge Plate Control Inspector
Shell Plate Forming - Before Forming Marked Designated
2.1 Shell Plate Part Number Marking AFCC Drawing Component Part No.
2 AFCC Drawing MTR
2.2 Material Heat No. Traceability Heat No. Marking and
2.3 Thickness Measurement Coding
Shell Plate Forming - After Forming CODE Material Traceability Curvature Tolerance Within
3.1 Shell Plate Part Number Marking Heat No. Traceability Engineering Detail - G9G-2000-01
3 3.2 Material Heat No. Traceability Random Thickness Check Limits
3.3 Thickness Measurement QCM Curvature and DIR
± 19.00 mm. H SW SW
3.4 Curvature and Roundness Roundness Measurement
Fabrication of Fish Bone for Plate Marking Correctness of Fish Acceptance by
4 using 1st Formed Shell Plate ( each type ) AFCC Drawing Bone Developmment Quality
4.1 Inspection of fish Bone for Each Type of Plate Control Inspector
Shell Plate Marking - After Forming, Correctness of
AFCC Drawing
Using Fish Bone Marked Dimensions
All Marked Dimensions Limits
1 Dimension Measurement and Squareness
CODE
5 2 Diagonal Measurement Material Heat
 5
3 Shell Plate Part Number Marking Number Traceability
4 Material Heat No. Traceability QCM Correctness of Marking ± 3.00 mm.
5 Type and Facing of Bevel Edge of Bevel Edge

Document No. SP-A595-SITP-001

Revision No. 0
SHOP INSPECTION AND TEST PLAN Date 21 07 08
Page Number 5 of 13
AR Approval Required SW Spot Witness C/P Control Point H Hold point - To Be Release prior to Next Production Stage
Legends
R Document Review FW Full Witness M Monitoring T/C Document / Procedures / Test Certificate / Report required
UDS User's Design Specification ARD Approved Reference Drawings AEP Accepted Examination Procedure ASMEII ASME Section II - Same Ed as Code
MDR Manufacturer's Design Report AFC Approved Construction Drawings ATP Accepted Test Procedure ASMEV ASME Section V - Same Ed as Code
Code ASME Sect VIII Div 2 07 Ed. AFCC Approved Code Construction Drawings AAP Approved Application Procedure ASMEIX ASME Section IX - Same Ed as Code
Abbr.
QCM Spheretech's QC Manual - Ed. 3 PO Purchase Order MCP Material Cutting Plan
RPE Registered Professional Engineer DIR Dimensional Inspection Report WTR Welding Traceability Report
SCOPE OF INSPECTION
MTR Materail Traceability Report MPS Material Purchasing Specification
ACTIVITY QUALITY RELATED REFERENCE CHARACTERISTIC ACCEPTANCE SESB A. I. Optimal
T /C
NO ACTIVITY DOCUMENT TO BE VERIFIED CRITERIA C/P SIGN C/P SIGN C/P SIGN
Shell Plate Cutting to Shape and Bevelling Curvature Tolerance Within
1 Dimension Measurement AFCC Drawing Cut Dimensions and Engineering Detail - G9G-2000-01
2 Diagonal Measurement Squareness of Plate Limits
6
3 Curvature and Roundness Roundness of Plate ± 19.00 mm.
H R SW DIR
Bevel Angle Measurement CODE Correctness of Bevel All Cut Dimensions
4
with Angle Gauge Angle ± 3.00 mm.
Fine Pressing After Cutting All Weld Bevel Angle
7 QCM Roundness of Plate
1 Curvature and Roundness ± 5.00 Degree
F2 Upper Column Forming, Cutting, Bevelling, Welding Into Cylindrical Cans and Cutting to Shape
Upper Column Plate Forming - Before Rolling Marked Designated
All Curvature Limits
and After Rolling into Cylindrical Cans Component Part No.
AFCC Drawing
1.1 Plate Part Number Marking Heat No. Marking
± 3.00 mm.
1 1.2 Material Heat No. Traceability Curvature and MTR
1.3 Dimension Measurement Roundness Measurement FW SW SW
All Cut Dimensions Limits
1.4 Bevel Angle Measurement Bevel Angle Facing and
CODE
1.5 Curvature and Roundness Bevel Angle Measurement
± 3.00 mm.
Upper Column Cylindrical Can Fitup Correctness of Orientation
Inspection Fitup Configuration
Alignment Limit
2 2.1 Orientation Marking Roundness Measurement FW SW SW DIR
QCM
2.2 Weld Joint Fit - Up Fitup Inspection Box
± 3.00 mm.
 2 FW SW SW DIR
QCM
± 3.00 mm.
2.3 Roundness and Alignment Marking

Document No. SP-A595-SITP-001

Revision No. 0
SHOP INSPECTION AND TEST PLAN Date 21 07 08
Page Number 6 of 13
AR Approval Required SW Spot Witness C/P Control Point H Hold point - To Be Release prior to Next Production Stage
Legends
R Document Review FW Full Witness M Monitoring T/C Document / Procedures / Test Certificate / Report required
UDS User's Design Specification ARD Approved Reference Drawings AEP Accepted Examination Procedure ASMEII ASME Section II - Same Ed as Code
MDR Manufacturer's Design Report AFC Approved Construction Drawings ATP Accepted Test Procedure ASMEV ASME Section V - Same Ed as Code
Code ASME Sect VIII Div 2 07 Ed. AFCC Approved Code Construction Drawings AAP Approved Application Procedure ASMEIX ASME Section IX - Same Ed as Code
Abbr.
QCM Spheretech's QC Manual - Ed. 3 PO Purchase Order MCP Material Cutting Plan
RPE Registered Professional Engineer DIR Dimensional Inspection Report WTR Welding Traceability Report
SCOPE OF INSPECTION
MTR Materail Traceability Report MPS Material Purchasing Specification
ACTIVITY QUALITY RELATED REFERENCE CHARACTERISTIC ACCEPTANCE SESB A. I. Optimal
T /C
NO ACTIVITY DOCUMENT TO BE VERIFIED CRITERIA C/P SIGN C/P SIGN C/P SIGN
Upper Column Cylindrical Can Welding Process, Weld Seam
Production Welding & Welder Treaceability.
AFCC Drawing
Welding Parometer-Preheating,
3 No. of Passes, Heat Input, Welding Performed by WTR
3.1 Circumferential Weld Seam
Weaving Width of Weldment
FW FW FW
Welder Qualification Range Qualified Welders
3.2 Longitudinal Weld Seam Approved WPS
Inspection Box Recording
Upper Column Cylindrical Can Surface Conditions of Weldment Applying the Correct WPS
Production Welding - Visual Reinforcement Height and Visual
Welder With
Inspection and NDE Examination Presence of Undercut Inspection
Grinding / Dressing of Tack Report
WPQ
4.1 Visual Inspection Weld Areas Visual Inspection Accepted
4
Inspection Box Recording
H R R PT
AEP - RT
Non Relevant Indications Report
4.2 RT Examination of Weldment RT Examination Accepted
Relevant Indications
Relevant Indications
Upper Column Cylindrical Can Cut Base Out of Level Limit
ASME IX
 ASME IX
to Shape of the Equator Plate Engineering Detail - G9G-2000-01
Full Development of the Zinc Correctness of Dimensions Limits DIR
5.1
Sheet Gauge Plate of the Development ± 6.00 mm.
Marking and Punching Cutting Correctness of Orientation All Weld Bevel Angle
5.2 ASME V
Line on Column Stub Fitup Configuration ± 5.00 Degree Visual
Cutting and Grinding of Cut Smooth Cutting Line for Inspection
5 Alignment Limit FW SW SW
5.3 Edges, and Weld Joint Edge Part - 6 Full Penetration Weld Report
Bevelling. Part - 7 Bevel Angle Measurement
± 3.00 mm.
Fitup End Plate to Lower End of Correctness of Orientation
5.4 CODE
Column Stub. Fitup Configuration WTR
Final Dimensional Limit
Perform Final Dimensional Welding Process, Weld Seam
5.5 Inspection, Weld the End Plate, QCM & Welder Treaceability.
± 3.00 mm.
Visual Inspection of Weldment. Sound Fillet Welding
 Document No. SP-A595-SITP-001
Revision No. 0
SHOP INSPECTION AND TEST PLAN Date 21 07 08
Page Number 7 of 13
AR Approval Required SW Spot Witness C/P Control Point H Hold point - To Be Release prior to Next Production Stage
Legends
R Document Review FW Full Witness M Monitoring T/C Document / Procedures / Test Certificate / Report required
UDS User's Design Specification ARD Approved Reference Drawings AEP Accepted Examination Procedure ASMEII ASME Section II - Same Ed as Code
MDR Manufacturer's Design Report AFC Approved Construction Drawings ATP Accepted Test Procedure ASMEV ASME Section V - Same Ed as Code
Code ASME Sect VIII Div 2 07 Ed. AFCC Approved Code Construction Drawings AAP Approved Application Procedure ASMEIX ASME Section IX - Same Ed as Code
Abbr.
QCM Spheretech's QC Manual - Ed. 3 PO Purchase Order MCP Material Cutting Plan
RPE Registered Professional Engineer DIR Dimensional Inspection Report WTR Welding Traceability Report
SCOPE OF INSPECTION
MTR Materail Traceability Report MPS Material Purchasing Specification
ACTIVITY QUALITY RELATED REFERENCE CHARACTERISTIC ACCEPTANCE SESB A. I. Optimal
T /C
NO ACTIVITY DOCUMENT TO BE VERIFIED CRITERIA C/P SIGN C/P SIGN C/P SIGN
F3 Fitup and Welding of Upper Column to Equator Plate, and NDE Examination of the Full Penetration Attachment Weld
Marking of Equator Plate Center Lines - Base Out of Level Limit
Horizontal and Longitudinal Center Lines AFCC Drawing Engineering Detail - G9G-2000-01
1 1.1 Mark the 2 Center Lines Correctness, Squareness Limits
1.2 Check the Squareness of Center Lines ± 6.00 mm.
1.3 Punch the Center Lines Approved WPS Column Fitup Gap
Upper Column Fitup onto Equator Correctness of Orientation 1.00 mm. Max.
Plate and Fitup Inspection Fitup Configuration
Welder With Alignment Limit
2 2.1 Longitudinal Center Line Matching Roundness Measurement DIR
2.2 Weld Joint Fit - Up Fitup Inspection Box
WPQ ± 3.00 mm.
2.3 Straightness and Alignment Marking FW SW SW
Upper Column Attachment Weld to Welding Process, Weld Seam
Final Dimensional Limit
Equator Plate - Full Penetration AEP - MT & Welder Treaceability.
Production Weld Welding Parometer-Preheating,
± 3.00 mm.
3 No. of Passes, Heat Input, WTR
Full Penetration Attachment ASME IX Weaving Width of Weldment Welding Performed by
3.1
Welding Welder Qualification Range
Inspection Box Recording Qualified Welders
Upper Column Attachment Weld to ASME V Surface Conditions of Weldment
Equator Plate - Full Penetration Weld Reinforcement Height and Applying the Correct WPS Visual
Visual Inspection and NDE Examination Presence of Undercut Inspection
Part - 6
Grinding / Dressing of Tack Report
4.1 Visual Inspection Weld Areas Visual Inspection Accepted
4 Part - 7
Inspection Box Recording
H R R MT
CODE Non Relevant Indications
Report
4.2 100% MT Examination of Weldment RT Examination Accepted
QCM Relevant Indications
 Document No. SP-A595-SITP-001
Revision No. 0
SHOP INSPECTION AND TEST PLAN Date 21 07 08
Page Number 10 of 13
AR Approval Required SW Spot Witness C/P Control Point H Hold point - To Be Release prior to Next Production Stage
Legends
R Document Review FW Full Witness M Monitoring T/C Document / Procedures / Test Certificate / Report required
UDS User's Design Specification ARD Approved Reference Drawings AEP Accepted Examination Procedure ASMEII ASME Section II - Same Ed as Code
MDR Manufacturer's Design Report AFC Approved Construction Drawings ATP Accepted Test Procedure ASMEV ASME Section V - Same Ed as Code
Code ASME Sect VIII Div 2 07 Ed. AFCC Approved Code Construction Drawings AAP Approved Application Procedure ASMEIX ASME Section IX - Same Ed as Code
Abbr.
QCM Spheretech's QC Manual - Ed. 3 PO Purchase Order MCP Material Cutting Plan
RPE Registered Professional Engineer DIR Dimensional Inspection Report WTR Welding Traceability Report
SCOPE OF INSPECTION
MTR Materail Traceability Report MPS Material Purchasing Specification
ACTIVITY QUALITY RELATED REFERENCE CHARACTERISTIC ACCEPTANCE SESB A. I. Optimal
T /C
NO ACTIVITY DOCUMENT TO BE VERIFIED CRITERIA C/P SIGN C/P SIGN C/P SIGN
F4 Fitup and Welding of Nozzle and Manhole - Neck, Flange and Reinforcing Pad to Shell Plate
Material Identification and Traceability The Correct Crown Plate
Top Center Crown
1.1 Center Crown Plate The Correct Component The Correct Manhole and
FW
1 Nozzle and manhole Attachment Part Number Nozzle to be Attached
Nozzle Layout
1.2 to the Particular Center Crown to be Fitup to the Particular
Plate Center Crown Plate
Bottom Center Crown
Marking of Center Crown Plate SPECIAL ACCEPTANCE
Center Lines - Both X - X and Y - Y axis CRITERIA BY
Nozzle Layout
2 2.1 Mark the 2 Center Lines Correctness, Squareness ENGINEERING MANAGER - DIR
H
2.2 Check the Squareness of Center Lines THE CORRECT REVISION
Manway, Nozzle Details
2.3 Punch the Center Lines NUMBER OF THE DRAWING
Marking of Nozzle Openings Center Lines - Measurement from USE AT SHOP FLOOR
Both X - X and Y - Y axis and opening Size AFCC Drawing Center of Crown plate Fabrication Tolerance Within
3.1 Mark the 2 Center Lines Location and orientation Engineering Detail - G9G-2000-01
3.2 Check the Squareness of Manhole and Nozzle Limits
3 3.3 Punch the Center Lines Openings
Part - 6 D ± 12.00 mm. SW W
3.4 Mark Size of Nozzle Opening Correct Size of opening
3.5 Punch the Opening Marking Bevel Angle Marking
E ± 6.00 mm.
Welding Bevel Angle Bevel Angle Facing -
3.6
Marking Inside or Outside
CODE F ± 6.00 mm.
Dimensional Inspection after Cutting Size and Roundness
of opening on Crown plates Bevel angle Facing and
4 G ± 6.00 mm. FW
Angle Measurement
4.1 Nozzle and manhole Openings MTR
Inspection Box Marking
J ± 2.00 mm.
Nozzle and Manhole Fitup and Weld Joint Details
Nozzles
Fitup Inspection Correctness of Projection Across the Flange Face
Correctness of Straightness Nozzle Fitup Root Gap
Manways
Nozzle and Manhole Neck, and Alignment
5 3.00 mm. Max.
5.1
 5 3.00 mm. Max.
Repad Fitup onto Crown Flange Bolt Hole
5.1
Plate Visual and Dimensional Straddle Check All Weld Bevel Angle
QCM
Inspection Inspection Box Recording
± 2.5 Degree

Document No. SP-A595-SITP-001

Revision No. 0
INSPECTION AND TEST PLAN Date 21 07 08
Page Number 11 of 13
AR Approval Required SW Spot Witness C/P Control Point H Hold point - To Be Release prior to Next Production Stage
Legends
R Document Review FW Full Witness M Monitoring T/C Document / Procedures / Test Certificate / Report required
UDS User's Design Specification ARD Approved Reference Drawings AEP Accepted Examination Procedure ASMEII ASME Section II - Same Ed as Code
MDR Manufacturer's Design Report AFC Approved Construction Drawings ATP Accepted Test Procedure ASMEV ASME Section V - Same Ed as Code
Code ASME Sect VIII Div 2 07 Ed. AFCC Approved Code Construction Drawings AAP Approved Application Procedure ASMEIX ASME Section IX - Same Ed as Code
Abbr.
QCM Spheretech's QC Manual - Ed. 3 PO Purchase Order MCP Material Cutting Plan
RPE Registered Professional Engineer DIR Dimensional Inspection Report WTR Welding Traceability Report
SCOPE OF INSPECTION
MTR Materail Traceability Report MPS Material Purchasing Specification
ACTIVITY QUALITY RELATED REFERENCE CHARACTERISTIC ACCEPTANCE SESB A. I. Optimal
T /C
NO ACTIVITY DOCUMENT TO BE VERIFIED CRITERIA C/P SIGN C/P SIGN C/P SIGN
Nozzle and Manhole Attachment Welding Process, Weld Seam
Weld - Production Welding AFCC Drawing & Welder Treaceability.
- Category D Corner Weld Welding Parometer-Preheating, Welding Performed by
6 No. of Passes, Heat Input, WTR
Approved WPS
Nozzle and Manhole Attachment Weaving Width of Weldment Qualified Welders
6.1 FW SW SW
Weld - Category D Corner Weld Welder Qualification Range
Welder With WPQ
Inspection Box Recording Applying the Correct WPS
Nozzle and Manhole Attachment Surface Conditions of Weldment
ASME IX
Welding to Crown Plate - Visual Reinforcement Height and Visual
Inspection and NDE Examination Presence of Undercut Inspection
ASME V
Grinding / Dressing of Tack Report
7.1 Visual Inspection Part - 7 Weld Areas Visual Inspection Accepted
CODE Inspection Box Recording
PT Examination of Weldment
7.2 AEP - PT PT Examination Accepted
7 After Back Gouging Non Relevant Indications
Table 7.2 - Part 7 - CODE Relevant Indications RT
H R R
Category C Weld - Full Pen. Relevant Indications Report
RT 100% AEP - RT RT Examination Accepted
Non Relevant Indications
7.3 Category D Weld - Full Pen. MT
d > 6" NB RT 100% Report
Relevant Indications
Category D Weld - Full Pen.
AEP - MT MT Examination accepted
d < 6" NB MT 100%
 Document No. SP-A595-SITP-001
Revision No. 0
INSPECTION AND TEST PLAN Date 21 07 08
Page Number 13 of 13
AR Approval Required SW Spot Witness C/P Control Point H Hold point - To Be Release prior to Next Production Stage
Legends
R Document Review FW Full Witness M Monitoring T/C Document / Procedures / Test Certificate / Report required
UDS User's Design Specification ARD Approved Reference Drawings AEP Accepted Examination Procedure ASMEII ASME Section II - Same Ed as Code
MDR Manufacturer's Design Report AFC Approved Construction Drawings ATP Accepted Test Procedure ASMEV ASME Section V - Same Ed as Code
Code ASME Sect VIII Div 2 07 Ed. AFCC Approved Code Construction Drawings AAP Approved Application Procedure ASMEIX ASME Section IX - Same Ed as Code
Abbr.
QCM Spheretech's QC Manual - Ed. 3 PO Purchase Order MCP Material Cutting Plan
RPE Registered Professional Engineer DIR Dimensional Inspection Report WTR Welding Traceability Report
SCOPE OF INSPECTION
MTR Materail Traceability Report MPS Material Purchasing Specification
ACTIVITY QUALITY RELATED REFERENCE CHARACTERISTIC ACCEPTANCE SESB A. I. Optimal
T /C
NO ACTIVITY DOCUMENT TO BE VERIFIED CRITERIA C/P SIGN C/P SIGN C/P SIGN
F6 PWHT of Weldment - Nozzle and manhole Attachment Weld to Center Crown plates
The Requirement for PWHT in Accordance in ASME Section VIII Division 1 Construction Code Rules Requirement for PWHT
Governing Section of Construction Code Rules
Service Restrictions
UW-2 When vessels are to contain lethal substances, either liquid or gaseous, all butt welded joints shall be fully radiographed, Not Design for Lethal Service
1
( a ) except under the provisions of UW-2(a)(2) and UW-2(a)(3), and UW-11(a)(4) PWHT is not Required
When fabricated of carbon or low alloy steel, such vessel shall be postweld heat treated
Requirements for Postweld Heat Treatment - Table UCS - 56 - Material P - No. 1 Gr. 1,2,3 Note (2)(a) Welded Joint Nominal Thickness = 12.7 mm. PWHT is not
Notes ( 2 ) Postweld heat treatment is mandatory under the following conditions : required. PWHT in this case is only to even out the Welding
2 UCS-56
(a) for welded joints over 1½ Inch ( 38.00 mm ) nominal thickness Stresses Induced in the Equator Plate due to the Upper
Column Attachment Weld - Full Penetration Weld
Postweld Heat treatment of Nozzle / Manhole
Attachment Weld - Full Penetration Weld
to Equator Plates - Catogory D Weld
Above 800°F, the rate of heating Rate of Heating
1
shall not be greater than 400°F/hr. Full Compliance
During heating, Temperature Accepted
variation shall not be a greater of Temperature Variation PWHT
2
the vessel being heated than 250° Accepted PWHT Full Compliance Procedure in PWHT
within any 15 ft. interval of length. Procedure in accordance Accordance Record
CODE QCM
Holding Temperature shall not be a with ASME Section VIII Holding Temperature with ASME Chart
greater difference than 150°F Div. 1 - UW - 40 Variation Section VIII FW SW SW
3
between the highest and lowest Full Compliance Div. 1
Temperature UW - 40
 FW SW SW

Above 800°F, cooling rate shall Rate of Cooling

4
not be greater than 500°F Full Compliance
Weld Repair after PWHT Accepted PWHT
5 Re - PWHT not required Full Compliance CODE QCM
UCS 56 ( f ) Procedure
NDE Examination after removal Presence of Relevant No Surface Cracks PT
6 PT using AEP
of Deffects Indications No Presence of Relevant Indication Report
NDE Examination after Weld Presence of Relevant No Surface Cracks PT
7 PT using AEP
Repair Indications No Presence of Relevant Indication Report