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PETROVIETNAM FERTILIZER AND CHEMICALS CORPORATION (PVFCCo)

AMMONIA PLANT REVAMP PROJECT

Project N Unit Document Code Serial N Rev. Page


2539 00 ITP 012 0 1/4
The present document or drawing is property of PetroVietnam Technical Services Corporation (PTSC) and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in

INSPECTION AND TESTING PLAN FOR PLASTIC PIPING WORKS


any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

0 31-MAR-2017 ISSUED FOR EXCUTION HVQ NXN NDN

A 12-JAN-2017 ISSUED FOR REVIEW HVQ NXN NDN

REV. DATE STATUS WRITTEN BY CHECKED BY APPROV./AUTHOR. BY


(name & visa) (name & visa) (name & visa)
DOCUMENT REVISIONS
______________________________________________________________________________________
PETROVIETNAM TECHNICAL SERVICES CORPORATION (PTSC)
1-5 Le Duan Street, District 1, Ho Chi Minh City (VIETNAM)
PETROVIETNAM FERTILIZER AND CHEMICALS CORPORATION (PVFCCo)
AMMONIA PLANT REVAMP PROJECT

Project N Unit Document Code Serial N Rev. Page


2539 00 ITP 012 0 2/4
The present document or drawing is property of PetroVietnam Technical Services Corporation (PTSC) and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in

Contents
1 PURPOSE................................................................................................................................3
2 REFERENCE ...........................................................................................................................3
3 DEFINITION. ............................................................................................................................3
3.1 H - Hold Point. ...................................................................................................................3
3.2 M - Monitoring Point. .........................................................................................................3
3.3 W - Witness Point. .............................................................................................................3
3.4 R - Review Point. ..............................................................................................................3
3.5 A - Approval ......................................................................................................................4
3.6 CA .....................................................................................................................................4
4 PROCEDURE. .........................................................................................................................4
5 SPECIAL REQUIREMENT. .....................................................................................................4
6 RECORD. ................................................................................................................................4
7 APPENDICE. ...........................................................................................................................4
any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

PETROVIETNAM TECHNICAL SERVICES CORPORATION (PTSC)


1-5 Le Duan Street, District 1, Ho Chi Minh City (VIETNAM)
PETROVIETNAM FERTILIZER AND CHEMICALS CORPORATION (PVFCCo)
AMMONIA PLANT REVAMP PROJECT

Project N Unit Document Code Serial N Rev. Page


2539 00 ITP 012 0 3/4
The present document or drawing is property of PetroVietnam Technical Services Corporation (PTSC) and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in

1 PURPOSE
This Quality Plan establishes the work process sequence, and inspections and tests of project
plastic piping works fabrication to be executed, documented with involvement of Sub-Contractor,
PTSC, PMFC and Project Certifying Authority in accordance with Project requirement.

This Inspection and Test Plan defines the minimum requirements for shop and field fabrication,
erection, inspection and testing of process and utility piping to be carried out by sub-contractor,
PTSC at Sub-contractors workshop as well as NH3 Plant Project.

This Inspection and Test Plan covers the fabrication of non-metallic piping only (like GRE, PVC
e.g).

2 REFERENCE
ASTM D1599 : Short-time hydraulic failure pressure of plastic pipe, tubing,
and
fittings

ASTM D2563 :Visual defects in glass-fiber reinforced plastic laminated parts.

2539-00-JSS-1328-01 : Job Supply Specification for Glass Reinforced Plastic Piping

Decree No. 46/2015/N-CP : On Quality control and maintenance of construction works.

Project Specification.

2539-00-MS-1320-51 : Construction Specification for Piping prefabrication, erection,


and nondestructive examination.
3 DEFINITION.
3.1 H - Hold Point.
To indicate mandatory to fully compliance in area of inspection beyond which work shall not
any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

proceed without the specified activity, work or function being witnessed or verified by Inspector
24 hours advance notice should be given to PTSC, PMFC and/or CA.
3.2 M - Monitoring Point.
Fabrication activities are being randomly monitored, work or function is observed by Inspector,
and normal notice is not required to be given.
3.3 W - Witness Point.
To indicate mandatory to fully compliance in area of inspection this will be witnessed or verified
by Inspector 24 hours advance notice should be given to PTSC, PMFC and/or CA. If Inspector is
not available fabrication process can proceed.
3.4 R - Review Point.
The inspection reports, quality records and certificates applicable will be reviewed and endorsed
by PTSC, PMFC and/or CA.

PETROVIETNAM TECHNICAL SERVICES CORPORATION (PTSC)


1-5 Le Duan Street, District 1, Ho Chi Minh City (VIETNAM)
PETROVIETNAM FERTILIZER AND CHEMICALS CORPORATION (PVFCCo)
AMMONIA PLANT REVAMP PROJECT

Project N Unit Document Code Serial N Rev. Page


2539 00 ITP 012 0 4/4
The present document or drawing is property of PetroVietnam Technical Services Corporation (PTSC) and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in

3.5 A - Approval
Document, record and test reports need to been approved by PMFC and /or CA.
3.6 CA Certificate Authority
CA is appointed by owner. SGS Viet Nam Ltd. Have been appointed as per letter X -P-T-0012,
on dated 1st, Feb, 2016.

4 PROCEDURE.
See attached Appendices:

Appendix 1: Inspection and testing plan for piping works.

5 SPECIAL REQUIREMENT.
All Sub-contractors, PTSC QCs and construction Team have to strictly follow this procedure and
any change shall be further agreement by PTSC QA/QC Manager.

6 RECORD.
All inspection documents QC Summary sheets shall be compiled by Quality management Team
on an ongoing basis to maintain for fabrication.

7 APPENDICES.
Appendix 1: Inspection and testing plan for piping works.

Appendix 2: Material receiving and inspection record.

Appendix 3: Over short and damage report.

Appendix 4: Material traceability record.


any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

Appendix 5: Visual inspection report.

Appendix 6: Punch list.

Appendix 7: Flushing and hydrostatic test report.

Appendix 8: Insulation report.

PETROVIETNAM TECHNICAL SERVICES CORPORATION (PTSC)


1-5 Le Duan Street, District 1, Ho Chi Minh City (VIETNAM)
AMMONIA PLANT REVAMP PROJECT
INSPECTION AND TESTING PLAN FOR PLASTIC PIPING WORKS
Appendix 1
Document No.: 2539-00-ITP-012

INSPECTION
INSP CONTROLLING INVOLVEMENT
INSPECTION ITEM CHECK POINT RECORD/REPORT
NO. DOCUMENT/CODES PTSC/ PMFC/
AECC
TECHNIP SGS

1. BEFORE FABRICATION

PREPARATION &
APPROVAL OF APPROVED DRAWINGS
DRAWINGS
FABRICATION/ ISOMETRIC DRAWINGS
QC-P01 MATERIALS H A R APPROVED DRAWINGS/
ISOMETRIC CUTTING PLAN
DRAWINGS EQUIPMENTS REGISTER

EQUIPMENT CALIBRATION
EQUIPMENT INSPECTION & TEST
QC-P02 CALIBRATION
MASTER LIST
EQUIPMENTS
H R R EQUIPMENT LIST
CALIBRATION CERTS

TECHNICIANS TRAINING TECHNICIANS TECHNICIANS REGISTER.


QC-P03 TECHNICIANS COURSE TRAINING COURSE
QUALIFICATION W/A R
H

PHISICAL
PURCHASE ORDER. IDENTIFICATION. MATERIAL RECEIVING
MATERIAL
MATERIAL CONTROL DIMENSION. INSPECTION REPORT (MRIR)
QC-P04 RECEIVING H H R
PROCEDURE QUANTITY OVERAGE, SHORTAGE &
INSPECTION
MILL / TEST CERTS. DAMAGE (OS& D ) REPORT.

2. PIPE SPOOL FABRICATION ( AT SHOP)


AMMONIA PLANT REVAMP PROJECT
INSPECTION AND TESTING PLAN FOR PLASTIC PIPING WORKS
Appendix 1
Document No.: 2539-00-ITP-012

INSPECTION
INSP CONTROLLING INVOLVEMENT
INSPECTION ITEM CHECK POINT RECORD/REPORT
NO. DOCUMENT/CODES PTSC/ PMFC/
AECC
TECHNIP SGS

SPOOL/ TAG NO.


MATERIAL
APPROVED ISO METRIC SPECIFICATION/ MATERIAL RECEIVING
INSPECTION ON DRAWINGS. GRADE. INSPECTION REPORT
QC-P05 MARKING/HEAT MATERIAL CONTROL MILL CERT / HEAT H M/R M/R TRACEABITITY RECORD.
NO. TRANSFER PROCEDURE. NUMBER.
(MRIR) & DIMENSION.
DIMENSIONS

SURFACE
SURFACE METHOD STATEMENT FOR ALIGNMENT TRACEABILITY REPORT
PREPARATION & GRP FABRICATION AND DIMENSION
QC-P06 H M/R M
DIM. INSPECTION ERECTION EDGE PREPARATION
CONECTION TYPE SPOOLS NAME AND
ISO METRIC DRAWINGS ORIENTATION

PIPE
CONNECTION HEAT TEMPERATURE
(Flanged; TECHNICIANS
METHOD STATEMENT FOR CERTIFICATE
Threaded; W M M
QC-P07 GRP FABRICATION AND
Adhesive-bonded ERECTION
joint, Hand- ISO METRIC DRAWINGS
laminated butt and
strap, etc)

ASTM D 2563 LEVEL II PITS


ISO METRIC DRAWING PIMPLES VISUAL INSPECTION RECORD
QC-P08 VISUAL H M/R M/R
AIR BUBBLES
INSPECTION
SURFACE
AMMONIA PLANT REVAMP PROJECT
INSPECTION AND TESTING PLAN FOR PLASTIC PIPING WORKS
Appendix 1
Document No.: 2539-00-ITP-012

INSPECTION
INSP CONTROLLING INVOLVEMENT
INSPECTION ITEM CHECK POINT RECORD/REPORT
NO. DOCUMENT/CODES PTSC/ PMFC/
AECC
TECHNIP SGS

TEST PRESSURE.
CLOSE OUT OF
FLANGE MANAGEMENT CATEGORY A
PROCEDURE PUNCHLIST
HYDRO TEST/FLUSHING CALIBRATED
QC-P09 HYDROTEST (IF
PACKAGE PRESSURE GAUGES H H W HYDROTESTING REPORT
ANY)
HYDROTESTING AND PRESSURE
/FLUSHING AND TEMPERATURE
PNEUMATIC PROCEDURRE RECORDER
VENTS ON HIGH AND
LOW POINTS

3. PIPE SPOOL ERECTION AT FIELD

PIPING FABRICATION
PIPING FABRICATION &
& ERECTION
ERECTION PROCEDURE
PROCEDURE
QC-P10 A. PIPE SPOOL P&ID DRAWINGS H M M
P&ID DRAWINGS
INSTALLATION ISO METRIC DRAWINGS.
ISO METRIC
DRAWINGS.

A.FIELD JOINT SEE QC-P06 TO QC-P08 SEE QC-P06 TO QC-P08 SEE QC-P06 TO QC-P08 SEE QC-P06 TO QC-P08
CONECTION

QC-P11
TORQUE
FLANGE MANAGEMENT REQUIREMENT
B. BOLT PROCEDURE FLANGE TAGGING
H M M
CONECTION BOLT TORQUE AND CORRECT GASKET
TIGHTENING PROCEDURE FLANGE JOINT
NUMBER
AMMONIA PLANT REVAMP PROJECT
INSPECTION AND TESTING PLAN FOR PLASTIC PIPING WORKS
Appendix 1
Document No.: 2539-00-ITP-012

INSPECTION
INSP CONTROLLING INVOLVEMENT
INSPECTION ITEM CHECK POINT RECORD/REPORT
NO. DOCUMENT/CODES PTSC/ PMFC/
AECC
TECHNIP SGS

LINE CHECK FOR


ISO METRIC DRAWINGS.
PUNCH LIST, CATEGORY A & B
QC-P12 P&ID DRAWINGS PUNCHLIST/OUSTANDING
OUTSTANDING ITEMS H W/R A
WORK HYDROTEST PACKAGES WORK LIST

PIPE INTERNAL
HYDRO TEST/FLUSHING
CLEANLINESS.
PACKAGE
CLOSE OUT OF
QC-P13 HYDROTESTING
FLUSHING CATEGORY A H W W
/FLUSHING AND FLUSHING REPORT
PUNCHLIST
PNEUMATIC PROCEDURRE
VENTS ON HIGH AND
LINE LIST ( INCLUDE JSA)
LOW POINTS
TEST PRESSURE.
CLOSE OUT OF
FLANGE MANAGEMENT CATEGORY A
PROCEDURE PUNCHLIST
HYDRO TEST/FLUSHING CALIBRATED
QC-P14
HYDROTEST PACKAGE PRESSURE GAUGES H H W HYDROTESTING REPORT
HYDROTESTING AND PRESSURE
/FLUSHING AND TEMPERATURE
PNEUMATIC PROCEDURRE RECORDER
VENTS ON HIGH AND
LOW POINTS
INSULATION TYPE
INSULATION
THICKNESS
INSULATION PROCEDURE INSULATION COVER
INSULATION AS ISO METRIC DRAWINGS. INSULATION
QC-P15 H M/R M/R PIPE INSULATION REPORTS
APPLICABLE P&ID DRAWINGS MATERIAL
REMOVABLE OR
PERMANENT
HYDROTEST
COMPLETED
AMMONIA PLANT REVAMP PROJECT
INSPECTION AND TESTING PLAN FOR PLASTIC PIPING WORKS
Appendix 1
Document No.: 2539-00-ITP-012

INSPECTION
INSP CONTROLLING INVOLVEMENT
INSPECTION ITEM CHECK POINT RECORD/REPORT
NO. DOCUMENT/CODES PTSC/ PMFC/
AECC
TECHNIP SGS

NEW GASKET
TORQUE
REQUIREMENT
INSTRUMENTS/VALVE
P&ID
S INSTALLED
FLANGE MANAGEMENT
CORRECT GASKET
REINSTATEMENT PROCEDURE.
QC-P16 INSTALLED H M/R M/R BOLT TIGHTENING REPORTS
(BOX UP) PUNCHLIST MANAGEMENT
PIPE SUPPORT
PROCEDURE.
INSTALLED
PIPING SPECIFICATION
INSULATION
COMPLETED
PAINT
MARKING/TAGGING

LEAK TEST PROCEURE


LEAK TEST AS
QC-P17 (INCLUDING JSA) LEAKAGES H W W LEAK TEST REPORTS
APPLICABLE
PIPING SPECIFICATION

DECREE No. 46/2013/ N- CP-


PUNCHLIST REPORT
FINAL QUALITY MANAGEMENT
OTHER REPORT/RECORD AS PER
QC-P18 INSPECTION/ AND CONSTRUCTION PUNCH LIST CLOSE
H H H/R PMFC. FORMS PROVIDED OR AS
CLOSED WORKS. OUT
PER DECREE No. 46/2013/N-CP
PUNCHLIST PUNCHLIST MANAGEMENT
RECOMMENDATION
PROCEDURE
FINAL DOCUMENTATION FOLLOW INDEX OF FINAL DOC
PROCEDURE PROCEDURE
CONTRACT ORDER OTHER REPORT/RECORD AS PER
DECREE No. 46/2015/N-CP FABRICATION PMFC. FORMS PROVIDED OR AS
QC-P19 FINAL
CONSTRUCTION WORKS- DOSSIERS H H A PER DECREE No. 46/2013/N-CP
DOCUMENTATION
DIARY RECOMMENDATION
VISUAL INSPECTION RECORD INSPECTION DOCUMENT OF
TRACEBILITY REPORT COMPLETED PIPING
AS BUILT DRAWINGS
PTSC Report No:
Request No: PETROVIETNAM FERTILIZER AND CHEMICAL CORPORATION
AMMONIA PLANT REVAMP PROJECT
P/O No:
Date of inspection:
MATERIAL RECEIVING INSPECTION REPORT
Supplier: FOR RECORD
Shipment No: Packing List No/ Invoice No.: REV: 00
Close
Item Material Received Heat No./ Colour OS&D
Description Rating SCH Size 1 Size 2 Size 3 Unit Trace No. Cert. No. Out Con-Clude
No. Grade Quantity Tag No. Code Report
Date

Remarks: ACC: Accepted; REJ: Rejected; O/S: Outstanding


All dimensions are in mm unless otherwise specified

REPRESENTATIVE OF PVFCCO MATERIAL CONTROLLER/ WAREHOUSE KEEPER REPRESENTATIVE OF TPIT:

NAME: NAME: DANG VAN TOAN/ NGUYEN HONG LAN NAME:

SIGNATURE: SIGNATURE: SIGNATURE:

DATE: DATE: DATE:

MATERIAL INSPECTOR (PTSC) REPRESENTATIVE OF CA DELIVERER:

NAME: NAME: NAME:

SIGNATURE: SIGNATURE: SIGNATURE:

DATE: DATE: DATE:

Page 1 of 1
Appendix 3

OVER, SHORT OR DAMAGE REPORT

Project: Report No.:

Non-conformance Shortage Packing list No:


Overage Material identification Delivery date:
Damage Other MRIR No.
P.O No. P.O Item Description of material Qty Description of Non-
No. conformance

OS&D raised by: Requester/Contractor: Material controller/Keeper: QC/QA Manager:

Date: Date: Date: Date:

Corrective Action Action by:

Due date:
Requester/Contractor: QC/QA Manager: Procurement Manager:

Date: Date: Date:


OS&D Closed-out

Requester/Contractor: QC/QA Manager: Procurement Manager:

Date: Date: Date:


Remarks:
PTSC Report No:
Request No: PETROVIETNAM FERTILIZER AND CHEMICAL CORPORATION
AMMONIA PLANT REVAMP PROJECT
P/O No:
Date of inspection:
MATERIAL RECEIVING INSPECTION REPORT
Supplier: FOR RECORD
Shipment No: Packing List No/ Invoice No.: REV: 00
Close
Item Material Received Heat No./ Colour OS&D
Description Rating SCH Size 1 Size 2 Size 3 Unit Trace No. Cert. No. Out Con-Clude
No. Grade Quantity Tag No. Code Report
Date

Remarks: ACC: Accepted; REJ: Rejected; O/S: Outstanding


All dimensions are in mm unless otherwise specified

REPRESENTATIVE OF PVFCCO MATERIAL CONTROLLER/ WAREHOUSE KEEPER REPRESENTATIVE OF TPIT:

NAME: NAME: DANG VAN TOAN/ NGUYEN HONG LAN NAME:

SIGNATURE: SIGNATURE: SIGNATURE:

DATE: DATE: DATE:

MATERIAL INSPECTOR (PTSC) REPRESENTATIVE OF CA DELIVERER:

NAME: NAME: NAME:

SIGNATURE: SIGNATURE: SIGNATURE:

DATE: DATE: DATE:

Page 1 of 1
Appendix 5

VISUAL INSPECTION REPORT

PROJECT : REPORT NO. :

CLIENT : DATE :

CONTRACT NO. : SHEET :

DRAWING NO. : REV:

No. JOINT No. JOINT TYPE SIZE/ LENGTH THICK BONDER ID PREHEAT VISUAL REMARKS

ALPHA ECC PTSC/TECHNIP PMFC/SGS

NAME: NAME: NAME:

SIGNATURE: SIGNATURE: SIGNATURE:

DATE: DATE: DATE:


PUNCHLIST
Appendix 6

Client: Project:
Contractor: Client:
Sub-Contractor: Purchase Order No.:
PunchList No.:

Code Reference Signature


TEST Cat. Closed
Item Line No. Punchlist Descriptions Punchlist Close-Out Status PTSC/ Remarks
Date (A/B/C) 1 2 3 4 Date AECC PMFC/SGS
TECHNIP

ALPHA-ECC PTSC/TECHNIP PMFC/SGS


Name Name Name

Signature Signature Signature

Date Date Date

Category:
Cat A: Punchlist item shall be Closed before Hydrotet/Installation. Witness closed-out item is required.
Cat B: Punchlist item shall be Closed before Hydrotest/Installation. Witness closed-out item is subject to PMFC/PTSC decision.
Cat C: Punchlist item shall be Closed before or after Hydrotest/Installation. Witness closed-out item is not required.
Code:
Code 1: Completion by Vendor prior to Test
Code 2: Completion by Vendor prior to Installation
Code 3: Completion by Vendor at Vendor's yard and submit to PTSC/PMFC approval
Code 4: Completion by Vendor at Ph M Plant

Page 1 of 1
Appendix 7

FLUSHING AND
HYDROSTATIC/PNEUMATIC
TESTING RECORD
Project :

Item :

Test Pack Number : Line service : P & ID Reference :

Design / Operating Pressure Min./ Actual Test Pressure Date :


Page :
Pack contains the following lines/ spools:

LINE No.: DWG No.: Remark

Test Acceptance:
This certifies that the above test pack has been pressure tested clean in accordance with applicable
standards and approved procedures
Remarks:

Test Instrument used:

ITEM DESCRIPTION / SERIAL NO RANGE CALIBRATION DATE

Test result :
SUCCESSFUL / UNSUCCESSFUL:
If unsuccessful, please state reason:
Conducted by Alpha-ECC QA/QC Dept.-Alpha-ECC PTSC/TECHNIP PMFC/SGS
Name Name Name Name

Signature Signature Signature Signature

Date Date Date Date

Page 1 of 2
Appendix 7

FLUSHING AND
HYDROSTATIC/PNEUMATIC
TESTING RECORD
Project :

Item :

Test Pack Number : Line service : P & ID Reference :

Design / Operating Pressure Min./ Actual Test Pressure Date :


Page :
Attachments:

1 A sketch showing the set-up and items included in the test


2 All recorder charts.

Additional Checks, Notes and Comment :

Specimen Data :
HYDROTEST PRESSURE: INITIAL TEMP. :
DESIGN PRESSURE : TIME END :
TEST DATE : FINAL TEMP. DEG C :
TIME START : TEST DURATION :

Equipment Data :
CHART RECORDER PRESSURE GAUGE 1 PRESSURE GAUGE 2
MODEL
SERIAL NO.
PRESSURE RANGE
DATE CALIBRATED

Conducted by Alpha-ECC QA/QC Dept.-Alpha-ECC PTSC/TECHNIP PMFC/SGS


Name Name Name Name

Signature Signature Signature Signature

Date Date Date Date

Page 2 of 2
Appendix 8
PETROVIETNAM FERTILIZER AND
CHEMICALS CORPORATION

NH3 PLANT REVAMP PROJECT

Report No:
INSULATION INSPECTION REPORT
Page:

Specification No:
Line/Equipment No:
Drawing no:
Spool No:

Acceptance
Inspection/Test operation Requirement
Yes No

A Insulation materials

1 Materials per speccification

B Field Application

1 Insulation type and thickness

2 Multi layering

3 Staggered Joint

4 Metal jacket thickness

5 Required overlap

6 Metail jacket, secure, spacing

7 Flashing

8 Sealing/caulking
Remarks:

Inspected by ALPHA-ECC Reviewed By PTSC/TECHNIP Reviewed by PMFC/SGS


Name: Name: Name:

Signature: Signature: Signature:

Date: Date: Date:

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