Inspection Test Plan Sample

DOCUMENT NO.
:
SEL-ITP-SA-009
AIOC-ACG PROJECT Rev. 1
Page 1 of 20
JOB NO.-1353
INSPECTION AND TEST PLAN

FOR PREPARATION & RECLAIMING OF OPENINGS IN BALLAST TANKS
WITHIN THE UPGRADE WORKS ON THE DERRICK BARGE “AZERBAIJAN”
Revised as per comments of

1 E.F. 26.12.2006 D.K. 26.12.2006 G.M. 26.12.2006
Saipem Quality Department
0 Issued for Approval E.F. 20.12.2006 D.K. 20.12.2006 G.M. 20.12.2006
ORIGINAT CHECKED
DATE DATE APP’D BY DATE APP’D BY DATE
ED BY BY
REV. Reason of Revision
MAIN CONTRACTOR
SWIFT-ENGINEERING LIMITED
(SAIPEM)
DOCUMENT NO.:
INSPECTION AND TEST PLAN SEL-ITP-SA-009
FOR PREPARATION & RECLAIMING OF OPENINGS ON Rev. 1
THE DERRICK BARGE “AZERBAIJAN” Page 2 of 20
JOB NO.-1353
PAGES AND REVISION TABLE
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DOCUMENT NO.:
FOR PREPARATION & RECLAIMING OF OPENINGS ON THE Rev. 1
DERRICK BARGE “AZERBAIJAN” Page 3 of 20
JOB NO.-1353
CONTENTS
Section Description Page
1.0 Scope 4-6
2.0 Responsibilities
2.1 Responsibilities of Swift Engineering Limited 6
2.2 Responsibilities of the Main Contractor 7
3.0 Explanation for Tables
3.1 Classifications of Checks, Examinations and Tests 7-8
3.2 Reference Document 8-9
3.3 Report Forms 9-10
3.4 Responsible Person 10
4.0 Equipment Mobilization 10
5.0 Personnel Mobilization 10
Table 1 Material Control 11
Table 2 Preparation of tank access openings 12
Table 3 Installation and reclaiming of openings 13-14
Table 4 Testing activities 15
Table 5 Painting activities control 16
Table 6 Final documentation and hand over 17
Appendix I 18
Appendix II 19
Appendix III 20
DOCUMENT NO.:
JOB NO.-1353
1.0 Scope.
1.0.1 This Inspection and Test Plan covers the checks, examinations and tests to be carried out on Renewal works of Wooden
Panels on the Derrick Barge “Azerbaijan”.
1.0.2 This Inspection and Test Plan is to be considered as a summary of information necessary for a correct performance of
these checks, examinations and tests and an interface document for the Client and any other organisations concerned to
clarify the relevant interventions and duties.
1.0.3 Routine checks, examinations, tests and any other inspection activities, which do not require the issue of relevant
documents, are not covered by this plan. They shall in any case be carried out to the extent necessary to satisfy the
contractual requirements and to ensure proper execution and control of the work being performed.
1.0.4 This plan may be formally updated through the Management Review Process taking into account any applicable indications
for reference documents, testing procedures, qualification records, etc., and for the recording forms, and by the Client or
any other organisation involved, for test witnessing and acceptance.
1.1 Definitions.
Acceptance Specified limits placed on characteristics of an item, process, or service defined in codes,
Criteria standards, or other requirement documents.
The Work All fabrication, installation & commissioning works undertaken by Swift-Engineering Limited.
The Contractor The organisation to whom Swift-Engineering Limited are under contract to.
Therefore the contractor is Saipem.
DOCUMENT NO.:
JOB NO.-1353
The SubContractor : Swift Engineering Limited (SEL).
The Owner : AIOC/BP
The Contract : Formally executed contracts and any attachments thereto between Swift Engineering Limited
and it’s Clients
The Standard : All technical Standards Listed in the Contract
The Specification : Technical Specifications referred to in the Contract
Checks : Activities including measuring, examination, testing, gauging one or more characteristics of
Product or service and comparing these with specified requirements to determine conformity.
Examinations : An element of inspection consisting of investigation of materials, components, supplies, or

Services to determine conformance to the specified requirements. Examination is usually
non-destructive and includes simple physical manipulation, gauging and measurement.
Test : An element of inspection for the determination of the capability of an item to meet specified
requirements by subjecting the item to a set of physical, chemical, environmental or
operating conditions as appropriate
Non-Conformity : The non-fulfilment of specified requirements
WPS : Welding Procedure Specification

DOCUMENT NO.:
JOB NO.-1353
PQR : Procedure Qualification Record
VE : Visual Examination
2.0 RESPONSIBILITIES
2.1 Responsibilities of Swift-Engineering Limited
2.1.1 SEL shall perform all checks, examinations and tests required for acceptance of the work and to report to the Contractor
the results unless otherwise specified.
2.1.2 SEL shall perform all preparation for checks, examinations and tests for witness by the Contractor where appropriate.
2.1.3 The Contractor shall have access at any time to the SEL working area to check inspections activities.
2.1.4 SEL shall perform the following:
▫ Checks, examinations and tests which are defined to be in scope of work in this Inspection & Test Plan.
▫ Interpret and evaluate the results.
▫ Issue the reports in the stated format.
DOCUMENT NO.:
JOB NO.-1353
2.2 Responsibilities of the Contractor
2.2.1 The Contractor will have the right to witness and/or review tests and inspections performed by SEL at any time provided that
the work is not unreasonably suspended or disturbed.
2.2.2 At his discretion, the Contractor may witness and/or review tests and inspections for items of which are listed in this
Inspection and test Plan and approve tests and inspections by signing the reports.
3.0 EXPLANATION FOR TABLES
3.1 Classifications of Checks, Examinations and Tests
3.1.1 Involvement of the Contractor and any other organisations concerned in the overall process for each check, examination and
test activity given in this Inspection and Test Plan may be inserted prior to issuance of this Inspection & Test Plan “For
Construction”. Such changes shall result in the document reference indicator number being changed to reflect the project
specific nature of the Plan.
3.1.2 Definitions of codes used for involvement are as follows and indicated at the foot of each page of this Inspection and test
Plan.
0: The party who executes the checks, examinations and tests given in the related paragraph,
1: The party who inspects the checks, examinations and tests given in the related paragraph,
2: The party who reviews the checks, examinations and tests given in the related paragraph,
3: The party who witnesses the checks, examinations and tests given in the related paragraph,
DOCUMENT NO.:
JOB NO.-1353
R: Shows that the activity given in that column is carried out randomly
H: Shows that the activity given in that column can not be carried out without any acceptance, review,
Witness or check of the Client
3.1.3 The Contractor may the review this Inspection & Test Plan and indicate their involvement for each check, examination and
test item by introducing above given definitions.
3.1.4 The involvement of Contractor responsible person nominated to execute each quality related activity during the performance
of the work is clearly defined in this Inspection & Test Plan.
3.1.5 If the Client introduces to add the Hold Points (H) and Witness points (3) on some more activities than assigned by SEL,
the Inspection and Test plan is revised in accordance with the Contractor requests and submitted to the Client for his
approval by the Contractor. After Contractor approval the Inspection and Test Plan shall be stamped as “For Construction”
and distributed in accordance with the Document and Data Control Procedure of Swift Engineering Limited.
3.2 Reference Document
3.2.1 Referenced Documents indicated in front of the each activity on the Inspection and Test Plan may by the Procedures
generated by SEL, Client Specifications, International Standards, Contracts and other Contractual Documents. The description
of the most used referenced documents is as follows :
DOCUMENT NO.:
JOB NO.-1353
SAIPEM SOW : Saipem Scope of Work for preparation and closing of openings
: Swift Method Statement for Openings
SPC-SPA-HSE-002-E : Health, Safety and Environmental Requirements for Subcontractors
SPC-COR-QUAL-002-E : Medium Criticality Specification
: Russian Maritime Register of Shipping
AWS D1.1 : Structural Welding Code
SEL-QP-019 : Fabrication and Installation of Steel Structure
SEL-QP-022 : General Welding Procedure
SEL-QP-023 : Visual Examination Procedure
SEL-QP-026 : Dimensional Survey Procedure
SEL-QA-006 : Product Identification and Traceability Procedure
SEL-QA-003 : Document and Data Control Procedure
3.3 Report Forms
Report Forms indicated in front of the each activity in the Inspection and Test Plan shall be produced for carried out work by
SEL. Quality forms shall be sent to the Contractor for their review and approval for construction upon their request. If it is not
required by the Contractor then SEL shall use them without any approval of the Contractor. All quality reports to be used in
construction works are given on this Inspection and Test Plan in the Table 1 through the Table 6 and additionally given as
Appendix I to this Inspection and Test Plan.
During the production the Non-Conformance report (NCR) can be filled by QC Inspector or Coordinator as shown on related
paragraphs on this Inspection and Test Plan.
Report forms shall be numbered in accordance with the Document and Data Control Procedure of SEL.
DOCUMENT NO.:
JOB NO.-1353
The Final Documentation Index is given as Appendix II to this Inspection and Test Plan.
3.4 Responsible Person
Responsible person is identified by the Project Manager and Quality Manager to follow up the activities shown in this
Inspection and Test Plan.
4.0 Equipment Mobilization
All materials and equipments will be brought onto the DBA under Sapiem control and personnel, and shall meet the
requirements of Saipem HSE specification SPC-SPA-HSE-002-E. All measuring equipments used on the Project shall be
calibrated. The equipments which the calibration date expired shall not be used on site and if any such situation occurs, the
equipment shall be removed from the site immediately. The all equipments, tools shall be stored in safe container. All
welders shall be provided with the quivers. All lifting equipments shall be given a present lifting code and shall have load test
certification. These cert’s shall be attached to the delivery notes during the equipment or material deliveries when they are
required in process.
5.0 Personnel mobilization
The number of personnel who will do the corresponding job under this project shall be defined by Project Manager. All
welders who are involved within this Project shall have the correct welder certificates. All gougers shall be experienced and
tested at the fab-shop if the Contractor require. NDT of welds will be MPI and to be done only by qualified technicians by
ASNT Level 2.
The Project organisation chart is given as Appendix III to this Inspection and Test Plan.
DOCUMENT NO.:
JOB NO.-1353
TABLE 1.0 : MATERIAL CONTROL

ITEM Description of checks, examinations and Procedure Responsible Involvement
Output Document
NO: tests Reference Person SEL SA BP RMRS
Apply receiving inspection to the Free Issue Delivery Notes,
Drawings, PO’s
1.0.1 Material delivered to the Contractor’s Non-Conformance QC Inspector 0-1
& Sel-QA-006
Warehouse or site. report
Verify availability and conformity of the Delivery Notes,
Drawings, PO’s
1.0.2 Manufacturer Certificate for the Free Issue Non-Conformance QC Inspector 0-1
& Sel-QA-006
Material delivered to the Contractor. report
Discrepancy report,
Apply receiving inspection to the material Drawings, PO’s
1.0.3 Non-Conformance QC Inspector 0-1
delivered to the Contractor’s Warehouse. & Sel-QA-006
report
Verify availability and conformity of the Delivery Notes,
Drawings, PO’s
1.0.4 Manufacturer Certificate for the materials Non-Conformance QC Inspector 0-1
& Sel-QA-006
delivered to the Contractor. report
Discrepancy report,
Check storing condition of the material in the Drawings, PO’s
1.0.5 Non-Conformance QC Inspector 0-1
warehouse. & Sel-QA-006
report
Verify that material type and ID is Drawings, PO’s Non-Conformance
1.0.6 QC Inspector 0-1
permanently marked on the material surface. & Sel-QA-006 report
Verify that receiving inspection has been
1.0.7 performed to the materials and they were SEL-QA-006 SC104 QC Inspector 0-1
released to use
LEGEND: SEL : Swift-Engineering Limited 0: Execution R : Random
SA : Saipem 1: Inspection H : Hold Point
RMRS : Certifying Authority 2: Review
3: Witness
DOCUMENT NO.:
JOB NO.-1353
TABLE 2.0 : PREPARATION OF TANK ACCESS OPENINGS

ITEM Description of checks, Procedure Responsible Involvement
Output Document
NO: examinations and tests Reference Person SEL SA BP RMRS
Saipem SOW,
2.0.1 Verify that a PTW in place HSE QC Inspector 0-1
HSE Plan
Ensure that all construction drawings
Document not
2.0.2 were reviewed b and approved by Saipem SOW QC Inspector 0-1
applicable
RMRS
Check that the marking of to be cut Document not
2.0.3 part of shell plate is correct and up to Related Drawings applicable (only visual QC Inspector 0-1
the drawings check)
Ensure that ballast tanks inside is safe
Saipem SOW, TRA,
2.0.4 secured and any unsafe action to be QC Inspector 0-1
HSE Plan PTW
suggested to happen is prevented
Document not
Check (visually) that cutting surfaces
2.0.5 SEL-QP-019 applicable (only visual QC Inspector 0-1
are free from any defects check)
Document not
Check that flame cut edges which are
2.0.6 SEL-QP-019 applicable (only visual QC Inspector 0-1
not welded have been ground smooth check)
Check that defects (if any) on the Document not
2.0.7 flame cut edges have been dressed SEL-QP-019 applicable (only visual QC Inspector 0-1
out/repaired check)
3: Witness * To be filled in case of any non-conformity.
DOCUMENT NO.:
JOB NO.-1353
TABLE 3.0 : INSTALLATION AND RECLAIMING OF OPENINGS
ITEM Description of checks, Procedure Responsible Involvement
Output Document
NO: examinations and tests Reference Person SEL SA BP RMRS
Apply dimensional inspection on plate
Drawings, Document not applicable
3.0.1 size for the openings and compare QC Inspector 0-1
Saipem SOW (only check & measure)
with the approved drawings by RMRS
Ensure that the bevel on the cut plate
Drawings, Document not applicable
3.0.2 and shell plate is not more than 30° QC Inspector 0-1
Saipem SOW (only check & measure)
(so the groove angle shall be 65° max)
Apply Visual Examination to the SEL-QP-019 Document not applicable
aligned component SEL-QP-022 (only check & measure)
SEL-QP-022
Verify that WPS has been qualified and
3.0.3 Related WPS’s NC 101* QC Inspector 0-1
meets the requirements of standards and PQR’s
Check that the surface of the material
within 50 mm from proposed weld is Document not applicable
3.0.4 SEL-QP-022 QC Inspector 0-1
dry, clean and free from any (only check & measure)
contaminants
Check that welders has valid certificate
3.0.5 SEL-QP-022 NC 101* QC Inspector 0-1
for the subject welding
SEL-QP-022
Check that welders are applying the
3.0.6 Related WPS’s Welder audit reports QC Inspector 0-1
welding variables given in the WPS and PQR’s
DOCUMENT NO.:
JOB NO.-1353
TABLE 3.0 : INSTALLATION AND RECLAIMING OF OPENINGS

ITEM Description of checks, examinations Procedure Output Responsible Involvement
NO: and tests Reference Document Person SEL SA BP RMRS
Apply visual examination to the
3.0.7 SEL-QP-022 QC 201-S001 QC Inspector 0-1
completed welds/weld repairs
Apply dimensional examination to the
3.0.8 Related Drawings QC 201-S003 QC Inspector 0-1
welded component
Raise NDT Request for the application of Company
3.0.9 QC200G-004 QC Inspector 0-1
100 % MPI Requirements
NDT Inspection
3.0.10 Apply 100% MPI on new welds NDT procedures QC Inspector 3
Reports
Document not
Check that ID of the welder is marked
3.0.11 SEL-QP-022 applicable (only QC Inspector 0-1
adjacent to the weld check & measure)
Apply final visual and dimensional
examination to the fabricated sections QC201-S003
3.0.12 SEL-QP-025 QC Inspector 0-1
prior to painting and raise structural QC201-S004
punch list
Company
3.0.13 Raise Steel structure weld control log QC201-S002 QC Inspector 0-1
Specification
Release sections for painting & raise Final Drawings, QC200-G001
completion report after painting Scope of Work QC200-G005
DOCUMENT NO.:
JOB NO.-1353
TABLE 4.0 : TESTING ACTIVITIES

Apply visual examination to the
4.0.1 SEL-QP-022 QC 201-S001 QC Inspector 0-1
completed welds/weld repairs
Apply dimensional examination to the
4.0.2 Related Drawings QC 201-S003 QC Inspector 0-1
welded components
Company
Raise NDT Request for the application of
4.0.3 Requirements & QC200G-004 QC Inspector 0-1
100 % MPI
RMRS Regulation
NDT Inspection
4.0.4 Apply 100% MPI on new welds NDT procedures QC Inspector 3
Reports
Inspection of the welds by UT to be
4.0.5 agreed with RMRS Surveyor (it is not - - - -
req’d at the moment by RMRS)
Ensure that the welds of ballast tank
openings are inspected after the ballast
4.0.6 RMRS Regulation QC 200G-001 QC Inspector 0-1
tanks filled with water up to the top of air
line ***
*** Agreed with RMRS. May be the method of “Watering with Kerosine” will be applied. The inspection method
will be advised by RMRS later stage.
DOCUMENT NO.:
JOB NO.-1353
TABLE 5.0 : PAINTING ACTIVITIES CONTROL (**) (IF REQUIRED)

ITEM Description of checks, examinations and Procedure Output Respons. Involvement
NO: tests Reference Document Person SEL SA BP RMRS
Apply receiving inspection to all materials to be PCH ITP Certification
used for painting works. SWIFT/30/ITP/01 check
Check paint ID /Lot No and expiry date prior to PCH ITP
5.0.2 NC101* QC Inspector 0-1
painting application SWIFT/30/ITP/01
Check that ambient temperature, dew point and
PCH ITP
5.0.4 humidity are convenient for blasting/painting NC101* QC Inspector 0-1
SWIFT/30/ITP/01
operation.
Check that compressed air free from oil, water PCH ITP
5.0.4 NC101* QC Inspector 0-1
and contaminates. SWIFT/30/ITP/01
Check required surface profile is achieved and
PCH ITP
5.0.5 surface to be painted is dry and free from any NC101* QC Inspector 0-1
SWIFT/30/ITP/01
containment.
Check dry film thickness and visually PCH ITP Related dry film
examination for primary & intermediate coat. SWIFT/30/ITP/01 thickness report
Check dry film thickness and visually PCH ITP Related dry film
examination for top coat. SWIFT/30/ITP/01 thickness report
QC
PCH ITP
5.0.8 Check documentation for painting Documentation QC Inspector 0-1
SWIFT/30/ITP/01
Package
RMRS : Certifying Authority 2: Review * To be filled in case of any non-conformity.
3: Witness ** The painting to be done by Swift Subcontractor.
DOCUMENT NO.:
JOB NO.-1353
TABLE 6.0 : FINAL DOCUMENTATION & HAND OVER

Collation and compilation of material Hand-Over Certification Clerk/QC
6.0.1 SEL-QA-003 0-1
and/or equipment certification Package Manager
Review of certification documentation
pertaining to completeness and compliance Hand-Over Certification Clerk/QC
6.0.2 SEL-QA-003 0-1
with Client requirements, inspection and Package Manager
test plans
Review an ongoing collation of all Hand-Over Certification Clerk/QC
6.0.3 SEL-QA-003 0-1
certification documents and certificates Package Manager
Submit certification dossier for Client Hand-Over Certification Clerk/QC
6.0.4 SEL-QA-003 0-1
approval Package Manager

3: Witness
APPENDIX I
DOCUMENT NO.:
LIST OF APPLICABLE REPORT SEL-ITP-SA-009

Rev. 0
FORMS
Page 18 of 20
JOB NO.-1353
DOC. NO. DOCUMENT NAME REV. NO
NC 101 Non-Conformance Report 0
SC104 Material receiving inspection report 0
QC 201S-001 Visual Examination Report for Structural Weld Joints 1
QC 201S-002 Structural Weld Control Log 1
QC 201S-003 Final Visual and Dimensional Control Report 1
QC201S-004 Punch List for Structural Works 1
QC 200G-001 Final Work Inspection and Completion Report 2
QC 200G-004 NDT Request 2
QC 200G-005 Release form for Painting 1
APPENDIX II
DOCUMENT NO.:
SEL-ITP-SA-009
FINAL DOCUMENTATION INDEX Rev. 0
Page 19 of 20
JOB NO.-1353
1.0 MATERIAL
1.1 Material certificates
2.0 PERSONNEL
2.1 Welder certificates and qualification certificates of
other personnel involved on this job
3.0 WELDING
3.1 WPS and PQR’s
4.0 CALIBRATION
4.1 Calibration certificates of all equipments involved on
this SOW
5.0 INSPECTION REPORTS

5.1 Final work inspection and mechanical completion
5.2 Stage inspection release certificate
5.3 NDT reports
5.4 Daily Quality Control reports for Steel Work
5.5 Reports for Electrical Works
6.0 APPLICABLE DOCUMENTATION

6.1 Drawings
6.2 Procedures
6.3 Standards
6.4 Contract requirements
APPENDIX III
DOCUMENT NO.:
SEL-ITP-SA-009
PROJECT ORGANIZATION CHART Rev. 0
Page 20 of 20
JOB NO.-1353
SAIPEM FIELD
HSE
COORDINATOR
MANAGING DIRECTOR
Glenn Markham
ENGINEERING
OPERATIONS MANAGER.
HSE MANAGER
PROJECTS PROJECT ENGINEER David Kavanagh
COORDINATOR Ruslan Mustafeyev
Alan Whitby
DESIGN & DRAWINGS HSE ADVISOR

Ruslan Mustafeyev Riad Bagirov
QA/QC MANAGER PR0CUREMENT &

Elshan Feyzooleyev COST CONTROL
Azer Bagirov
QA/QC INSPECTOR QA/QC OPERATIONS

Arif Bayramov Nassiyat Hajiyev MANAGER
Dave Mathewson
FABRICATION
SUPERINTENDANT
Tafakul Shiraliyev
PIPING SUPERVISOR FABRICATION

SUPERVISOR MATERIAL CONTROLLER
Samir Mamedzadeh Vadim Ramaldanov
Andrey Skripil

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DOCUMENT NO.

INSPECTION AND TEST PLAN

Revised as per comments of

PAGES AND REVISION TABLE

Page Revision Table Page Revision Table

1.0 Scope 4-6

The SubContractor : Swift Engineering Limited (SEL).

The Owner : AIOC/BP

The Standard : All technical Standards Listed in the Contract

The Specification : Technical Specifications referred to in the Contract

Examinations : An element of inspection consisting of investigation of materials, components, supplies, or

Non-Conformity : The non-fulfilment of specified requirements

WPS : Welding Procedure Specification

PQR : Procedure Qualification Record

2.1 Responsibilities of Swift-Engineering Limited

2.1.4 SEL shall perform the following:

2.2 Responsibilities of the Contractor

3.0 EXPLANATION FOR TABLES

3.1 Classifications of Checks, Examinations and Tests

3.2 Reference Document

3.3 Report Forms

3.4 Responsible Person

4.0 Equipment Mobilization

5.0 Personnel mobilization

TABLE 1.0 : MATERIAL CONTROL

TABLE 2.0 : PREPARATION OF TANK ACCESS OPENINGS

TABLE 3.0 : INSTALLATION AND RECLAIMING OF OPENINGS

TABLE 4.0 : TESTING ACTIVITIES

TABLE 5.0 : PAINTING ACTIVITIES CONTROL (**) (IF REQUIRED)

TABLE 6.0 : FINAL DOCUMENTATION & HAND OVER

LEGEND: SEL : Swift-Engineering Limited 0: Execution R : Random

LIST OF APPLICABLE REPORT SEL-ITP-SA-009

5.0 INSPECTION REPORTS

6.0 APPLICABLE DOCUMENTATION

DESIGN & DRAWINGS HSE ADVISOR

QA/QC MANAGER PR0CUREMENT &

QA/QC INSPECTOR QA/QC OPERATIONS

PIPING SUPERVISOR FABRICATION

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