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ESIGN AND CONSTRUCTION OF THE UNDERGROUND CAVERNS, ASSOCIATED UNDERGROUND / ABOVEGROUND FACILITIES AND JETTY OF PHASE 1 JURONG ROCK

CAVERN AT BANYAN BASIN, JURONG ISLAND, SINGAPORE

Inspection and Test Procedure & Plan


(Doc. No : JRC-C05-VD-1013M-172-PIG-001-Q003)

DOCUMENT CODE 1 2 3 4 : : : : ACCEPTED ACCEPTED WITH COMMENTS TO BE REVISED / RESUBMITTED INFORMATION ONLY

NOTE: Permission to proceed does not constitute acceptance of approval of design details, calculations, analyses, test methods or materials developed/selected by the supplier and does not relieve the supplier from full compliance with contractual obligations. REVIEW DATE: ENGINEER . . LEAD ENGINEER .

2011,Aug.26

Revision No. Number of Pages Date of Issue Purpose


Employer

:0 : 16 pages : 22 Aug. 2011 : For Approval


Project Manager

Description Prepared Checked Approved

Name J.S,SEO J.K,LEE T.H,HAN

Position
Senior Engineer Engineering Manager Project Manager
Contractor

Superintending Officer

Inspection and Test Procedure Plan

Doc. No. JRC-C05-VD-1013M-172-PIG-001-Q003 (Rev.0)

Revision log
Rev. No.
0

Rev. date

Rev. page

Revision description
For Approval

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Table of contents

1. 2. 3. 4. 5. 6. 7. 8. 9.

Scope Applicable code and Specifications General Inspection of Materials Inspection of Marking and cutting for materials Inspection and Test of welding Inspection of Formed head Visual inspection for welded joints Nondestructive examination (NDE)

10. Dimensional and Visual inspection 11. Pressure test 12. Leak test for reinforcement pad 13. Inspection of Cleaning, Painting and Shipping 14. Inspection and Test Plan

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Inspection and Test Plan


1. Scope. This procedure shall be applied to the shop Inspection and Test for Pig Launcher & Receiver station. 2. Applicable Codes and Specifications Applicable codes and specification are follows. 2-1. ASME boiler and pressure vessel code, Section , DIV.1 2-2. ASME B 16.5 : Steel pipe flange, flanged valves and fittings 2-3. Engineering Spec. Doc No. JRC-CO5-VD-1013M-172-PIG-001-M0001 2-4. Fabrication Drawing. Doc No. JRC-CO5-VD-1013M-172-PIG-001-M001 3. General 3-1. All the inspection shall be performed at the APC shop in accordance with the above applicable cods standards, job specifications and fabrication drawing as approved by HDEC. 3-2. All inspection records to be submitted shall be filled out in English with all dimensions and measures in "SI UNIT", except pressure rating and nominal pipe size. 3-3. The copy of inspection reports shall be submitted to HDEC. (1) Manufacturers Data Report. (2) Material mill test (MTR) with material check list. (3) Pressure test record. (4) Dimensional inspection record. (5) Leak test for reinforcement pad. (6) Rubbing sheet of name plate. (7) Other inspection and tests, where specified

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4. Inspection of materials 4-1. Materials to be used shall be inspected visually prior to ant fabrication in accordance with Fabrication drawings, job spec. applicable standards, codes, and CTR submitted by manufacturer. 4-2. All materials shall be inspected to ensure that thee have NO Injurious defects such as crack, lamination and of thickness. 4-3. Mill test report of materials for all pressure parts shall be submitted. 4-4. Prior to fabrication of vessels, APC inspector shall check the charge number of heat number all the chemical compositions. Mechanical properties and heat treatment must be reviewed by APC inspector in accordance with each material specification. 4-5. Renascence pad and vessel nozzles shall be of the same quality of steel as the shell or head to which they are attached. 4-6. Material certificates are required according to ASME. (For all stressed part.) 4-7. Substitute material shall have same chemical and mechanical.

5. Inspection of marking and cutting for materials 5-1. All the plates, pipes and forgings used in the manufacture of pressure part shall be identified with the markings corresponding to the related mill test report and the marking shall comply with ASME Code section , DIV. 1, UG-77. 5-2. longitudinal and circumferential welded seams shall not interfere with nozzle openings, Reinforcement plates and saddle pads as far as possible 5-3. When materials are cut into pieces, they shall be inspected for dimension before cutting And ant defects on cut edges and surface after cutting shall be repaired in accordance

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With the repair procedure approved by HDEC or shall be rejected 5-4. In case the original I.D marking are unavoidably cut out or the material is divided into two Or more parts, one set shall accurately transferred and prior to cutting all mark shifts shall Be verified by APCs inspector 5-5. The transfer of I.D marking shall be cone by low-stress stamp on material over 6mm nominal thickness by stenciling or painting on material below and 6mm nominal thick.

6. Inspection and tests of welding 6-1. Qualification of welding procedure specification (WPS) All WPS shall be qualified in accordance with the requirement of ASME Sec. IX and Approved by HDEC. 6-2. Qualification of welders and welding operators welders and welding operators shall be a Person who has been qualified in accordance with the specified codes or standards. 6-3. Edge preparation and tack welding plate edges shall be beveled by any method that Will produce a reasonable smooth surface suitable for welding. A reasonable smooth surface suitable for welding. Shape of the edge shall be as shown on Approved drawings. The inspection for tack welding shall be cared out in accordance with the qualified WPS. (1) The surface to be welded shall be cleaned and have no sticking of harmful for welding. (2) Stainless steel equipment shall be welded in accordance with ASME Code. (3) All tack welds shall be removed. (4) Dimension of groove (Such as angle, Root gap, height of root ETC.) shall be checked In accordance with the fabrication drawing.

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1) Tolerance if groove shall be as follow. NOMINAL TH'K T(mm) T 4.5 4.5 T 6 6 T 20 20 T 38 38 < T CIRCUM. JOINT (mm) 1.0 1.5 T X 0.25 5 TX0.125 (MAX. 6) {TABLE 6-1} T 4.5 4.5 T 6 6<T 1.0 1.5 T X 0.25 (MAX. 3) NOMINAL TH'K T (mm) LONGI. JOINT (mm)

2) Alignment of section at edges to be butt welded shall be such that maximum offset is prescribed in the following. Root not gouged Root gap of joint without backing Groove angle of joint Alignment of joint (Butt joint) Groove profile of joint Root face of joint 1.2mm (3/64") 5 1.0mm at root side max.( 3/64") Root gouged 1.2mm (3/64") 5 See table 6-1

In accordance with the drawing concerned 0.8mm (1/32") {TABLE 6-2} 1.6mm(1/16")

6-4. Pressure retaining welds, nozzle, main way attachments and similar joints shall be full Penetration.

7. Inspection of formed head 7-1. Formed heads shall be inspected in accordance with UCS-79,UG-80, UG-81, Of the ASME CODE SECTION , DIV.1.

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7-2. After having formed, dimensional and visual inspection shall be checked for each head plat. 7-3. The shape of formed head shall be checked by a gauge plate in accordance with UG-81 OF ASME CODE SECTION , DIV.1. 7-4. Formed materials shall gave smooth surface free from press marks and other damage.

8. Visual inspection for welded joints 8-1. The surfaces of the welded joints and the adjacent area on both sides of welded joint shall be inspected against the following item by QC inspector in accordance with ASME SECTION V 8-2. All adjacent area on both sides of welded joint shall be checked to insure wall thickness Is not reduced below minimum wall thickness shown on drawing. 8-3. When defects are repaired, removal of defects and repaired area shall be examined by PT To insure complete removal of defects. 8-4. The inside edge of the nozzle shall be rounded. 8-5. Vents and drains shall be flush with the inside of the vessel. 8-6. After completion of welding, the following items shall be visually inspected.

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A) Crack B) Overlaps C) Undercut D) Bead width un-uniformity E) Bead height un-uniformity F) Crater G) Bead dripping H) Spatter I) Slag and porosity J) Incomplete penetration and lack of fusion K) Insufficient toe length of fillet weld L) Fitting and welded spots for temporary assembly M) Eccentricity of weld seam N) Deformation due to welding stress O) Thickness of reinforcement

Not permitted, remove if any Not permitted Not to exceed 0.3mm Not to exceed 5mm Not to exceed 1.5mm Remove Remove Remove Not to be exposed Not permitted Add welding Remove Not to be abnormal Not to be abnormal Not to exceed the following values

Plate thickness t (mm) T 12 12 < T 25 25 < T

Allowable thk of reinforcement (mm) 1.5 2.5 3

9. Nondestructive examination (NDE) After having finished visual inspection, NDE shall be performed as required by ASME SEC. , DIV. 1, UW-51 and UW-52, applicable drawings and job specifications. 9-1. Radiographic examination (RT) (1) RT procedures technique shall be in accordance with ASME SEC., ARTICLE 2. (2) If -Ray will be used of material below 19mm nominal thickness, demonstration for A -Ray shall be cone with X-Ray source to ensure same sensitivity and density as

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X-Ray, using minimum thickness plate in production thickness, as per ASME CODE SECTION (3) The butt welded joint of the main seams, long, and circum. Joint retaining pressure shall be Performed with the RT on the basis of the fabrication drawings prior to PWHT. (4) When rolled and welded plate is used for nozzle, manhole, the long, joint shall be Radiograph in accordance with ASME CODE SECTION , DIV. 1, UW-51. (5) When full RT is specified, main long and circum. Welding seams, butt welded joint of Nozzles made steel plate and butted shell- to-nozzle welded joint of nozzle and handholes with nominal diameter either exceed 10" or over 1.125" wall thickness shall be full examined. (6) When 100% radiography is specified all welds, including flange butt welds and nozzle to Shell connecting welds, shall be fully radiographed. Where radiography is considered to be impractical ultrasonic inspection may be substituted With prior approval of the HDEC. (7) RT for weldment of head shall be performed after forming. (8) The evaluation of indications and the acceptance criteria for RT shall be in accordance With ASME CODE SECTION , DIVISION 1, UW-51 for full RT and UW-52for spot RT. 9-2. Liquid penetrant examination (PT) (1) PT procedures shall be in accordance with the requirements and methods specified in ASME CODE SECTION , ARTICLE 7 (2) When temporary attachments are required during the forming work and pressure retaining part, They shall be welded to the shell pate using the same procedures as for the main seam after removing these attachment, the surface shall be ground flush and examined by PT (3) Are strikes on the pressure shell shall be avoided. When they occur the surface shall be Examined By the appropriate PT after removed they are strikes. Jurong Rock Cavern Phase 1 10 Page

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10. Dimensional and visual inspection 10-1. Dimension of shell and other main parts shall be checked in accordance with applicable Approved drawings at suitable stage during fabrication & after completion of construction main check items are as follows,(The check items shall be followed) with standard (1) Overall length (2) Inside diameter (3) Out of roundness (4) Location of nozzles and other attachments (Orientation and elevation) (5) Material designation, size and of nozzles (6) Projection of nozzle & manhole. 10-2. The inside diameter shall be measured at two or more positions for each section at a Distance of about 100mm from one side of a circum. Welded seam when direct measurement of the inside diameter (ID) is impractical, the external circumference mat be measured and the ID calculated. 10-3. Permissible dimensional tolerance shall be followed with standard 10-4. Out of roundness of shell section is measured horizontally for four directions.. 10-5. Actual wall thickness of main parts retaining pressure shall be measured and not less Than design calculated Thickness plus corrosion allowance or thickness shown on approval drawing 10-6. Final dimensional inspection shall be performed before hydrostatic or pneumatic test. 11. Pressure test Hydrostatic/pneumatic test shall be performed at the condition specified on the approved Fabrication drawings. The pressure test procedure for pneumatic test in accordance with ASME SECTION , DIV. 1 UG-100(D)

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11-1. Personnel All personnel performing hydrostatic testing in accordance with the requirements of this Procedure shall demonstrate that they possess sufficient knowledge and understanding of the principles and method of hydrostatic testing 11-2. Test condition The hydrostatic test shall be performed in accordance with requirements of hydrostatic Test pressure specified on the concerned drawings. (1) Holding time : At least half an hour (2) Water to be test : Clean fresh water (3) Temperature of water and metal during test : Minimum 7 11-3. Procedure The pressure in the vessel shall be increased until the required test pressure has been reached. A visual inspection for leaks shall be performed at a design pressure. (1) All welded joints shall be left insulated, unpainted, and exposed for examination during the Test. The areas to be examined shall be dry and free of oil, grease, paint or other contaminants which might mask a leak. (2) Equipment that is mot be subjected to the pressure test shall be disconnected from the unit under test or isolated by means of flanges or similar isolation methods. (3) Test gauge At least two pressure gauge shall be applied, which have measurement range of not less. Than 1.5 times and of not more than 4 times of the test pressure. If the indicating gauge is not readily visible to personnel controlling pressurization, an additional indication gauge shall be provided Where it will be visible to the operator throughout the duration of the test

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(4) Test gauge shall be calibrated and maintained good condition in. (5) Test set up : The test part shall be restrained in such a manner as to assure no elongation Or compression during the test. (6) Examination 1) All permanent joints, welds and regions of high stress such as be examined for any evidence Of leakage. 2) Leakage of temporary gaskets and seals, installed for the purpose of conducting the Hydrostatic test is not permitted leaks form permanent seals, seat and gasket joints is not permitted. 3) When performing the examination, access to the area to be viewed shall permit placing the Eye within at reasonable distance of the surface being examined at an angle of no less than 30.

Mirrors may be used to improve the angle of vision. Other aids such as magnifying lenses may be used to assist examination.
4) Upon completion of examination, the pressure shall gradually be reduced to zero. 5) Vessel which undergo a repair shall be retested to the identical pressure as the original test. (7) Acceptance criteria 1) Any indication of leakage or deformation due to test pressure shall be unacceptable. 2) If moisture caused by leakage is observed locations shall be marked and the areas shall be Repaired and retested. Any repairs made by welding shall be done in accordance with Approved repair procedure. (8) Post test cleanliness After testing, the part shall be cleaned and dried out in accordance with drawing or Customer requirements

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12. Leak test for reinforcement pad After pressure rising, the nozzles attachment welds. Welds of reinforcing PADS (Include lining weld parts) Shall be checked for leakage by soap-suds prior to hydrostatic test Test pressure : 13.5kg/ G, (Using shop air pressure) Holding time : Not less than 5 MIN. Before checking for leakage

13. INSPECTION OF CLEANING, PAINTING, AND SHIPPING 13-1. Cleaning for internal and external surface of the vessels shall show no evidence of Of excessive adherent particle on hydrocarbon. To meet these requirements, Mill scale Rust, welding slag, coatings, grease, oils, shop dirt, slips, slips, water, other foreign material and weld spatter shall be removed. 13-2. Shop painting The inspection of painting shall be performed as the following table NO 1 2 Inspection Item Surface preparation Dry film thickness Method of inspection Visual inspection Sampling inspection Selected by gauge Frequency of inspection All surfaces At random

All instruments and equipment which recommended to be used for inspection and Coating shall be readily at work area and the dry film thickness gauge shall be calibrated.

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14. Inspection and test plan 14-1. Abbreviation M : Manufacturer Vendor and / or sub vendors inspection. R : Review and acceptance of documents, report includes radiographs. W : (Witness) The operation test or examination where the Owners inspector must Be present during the specified activities. SW : Spot witness H : Hold point Application for inspection is required, Vendor / Supplier shall not proceed With work until presence of inspector or written consent of inspector APC : ASIA PROTECH CO., LTD.

HDEC : HYUNDAI Engineering & Construction Co., Ltd.

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DESCRIPTION OF TEST AND INSPECTION 1. Material Inspection 1) Visual and dimensional inspection 2) Material identification(Material cert. review) 2. Fabrication 1) Transfer of identification marking 2) Inspection of formed head 3. Visual Inspection 1) Crack for leakage 2) Welding part spatter, crack and undercut 3) Edge, fillet part beveling 4) Danger damage for machine preparation 4. Dimensional Inspection 5. Pressure Test 1) Hydrostatic test 6. NDT Review-Radiography and PT Report 7. Painting / Rust Prevention 1) Shot blast 2) 3 coat system as per painting procedure 8. Packing Inspection 9. Inspection for Shipment

APC

HDEC SW

TPI

M M R

M M W M M M M M W W W

M R

H R

M M M

R R

Issue for IRC .

R H

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