Preparation of

Inspection and Test

Plans for Piping
fabrication, xxxxx-8830-PR-nnnn
erection and FOSTER WHEELER PAGE 1 of 11
testing QUALITY MANAGEMENT REV: 01

REVISION REV 01 REV A1 REV A2 REV A3 REV A4 REV A5

DATE
ORIG BY
APP BY
QA REVIEW

Contract No :

Clients Name :

Project Title :

Project Location :

CONTENTS

SECTION SUBJECT

1
PURPOSE

2
SCOPE

3
DEFINITIONS

4
REFERENCE DOCUMENTS

5
RESPONSIBILITIES

6
PROCEDURE

6.1
General Overview
6.2
Responsible Parties
6.3
Responsibility Definition
6.4
Inspection Forms
6.5
Submission of Inspection Forms

ATTACHMENTS

1
INSPECTION AND TEST PLAN
 Preparation of
Inspection and
Test Plans for
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PAGE 2 of 11 FOSTER WHEELER erection and
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1. PURPOSE

The purpose of this procedure is to define the project requirements for the Piping fabrication erection
and testing works inspection and test plan preparation.

2. SCOPE

The scope of this document is limited to piping fabrication, erection and testing works.

3. DEFINITIONS

ASNT American Society for Non-destructive Testing

CSWIP Certification Scheme for Welding and Inspection Personnel
FW Foster Wheeler
RT Radiographic testing
UT Ultrasonic testing
MPI Magnetic particle inspection testing
DP Dye penetrant inspection testing
PMI Positive Material Identification
PT Pressure testing
NDE Non-destructive examination
MIR Material issue request
BOM Bill of Material
WPS Weld procedure specification
EFD Engineering Flow Diagram (P&ID)

4. REFERENCE DOCUMENTS

ASME V Non-destructive Examination

ASME IX Welding and Brazing Qualifications
ASME B31.3 Process piping
59B50 Pipe supports standard
80A3 PMI of alloy materials during site fabrication and erection
83A1 Protective paint and coatings
88A1 Submission of welding and manufacturing procedures for review
88C2 General requirements for pipework fabrication
89A1 Pressure testing of piping and equipment

5. RESPONSIBILITIES

5.1 Piping Contractor

The Piping Contractor shall be responsible for preparing an inspection and test plan in accordance
with the requirements of this procedure and for undertaking work in accordance with the contract and
documents referenced in Section 4 above and Attachment 1.

5.2 Foster Wheeler

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Inspection and Test
Plans for Piping
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erection and FOSTER WHEELER PAGE 3 of 11
testing QUALITY MANAGEMENT REV: 01

Foster Wheeler shall be responsible for monitoring the Piping Contractor in the execution of the
contract and for ensuring the inspection and test plan produced by the Contractor is produced to
meet the requirements specified. Foster Wheeler shall also be responsible for monitoring the
adherence by the Contractor to the agreed inspection and test plan for the work.

5.3 Client

The Client shall review and monitor Foster Wheeler and the Piping Contractor in the execution of the
agreed inspection and test plan as specified in Attachment 1.

6. PROCEDURE

6.1 General Overview

Attachment 1 provides guidelines for the preparation of an inspection and test plan for the Piping
fabrication, erection and testing works. The Contractor shall prepare a specific Inspection and Test
Plan and necessary associated procedures that define how the quality of the listed activities in
Attachment 1 shall be controlled. In developing the inspection and test plan, the Contractor shall as a
minimum, include the requirements contained in Attachment 1. The inspection and test plan shall be
prepared and issued for agreement to Foster Wheeler prior to the kick-off meeting.

The inspection and test plan shall be used in the control of the execution of the contract. A copy of
the inspection and test plan shall be signed by all parties involved in the inspection of the works. A
completed inspection and test plan shall be included in the final data book. A data book shall be
prepared to record all inspection and testing undertaken in executing the contract.

6.2 Responsible Parties

Responsible parties listed in Attachment 1 of this overall Inspection and Teat Plan are as follows:

C = Contractor
F = Foster Wheeler
N = Client
T = Third Party Inspection

6.3 Responsibility Definition

Responsibilities listed in Attachment 1 of this overall Inspection and Test plan are as follows:

X = Responsible for implementing the work and for undertaking Quality Control
inspection of the work on an ongoing basis
R = Responsible for reviewing and authorising submissions
H = Responsible for witnessing and signing work releasing Hold Points. Foster Wheeler
and Client inspectors are to be advised by the Contractor of witness points.
Inspection may not be waived by identified participants.
I = Responsible for sample witnessing and signing work releasing Hold Points. Foster
Wheeler and Client inspectors to be advised by the Contractor of witness points.
Sample witness inspection may be waived by identified participants.
W = Responsible for witnessing and signing work releasing Hold Points. Foster Wheeler
and Client inspectors are to be advised by the Contractor of witness points.
Witness inspection may be waived by identified participants.

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6.4 Inspection Forms

Inspection forms have been defined in Attachment 1 that are available for use by the Piping
Contractor in undertaking the work. Contractors inspection forms may be submitted for approval for
the work, providing they meet the minimum content of those Foster Wheeler forms listed as available
for use. Where Contractor inspection forms are approved for use, the Contractor shall substitute the
agreed forms for those identified in Attachment 1. Supplementary Contractor forms may also be
added to those identified. Inspection forms shall be completed by the Contractor on an ongoing basis
for all inspections undertaken.

Completed inspection forms shall be compiled into the data books on an ongoing basis. Upon
completion of work, the data book shall immediately be submitted to Foster Wheeler.

6.5 Submission of Inspection Forms

The Contractor shall submit completed inspection forms to Foster Wheeler for acceptance in those
instances where work has been inspected by Foster Wheeler personnel. Such submission shall take
place within 24 hours of the actual inspection having taken place. Foster Wheeler shall be
responsible for ensuring that Client acceptance is obtained for those inspections also witnessed by
Client personnel.
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erection and testing ATTACHMENT 1 INSPECTION AND TEST PLAN REV: 01
ITEM ACTIVITY CONTROL DOCS PROCEDURE REQUIRED REPORT HOLD RESPONSIBILITY COMMENTS
FORM /
CHK. LIST C F N T
No.
1.0 Design Documents
1.1 Review Workscope Contract Requisition X
and associated
documents and
drawings
1.2 Review FW Drawings/documents X
1.3 Prepare Inspection and Test Plan Agreed Inspection and Test Plan No work to proceed X R R R
without an agreed
inspection and test
plan
1.4 Contract kick-off meeting Contract Requisition Notes of X X X X
and associated meeting
documents and
drawings
2.0 Documents Requiring Approval
2.1 Weld Procedure Specifications 88A1 Submission of Weld Procedure X R R R
ASME IX Specifications and Weld Procedure
Qualification Records
2.2 Welder Qualification Records 88A1 FWEL 3417 X R R R
ASME IX
2.3 Dye Penetrant Test Procedure 88C2 X R R R
ASME V
Procedures and
2.4 Radiographic Test Procedure 88C2 qualifications to be X R R R
ASME V reviewed and
approved prior to
2.5 Magnetic Particle Inspection 88C2 X R R R
performing any
Procedure ASME V welding or Non-
2.6 Ultrasonic Test Procedure 88C2 destructive X R R R
examination work
ASME V
2.7 Post Weld Heat Treatment 88C2 X R R R
Procedure ASME B31.3
2.8 Positive Material Identification 80A3 X R R R
Procedure
2.9 Pressure Test procedure 89A1 X R R R

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ITEM ACTIVITY CONTROL DOCS PROCEDURE REQUIRED REPORT HOLD RESPONSIBILITY COMMENTS
FORM /
CHK. LIST C F N T
No.
ASME B31.3
2.10 Non Destructive Examination ASNT or CSWIP Technician certificates X R R R
Operator Qualifications to be provided for RT,
UT, MPI, DP, PMI and
PT testing activities
prior to any NDE
testing.
2.11 Painting Procedure 83A1 X R R
2.12 Method Statements X R R
3.0 Materials
3.1 Free Issue Materials
3.1.1 Raise issue request and obtain Approved MIR Requests to be X R
approval approved by
appropriate FW
supervisor prior to
being submitted to site
Material
Controller/Stores.
Material to be
requested on a
drawing basis
3.1.2 Obtain material from stores Approved MIR X X
3.1.3 Receipt of materials Quality of materials to X X
be checked.
Certification and
marking to be
checked. Contractor to
confirm all material is
in accordance with
drawing, BOM and
MIR and undamaged
3.1.4 PMI at FW warehouse PMI of alloy and stainless steel FWEL 3415 X W R
items
3.1.5 Receipt of in-line instruments and Approved MIR Quantity of items X R
other tagged items received and tag
numbers to be
checked.
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erection and testing ATTACHMENT 1 INSPECTION AND TEST PLAN REV: 01
ITEM ACTIVITY CONTROL DOCS PROCEDURE REQUIRED REPORT HOLD RESPONSIBILITY COMMENTS
FORM /
CHK. LIST C F N T
No.
3.1.6 Preservation of materials and X I I Maintenance log to be
equipment maintained by
Contractor throughout
duration of Contract from
receipt to system
Turnover.
3.2 Contractor supplied materials
3.2.1 Assessment of suppliers Contractor to assess X R Suppliers to operate a
suppliers to ensure Quality Management
technical requirements System meeting ISO
are met and to the 9000 requirements.
appropriate quality Certification not
level. essential.
3.2.2 Purchase order placement X R Purchase orders to be
maintained
3.2.3 Inspection of purchased items All purchased items to X R Purchased items without
be inspected against appropriate certification
the requirements of to be rejected and
the purchase order. quarantined. No material
Accompanying to be released for use
certification to be until appropriate
checked and included certification is available.
in data book
4.0 Inspection Measurement and Test Equipment
4.1 Calibration Control All inspection, X R R Calibration status to be
measurement and test identified on the
equipment to be equipment. Out of
calibrated. Certificates calibration equipment to
to be available for be removed from use.
review.
5.0 Welding and Non Destructive Testing Operations
5.1 Storage of Welding consumables Segregation and storage of welding X I I
rods. Issue and return of unused
consumables
5.2 Calibration of ovens Oven temperatures to X I I Oven temperature
be checked and gauges to be checked
recorded daily against thermometer.
Ovens to be calibrated.
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ITEM ACTIVITY CONTROL DOCS PROCEDURE REQUIRED REPORT HOLD RESPONSIBILITY COMMENTS
FORM /
CHK. LIST C F N T
No.
5.3 Issue of consumables Only the appropriate X I I Issue log to be
quantity of maintained showing
consumables to be welder and quantity.
issued to welders that Returns to be recorded.
can be used in one
shift
5.4 Control of consumable quivers Quivers to be heated. X I I No quivers to be left
Temperatures to be open during welding
maintained within operations
quivers.
5.5 Weld Procedure Specifications Approved WPS FWEL 3414 Weld procedure X I R
specifications to be
displayed for welders
reference. Approved
welders list to be
displayed
5.6 Welder performance Individual welder FWEL 3407 Logging welders IDs X R Contractor shall submit
daily performance FWEL 3409 to welds welders performance
record daily for NDE selection
5.7 Weld reports, Weld tests, Weld 88A1 FWEL 3407 X R R Completed NDE packs
inspection summary sheet ASME B31.3 to be submitted to FW
and approved prior to
any hydro testing
5.8 Visual Inspection of welds 88A1 FWEL 3460 X W W
ASME B31.3
5.9 MPI examination 88C2 FWEL 3411 X R R
ASME B31.3
5.10 DP examination 88C2 FWEL 3411 X R R
ASME B31.3
5.11 Radiographic examination 88C2 FWEL 3410 X R R
ASME B31.3
5.12 UT examination 88C2 FWEL 3412 X R R
ASME B31.3
5.13 PMI examination 80A3 FWEL 3415 X W R
5.14 Post weld heat treatment and 88C2 FWEL 3413 X W R
hardness testing ASME B31.3 FWEL 3416
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FORM /
CHK. LIST C F N T
No.
FWEL 3418
6.0 Pipe Supports
6.1 Fabrication 59B50 X I W Welding and NDE see
Pipe support section 5
drawings
6.2 Erection 59B50 X I I
Pipe support
drawings
6.3 Inspection and Acceptance Pipe support X I I
drawings
7.0 Piping Fabrication and erection
7.1 Visual inspection of fit-up conditions, ASME B31.3 FWEL 3460 Check and record X W I For welding and NDE
root gap, groove, bevelling, joint Isometric drawings material used, root refer to section 5
alignment and dimensioning gap, bevelling, joint
alignment and
dimensions prior to
starting full welding
7.2 Visual inspection of orifice flange FWEL 3460 X W I
root weld grinding
7.3 Install fabricated spools, pipe and Isometric drawings X I I
piping accessories
7.4 Install standard and special pipe 59B50 X I
supports Pipe support
drawings
7.5 Piping pre-hydrotest inspection Approved test pack. FWEL 3419 No pipe testing to take X H H Punch-out line, supports,
Welding/NDE place until test pack is spades, vents, drains,
clearance released for test by EFD checks and ensure
FW. test gaskets installed
7.6 Pre-test punch list Isometric drawing FWEL 3454 Line walk prior to X H H
hydrotesting
7.7 Hydrotesting (or service testing) ASME B31.3 FWEL 3420 No tests to commence X H W Test circuits to be
Approved test packs until all inspection defined by FW.
certificates are Calibrated test gauges
complete. Re-test to to be used.
be performed after
remedial work until
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ITEM ACTIVITY CONTROL DOCS PROCEDURE REQUIRED REPORT HOLD RESPONSIBILITY COMMENTS
FORM /
CHK. LIST C F N T
No.
test pack passes test
7.8 Service test foam pipework FWEL 3420 X H W
7.9 Valve pressure test FWEL 3420 X H W
7.10 Flushing and air blow, Internal pipe FWEL 3421 X H W
cleaning FWEL 3426
7.11 Install Relief valves FWEL 3425 X H W Relief valve test by
Instrument contractor
7.12 Re-instatement FWEL 3422 X H W
7.13 Post test punch list Isometric Drawing FWEL 3422 X H W Reinstate all lines post
FWEL 3415 test as defined in test
pack. PMI of items
reinstated.
8.0 Piping Erection (Underground)
8.1 Install Underground Piping Underground FWEL 3353 X I I
schematics, FWEL 3354 Fit-up, welding, punch
isometrics listing, bolt tightening
8.2 Coating, wrapping and holiday FWEL 3354 X W I and hydrotest refer to
testing sections 5 and 7 above.

9.0 Hot Tap Tie-in

9.1 Pre hydrostatic test Hot-Tap FWEL 3420 Test at 1.5 times X H H
machine operating/tapping
pressure
9.2 Pre-hot tap check FWEL 3481 Confirm no hazardous X H H Fit up, welding, punch
items or risk for hot listing, bolt tightening
tap work and hydrotest refer to
sections 5 and 7 above.
9.3 Post hot tap check FWEL 3482 X H W
10.0 Coating and Painting
10.1 Surface preparation 83A1 FWEL 3461 X H W Measurement of
achieved surface profile
10.2 Measurement of temperature and 83A1 FWEL 3461 X H W Morning and afternoon
humidity levels recording to be taken
and recorded
10.3 Coating system inspection 83A1 FWEL 3461 X H W Dry film thickness
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ITEM ACTIVITY CONTROL DOCS PROCEDURE REQUIRED REPORT HOLD RESPONSIBILITY COMMENTS
FORM /
CHK. LIST C F N T
No.
measurement of primer,
intermediate and top
coats
10.4 Galvanising inspection 83A1 FWEL 3461 X W I Visual inspection of
galvanising finish quality
10.5 Coating and Paint Completion 83A1 FWEL 3456 X H I

11.0 System Completion

11.1 Request final acceptance of line/ FWEL 3423 X H R
system
11.2 Final punchlist of pipework FWEL 3293 X H H
11.3 Turnover pack preparation and FWEL 3295 X H R
handover to FW for system
Mechanical Completion
11.4 Piping System Acceptance FWEL 3294 X H R
11.5 Prepare red-line mark up of X
drawings (as builts) and submit to
FW

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