Pearl GTL

Project
LINDE ENGINEERING

Shell Project No: HP-3000-QAT

Project Document Number: T- 4.234.577

Purchase Order Number:

2MH127

Tag/Item Number(s):

N/A

Unit(s):

ASU

PCWBS:

Contractor Project No : 5887

Project Rev.: D

Page 2 of 16

QATAR SHELL GTL PROJECT (PEARL)

C2 AIR SEPARATION UNITS CONSTRUCTION
H

10.02.09

After clarification with PMC, Issued for Review

SK

EO

AG

IFR

10.12.08

As per Site Condition, Issued for Review

SK

EO

AG

IFR

31.07.08

Issued for Company Comments

SB

EO

AG

ICC

15.07.08

Ready for Construction

KC

EO

AG

RFC

25.06.08

Issued for Company Comments

KC

EO

AG

ICC

10.06.08

Issued for Company Comments

FB

EO

AG

ICC

10.06.08

Issued for review

FB

EO

AG

IFR

09.06.08

Issued for internal review

FB

EO

AG

IIR

Date

Description

GAMA
Rev.
No.

Project
Rev
No.

Prepared Checked Approved

By
By
By
ORIGINATOR

Status

Document Title:

ITP FOR U/G GRP PIPING

LINDE ENGINEERING AG

Document No.

Contractor

Gama Qatar Co. W. L. L.

GAM

ITP

QAC

GTL

030

Org.
Code

Doc.
Type

Disc.
Code

Geogr.
Area

Seq.
No

Rev.
No

Project Document Number: T-4.234.577

LOC470
Vendor Code

Rev No: D

QSGTL PEARL PROJECT

Document No : GAM-ITP-QAC-GTL-030

C2 ASU Construction Works

Rev / Date

ITP FOR U/G GRP PIPING

S : GAMA QATAR
I: INSPECTION
Item

1.0

1.1
1.2

R: DOCUMENT REVIEW

Activity

Characteristic to be
Verified

C : COMPANY

S: SURVEILLANCE

Control Procedure
Reference

Acceptance Criteria

V : VENDOR

H: HOLD POINT. W:
Responsible
Party

WITNESS

Verifying Documents

METHOD STATEMENTS / PROCEDURES

Method statement for fabrication and
installation of GRP PIPING

Applicable to ASU
Pearl GTL

Testing of GRP piping systems

Applicable to ASU
Pearl GTL

1.3
2.0

Verification of qualification of personnel

2.1

Torque Wrench

2.2

X : CONTRACTOR QC

: Rev-H / 10.02.2009

T-4.234.087

Approved RFC

Approved Documents
I

T-4.234.087

Manufacturers
recommendation

ISO 14692 Part 4

Annex D

Training by Vendor /
Manufacturer

Manufacturer
Certificate

Torque Value
Achieved

T-4.250.955

1 Month

Calibration Certificate

Validation Sticker

T-4.234.548

1 Month

QA/QC
Engineer

Calibration Certificate

Visual Damage

QC Inspector

GAM-QCR-QAC-GTL-079

Previous Experience

Site Engineer

Approved Documents

CONTROL OF INSPECTION ,MEASURING AND TEST EQUIPMENT

Pressure Test Gauges

2.3

Visual Inspection of GRP Pipes and

components

3.0

MATERIAL

3.1

Material Receipt & Visual Inspection

As per Company
Specification

3.2

Storage and Preservation

As per Manufacture
recommendation

3.3
4.0

Sub-Contractor Material Approval

INSPECTIONS

T-4.234.577 Rev. D

DELETED

Manufactures
Data Sheets

As per Manufacturer
Manufactures
recommendation
Data
Sheets
DELETED

Store In
charge

As per specification

Page 4

QSGTL PEARL PROJECT

Document No : GAM-ITP-QAC-GTL-030

C2 ASU Construction Works

Rev / Date

ITP FOR U/G GRP PIPING

S : GAMA QATAR
I: INSPECTION
Item

X : CONTRACTOR QC

R: DOCUMENT REVIEW

Activity

Characteristic to be
Verified

4.1

Verification of Trench Excavation

Elevation, Orientation
& Width

4.2

Laying of bedding material, prior to

Installation of the GRP pipes

Bedding Granules
level

4.2.1

4.3

Cleanliness before laying of pipes into the

bed

Bell and Spigot

a)

QC Inspector shall verify correct O

Ring for the service has been
selected

The surfaces to be connected,

including the gasket grooves, shall be
clean
c) The Seal ring and groove to be
checked for the correct dimension.
d) Non-symmetric seals, such as lip
seals, shall be checked for correct
installation in the grooves
e) Clean non-contaminated lubricant shall
be used on both seals and spigot

Internal Cleaning
As per Manufacturer
recommendations

C : COMPANY

S: SURVEILLANCE

Control Procedure
Reference

As per the drg.

T-4.259.773
As per the
drawing
T-4.259.773
T.13.377.360 Rev
E
& DEP 31.40.19Gen
ISO 14692-4:2002
Annex C Figure
C.3

Acceptance Criteria

Survey Report

QA/QC Civil Report

No foreign materials
inside the pipe &
Internal Cleaning
before laying into
trench
As per Manufacturer
recommendation
As per Manufacturer
recommendations

: Rev-H / 10.02.2009
V : VENDOR

H: HOLD POINT. W:
Responsible Party

WITNESS
S

Excavation Survey Report

Sand Bedding Survey

Report

Site Engineer

GAM-QCR-QAC-GTL-139

Site Engineer

GAM-QCR- QAC-GTL045

QA/QC
Engineer

QA/QC
Engineer

Verifying Documents

b)

T-4.234.577 Rev. D

Page 5

QSGTL PEARL PROJECT

Document No : GAM-ITP-QAC-GTL-030

C2 ASU Construction Works

Rev / Date

ITP FOR U/G GRP PIPING

S : GAMA QATAR
I: INSPECTION
Item

X : CONTRACTOR QC

R: DOCUMENT REVIEW

Activity

Characteristic to be
Verified

C : COMPANY

S: SURVEILLANCE

Control Procedure
Reference

V : VENDOR

H: HOLD POINT. W:

f) The correct tooling shall be used to

enter the spigot into bell to avoid
damage to the seals

g) Entry location marks on the spigot (If

applicable) should be checked to
ensure correct entry distance

h) Pipe sections shall be aligned as

straight as possible in order to retain
the O-rings in their groves

i) A feeler gauge shall be used to

establish good seating of the seals

j) For key lock tensile resistance joints,

clean and lubricated locking strip
should be inserted in complete
circumference of the locking strip
groove ,and the locking strip shall have
the correct cross section and length

T-4.234.577 Rev. D

No leak

Manufacturer
receipt,
T.13.376.808E&
DEP 31.40.10.19

As per Manufacturer
recommendation

Responsible Party

WITNESS
S

k) Identification and repairing of defective

joints / pipes etc (if any)

Acceptance Criteria

: Rev-H / 10.02.2009

Site Engineer

Verifying Documents

GAM-QCR-QAC-GTL045,047,048

Page 6

QSGTL PEARL PROJECT

Document No : GAM-ITP-QAC-GTL-030

C2 ASU Construction Works

Rev / Date

ITP FOR U/G GRP PIPING

S : GAMA QATAR
I: INSPECTION
Item

R: DOCUMENT REVIEW

Activity

l) Sealing Test of Joints

4.3.1

4.4

X : CONTRACTOR QC

Test Pack Preparation

Torque of the flange Bolts

C : COMPANY

S: SURVEILLANCE

Characteristic to be
Verified

Control Procedure
Reference

Acceptance Criteria

Leaks

T-4.240.925

No Leak

As per Specification

Bolt Tightness

T.4.234.548 &
Manufacturers
recommendation
T.13.376.808E&
DEP
31.40.10.19,T.13.
377.360

GRP Test Pack

: Rev-H / 10.02.2009
V : VENDOR

H: HOLD POINT. W:
Responsible Party

QA/QC
Engineer
Site Engineer

WITNESS

Verifying Documents

GAM-QCR-QAC-GTL-045
As per
specification

GAM-QCR- QAC-GTL041

R/A

R/A

Torque Value
Achieved

Site Engineer

Category A
Completed/ Corrected

Site Engineer

Linde Mechanical Check

of test System(R 01)
including punch list

GAM-QCR-QAC-GTL050

Site Engineer

Visual

Final Inspection Before Test

1. Visual Check.
2.

Flange alignment verification

3.

Permanent gaskets installation, bolts

& nuts (if any)

4.5

4.6

4.

Valve installation

5.

Dimensionnel check, elevation,

orientation etc.

6.

Support installation (If any)

Intermediate Back Fill

4.7

T-4.234.577 Rev. D

Installation Complete

As per Manufacturers
recommendation & As
per Company
Specifications

T.13.377.421

T-4.234.069,
Manufacturers
Recipe,
T13.376.808
&DEP 31.40.19

Shifted to 4.3.1

Page 7

QSGTL PEARL PROJECT

Document No : GAM-ITP-QAC-GTL-030

C2 ASU Construction Works

Rev / Date

ITP FOR U/G GRP PIPING

S : GAMA QATAR
I: INSPECTION
Item

X : CONTRACTOR QC

R: DOCUMENT REVIEW

Activity

C : COMPANY

S: SURVEILLANCE

: Rev-H / 10.02.2009
V : VENDOR

H: HOLD POINT. W:

Characteristic to be
Verified

Control Procedure
Reference

Acceptance Criteria

No Leak

T-4.234.548 &
Manufacturers
Recipe & DEP
31.40.19/Design
Code

Manufacturers
recommendation

Site Engineer/
QA-QC
Engineer

Water disposal

Manufacturers
recommendation

Manufacturers
recommendation

Responsible Party

WITNESS

Verifying Documents

Test Pack (MC Inspection

& Test record (R02))

Site Engineer

MC Inspection & Test

record (R02)

Manufacturers
recommendation

Site Engineer

Reinstatement Check List

(R03)

Manufacturers
recommendation

Site Engineer

QAM-QCR-QAC-GTL-050

Manufacturers
recommendation

Site Engineer

Manufacturers
recommendation & As per
Test Pack

4.8

4.9

Hydrostatic Pressure Testing

4.9.1

Flushing / Water disposal

4.10

Re instatement Punch Out

4.11

Final Back Fill Trench

4.12

Gross leak test for the completed

subsystems (for pressure lines).

Restoration
No damage of pipe &
No voids at bottom of
pipe
No Leak

T-4.234.074 &
DEP 31.40.19
Manufacturers
recommendation
& DEP 31.40.19
DEP 31.40.10.19,

4.13

Flawless Start-up Initiative (FSI) Tightness (in Valve boxes)

a)

Bolt

a) Loose Bolt
b) Wrong Type of Bolt
c) Flange Face
Condition

T.13.377.360 Rev
E,
DEP 70.10.70.11Gen

Full Tight without leak

Site Engineer

Joint Integrity Control

Procedure T.13.377.453 ,
T.13.377.454 ,

T.13.376.815 & Flaw

List

DEP 31.38.01.11-

T-4.234.577 Rev. D

Page 8

QSGTL PEARL PROJECT

Document No : GAM-ITP-QAC-GTL-030

C2 ASU Construction Works

Rev / Date

ITP FOR U/G GRP PIPING

S : GAMA QATAR
I: INSPECTION
Item

R: DOCUMENT REVIEW

Activity

b)

X : CONTRACTOR QC

Gasket Installation

Characteristic to be
Verified

a) Damaged Gasket
b) Gasket Installed off
centre
c) Old Temporary
Hydro test Gaskets
still in place
d) Incorrect Flange
alignment in line
flanges
e) Debris in valve seat
as a result of
transport form
manufacturer

C : COMPANY

S: SURVEILLANCE

Control Procedure
Reference

Acceptance Criteria

Full Tight without leak

V : VENDOR

H: HOLD POINT. W:
Responsible Party

DEP 31.40.10.19Gen,
T.13.377.360 Rev
E,

: Rev-H / 10.02.2009

Site Engineer

DEP 70.10.70.11Gen

WITNESS

Verifying Documents

Joint Integrity Control

Procedure T.13.377.453 ,
T.13.377.454 ,

T.13.376.815 & Flaw

List

DEP 31.38.01.11-

Flawless Start-up Initiative (FSI)

4.14

Deleted (REF. ITEM CODE 4.2.1)

Cleanliness

4.15

5.0

Closing of the pipe ends after Flushing

Video Recording Internal Inspection of the

Pipes

T-4.234.577 Rev. D

Internal Cleaning

Internal Cleaning

T-4.231.172
T-13.377.561
Project Spec. Part
4, Chapter 6

No foreign materials
inside the pipe after
flushing

QA / QC
Engineer

Visual

No foreign materials
inside the pipe after
flushing

QA / QC
Engineer

Recorded Video

Page 9

C2 ASU PEARL GTL PROJECT

RASLAFFAN INDUSTRIAL CITY
BOLT TIGHTENING INSPECTION
REPORT

Subcontract Ref.:

Report No.:

Item Description:

Inspection Date:

Item Location /
Area:

Test Code No.:

Subsystem:

ITP No.:

Ref. DWG / Docs:

Used Measuring and test equipment ref. (if applicable):
INSPECTIONS
Item No/Spool
No

Mark No./Joint No
Grade

Accepted By

ORGANIZATIONS

DATE

THIRD PARTY REP.

GAMA REP.
LINDE REP.
QSGTL OR its PMC REP.

GAM-QCR-QAC-GTL-041

Bolting

Rev. O

Size

NAME

Bolt Tightening
(Torque Value)

Inspectors
Signature

SIGNATURE

QATAR - PEARL GTL PROJECT- C2 ASU

Q
Q

A
A

T
T A
A

GRP SPOOL VISUAL + NIPPLE TEST INSPECTION REPORT

R
R

Report No.:

Item Description:

Inspection Date:

Item Location / Area:

Test Code No.:

Subsystem:

ITP No.: GAM-ITP-QAC-GTL-

Ref. DWG / Documents:

Used Measuring and test equipment ref. (if
applicable):

Line No.:
Unit No:

Isometric No.:
Pressure Class

Sl.
Joint
Spool/ item No.
No
No.

Dia
(Inch)

Sealing
Test

Joint Type
Test
Medium

Bonder Shop
No.
/Field

INSPECTION ACTIVITIES
Visual
Fit-up &
Repair
Cutting
(Rep. Ref.
O-Ring
/Tapering Cleanliness Allignmen
Defective Remarks
Installation
QCR
of Joints
t
Joints
FORM-

Note : DSC for lamination and adhesive joint only

ACCEPTED

ORGANIZATIONS

GAMA QATAR REP.

LINDE REP.

QS GTL or its PMC

GAM-QCR-QAC-GTL-045, Rev-A

NAME

SIGNATURE

DATE

C2 ASU PEARL GTL PROJECT

RASLAFFAN INDUSTRIAL CITY
BARCOL HARDNESS TESTING
REPORT
Subcontract Ref.:

Report No.:

Item Description:

Inspection
Date:

Item Location / Area:

Test Code No.:

Subsystem:

ITP No.:

Ref. DWG / Documents:

Used Measuring and test equipment ref. (if applicable):
INSPECTIONS
SPOOL NO

REMARKS:

JOINT NO

BASE LINE VALUE

PERCENTAGE

INSPECTOR
SIGNATURE

The Actual value should not be less than 90% of the Minimum Base line value

ORGANIZATIONS

Accepted By

ACTUAL VALUE

THIRD PARTY REP.

GAMA REP.
LINDE REP.
QSGTL OR its PMC REP.

GAM-QCR-QAC-GTL-047 Rev. O

DATE

NAME

SIGNATURE

PEARL GTL PROJECT-RLC-QATAR

Q A T A R

DAILY GRP LAMINATION FOLLOW-UP REPORT

Subcontract Ref.:
Item Description:
Item Location / Area:
Subsystem:
Ref. DWG / Documents:
Used Measuring and test equipment ref. (if applicable):

Report No.
Inspection Date:
Test Code No.:
ITP No.:

Drawing No. :

Pipe Dia. :

Spool No. :
Lam. kit No. :
Bond Width :

Nominal Pressure :
Test Pressure :
Bond Thickness :
Finishing Date on :

Starting Date on :

at

hrs.

at

hrs.

Temperature:
Humidity:
Manufacturer Recipe Ref:

Bonder No.:

Fit Layer
No. of Layers

W/R Type

Resin Type

Resin Quantity

Catalyst LPT Quantity

Resin Quantity

Catalyst LPT Quan. Delayer

Vinylester

Structure Lay up
No. of Layers

W/R Type

Resin Type

Vinylester
Top Tape

Internal layer
Bond Widt
W/R Type

Bond Thickness :

No. of Layers

Resin Type

Resin Quantity

Catalyst LPT Quantity

Vinylester
Surface mat.

Accepted By

ORGANIZATIONS

DATE

THIRD PARTY REP.

GAMA QATAR REP.
LINDE REP.
QS GTL

GAM-QCR-QAC-GTL-048, Rev-0

NAME

SIGNATURE

Q A T A R

PEARL GTL PROJECT- RLCQATAR

EXCAVATION / BACKFILLING
REPORT

Subcontract Ref.:

Report No.:

Item Description:

Inspection Date:

Item Location / Area:

Test Code No.:

Subsystem:

ITP No.:

Ref. DWG / Documents:

Used Measuring and test equipment ref. (if applicable):

Area

Location

Description of Filling

a) Sand

b) Gravel (SC1)

Site Clearance

Excavation

ELEVATION AS PER DRAWING :

ACTUAL ELEVATION

ACCEPTABLE

REMARKS:

YES

Accepted By

ORGANIZATIONS

DATE

THIRD PARTY
REP.
GAMA
LINDE
QS GTL

GAM-QCR-QAC-GTL-050 Rev. O

NAME

NO
SIGNATURE

C2 ASU PEARL GTL PROJECT

RAS LAFFAN INDUSTRIAL CITY

MATERIAL RECEIPT CHECK SHEET

ITEM No:

PO No:

UNIT No:

MANUFACTURER :

ITEMS TO BE CHECKED

1 Visual damage
2 Quantity
3 Test certificates
4
5
6
7
8

Date of initial inspection:

Name and signature of Inspector:

GAM-QCR-QAC-GTL-079 Rev. O

INSPECTOR
INITIAL

REQ No:

REMARKS

SYSTEM CLEANLINESS ACCEPTANCE REPORT

1110 A05M

Project No

Doc.No: 0100-W-QA-1825

Isometric No:
(Line No)

Page 1 of 1

GAMA

Preservation
Method

Inspection
result

Spool

Cleaning
Method

Prefabrication

Cleanliness Class

Sheet

Piping
Contractor:

Inspection
method

Project No:

Piping Contractor

Date

Signature

Erection
Company

Date

Signature

LINDE

Date

Signature

PMC

Name:

Name:

Name:

Signature:

Signature

Signature:

Date:

Date:

Date:

GAM-QCR-QAC-GTL-139 Rev. O

Piping Contractor-GAMA

Company-Linde

Date

Signature