046-itp for installation of mac-bac-st machinery unit.pdf
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Pearl GTL Project
LINDE ENGINEERING
Shell Project No: HP-3000-QAT Contractor Project No: 5887
Project Document Number: T- 4.234.557 Project Rev.: O Page 2 of 17
Purchase Order Number:
2MH127
Tag/Item Number(s): N/A
Unit(s): ASU
PCWBS: Z
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QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION
D O 11.02.09 Company Comments Incorporated SK EO AG CCI
C O 27.01.09 Issued for Company Comments SK EO AG IFR
B 27.01.09 Issued for Review SK EO AG IFR
A 12.01.09 Issued for Internal Review SK EO AG IIR
GAMA Rev.
Project Rev Date Description
Prepared By
Checked By
Approved By
Status
No. No. ORIGINATOR
LINDEGINEERING AG
Document Title:
INSPECTION TEST PLAN FOR INSTALLATION OF MAC/BAC/ST MACHINERY UNIT
Contractor
Gama Qatar Co. W. L. L.
Document No. LOC470
GAM ITP QAC GTL 046 D
Org. Code
Doc. Type
Disc. Code
Geogr. Area
Seq. No
Rev. No Vendor Code
Project Document Number: T-4.234.557
Rev No: O
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QSGTL PEARL PROJECT C2 ASU Construction Works
ITP NO: GAM-ITP-QAC-GTL-046
ITP FOR INSTALLATION OF MAC/BAC/ST MACHINERY UNIT
DATE: 11.02.09-REV. D
S. GAMA QATAR X. CONTRACTOR QC C. COMPANY A. VENDOR (MAN)
I: INSPECTION / TEST R: DOCUMENT ISSUED/REPORT REVIEW S: SURVEILANCE H: HOLD POINT (Notification Required and Presence Mandatory). W: WITNESS (Notification Required but Presence not Mandatory)
Item Activity Test Frequency Reference Document Acceptance Criteria Responsible
Party Verifying Documents S A X C
T-4.234-557 REV-O Page 4 of 17
1.0
DOCUMENTATION
1.1 Contractor drawings, project specifications, manuals, codes 100% - -
TECHINICAL OFFICE - H R R
1.2 Lifting studies (For Heavy Equipments) 100%
T.4.234.084,T.4.129.859 - HSSE - H R R
2.0 EQUIPMENTS
2.1
Receiving inspection (Including nameplate verification) & Open Box Inspection during unpacking
100% T-4.250.945;T.4.250.927 Packing list
DEP 31.29.00.10 DEP 31.10.03.10
STORE
INCHARGE
GAM-QCR-QAC-GTL-080
I S I S
2.2 Storage, preservation and documentation(FSI) 100% T.13.377.360E;T.4.250.932
Approved drawing, DEP 31.29.00.10;DEP
70.10.70.11 T.13.377.454E; Vendor instruction,
FSI GAM-QCR-QAC-GTL-069
I R S S
2.3 Inspection measuring and test equipment calibration 100% T.4.250.915 - QCI Calibration certificates H R R R
3.0 INSTALLATION
3.1 Foundation complete and accepted 100% T-4.095.567, T-4.250.945
MC documents, DEP 34.19.20.31;
T.13.376.358 DEP 31.29.00.10,
QCI Ref. ITP 023; MC certificates H R R R
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QSGTL PEARL PROJECT C2 ASU Construction Works
ITP NO: GAM-ITP-QAC-GTL-046
ITP FOR INSTALLATION OF MAC/BAC/ST MACHINERY UNIT
DATE: 11.02.09-REV. D
S. GAMA QATAR X. CONTRACTOR QC C. COMPANY A. VENDOR (MAN)
I: INSPECTION / TEST R: DOCUMENT ISSUED/REPORT REVIEW S: SURVEILANCE H: HOLD POINT (Notification Required and Presence Mandatory). W: WITNESS (Notification Required but Presence not Mandatory)
Item Activity Test Frequency Reference Document Acceptance Criteria Responsible
Party Verifying Documents S A X C
T-4.234-557 REV-O Page 5 of 17
3.2 Sole plates and spindles/wedges or shims Installation
100% T-4.095.805, T-4.250.945 Approved drawings,
T-4.260.824 DEP 31.29.00.10,
QCI GAM-QCR-QAC-GTL-169
Surveyor report I I S S
3.3 Erection of pre alignment of coolers/wash water unit/steel structure of skid/ oil system
100% T-4.095.567, T-4.250.945, Approved drawings,
T-4.260.824 DEP 31.29.00.10,
QCI GAM-QCR-QAC-GTL-169 Surveyor report I I S S
3.4 Installation/levelling of steel struts for base frame 100%
T-4.095.567, T-4.250.945, T-4.233.680
Approved drawings, T-4.260.824
DEP 31.29.00.10, QCI GAM-QCR-QAC-GTL-038 H I S S
3.5 Installation & alignment of skid on steel structure 100%
T-4.095.567, T-4.250.945, T-4.233.680
Approved drawings, T-4.260.824
DEP 31.29.00.10, QCI
GAM-QCR-QAC-GTL-169
H I I I
3.6 Check alignment of gear box (soft foot, coupling, slope etc.) 100%
T-4.095.567, T-4.250.945, T-4.233.680
Approved drawings, T-4.260.824
DEP 31.29.00.10, QCI
GAM-QCR-QAC-GTL-170
H I I S
3.7 Steam Turbine alignment / coupling check 100%
T-4.095.567, T-4.250.945, T-4.233.680
Approved drawings, T-4.260.824
DEP 31.29.00.10, QCI Linde/MAN Report H I I S
3.8 MAC Alignment to steam turbine 100%
T-4.095.805, T-4.250.945, T-4.233.680
Approved drawings, T-4.260.824
DEP 31.29.00.10, QCI Linde/MAN Report H I I S
3.9 BAC Alignment to gear box 100% T-4.095.805, T-4.250.945, T-4.233.680
Approved drawings, T-4.260.824
DEP 31.29.00.10, QCI Linde/MAN Report H I I S
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QSGTL PEARL PROJECT C2 ASU Construction Works
ITP NO: GAM-ITP-QAC-GTL-046
ITP FOR INSTALLATION OF MAC/BAC/ST MACHINERY UNIT
DATE: 11.02.09-REV. D
S. GAMA QATAR X. CONTRACTOR QC C. COMPANY A. VENDOR (MAN)
I: INSPECTION / TEST R: DOCUMENT ISSUED/REPORT REVIEW S: SURVEILANCE H: HOLD POINT (Notification Required and Presence Mandatory). W: WITNESS (Notification Required but Presence not Mandatory)
Item Activity Test Frequency Reference Document Acceptance Criteria Responsible
Party Verifying Documents S A X C
T-4.234-557 REV-O Page 6 of 17
3.10
Pre alignment of coolers MAC/BAC to machine skid and ACC Condensate Piping to steam turbine
100% T-4.095.805, T-4.250.945, T-4.233.680
Approved drawings, T-4.260.824
DEP 31.29.00.10, QCI Linde/MAN Report H I I S
3.11 Oil Unit Alignment on foundation 100%
T-4.095.451, T-4.209.390, T-4.250.945
Approved drawings, T-4.285.227
DEP 31.29.00.10, QCI
GAM-QCR-QAC-GTL-115
H I I S
3.12 Alignment of Motor Pump for oil unit 100%
T-4.250.927, T-4.209.390, T-4.248.567
Approved drawings, T-4.285.227
DEP 31.29.00.10, QCI Linde/MAN Report H I I S
3.13 Grouting Release for all unit contents 100%
T-4.095.567, T-4.250.945, T-4.233.680
Approved drawings, T-4.260.824
DEP 31.29.00.10, QCI Ref. ITP 024
3.14 Recheck Alignment after grouting 100%
T-4.095.805, T-4.250.945, T-4.233.680
Approved drawings, T-4.260.824
DEP 31.29.00.10, QCI
GAM-QCR-QAC-GTL-115
H I I S
3.15 All piping installation, alignment, & connection without any objectionable load
Ref. ITP 033 (T-4.250.918 Rev. A)
3.16 Verification of piping pressure test acceptance Prior to final alignment
Ref. ITP 033 (T-4.250.918 Rev. A)
3.17 Erection Damage(Equipments) 100% T.4.251.035 - QCI GAM-QCR-QAC-GTL-127 I I I R
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QSGTL PEARL PROJECT C2 ASU Construction Works
ITP NO: GAM-ITP-QAC-GTL-046
ITP FOR INSTALLATION OF MAC/BAC/ST MACHINERY UNIT
DATE: 11.02.09-REV. D
S. GAMA QATAR X. CONTRACTOR QC C. COMPANY A. VENDOR (MAN)
I: INSPECTION / TEST R: DOCUMENT ISSUED/REPORT REVIEW S: SURVEILANCE H: HOLD POINT (Notification Required and Presence Mandatory). W: WITNESS (Notification Required but Presence not Mandatory)
Item Activity Test Frequency Reference Document Acceptance Criteria Responsible
Party Verifying Documents S A X C
T-4.234-557 REV-O Page 7 of 17
4.0 FINAL INSPECTION
4.1 Final alignment checks 100% T-4.095.805, T-4.250.945, T-4.233.680
Approved drawings, T-4.260.824
DEP 31.29.00.10, QCI
GAM-QCR-QAC-GTL-117
I I S S
4.2 FSI Checks (cleaning, preservation) 100%
T-4.095.805, T-4.250.945, T-4.233.680
Approved drawings, T-4.260.824
DEP 31.29.00.10 FSI GAM-QCR-QAC-GTL-069 I I S S
4.3 MC Inspections 100% T-4.095.805, T-4.250.945, T-4.233.680
Approved drawings, T-4.260.824
DEP 31.29.00.10 QCI Linde MC Records I S I S
4.4 Installation Completion , sign-off quality records and hand over to Linde MC Dept
100% T-4.250.945 T.13.377.555G QCI All Reports H R R R
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GAM-QCR-QAC-GTL-038 Rev. O
C2 ASU PEARL GTL PROJECT
RASLAFFAN INDUSTRIAL CITY
STEEL STRUCTURES ELEVATION REPORT
( BASED ON SURVEY 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
Column No Planned Level Actual Level Level/Difference Plumb
0 Degree 90 Degree
ORGANIZATIONS DATE NAME SIGNATURE
Acce
pted
By THIRD PARTY REP.
GAMA REP.
LINDE REP.
QSGTL OR its PMC REP.
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PROJECT: C2 ASU PEARL GTL PROJECT, RAS LAFFAN INDUSTRIAL CITY
EQUIP. TAG.NO.: DESCRIPTION: LOCATION:
MANUFACTURER: DRG.NO.: RFI NO:
MONTH
1 2
3 4 5 6
7
8
9
10
11
12
ACTIVITY Month
Date Checked
Check all internal and accessories storage is acceptable
Visual Check : Is there any damage
Check for protective covers on all the openings
Check all warning labels,like N2 warning plate are existent
Actual Pressure level
Required Pressure Level
GAMA SIGN WITH DATE
LINDE SIGN WITH DATE
QSGTL or its PMC
NOTE:
GAM-QCR-QAC-GTL-069 Rev. O
STORAGE, PRESERVATION AND NITROGEN PURGING REPORT
FORM NO:
SHT:
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C2 ASU PEARL GTL PROJECT
RAS LAFFAN INDUSTRIAL CITY
GAM-QCR-QAC-GTL-080 Rev. O
EQUIPMENT RECEIPT CHECK SHEET
ITEM No: PO No: REQ No:
UNIT No: MANUFACTURER :
ITEMS TO BE CHECKED INSPECTOR
INITIAL REMARKS
1 Name Plate
2 Preparation and painting
3 Desiccant installed
4 Moisture present
5 Nozzle flange faces acceptable
6 Temporary nozzle protection acceptable
7 Internals and accessories complete and storage acceptable
8 Purge - pressure:
Purge monitoring date: Pressure
Date of initial inspection:
Name and signature of Inspector:
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GAM-QCR-QAC-GTL-115 Rev. O PAGE 1 OF 2
EQUIPMENT LEVELLING & ALIGNMENT REPORT
Report No:
Date:
PROJECT: C2 ASU PEARL GTL PROJECT-RAS LAFFAN INDUSTRIAL CITY
Tag No: Manufacturer: Drg. No:
Equip. Description
No. of reading Orientation Elevation Plumpness Tolerance Remarks
ORIENTATION : ACCEPTED REJECTED
LEVELLING REQUIRED ACTUAL ACC REJECTED
GRADIENT / SLOPE REQUIRED
ACTUAL ACC REJECTED
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GAM-QCR-QAC-GTL-115 Rev. O PAGE 2 OF 2
REMARKS: ..
GAMA LINDE QSGTL or its PMC
Name
Sign
Date
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C2 ASU PEARL GTL PROJECT RAS LAFFAN INDUSTRIAL CITY
TURBINE INSTALLATION PROCESS SHEET
Item No: Report No: Item Description: Date: Drawing No: Area:
Item No
Description
Signature & Date Gama Linde QSGTL
1. Foundation complete, Level & Accepted. 2. Sole plates level 3. Align base 4. Align casing 5. Align rotor 6. Anchor bolts tight 7. Piping complete & connected with no objectionable loads or
strains on the flanges
8. Verify pressure test accepted 9. Coupling face gap checked & acceptable 10. Final alignment checked 11. Coupling set screws tight 12. Accessories Installed & Ready for service
(i.e,Vents,Drains,strainers,etc)
13. Auxiliary System Complete(i.e. lube system, Water cooling etc) 14. Lubrication system flushed & recharged with appropriate lubricant 15. Turbine rolls freely, By hand 16. Governor Mechanism: Linkages checked Manual Trip Level Free 17. Relief valves checked & installed 18. Expansion bellows for condensing turbines installed properly Remarks:
The Installation of the above compressor has been satisfactorily completed in accordance with the Drawings & Specifications ORGANIZATIONS DATE NAME SIGNATURE GAMA QATAR REP
LINDE REP
QSGTL REP
GAM-QCR-QAC-GTL-117 Rev. O
QQQ AAA TTT AAA RRR
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PROJECT: C2 ASU PEARL GTL PROJECT RAS LAFFAN INDUSTRIAL CITY
Originator Date of observation:
Discipline:
Location / Area:
Unit No :
SYSTEM NUMBER:
Drawing / Specification Numbers Description of Discrepancy/Observation (Be specific, events, time, date, location, etc :)
Corrective Action:
Originator: Name: _____________________________Signature: _____________________Date: ________________ NCR Required YES NO (Circle one) CTQ to Contractor Required YES NO (Circle one) Remarks if any: Site Engineer: Name: _______________________ Signature: ________________ Date: ______________ QA/QC Manager: Name: _________________________ Signature: _______________ Date: ______________ Discrepancy Corrected/Remarks: GAMA Representative: Name: ____________________ Signature: ______________ Date: ________________ Close-out of Corrective Action - Remarks: NCR No.: ___________________ CTQ No: ______________ Site Engineer: Name: ___________________ Signature: __________________ Date: ___________ DISTRIBUTION (Original QA/QC file)
QA/QC Manager Site Manager
Site Engineer Project Manager
Construction Manager Originator GAM-QCR-QAC-GTL-127 Rev. O
SITE INSPECTION REPORT
REPORT NO.:
DATE:
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C2 ASU PEARL GTL PROJECT RAS LAFFAN INDUSTRIAL CITY
MAC/BAC/ST MACHINERY UNIT INSTALLATION PROCESS SHEET
Item/Tag No: Report No: Item Description: Date: Drawing No: Area: System No: Subsystem No:
Item No
Description
Signature & Date Gama Linde QSGTL
1. Foundation complete, Level & Accepted. 2. Sole plates and spindles/wedges or shims installation accepted 3. Erection of pre alignment of coolers/wash water unit/steel
structure of skid/oil system
4. Skid alignment accepted 5. Alignment of all equipment accepted 6. Piping complete & connected with no objectionable loads or
strains on the flanges
7. Verify pressure test accepted 8. Coupling Installation (face gap checked & acceptable) 9. Final alignment checked 10. Accessories Installed & Ready for service (i.e. Vents, Drains,
strainers, etc)
11. Auxiliary System Complete(i.e. lube oil system, Water cooling etc) 12. Turbine rolls freely, By hand 13. Governor Mechanism 13.1 Linkages checked 13.2 Manual Trip Level Free 14. Expansion bellows for condensing turbines installed properly Remarks:
The Installation of the above Machinery Unit has been satisfactorily completed in accordance with the Drawings & Specifications ORGANIZATIONS DATE NAME SIGNATURE GAMA QATAR REP
LINDE REP
QSGTL REP
GAM-QCR-QAC-GTL-169 Rev. O
QQQ AAA TTT AAA RRR
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GAM-QCR-QAC-GTL-170 Rev. O PAGE 1 OF 2
GEAR BOX LEVELLING & ALIGNMENT REPORT
Report No: Date:
System No:
PROJECT: C2 ASU PEARL GTL PROJECT-RAS LAFFAN INDUSTRIAL CITY
Tag No: Manufacturer: Drg. No:
Equip. Description:
No. of reading Orientation Elevation Plumpness Tolerance Remarks
ORIENTATION : ACCEPTED REJECTED
LEVELLING REQUIRED ACTUAL ACC REJECTED
GRADIENT / SLOPE REQUIRED
ACTUAL ACC REJECTED
SOFT FOOT : ACCEPTED REJECTED
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GAM-QCR-QAC-GTL-170 Rev. O PAGE 2 OF 2
REMARKS: ..
GAMA LINDE QSGTL or its PMC
Name
Sign
Date
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