DANEM ENGINEERING WORKS WLL

DOHA -QATAR Outotec

INSPECTION AND TEST PLAN FOR FABRICATION- MAIN STACK WITH ACCESS PLATFORMS
Project: MADEN ALUMINIUM Document No/Revision : DEW- ITP-001 / Rev-0
Vendor: Outotec Purchase Order:
Sub-vendor:DANEM ENGINEERING WORKS WLL Item Covered:Main Steel Stack with Access Platforms
QA/QC Engineer: Sahdudheen vk
Prepared by: Ajay achuthan Date: 09-07 -2013 Signature:
Validated by: Sahdudheen V K Date: 09-07-2013 Signature:

Approved By: Date: Signature: -

Surveillance Point
Item No. Quality Control Point Specific Reference Kind of protocol Accept Comments
(Activity, by, Frequency) (PO,Contract,Doc.,Specs) Procedure (Characteristic, Status
Methods, Criteria) DANEM Outotec

1 Preliminaries
Purchase order /
1.1 Approval of ITP
TPS 1136-I1-03370-REV-B
Project Specification ITP H H

Approval of Welding Purchase order /

1.2
Procedures- WPS TPS 1136-I1-03370-REV-B
ASME Sec IX/AWS D1.1 WPS H H

Welder Qualification Purchase order / Welder

1.3
Records TPS 1136-I1-03370-REV-B
ASME Sec IX / AWS D 1.1
Certificates H H

OPS-PR-LPI-004 Revision -0, Radiographic Testing

OPS-PR-MPI-006 Revision 0, Ultrasonic Testing
1.4 Approval Of NDE Procedures OPS-PR-RT-011 Revision 0, Magnetic Particle NDE Procedures H H
OPS-PR-UTA-012 Revision 0 Test & DP Testing Procedure

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 Surveillance Point
Item No. Quality Control Point Specific Reference Kind of protocol Accept Comments
(Activity, by, Frequency) (PO,Contract,Doc.,Specs) Procedure (Characteristic, Status
Methods, Criteria) DANEM Outotec

2.0 Material Receipt

Inspection of incoming Material Test

2.1 Materials
TPS 1136-I1-03370-REV-B IMS-PRS-22 Certificates H R
In acc. EN 1024-3.1
Identification &
2.2 Traceability TPS 1136-I1-03370-REV-B IMS-PRS-22 IMIR DG/FORM/QC/027 H R

3.0 Fabrication & Welding

Verification of actual welding

3.1 parameters 10%Mini.(WPS/PQR)
TPS 1136-I1-03370-REV-B ASME Section IX/AWS D1.1 WPS /PQR H R

Verification of welder
3.2 Qualification 100% (WQTR)
TPS 1136-I1-03370-REV-B ASME Section IX/AWS D1.1 WQTR H R

Plate Rolling for -

3.3 Shell TPS 1136-I1-03370-REV-B AFC Drawings H S
Dimensional control of cutting
3.4 plates Ishapes TPS 1136-I1-03370-REV-B AFC Drawings AFC drawings H S

Visual examination and Adequate Distortion control,

dimensional control of weld SIR
3.5 TPS 1136-I1-03370-REV-B measures,Joint Preparation DG/FORM/QAQC/007
H W
setup I FIT- UP etc..

4.0 Inspection

Verification of
4.1 Welding related activities
TPS 1136-I1-03370-REV-B Joint No, Welder ID etc WPS, Welding Map H R

Weld visual examination General Inspection

4.2 (ISO 5817 "C") / TPS 1136-I1-03370-REV-B Approved Drawing Report WIR H W
100% Welds DG/FORM/QC/018

4.3 Full penetration -Butt weld TPS 1136-I1-03370-REV-B

Approved NDE Procedure UT Report H W
(Splice joint)by UT OPS-PR-UTA-012 Rev-0

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 Surveillance Point
Item No. Quality Control Point Specific Reference Kind of protocol Accept Comments
(Activity, by, Frequency) (PO,Contract,Doc.,Specs) Procedure (Characteristic, Status
Methods, Criteria) DANEM Outotec

Fillet welds Approved NDE Procedures

4.4 (Primary members)by MT
TPS 1136-I1-03370-REV-B
OPS-PR-MPI-006 Rev- 0, MPI Report H W

Dimensional control AFC Drawings&

Inspection Report
4.4 TPS 1136-I1-03370-REV-B Circumference H W/R
& alignment DG/FORM/QC/023

General Inspection
Pre assembly of Report
4.5 TPS 1136-I1-03370-REV-B AFC Drawings DG/FORM/QC/018 H W/R
Stack Parts.

NDT applicable to structural welding ( access platforms )

4.6 MPI for Butt weld full TPS 1136-I1-03370-REV-B MPI Report H W/R
penetration . AWSD1.1

4.7 MT Butt weld partial penetration TPS 1136-I1-03370-REV-B AWSD1.1 MPI Report H W/R
·

5.0 Main Stack with access platforms Surface Preparation & Painting.

Receipt Inspection of
5.1 Abrasives,Paints&Thinner
MD-402-100-EG-ME-SPC-00026 Painting Procedure Batch Certificate H R

Inspection Report
5.2 surface cleaning -Sa2 1/2 MD-402-100-EG-ME-SPC-00026 Painting Procedure DG/FORM/QAQC/020 H W

Inspection Report
5.3 Paint DFT Checking MD-402-100-EG-ME-SPC-00026 Painting Procedure DG/FORM/QAQC/020 H W

6.0 Main Stack access platforms Galvanizing.

Surface cleaning -SP8 Galvanizing Procedure/

6.1 (Acid pickling) MD-402-100-EG-ME-SPC-00026 ASTM A123 Galvanizing Report H R

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 Surveillance Point
Item No. Quality Control Point Specific Reference Kind of protocol Accept Comments
(Activity, by, Frequency) (PO,Contract,Doc.,Specs) Procedure (Characteristic, Status
Methods, Criteria) DANEM Outotec

In process: Zinc quality, Bath Galvanizing Procedure/

6.2
composition&Bath Temperature
MD-402-100-EG-ME-SPC-00026
ASTM A123
- H R

Adhesion- Galvanizing Procedure/

6.3 Stout knife test
MD-402-100-EG-ME-SPC-00026
ASTM A123
Galvanizing Report H R

Visual Inspection Galvanizing Procedure/

6.4 of Zinc coating
MD-402-100-EG-ME-SPC-00026 ASTM A123 Galvanizing Report H W

6.0 Dispatch.

QC Release Note /
6.1 Final Inspection before dispatch TPS 1136-I1-03370-REV-B Tags, Mark No. Pack List H W/R
Paint Touch up etc

Inspection Release by Outotec /

Preparation for shipment Tags, Mark No. Release note signed by
6.2 TPS 1136-I1-03370-REV-B H W/R
Paint Touch up etc Outotec

7.0 Review of Documentation

Final documentation Manufacturer's Final Inspection

All documents as per
7.1 Data Book/Certificate of
TPS 1136-I1-03370-REV-B - Books- Hard & H R
Compliance electronic copy

LEGEND IMS :Integrated Management System MDR : Manufacturing Data Records AFC : Approved For Construction
IMIR:Inward Material Inspection Report SIR: Stage Inspection Report WIR: Welding Inspection Report

ITP INTERVENTION POINTS:

H;Hold Point W:Witness Point R: Records Review S : Surveillance

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