9200 9P 006 - R2

CONOCOPHILLIPS INDONESIA INC. LTD.
PROJECTS DEPARTM ENT

SPECIFICATION
DOCUMENT NUMBER
REV
TITLE
INSPECTION AND
TESTING REQUIREMENTS
FOR EQUIPMENT AND
MATERIAL
84501 -9200-9P-006
DATE
PAGE
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REVISION CONTROL SHEET

LATEST REV
DATE ISSUED
PREPARED
REVIEWED
APPROVED
COMMENTS
1 Oct 2002
B. Burn
R.Ford
A.McIntosh
Issued For Use
1 Mar 2003
B. Burn
R.Ford
A.McIntosh
Department Name
Change
8 March 04
B. Burn
R. Ford
Cino Calfino
Section 7.4 AML

Number corrected
Paper Copies are UNCONTROLLED - Check with Document Control for latest available
Revision CONTROLLED copies should be RED stamped

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INSPECTION AND
FOR EQUIPMENT AND
MATERIAL
SPECIFICATION
DOCUMENT NUMBER
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DATE
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T ABLE OF CONTENTS
1.
INTRODUCTION ................................................................................................................4
2.
SCOPE .................................................................................................................................4
3.
PURPOSE............................................................................................................................4
4.
DEFINITIONS ......................................................................................................................4
5.
RESPONSIBILITIES..........................................................................................................6
6.
APPLICATION....................................................................................................................7
7.
PROCEDURE FOR PROCUREMENT............................................................................8
8.
PROCEDURE SITE FABRICATION/INSTALLATION ................................................9

APPENDIX 1 .....................................................................................................................10
APPENDIX 2 .....................................................................................................................12
APPENDIX 3 .....................................................................................................................13
APPENDIX 4 .....................................................................................................................21
APPENDIX 5 .....................................................................................................................22
APPENDIX 6 .....................................................................................................................26
APPENDIX 7 .....................................................................................................................29
APPENDIX 8 .....................................................................................................................30
APPENDIX 9 .....................................................................................................................31
APPENDIX 10 ...................................................................................................................33

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FOR EQUIPMENT AND
MATERIAL
1.
SPECIFICATION
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INTRODUCTION
This procedure, in addition to Project Procedure 84501-9200-9P-005, (Equipment
Criticality Rating),shall be used to establish project quality and certification and
program requirements
2.
SCOPE
This procedure is restricted to Contractors responsible for engineering and
design, procurement and construction activities.
3.
PURPOSE
The purpose of this procedure is to provide guidance in the determination of
inspection requirements for inclusion in the following documents produced by the
Contractor:
4.
Purchasing Inspection Specifications and Plans
Site Fabrication, Erection/Installation Specifications
Site Inspection and Testing Plan
DEFINITION
For the purpose of this procedure, the following definitions apply:
Shall - Denotes a mandatory action
Should - Denotes a strongly recommended action
Contractor - Each organization that carries out all or part of the detailed
engineering and design and procurement of project equipment and materials.
Owner ConocoPhillips Indonesia Inc. Ltd
Project
Quality Plan - A document produced by the Supplier and Contractor
summarizing the specific activities relevant to a Suppliers and Contractors scope
of work. The document shall reference those activities pertinent to the purchase
order scope and identify procedures appropriate to the management and control
of those activities.
Procurement Inspection Plan - A document produced by the Contractor
outlining the overall inspection requirements pertinent to the procurement of

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equipment and materials. The plan shall ensure appropriate reference to or

incorporate Belanak Project inspection requirements.
Purchase Order Supplier Quality Control/Inspection Plan - A document
defining the requirements for the specific inspections to be performed during
manufacture, and test.
Site Inspection and Test Plan - A document produced by the Contractor
defining specific inspection and test activities relevant to site fabrication,
installation and test.
Positive Material Identification (PMI) - The ability to trace material to a Material
Test Report (MTR).
Alloy Verification (AV) - Physical verification of material composition using
material analyzers. It is used to supplement PMI in order to verify a Material Test
Report.
Material Test Report (MTR) - A document issued and authenticated by the
material manufacturer defining the chemical composition and mechanical
properties of a material.
Material Traceability - Ability to trace material to a material trac eability report
during any stage of procurement, manufacture, storage or installation.
Certificate of Conformance (COC) A document issued by a relevant
organization certifying that the products supplied conform in every respect to the
purchase specifications.
Inspection Certificate - A document certifying the satisfactory completion of a
stage inspection, final inspection or test. The document is authenticated by the
purchaser's appointed inspection authority and, where required by the design
code, also s igned by an independent inspection authority.
Concession Request - A formal document raised by a Supplier or Contractor
requesting the purchaser's permission to deviate from a purchase specification.
Positive Material Identification (PMI) Program - A document produced by the
Contractor defining the extent of PMI to be performed on specific materials in
order to enable verification and traceability of material to MTR's during any stage
of supply, storage, manufacture or final installation
Project Specifications - The project engineering standards those are developed
for a Specific Project incorporating requirements for specific inspections and tests
to be performed in the procurement, fabrication, installation and commissioning of
equipment, systems and materials.

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Specification Deviation Request - A formal document issued by the Contractor

to request permission to deviate from a specification or Project inspection
requirement.
5.
RESPONSIBILITIES
5.1
Contractor
5.1.1 The Contractor is responsible for maintaining a documented system to ensure

that required inspection activities are planned, performed, witnessed and verified
and to provide adequate assurance that all equipment, materials fabrication,
installation and tests fully comply with the requirements of this procedure and
project specification and design code requirements.
5.1.2 The system shall provide an auditable trail verifying that inspection and
certification requirements satisfy quality and safety standards indicative of
equipment or system criticality as determined b y the Contractor.
5.1.3 Other responsibilities shall include the following:Preparation of the overall Procurement Inspection Plan for approval by Company.
Documenting the inspection practices to be considered in association with
procurement of equipment and materials. The Plan and associated Contractor's
procedures shall clearly define responsibilities within the Contractors organization
for specifying and approving inspection plans and performing inspection
activities.
5.2
approval of agreed Supplier or Inspection Plans prior to manufacture,

fabrication, installation and test.
performing necessary inspection and verification activities to ensure

equipment, materials and installation conform in every respect with relevant
approved Project specifications and design codes.
the review of Inspection Requirements to ensure the

requirements are incorporated in the final inspection plans.
issue of Deviation Requests for approval by the Project Team where

deviations from Project Inspection requirements are requested.
ensuring that inspection requirements are cost effective and fully comply
with relevant Project design codes.
necessary
Specific Project Development
5.2.1 The Contractors Engineering Manager shall be responsible for the maintenance,
revision, implementation and update of this procedure.

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5.2.2 The Specific Project Team shall be responsible for providing guidance in the
interpretation of inspection and certification requirements to Contractors and
undertaking technical assessments and audits to ensure compliance with
requirements.
5.2.3 The Contractors engineering function shall be responsible for approving
deviations to Project Inspection Plans and communicating such concessions to
the Company for approval
5.2.4 When a deviation is deemed to be of a general nature and affects all Contractors,
this shall be notified accordingly to the Company the Project team shall be
responsible for ensuring that inspection requirements, particularly on systems or
equipment interfacing with other packages, are consistent.
5.3
Quality Assurance
5.3.1 The responsibilities defined in this section apply to both Company Project Team
and Contractors.
5.3.2 Quality Assurance shall be responsible for ensuring that systems and programs
employed by the Contractor's engineering, procurement, and construction
organizations demonstrate that quality objectives and Project requirements, as
defined in the contract document and described in this procedure, are being
achieved.
5.3.3 Contractors Quality Assurance shall perform and document assessment, and
audits relevant to engineering and design, procurement and construction
activities to provide assurance that the Project Quality Assurance Program and
contract requirements are being implemented by all organizations contracted to
supply products or services to the Project.
5.4
Safety
5.4.1 As a function of the Project Safety Reviews, shall ensure that in review and
implementation of the Contractors systems for control of design, procurement,
and construction activities that quality systems and inspection requirements are
consistent, documented, and provide confidence in the design and operational
safety of the facilities.
6.
APPLICATION
6.1
This procedure is for INTERNAL project use by Contractors, and shall not be
issued to Suppliers or Sub-Contractors.
6.2
This procedure shall be used by all Contractors following the establishment of

criticality ratings as a guidance document in the determination of Inspection

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requirements pertaining to, Material Certification, Material Traceability, Positive

Material Identification requirements.
6.3
The Inspection requirements detailed in Appendices 3-10 defines the basis for
the inspection activities to be incorporated in supplier and site inspection plans.
They are NOT an instruction to Contractors to perform an inspection task.
6.4
The determination of Purchaser, Supplier and Site Inspection involvement is the

responsibility of each Contractor and will demonstrate to the Company that
adequate inspection tasks are being performed by the Contractor to provide
assurance of the integrity of equipment and the completed facilities.
6.5
Site inspection activities will be documented and agreed in appropriate Inspection

Plans and indicate the level of Inspection involvement performed by the
company, Contractor.
6.6
Certification shall be produced to certify satisfactory acceptance of products

during all stages of manufacture, fabrication, installation and testing.
6.7
Certification requirements shall be defined by the Contractor and shall satisfy the
requirements of the Contract document.
6.8
It shall be the Contractor's responsibility to ensure that requirements of any

Independent Inspection Authority, Company Project and applicable design codes
are defined in the appropriate Purchase Orders.
6.9
Requirements for Site Inspection and Testing are described in more detail in
Contractors Procedures.
7.
PROCUREMENT PROCEDURE
7.1
Following award of Criticality Rating and determination of Quality Program

requirements for an item of equipment (reference Project Procedures 845019200-9P-005), the Contractor shall use this procedure as a basis for advising the
supplier of the Inspection and Certification requirements associated with the
purchase order.
7.2
Appendices 2-10 shall be used to assist in preparing the appropriate

documentation to advise the Contractors Supplier of the required inspection,
material certification, Material traceability and positive material identification
requirements.
7.3
Depending on the equipment or material, the final clarification and agreement of

inspection and certification requirements with the supplier; the levels of purchaser
and any Independent Inspection Authority involvement will be determined by the

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Contractor and prior agreement with Company or at Supplier pre-production

meeting or by return of an agreed QC Inspection Plan.
7.4
The originator of the material requisition or equivalent document shall determine

the extent of inspection in accordance with the requirements of 84501-9200-9P005 Equipment Criticality Rating to be imposed on supplier of bulk materials or
standard "off the shelf" items. Requirements for such suppliers to submit detailed
Quality Assurance Plans will be determined by the Contractor but such suppliers
should have demonstrated an ability to comply with appropriate project quality
requirements and be included on the Company Approved Manufacturers List.
84501-9400-9W-001
8.
SITE FABRICATION AND INSTALLATION PROCEDURES
8.1
The Contractor shall reference Appendices 2-10 to assist in the determination of

Site Inspection, Testing and Certification requirements for Project Site Fabrication
and Installation Specifications.
8.2
The Site Fabrication and Installation Specifications shall form the basis against
which Site QC and Inspection Plans are developed for each Sub-Contractor. The
Site Inspection, Test and Certification Requirements describe the requirements,
procedures, documentation and certification requirements to be utilized to verify
the acceptance of the prescribed site inspection activities.
8.3
Completed system certification packages are coming together with Suppliers

Certification in Fabrication Dossiers to form System Handover Packages.
8.4
The System Handover Packages are subsequently referenced in the appropriate

completion certificates prepared by the Contractor for Project Company
acceptance.

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APPENDIX 1
GENERAL NOTES FOR DETERMINING INSPECTION
AND CERTIFICATION REQUIREMENTS
1.
It is the Contractors ultimate responsibility to ensure adequate levels of

inspection and test are performed and that certification and traceability provide
adequate verification to certify products and systems have been manufactured,
installed and tested to the satisfaction of the Company. The Company shall
perform such inspections and audits as desired to monitor activities of Contractor,
Suppliers
2.
Appendices 3 through 8 define the basis for the determination of Inspection

Requirements with respect to the categories listed.
3.
For equipment, Criticality Rating 1 or Criticality Rating 2, these requirements shall

be mandatory as relevant to the type of equipment being considered and shall be
incorporated in appropriate manufacturing or fabrication inspection plans.
4.
These requirements do NOT preclude the Contractor from incorporating

additional requirements where considered necessary to provide assurance that
levels of equipment integrity have been achieved.
5.
The difference between levels of inspection for Criticality Rating 1 and Criticality
Rating 2 items are determined by the Contractor. These levels shall clearly
demonstrate that the percentage of inspection, non-destructive testing, leak and
pressure testing performed reflect the significance of the item being considered.
6.
Detailed requirements where listed on the attached inspection plans for Criticality
Rating 1 and Criticality Rating 2 equipment, supplement requirements outlined in
the present specification's. All present specification requirements for Inspection,
Testing, and Certification shall be complied with where referenced in Appendices
2 through 10.
7.
Facility to deviate from Project specifications and minimum inspection and

certification requirements as referenced herein shall be permitted where cost
effectiveness can be demonstrated without loss or risk to equipment or system
integrity. Contractor's deviations to inspection requirements on Criticality Rating 1
and Criticality Rating 2 equipment will be by exception only and must be fully
supported.
8.
For the purpose of satisfying the requirements of this procedure the Contractors
responsible for ensuring that requirements for deliverables, approvals, inspection,
documentation, traceability and certification, comply with those sections of the

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contract document pertinent to the

engineering,
procurement
construction activities that may not be specifically stated in this document.
and
9.
It shall be deemed by the Company that the Contractor has considered and
incorporated all relevant inspection, test and certification requirements as
required by this and referenced documents contained herein and in all purchase
orders issued either by Contractor or by organizations acting on his behalf. The
Contractor shall also ensure that orders placed by suppliers comply with the
primary requirements.
10.
The Contractors system shall ensure that ALL concessions deviating from Project
Specifications are documented and controlled.
11.
Where necessary or considered appropriate by Company the requirements of this

procedure and shall also apply to modifications, refurbishment or tie-ins to
existing equipment.
12.
Requirements for Material Traceability, Material Test Reports (MTR's), Positive

Material Identification (PMI), and Alloy Verification (AV) apply to all engineering
disciplines and should be read in conjunction with the relevant sections of
Appendices 2-7

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APPENDIX 2
MINIMUM INSPECTION REQUIREMENTS
CIVIL, ARCHITECTURAL, STRUCTURAL, HVAC
1.
Minimum inspection requirements for this category shall comply with the relevant
Project specifications; Project approved standards and design codes as stated in
the Contract document. These may be supplemented by Contractors established
codes, standards, and practices where approved by Company
NOTE:
Refer to Appendices 8-10 for Material Traceability, Certification and

Positive Material Identification requirements.

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APPENDIX 3
VESSELS/EXCHANGERS/TANKAGE
GENERAL NOTES:
1.
The supplementary inspection requirements as defined in this Appendix only

apply to equipment with Criticality Rating 1 and Criticality Rating 2. In
distinguishing the requirements for levels of inspection between the two groups,
refer to General Notes Appendix 1, Paragraphs 1. and 5.
2.
The requirements of this Appendix cover the minimum engineering quality

control/inspection requirements for vessels, tankage and heat exchangers
whether individual or part of a package unit and supplement Project
specifications and Design Code Requirements.
3.
Where necessary, the requirements of this Appendix shall apply both o

t new
items and to modifications or refurbishment to existing equipment.
4.
Requirements for site erected tanks or fabricated equipment shall comply with all
relevant inspection requirements and supplemented by activities specific to the
type of equipment
5.
As a minimum, inspection requirements for Criticality Rating 3 equipment shall

comply with Project specifications and Project Approved design codes.
Deviations are subject to Company approval and should be sought where cost
effectiveness and proven established practices can be justified.
6.
Above equipment groups classified as Criticality Rating 4 shall satisfy the

Contractors purchasing specification requirements as defined by the Contractor.
Standard equipment or off the shelf items, which are tested and certified as
conforming to the product purchase specification would be acceptable.
NOTE:

INSPECTION ACTIVITY
REF. DESCRIPTION OF INSPECTION ACTIVITY
1.
Pre-production visit to Supplier's works to monitor the Contractors adherence the

following:
-
Supplier has relevant Standards and Specifications.
Final drawings approved before manufacture commences.

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Suppliers sub-orders have been placed and copies forwarded to

Purchaser.
Quality Control/Stage Inspection Plan agreed.
Schedule of Welding Procedures available and approved before

production commences.
COMMENTS:
2.
3.
4.
Record Specification and drawing numbers and status.
Copies of sub-orders where indicated in Quality Program and

Purchase Order to Contractor.
Review to include suppliers Quality Control Plans where indicated

in Quality Program.
Following materials inspected and positively identified against material test

certificates:
-
Plates, pressings, tubes, forging, castings and joint materials necessary

for pressure containment.
Materials forming internals welded to pressure containment parts,
Materials forming external appendices, e.g., compensating pads, saddles,

doubling plates where welded directly to pressure containing parts.
Alloy verification of above by portable material analyzer as per Contractors

PMI positive material identification program.
Check material control implemented at following stages and that identification

and traceability are maintained:
-
Stores inward (include free issue material)
During storage.
Fabrication through to final acceptance
Control of weld consumables.
Undertake full dimensional checks on:

-
Receipt of materials
Following set up of strakes/shell sections
On completion of welding of strakes
Prior to heat treatment, if applicable

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COMMENTS:
5.
Dimensional check shall ensure manway/nozzle/ flange

orientations, hold-down orientations are in accordance with AFC
drawings, actual dimensions where different are noted on As Built
drawings.
On columns, checks to include: (a) Spacing and level of tray

supports. (b) Distance between downcomer and tray levels. (c)
Weir heights.
Witness welding procedure qualifications and welder qualifications (to include all
Mechanical Tests/NDT and test plates as required.
N.B.
Existing qualifications may be acceptable if they are current and valid in

accordance with code requirements. Review/approve WPS/PQR.
6.
Inspect welding set ups of longitudinal and circumferential seams.
7.
Check welding being performed in accordance with procedure and inspect:

-
Root pass
Filler runs
Final after capping run
Grinding back to sound metal where second side weld required.

COMMENTS:
-
Check to include:
Application of preheat and inter-pass temperature
Correct type and size of electrode or wire for root and capping runs
Each weld to carry welder's identification (method of identification to be agreed

with Purchaser for alloy, austenitic and low temperature steel plus non-ferrous
material).
8.
Inspect during fabrication and check shape and workmanship of dished head
manufacture as 5. through 7. above. Note minimum thickness at knuckle radius.
9.
Inspect branch connections before welding. Particularly for excessive root gap,
misalignment with hole penetration in plate/tube; surface condition of weld
preparation. Note: Flame cut holes to have all heat affected areas removed by
grinding.
10.
Inspection of completed branch attachment welds and flange/neck welds. Check

no flange face distortion or damage to joining faces. Ensure that where

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compensating pads are fitted, API tapped vent holes are provided (provision for
vent holes in slip-on flanges where specified).
11.
Inspection of completed external attachment welds. Ensure API tapped vent

holes are provided on saddles/ doubling plates which cross main longitudinal or
circumferential shell welds.
N.B. Where vessel to be insulated, all tapped holes to be fitted with extension
tube extending beyond insulation prior to shipment from works.
12.
Check and approve NDT operator qualification meets NDT criteria. Where
Contractor has own NDT facility, check competence of operator and assess
facilities/ equipment.
13.
Check and approve NDT procedures:
14.
Dye penetrant
Magnetic particle
Ultrasonic
Radiographic
Witness following NDT:

Dye Penetrant:
-
Root run (including second side if applicable)
Completed weld
After heat treatment
Review all reports
Magnetic Particle:
-
Root run (including second side if applicable)
Completed weld
After heat treatment
Review all reports
Ultrasonic Examination:
-
Review examination report
Radiography:
-
Interpret radiographs
Review report

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percentage radiography to include a random sample from each welder for

spot R.T.

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COMMENTS:
-
MT of all seam/nozzle/ branch and internal attachment welds in

ferrous materials.
Review all required radiographs.
All seams covered by compensating pads on doubling plates to be

radiographed prior to their attachment.
15.
Visual examination; all external and internal attachment welds to the pressure
shell complete/ acceptable; (before stress relieving if applicable).
16.
Review Heat Treatment Procedures.
17.
Witness soapy water/air test on compensating and doubling plates (before stress
relieving where applicable). 10% witnessing as a minimum requirement and
review test reports.
18.
Check suitability and calibration records of thermal measurement equipment and

positioning of temperature probes.
19.
Review Heat Treatment Record chart for compliance with ASME Code and P.O.
specifications.
20.
Witness hydrotest. During test check for any undue deflections, pressure
drops/variations, water temperature and chloride content.
21.
Verify nameplate detail correct and stamped with relevant Inspection Authority
stamp when required. Ensure correct weight indicated and verified.
22.
Witness vessel draining; ensuring adequate venting and vessel fully drained prior
to shipment.
23.
Final external, internal inspection and dimensional check. Before final close
check that all relevant bolts and gaskets are in place and that vessel internals are
supported and protected to avoid damage in transit, e.g., dip pipes. All internal
bolts are tightened and locked. All external openings are protected and sealed.
24.
Inspect painting system or other protection specified. Ensure preparation,

application, thickness and paint specification in accordance with specified
requirements.
25.
Inspect insulation, ensure where vent holes have been provided in vessel
external attachments that vent pipes are fitted. Check vapour barrier, insulation
and cladding grade, thickness. All seams or apertures in cladding sealed with
mastic.

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26.
Review, approve and countersign Manufacturing Data Books and Fabrication

Data Dossiers.
27.
Inspect shipment preparation, packing, opening protection, dry-out, purging and

marking.
28.
Additional minimum requirements for site erected tankage only.

-
Vacuum box test floor
MT/DP floor to shell welds internal/external
Air on water roof test.
Additional Requirements for Heat Exchangers

29.
Tube end weld procedure approved and in accordance with Contractors

specification (if applicable).
30.
Tube roll expansion procedure approved and in accordance with Contractors

specification.
31.
Inspect weld procedure qualification test blocks for tube end welding process and
approve mechanical testing and NDT results. (to include any shift test block
requirements where specified)
32.
Review and approve results of ultrasonic examination of tube-sheet before drilling

and following explosive cladding where applicable.
33.
Inspect tube-sheets following machining and check ligament size, weld

preparations and detail of rolling grooves in accordance with appropriate TEMA
classification. Tube holes to be checked for ovality, diameter, tolerance and
surface finish.
NOTE: Check minimum of 10%
34.
Inspect bellows assembly following welding of;

-
Root pass
Final capping run
Second side where applicable
35.
Witness dye penetrant/MT examination of bellows assembly finished weld.
36.
Review NDT reports, DP, MT, radiographic, other, bellows assembly.

-
Interpret radiographs

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37.
Check and inspect test rings/glands available for leak and hydrostatic testing
where applicable; i.e.; "U" tube and floating head exchangers (will be supplied as
specified in Purchase Order).
38.
Material inspected and positively identified against material certificate.
39.
Examine assembly of tubes, baffles, tie rods, spacers. Note provision of sliding
strips on floating head and 'U' tube exchangers. Check tolerances before tube
end welding or expansion is performed; baffle clearance correct, tube/tube hole
clearances in baffles correct; tube/tube-sheet is fully de-greased prior to welding.
40.
Where measured tube expansion is specified check tube ends for scoring or
damage after expansion.
NOTE: Examine a minimum of 50%
41.
Inspect during tube expanding or tube end welding for compliance with
procedure.
NOTE: Examine as necessary to determine compliance.
42.
Witness dye penetrant examination of tube end welds.

-
Final
NOTE: Examine 100%

43.
Witness leak test of tube end welds (before and after post weld tube expansion if
called for) before hydrotest. Assess results of test and if leaks exceed 1% of the
tube welds per tube-sheet refer to Contractor for full investigation.
44.
Check gasket material and installation is correct prior to assembly for test. Also
conduct following test if bundle removed. In such cases, new gaskets to be fitted.
45.
Witness shell side hydrostatic test (tube sheets exposed).
46.
Witness tube side hydrostatic tests including channels and covers.
47.
Ensure all exchanger test rings/glands, etc. as specified on purchase order are
available for shipment with exchanger. Test rings should be those incorporated
in final hydrostatic test.
48.
Witness tubing bundle insertion to assure no undue strain is imposed.

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APPENDIX 4
PIPING
1.
Minimum inspection requirements for piping systems incorporating all pipe,

valves, flanges, fittings etc. shall be in accordance with ANSI B31.3
supplemented by any additional requirements defined in Company specifications.
2.
All piping system specifications shall be reviewed by Company to ensure

consistency in application of inspection and certification requirements with
respect to piping classes, components, material and duty. This requirement is
particularly important on piping systems interfacing with other Contractors where
consistency of requirements is essential both on safety grounds and also to
facilitate system handover.
3.
Procurement specifications for bulks shall, as a minimum, comply with the

requirements of the Contract documents.
4.
Procurement specifications for valves shall comply with Project approved codes
and standards and should be consistent with respect to Contractors piping
classes, duty and materials of construction.
5.
Requirements for supplementary inspection and certification as referenced in

applicable codes and standards shall be determined by the Contractor.
NOTE:
Refer to Appendices 8-10 for Material Traceability and Certification

and Positive Material Identification requirements.

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APPENDIX 5
MACHINERY
1.

apply to machinery in Criticality Rating 1 and Criticality Rating 2. In distinguishing
the requirement for levels of inspection between the two classifications, refer to
the General Notes, Appendix 1 Notes 1. and 5.
2.
The requirements of this Appendix cover the minimum engineering QC/

Inspection requirements for machinery whether individual or part of a package
unit.
3.
As a minimum, all Criticality Rating 3 machinery shall comply Project

specifications Deviations are subject to Company approval and should be sought
where cost effectiveness and proven established practice can be justified.
4.
Machinery classified as Criticality Rating 4 shall satisfy the Contractors

procurement specification requirements. Standard equipment or off the shelf
items as determined by the Contractor, which have been tested and certified as
conforming with the product purchasing specification would be acceptable.
NOTE: Refer to Appendices 8-10 for Material Traceability, Certification and
INSPECTION ACTIVITY
5.
Pre-production visit to Supplier's works to check the following:

-
Supplier has and understands all relevant standards and specifications.
Drawings approved before manufacture commences.
Any special manufacturing process as defined by the Contractors or

suppliers specification or standards are approved.
Sub orders have been placed and contain relevant specifications,

standards, and drawings as appropriate.
Manufacturing
commences
Documentation, certification, mechanical data and fabrication data dossier

requirements defined.
quality
control
plan
approved
before
manufacture
COMMENTS:
-
Check and record all document/drawing numbers and revision

status.

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7.
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Special manufacturing procedures should typically include:
Welding procedures
NDT procedures
Heat treatment procedures
Hard facing/coating procedures
Forming procedures unique to manufacturing process.
Function and Performance Test procedures.
Inspect material and verify compliance with certification, design and specification
requirements for:
-
Chemical analysis and physical properties
Material tests
Heat treatment
NDT examinations
Alloy verification (portable material analyzer)
Check that material control implemented at following stages and that

identification and traceability are maintained:
-
Stores inward
During storage
During manufacture through to final acceptance
Control of welding consumables
8.
Check material in accordance with Purchaser's specification; i.e.; ASTM, API;

schedule/rating, welded or screwed connections.
9.
Witness welding procedure qualification (to include all mechanical tests, NDT and
test plates as required by code).
Review/approve WPS weld procedure specification and
procedure qualification record
WPQR weld
N.B. existing weld procedures may be acceptable if they are current and valid as
determined by applicable code.
10.
Verify welder qualifications current and applicable to approved procedure.
11.
Dimensional check of:

-
Major static/rotating components

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Bearing/sleeve/thrust/seal sizes; clearances
Nozzle elevation/orientations
Bed-plate/hold down bolt hole location
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12.
Verify NDT operators' qualifications are current and applicable to NDT scope.
Where supplier has own NDT facility, assess suitability and operator
competence.
13.
Witness following NDT activities of castings or welded fabricated components:

-
Dye penetrant
Magnetic particle
Ultrasonic (Review reports only)
Radiography (Inte rpret radiographs and review reports, only)

COMMENTS:
-
Machined components only; extent of NDT examination to be in

accordance with procurement specification and as agreed on
Suppliers manufacturing quality plan.
NDT requirements for ancillary equipment and pipe work to be in

accordance with this section of the procedure.
14.
Check surface finish in accordance with specification requirements on critical

components, i.e.; bearings, journals, thrust collars, and fitted bonnets.
15.
Witness balancing of rotating element:
16.
Couplings
Impellers
Gearwheels
Rotor and rotor assembly
Witness over-speed checks on rotating components:

-
Impellers
17.
Where applicable, check heat treatment procedure approved; verify calibration

and location of temperature probes correct. (stress relieving of fabricated
components)
18.
Where applicable, check heat treatment record chart, verify treatment controlled
within parameters.

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19.
Hydrostatic test of machine casing, to include where applicable, all ancillary pipe
work and equipment.
20.
Mechanical running test of machine and auxiliaries when specified.
21.
Performance test, when specified on equipment data sheet.
22.
Strip test - bearing and seal examination.
23.
String test (complete unit test) when specified on equipment data sheet.
24.
Witness and verify noise level measurement complies with contractor's

specification.
25.
Witness and verify vibration levels within limits as defined in Contractors

specification.
26.
Final inspection and cleanliness check prior to shipment. Ensure all machine
surfaces protected, openings sealed, paint coatings applied where specified; all
nameplates fitted and correctly labelled (including ancillary components). Ensure
any temporary transportation restraints, supports secure and clearly identified.
27.
Review and approve Mechanical Data and Fabrication dossiers, Operating and
Maintenance Manuals, Spares Schedules.
28.
NPSH test to API and ANSI standard, as required.
29.
Operational tests of lube oil console, including cleanliness test. (API) standard
minimum supplemented by Contractor's standard.)
30.
Final dimensional check for field corrections in relation to anchor bolt holes,
grade, etc are per approved outline drawing.
31.
Electrical function test to NEMA and order specifications.
32.
Witness gas leak test when specified. (API standard)

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APPENDIX 6
ELECTRICAL
1.

apply to electrical equipment such as motors, transformers, variable speed drives
and switch gear in Criticality Rating 1 and Criticality Rating 2. In distinguishing the
requirements for levels of inspection between the two classifications, refer to the
General Notes, Appendix 1 notes 1. and 5.
2.
The requirements of this section cover the minimum engineering quality

control/inspection requirements for classes of electrical equipment as defined in
1.0 above and whether individual or part of a package unit.
3.
As a minimum, inspection requirements for all Criticality Rating 3 electrical

equipment shall comply with appropriate IEEE Institute of Electric al and
Electronic Engineers inc. regulations, Contractor's specifications and Deviations
are subject to Company approval. Company approval should also be sought
where cost effectiveness and proven established practice can be justified.
4.
Electrical equipment classified as Criticality Rating 4 shall satisfy the Contractors

procurement specification requirements. Standard proprietary equipment or off
the shelf items as determined by the Contractor, and which has been tested and
certified as conforming with the product purchasing specification would be
acceptable.
5.
For major electrical machines, refer also to Appendix 5, Machinery inspection

Requirements.
NOTE:
Refer to Appendices 8 and 9 for Material Traceability and

Certification Requirements.
INSPECTION ACTIVITY
6.
Pre-production visit to Supplier's works to check the following:

-
Supplier has and understands all relevant standards and specifications.
Drawings approved before manufacture commences when required in the

purchase order.
Any special manufacturing process as defined or supplier's specification or

standards are approved.
Sub orders have been placed and contain relevant specifications,

standards, and drawings as appropriate.

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Manufacturing quality control plan approved

commences (including those of sub suppliers).
before
manufacture
Documentation, certification, data dossier and QC dossier requirements

defined.
COMMENTS:
-
Check and record all document/drawing numbers and revision

status.
7.
Audit/examine material and verify compliance with material certification, design,

specification and IEEE regulations as defined in the Contractors specification.
Review manufacturers test certificate.
8.
Where specified, check that material control is implemented and that

identification and traceability are maintained throughout manufacture and final
acceptance.
9.
Pre-assembly components inspection, ensure all components which make up a

complete item/system are inspected and checked to ensure:
10.
Traceability maintained
Rating in accordance with specifications
Components are free from injurious defects.
Where specified in Contractors specification or IEEE regulations ensure all

pressure containment components are hydrostatically tested.
-
Review certificate of test only.

COMMENTS:
Where ancillary items or pipe work are used to provide cooling, etc., these
shall be subjected to hydrostatic test
-
Associated motor oil coolers, etc.
Electrical items such as oil reservoirs on transformers.
11.
Initial assembly and function test (including all calibration checks, tests as defined
in the Contractors specifications, engineering standards and IEEE regulations
referred to therein).
12.
Final acceptance test.
13.
Review and approve Mechanical Data and Fabrication dossiers, Operating and
Maintenance Manuals and Spares Schedules.

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Preparation of shipment, ensure all machine surfaces are protected, openings

are sealed, paint coatings are applied where specified; all nameplates are fitted
and correctly labelled, including hazard warning labels.
Ensure that all temporary transportation restrain ts and supports are secure and
clearly identified.

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APPENDIX 7
INSTRUMENTATION
1.
The minimum inspection requirements for standard instruments shall comply with
relevant Company specifications and Contractors procedures and sta ndards.
2.
Instrument "specials" i.e. items which are not normal supply, or are unique to the
process design requirements shall be identified on a specific list copied to the
Company. Such instrumentation particularly where manufacturing processed
involve specialized techniques, i.e. specialized castings, welding, NDT or heat
treatment, adequate levels of inspection and test in the purchase order
specifications.
NOTE:


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APPENDIX 8
MATERIAL TRACEABILITY REQUIREMENTS
To be read in conjunction with Appendices 9 and 10. Refer to the Contract document for
definition of Material Traceability.
1.
Material traceability is the ability to trace to Material Test Reports (MTR's) at any
stage from purchase to installation.
2.
The scope of Material Traceability required is outlined in Appendices 9 & 10.
3.
Marking of materials shall as a minimum comply with relevant US codes and

standards and be transferred to off cuts where appropriate to maintain required
levels of traceability.
4.
Individual Contractors shall be responsible for implementing their own systems to

achieve required levels of material traceability. The system shall demonstrate that
material control, segregation, marking and traceability is planned and
documented to provide the necessary level of assurance to the Company that
installed materials of construction are certified and fully comply with the
applicable code and specification requirements.
5.
Where Material Test Reports are required, heat numbers will be traceable to the
individual material component.
6.
Where Material Test Reports are not required, marking shall be in accordance
with relevant Codes and Standards.
7.
The Contractors system for Material Traceability during site fabrication shall
facilitate compliance with requirements of the Contract document with respect to
system acceptance certification.
8.
Material color coding requirements shall comply with Project specifications

requirements.

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APPENDIX 9
M ATERIAL TEST REPORT REQUIREMENTS
To be read in conjunction with Appendices 8 and 10. Refer to the Contract document for
definition of Material Test Reports (MTR's).
1.
General Notes:
Section A: For ANSI/ASME P1 Material Grades
I.
MTR's will only be required if specifically requested in Contractors

specifications. Approved design codes or purchase orders. Typically the
following examples would be advised:
-
carbon steel vessels where metallurgy is critical i.e. low

temperature equipment.
boiler code piping; SA 106
materials are required to satisfy NACE standards in H2S or other

similar duties where composition and metallurgy of finished
condition is critical.
materials restricted to maximum carbon content below standard.
II.
Contractor will be clearly defined in the appropriate design and purchase

documents.
III.
For vessels fabricated in accordance with ASME rules, the Authorized

Inspection may require MTR's for other specific cases in which case they
will be provided.
IV.
Other standard carbon steel products will require a certificate of

conformance issued by the organization qualified to certify that products
comply with specified requirements.
Section B: For ANSI/ASME materials higher than P1

V.
MTR's shall be required for all materials higher than P1, i.e. alloy steels,
stainless steel grades, etc.
VI.
Exceptions to the above may be referred to the Project Specialist where

use of the material is not relevant to process design conditions or for
safety reasons but constitutes Contractors or manufacturers normal
standard i.e. instrumentation components. Such concessions shall be
documented in accordance with the Company specifications.

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Section C: Form of Certificates

VII.
Standard Material Test Report/Material Certificates satisfying the

applicable Code requirements are acceptable. The European
requirements for type A, B, or C material certificates shall not be
mandatory.
VIII.
The form of the certificate shall contain a record of chemical composition,

supplied condition and physical properties, including the results of any
specific tests required by the purchase order or specification; i.e. hardness
values, Charpy impact test results etc.
IX.
Such MTR's shall be furnished and authenticated by the material

manufacturers and traceable to individual components. Copies of original
MTR's are acceptable.
Section D: Civil
X.
As a minimum, the Contractor shall provide MTR's for structural

assemblies employing critical materials of construction. The scope shall be
determined by the Contractor but should typically include for:
- primary structural steel
- lifting devices, runway beams, gantries, cranes, etc.
- equipment anchor bolts where critical to security of the item.
Section E: Electrical
XI.
As a minimum, the Contractors system shall ensure certification is

available for electrical equipment consistent with an item's electrical rating
and classification in compliance with hazardous zone ratings. Certification
is to be verified during installation and site acceptance.
Section F: Bolting
XII.
`The Contractors system for the inspection and verification that bolting
materials comply with specified requirements shall ensure incorrect or
rogue bolting materials are rejected at the suppliers or prior to receipt in
module yard or site stores.

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APPENDIX 10
POSITIVE MATERIAL IDENTIFICATION REQUIREMENTS
To be read in conjunction with Appendices 8 and 9 for definition of Positive Material
Identification (PMI) and Alloy Verification (AV).
1.
Attention is drawn to the need for each Contractor to read and familiarize itself
with the Contract Document.
2.
Alloy materials shall as a minimum comply with the Project requirements for PMI,
which includes the requirements of MTR's, marking, traceability and AV.
3.
Specific traceability to as built drawings will not be required by the Company as

part of the final handover documentation; refer to Project Procedure 84501-92009L-002
4.
The Contractors PMI program shall demonstrate that the system for tracing
material to MTR's provides for simple traceability during purchasing, stores
control, fabrication and installation. The following sections provide guidance to
the Contractor for the determination of PMI requirements, but does not relieve the
contractor from its obligation to include any additional materials in the PMI
programme where it considers this to be justified or necessary.
5.
Components subject to PMI:
5.1
Vessels and Piping Systems

All pressure retaining parts. PMI for internals as determined by the Contractor
and defined in procurement documentation.
5.2
Machinery:
Pressure containing casing. PMI of ancillary components and internals as
determined by the Contractor and defined in procurement documentation.
5.3
Instruments:
As determined by the Contractor.
5.4
Bolting:
As determined by the Contractor, but as a minimum:
-
to include sampling check of all bulk alloy steel stud bolts included in the
ASTM A-193 classification.
alloy bolts critical to and used in equipment subject to PMI.

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Welding:
As determined by the Contractor but as a minimum PMI of sample deposit of
finished weld.

9200 9P 006 - R2

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CONOCOPHILLIPS INDONESIA INC. LTD.

PROJECTS DEPARTM ENT

REVISION CONTROL SHEET

Issued For Use

Section 7.4 AML

CONOCOPHILLIPS INDONESIA INC. LTD.

PROCEDURE FOR PROCUREMENT............................................................................8

PROCEDURE SITE FABRICATION/INSTALLATION ................................................9

CONOCOPHILLIPS INDONESIA INC. LTD.

Purchasing Inspection Specifications and Plans

Site Fabrication, Erection/Installation Specifications

Site Inspection and Testing Plan

CONOCOPHILLIPS INDONESIA INC. LTD.

equipment and materials. The plan shall ensure appropriate reference to or

CONOCOPHILLIPS INDONESIA INC. LTD.

Specification Deviation Request - A formal document issued by the Contractor

5.1.1 The Contractor is responsible for maintaining a documented system to ensure

approval of agreed Supplier or Inspection Plans prior to manufacture,

performing necessary inspection and verification activities to ensure

the review of Inspection Requirements to ensure the

issue of Deviation Requests for approval by the Project Team where

Specific Project Development

CONOCOPHILLIPS INDONESIA INC. LTD.

This procedure shall be used by all Contractors following the establishment of

CONOCOPHILLIPS INDONESIA INC. LTD.

requirements pertaining to, Material Certification, Material Traceability, Positive

The determination of Purchaser, Supplier and Site Inspection involvement is the

Site inspection activities will be documented and agreed in appropriate Inspection

Certification shall be produced to certify satisfactory acceptance of products

It shall be the Contractor's responsibility to ensure that requirements of any

Following award of Criticality Rating and determination of Quality Program

Appendices 2-10 shall be used to assist in preparing the appropriate

Depending on the equipment or material, the final clarification and agreement of

CONOCOPHILLIPS INDONESIA INC. LTD.

Contractor and prior agreement with Company or at Supplier pre-production

The originator of the material requisition or equivalent document shall determine

SITE FABRICATION AND INSTALLATION PROCEDURES

The Contractor shall reference Appendices 2-10 to assist in the determination of

Completed system certification packages are coming together with Suppliers

The System Handover Packages are subsequently referenced in the appropriate

CONOCOPHILLIPS INDONESIA INC. LTD.

It is the Contractors ultimate responsibility to ensure adequate levels of

Appendices 3 through 8 define the basis for the determination of Inspection

For equipment, Criticality Rating 1 or Criticality Rating 2, these requirements shall

These requirements do NOT preclude the Contractor from incorporating

Facility to deviate from Project specifications and minimum inspection and

CONOCOPHILLIPS INDONESIA INC. LTD.

contract document pertinent to the

Where necessary or considered appropriate by Company the requirements of this

Requirements for Material Traceability, Material Test Reports (MTR's), Positive

CONOCOPHILLIPS INDONESIA INC. LTD.

Refer to Appendices 8-10 for Material Traceability, Certification and

CONOCOPHILLIPS INDONESIA INC. LTD.

The supplementary inspection requirements as defined in this Appendix only

The requirements of this Appendix cover the minimum engineering quality

Where necessary, the requirements of this Appendix shall apply both o

As a minimum, inspection requirements for Criticality Rating 3 equipment shall

Above equipment groups classified as Criticality Rating 4 shall satisfy the

Refer to Appendices 8-10 for Material Traceability, Certification and

Pre-production visit to Supplier's works to monitor the Contractors adherence the

Supplier has relevant Standards and Specifications.

Final drawings approved before manufacture commences.

CONOCOPHILLIPS INDONESIA INC. LTD.