Microsoft Word - FOXTROT-I-PLA-0002_0'' ITP for Offshore Pipeline 10 InchFPRO-ECOM PIPELINE PROJECTCONTRACTOR RESPONSE SHEET (CRS)Document NumberFOXTROT-I-PLA-0002Rev0Document TitleITP FOR OFFSHORE PIPELINE INSTALLATION 10 INCHDocument Receipt Date26-Feb-2015PHE Comments ByIY, GMCONTRACTORResponse ByANComment Code*123PHE Comments Date04-Mar-2015CONTRACTORResponse Date04-Mar-2015PHE CRS No.CONTRACTORResponse No.CRS-I-PLA-0002ItemParagraph/ Section RefComment#PHE CommentCONTRACTOR ResponseStatus1Page 6Added content 1.4 Reference DocumentYes, has added2Page 8Revised content : A. REVIEW DOCUMENT Deleted 11. Safety Device Procedure, Revised Reference DocumentYes, has revised3Page 11Revised content : C. STRUCTURAL WORKTo be : 1. Material SpecficationFabrication WorkInstallation WorkYes, has revised*Comment Codes Status:ApprovedApproved as NotedNot Approved / RejectedPage 1 of 1FPRO-ECOM PipelineDocument Number :Replacement ProjectSTC-0949 FOXTROT -1-PLA-0002Author's Organization1-' PERTAMINAValidationPT. HDK - PT. HDSConsortium PH EONWJ6 Months Expired Date04-Sep-2015ITP FOR OFFSHORE PIPELINE INSTALLATION 10 INCHApproval SheetNameTitleDateS!_gnatureAto SuyantoProject ManagerEdim T. SinulinggaProject Leadlndra Ashari I Ahmad Y aniProject EngineerGarniko Mulia NugrahaProject QA/QC LeadRevision StatusRevIssue DateByCheckAppIssue PurposeOwnerSignatureA17-Feb-2015ANYFFSIssued for Review026-Feb-2015ANYFFSIssued for Approval004-Mar-20 15AN Lh-YF /'-FS1Re-Issued for ApprovalPT. PHE ONWJITP OFFSHORE PIPELINEReview & Endorsement RecordsNameTitleDateignatureFrengki SiagianProject Manager4-Mar-2015_j\A\I --- }YanferizalQA/QC Manager4-Mar-2015This document has been reviewed and endorsed by:J+FOXTROT-1-PLA-0002 Rev. 0Paper copies are uncontrolled Page 2 of 20PT. PHE ONWJITP OFFSHORE PIPELINEFOXTROT-I-PLA-0002 Rev. 0Paper copies are uncontrolledPage of 20Revision Log RegisterRevisions had been performed on following pages:PageDateRevision625-Feb-2015Edited Reference Document925-Feb-2015Deleted Engineering Design925-Feb-2015Added Qualification QC Personal & Inspection8-1225-Feb-2015Revised Acceptance Criteria10-1125-Feb-2015Added Field Joint Coating & Painting Inspection62-Mar-2015Added content 1.4 Reference Document82-Mar-2015Revised content : A. REVIEW DOCUMENTDeleted 11. Safety Device Procedure, Revised Reference Document112-Mar-2015Revised content : C. STRUCTURAL WORKTo be : 1. Material SpecficationFabrication WorkInstallation WorkTABLE OF CONTENTSPageREVIEW & ENDORSEMENT RECORDS2REVISION LOG REGISTER3TABLE OF CONTENTS4INTRODUCTION5General5Purpose5Definitions5Reference Document6LEGEND OF INSPECTION LEVEL6NOTES7ITP TABLE7ATTACHMENT7INTRODUCTIONGeneralPHE ONWJ intends to re-develop Foxtrot Area thru new developments and platform reactivation including replacement of pipelines in 2013 2015. Production level from Foxtrot flow-station will return to around 10000 BOPD and producing significant natural gas. Unfortunately there is only single export pipeline (MOL) connecting Foxtrot to ECHO flow-station. The produced gas from Foxtrot is currently being flared due to no gas pipeline from Foxtrot to other flow-station connecting to NGLB.Figure 1. East Area Pipeline NetworkNew export pipeline connecting Foxtrot and ECHO flow-station will be installed (length 32 km with 10 nominal diameter). The new pipeline will be functioned as oil line, while the existing 16 pipeline will be as gas line (as its original design).Top modification at FPRO and ECOM platform are designed to accommodate contingency scenario for the two export pipeline and reserve gas flow ECOM to FPRO for a case when FPRO experience black-start-up. Additional scope of top side facility is reactivation of water dumping system at FPRO platform due to limitation of existing 14 FPRO-Junction pipeline.PurposeThis document describes the minimum requirements of the quality control activities, Inspection & Test items during fabrication and/or construction phase, reference documents, required acceptance criteria, certifying or verifying documents, and inspection parties involve. Its all for assure that the product will be built in accordance with project specifications, code & standard requirements, and meet local government regulations.DefinitionsCOMPANY - PT. Pertamina Hulu Energi ONWJ, the owner for EPCI forFPRO/ECOM Pipeline Replacement Project.CONTRACTOR - PT. Hafar Daya KonstruksiMIGAS- Indonesian Government Body responsible for issuing approvals and licenses for oil and gas facilities.PROJECT - EPCI for FPRO/ECOM PIPELINE REPLACEMENT PROJECT.Shall/ Must/ Will- Indicate requirement strictly to be followed in order to conform to thisspecification and from which no deviation is permitted.Should- Indicates that among several possibilities, one is recommended as particularly suitable, without mentioning or excluded others, or that certain course of action is preferred but not necessarily required. Other possibilities may be applied subject to agreement.May/ Can- Verbal form used to indicate a course of action permissible within thelimit of the specification.Reference DocumentFOXTROT-G-PLA-0001Project Execution PlanFOXTROT-I-PLA-0001Project Quality PlanPHEONWJ-W-PRC-0011~0Guidance on Offshore Pipeline Installation PHEONWJ-W-PRC-0005~2Guidance on Pipeline WeldingPHEONWJ-W-SPE-0016~0Pipeline Field Joint CoatingPHEONWJ-L-SPE-0001~2Painting Specification for External Metal urface PHEONWJ-W-PRC-0014~0Guidance on Pipeline Testing andPrecommissioningAPI 1104Welding of Pipelines and Related FacilitiesASME B31.4Pipeline Transportation System for Liquid Hydrocarbons and Other LiquidsAWS D1.1Structural Welding Code - SteelLEGEND OF INSPECTION LEVELWithin the ITP Table, the following definitions shall be used:P means the Primary Responsibility as defined in the attached ITP.A means the Approval.R means the Review being undertaken by the responsible parties as indicated in the attached ITP.V means the Verification being performed by the responsible parties as indicated in the attached ITP.SW means the Spot Witness being undertaken by the responsible parties as indicated in the attached ITP.W means a Witness Point.Witness Point is defined as critical steps in the installation and testing process, in respect of which the Contractor is obligated to agree a time with the Company in advance of the operation so that it may be witnessed by Companys authorized representatives and, where indicated in the Procedure, by representatives from PJIT and/or MIGAS. If the Company advises the Contractor that the indicated witnesses cannot attend, then the Contractor may proceed the witness point.H means a Hold Point.Hold Points is defined as critical steps in the installation and testing process, in respect of which the Contractor is obligated to advise the Company by an agreed timeNOTES period in advance of the operation so that it may be witnessed by the Companys authorized representatives, and, where applicable, by PJIT and/or MIGAS representatives. The Contractor may not proceed the such operation with the hold point without it being witnessed by the requisite representative(s), except by prior written agreement from the Company.Test/Inspection shall be carried out if specified or required in the applicable requisition or specification.Inspection and Testing of the items and materials not listed in this ITP but required by other specification or applicable code/standard shall be carried out by Vendor.Random means as little as possible of the test number will be performed at shop in respect of which the employee is obligated to agree with other parties who witness the shop test.Random does not confine to set a frequency or level of inspection.ITP TABLESee Page 8 - 12ATTACHMENTInspection Form SheetITP OFFSHORE PIPELINEPT. PHE ONWJFOXTROT-1-PLA-0002 Rev. 0Paper copies are uncontrolledPageB of20P'l(jERTAMINAINSPECTION A ND TEST PLAN FOR OFFSHORE PIPELINELegend of Inspection Level P Primary Responsibility A ApprovalR ReviewV Verificat onSW = Spot Witness W = Witness Point H = Hold! PointM =MonitorJOB NO. : 0949REVISION0DOC.NO.:FOXTROTIPLA-0002DATE4-Mar-t5I BYCHK IAPVDANYFFSNOINSPECTION ACTIVITY I TEST ITEMREFERENCE DOCUMENTACCEPTANCE CRITERIAINSPECTION LEVELVERIFYING DOCUMENTREMARKVENDORHAFARPHEONWJThirdPartyMIGASADOCUMENT REVIEW1. Project OUal y PlanQuality Requirement forContractorQuality Requirement forContractor.RRR.Approved Project QualityPlan2. Construction Completion ScheduleProject ScheduleProject Schedule.RRR.Approved Project Schedule3. Material SpecificationSpecification for Line Pipe MaterialSpecification for Line PipeMaterial.RRR.Approved MaterialSpecication and Certificate4 . Welding Procedure Spec icationGuidance for Pipeline Welding-API 1104&AWS D1.1Guidance for PipelineWelding-API 1104&AWSD1.2.RRRRApproved WPSIPQR5. Welder & Welding Operator Certificate- Specdication for Pipeline Installation-API 1104&AWS 01.1- Specification for Pipeline Installation-API 1104&AWS01.2-RRRRApproved Welder andOperator Certificate6. Repair Procedure- Specffication forPipeline Installation-API 1104 & AWS 01.1- Specification for Pipeline Installation-API 1104&AWSD1.2-RRR-- Approved Repair Procedure'-General Welding ProcedureCoating Procedures i.e Concrete weight,FBE,Asphatt Enamel7. and Field Joint Coating- Specification for Pipeline Corrosion Protection Coating-Specification forOffshore Pipeline WeightCoating-Specification for Riser Corrosion Protection CoatingSpecification for Pipeline Corrosion Protection Coating- Specification for OffshorePipeline Weight Coating-Specification for Riser Corrosion Protection Coating-RRR-- Approved Manutacture Coating Procedure-Approved Manufactu reSpec ificat on Procedure8. Installation ProcedureSpecification for PipelinelnstanationSpecification for PipelineInstallat on-RRRRApprovedInstallationProcedureFlooding,Cleaning,Gauging,Hydrotest,Dewatering,9. Swabbing,Drying and Purging Procedure-Guidance on Pipeline Testing and Precommissioning-Applicable Codes andStandards- Guidance on Pipel ne Testing andPrecomm issioning-Applicable Codes andStandards-RRRRApproved Flooding, Cleaning,Gauging & Hydrostatic Testing ProcedureI'Pt1 ONWJFOXTROT+PLA-0002 Rev. 0Paper copies are uncontrolledPage9 of20P'l(jERTAMINAINSPECTION A ND TEST PLAN FOR OFFSHORE PIPELINELegend of Inspection Level P Primary Responsibility A ApprovalR ReviewV Verificat onSW = Spot Witness W = Witness Point H = Hold! PointM =MonitorJOB NO. : 0949REVISION0DOC.NO.:FOXTROTIPLA-0002DATE4-Mar-t5I BYCHK IAPVDANYFFSNOINSPECTION ACTIVITY I TEST ITEMREFERENCE DOCUMENTACCEPTANCE CRITERIAINSPECTION LEVELVERIFYING DOCUMENTREMARKVENDORHAFARPHEONWJThirdPartyMIGASBQUALIFICATION PROCEDURE and VERIFICATION OF EQUIPMENT,CONSUMABLE$, PERSONNEL9.1Welding1. Qualif cation of WPS (including mechanicaltesting)> PHEONWJ-W-PRC-ooos 2> General Welding Procedure> Welding & WelderQualification Procedure> WPS/PQR for Pipeline(API 1104) 10 Inch> WPS/PQR for Steel Structure (AWS D1.1) 10 Inch> Welder Qualificat onRecords> QA/QC Personnel Competence Record> QC Equipment Calibration RecordAPI1104&AWSD1.1FOXTROT-1-PRC-0005-pwRHWPSIPQR2. Qualiijcation of Welder-pwRHWelder Cermicate3. Review and Verification of Welding Consumable-pwRMaterial Certificate4 . Review and Verijication of Base Metal.pwRMaterial Certij cate5. aualiijcation of ac PersonnelAPI1104 & AWS D1.1FOXTROT-1-PRC-0010-pRIAR-QC Personnel Cert f cate6. Review and Verificat on of Inspect on ToolsFOXTROT-1-PRC-00 11-pRIAR-Calibration Tools/Equipment Certificate9.2Non Destructive Test1. NDT Procedure (RT,UT,MPI, and PT)API1104/ PHEONWJ-W-PRC- 0005-2API 1104/ FOXTROT-1-PRC-0006pwwRRNDT ProcedureReview NDT Operator I Personnel2. Qualification I CertificationpRRRRNDT Operator Certificate3. Review Equipment Certification and CalibrationpRRR-Calbrat on CertificateB.SPainting & Coating Protection (HSS & HOPUF)1. Material SpecificationPHEONWJ-L-SPE-000 1/PHEONWJ-W-SPE- 0016-0FOXTROT-1-PRC-0008 I FOXTROT-1-PRC-0007pvwR-Material Certificate2. Procedure Qua lification TestpwwR-POT ReportI'Pt1 ONWJFOXTROT-1-PLA-0002 Rev. 0Paper copies are uncontrolledPage of20P'l(jERTAMINAINSPECTION A ND TEST PLAN FOR OFFSHORE PIPELINELegend of Inspection Level P Primary Responsibility A ApprovalR ReviewV Verificat onSW = Spot Witness W = Witness Point H = Hold! PointM = MonitorJOB NO. : 0949REVISION0DOC. NO. :FOXTROTIPLA-0002DATE4-Mar-t5I BYCHK IAPVDANYFFSNOINSPECTION ACTIVITY I TEST ITEMREFERENCE DOCUMENTACCEPTANCE CRITERIAINSPECTION LEVELVERIFYING DOCUMENTREMARKVENDORHAFARPHEONWJThirdPartyMIGAScPIPELINE, RISER & DOG LEG INSTALLATION1. Pipe Unloading, Receiving Inspection.Handling and StoragePHEONWJ-STC-0819FOXTROT-1-PRC-0009-pvR-H-QC-1112-MIP I H-QC.1112-IPS(Material Inspect on Report/ Incoming Pipe TallySheet)2. Weldinga. Confirm Approved WPS (including welding repair)API1104/ PHEONWJ-W-PRC- 0005-2API 1104/FOXTROT-1-PRC-0002-pswsw-Approved WPSb. Confirm Welder Qualnicat on.pswsw.Welder Certnicatec. Edge Preparation and Cleaning.pswsw--d. Pipe No.Record-pRR-H-QC-1112-APS(As laid Pipe Tally Sheet)Alignment and Fit-Upe. (Position of ong Seam Orientation 45 each side of vertical)-pswsw-H QC- 1112-FU-VI(Fit Up & Visua lInspectionReport)f. Check Pre-Heat & lnterpass Temperature-pswsw-Approved WPSg. Check Welding Consumable Used-pswR-Check Welding Parameters, Volts.Amps, TravelSpeed,h. etc.(2 times per shift & for every repair activity)-pswsw-H-QC-1112-WPM(Welding Parameter Monitoring)i. Welding VisualInspection-pswsw-H-QC-1112-DWR(Daily Welding Report)j Joint ldenutication and Welder SymbolMarking-pMR--3. Non Destructive Testing-a. Radiography Testing (100% for butt weld)API1104/ PHEONWJ-W-PRC- 0005-2AP1 1104 / FOXTROT+PRC-0006pwwR-RTReportb. Uttrasonic TestingpwwR-UT Report> Performed UT for every joint during pipelaying (bottomside of pipe which identified buckle detector wire)c. Magnetic Particle ExaminationpwwR-MPI Reportd. Dye Penetra ntTestingpwwR-PT ReportI'Pt1 ONWJP'l(jERTAMINAINSPECTION A ND TEST PLAN FOR OFFSHORE PIPELINELegend of Inspection Level P Primary Responsibility A ApprovalR ReviewV Verificat onSW = Spot Witness W = Witness Point H = Hold! PointM = MonitorJOB NO. : 0949REVISION0DOC. NO. :FOXTROTIPLA-0002DATE4-Mar-t5I BYCHK IAPVDANYFFSNOINSPECTION ACTIVITY I TEST ITEMREFERENCE DOCUMENTACCEPTANCE CRITERIAINSPECTION LEVELVERIFYING DOCUMENTREMARKVENDORHAFARPHE ONWJThirdPartyMIGAS4. Field Joint Coatinga. Receipt of MaterialPHEONWJ-W-SPE-00160FOXTROT-1-PRC-0007-pvR-H-QC-1112-FJCR(Field Joint Coating Report)b. Surface Preparation-pswR-c. Coating Applica on-pswR-d. Final Inspection-pwR-5. Pipeline RouteAFC DrawingAIFC Drawing-pswR-As Bum DrawingcSTRUCTURAL WORK1. Mater al Specification and CemficatePHEONWJ-G-PRC- 0016-0AIFC DrawingpRRR-Material Cert cate2. Fabrication WorkRa . Check Engineering DrawingPHEONWJ-G-PRC-0016-0PHEONWJ-G-PRC-0016-0AFC Drawing IWP8-PQR/ProcedureAFC Drawing I WPS-PQR/Procedure-P RRiAR-Inspection ReportInspection Reportb. Check Fabrication Procedure-PIRRiAR-c. Material Inspection (Spec & Physical)-pswR-d. Check Fit up & Dimensionalprior welding-P/WswR-e. WeldingInspection (compliance to WPS)-P/WswR-f. Welding V isua!Inspection-P/WswR-g. NOT PenetrantTestl MPI (if specified )pswRR-h. Painting (Riser Clamp & Pipe Bend)- Paint MaterialPHEONWJ-L-SPE- 0001-2FOXTROT-1-PRC-0008pswRR-Inspection Report-Surface PreparationpswRR-- Painting A pplication (Primer,lntermidiate & Final CoatpswRR-- WFT & OFT ChecKpSWRR-- Painting VisualInspect on-P/WswR-i. PacKing & IRN {Inspection Release Note)pswRR-3. Installation Worka. ChecK Engineering DrawingPHEONWJ-G-PRC-0016-0PHEONWJ-G-PRC-0016-0AFC Drawing IWP8-PQR/ProcedureAFC Drawing IWP8-PQR/Procedure-P/RRiAR-Inspection ReportInspection Reportb. ChecK Installat on Procedure-P/RRiAR-c. ChecK Fit up-P/WSWR-d. Inspection of steel structural-P/WswR-e. Dimensional Check (position, centreline and alignment)-P/WswR-f. Inspection for bolt t ghtening-P/WswR-g. Finishing-P/WswR-I'Pt1 ONWJP'l(jERTAMINAINSPECTION A ND TEST PLAN FOR OFFSHORE PIPELINELegend of Inspection Level P Primary Responsibility A ApprovalR ReviewV Verificat onSW = Spot Witness W = Witness Point H = Hold! PointM = MonitorJOB NO. : 0949REVISION0DOC. NO. :FOXTROT IPLA-0002DA TE4-Mar-t5I BYCHK IA PVDA NYFFSNOINSPECTION ACTIVITY I TEST ITEMREFERENCE DOCUMENTACCEPTANCE CR ITERIAINSPECTION LEVELVERIFYING DOCUMENTREMARKVENDORHAFARPHEONWJThird PartyMIGASEFINAL TESTE. 1Flooding,Cleaning and Gauging OperationPHEONWJ-W-PRC-00 14Rev. 0FOXTROT-Y-PRC-0001a. Verif ication of Material& EquipmentpwwR-Mate rialInspection Reportb. Chem icalAdditive Dosage (if any)pwwR-Cleaning & Gauging Reportc. Water Filling-wwR-d. Debris quant ty checkpwwR-e. Gauge Plate inspection (after gauging operatio n)pwww.E.2Hydrostest,Dewatering,Swabbing,Drying dan Purginga. Hydrotest Equipment Calibrat on CertificatePHEONWJ-W-PRC-0014Rev.0/Peraturan MIGAS 84KFOXTROT-Y-PRC-0001pRRR-Calibration Reportb. Pressurizing,stabil zat onand holding for 8 hourspwww-Pressurization Recordc. Sign Off Recorder Chart at start and Finish of Test (8 hours)pHHHHH-QC-1112-PLO(Hydrotest Pressure Log Operation)H-QC-1112-PLO(Swabbing,Drying &Purging Report)d. Pressure Test Complet onpHHHHe. SwabbingpHHHHf. DryingpHHHHg. PurgingpHHHHh. Sign-Off Test ReportpHHHHFFINAL REPORT AND ISSUANCE CERTIFICATEPHEONWJ-G-PRC-0362-0FOXTR OT-1-PRC-0012-pR /ApPIAMDRI'Pt1 ONWJPrepared By,Approved By,Reviewed By,Ac knowledge By,HAFAR CONSORTIUMPT. PHE ONWJThird PartyMIGASSIGNATURENAM EDATEPT. PHE ONWJITP OFFSHORE PIPELINEFOXTROT-I-PLA-0002 Rev. 0Paper copies are uncontrolledPage of 20INSPECTION FORM SHEETFOXTROT-1-PLA-0002 Rev. 0Paper copies are uncontrolledPage 15 of 20No.Joint No.Pipe No.eweVisualPlain/AnodeHeat No.MillLengthCummulative LengthRemarkf--f--f--f--r--f--f--1'-f--r--1'-f--1'-f--r--1'-r--1'-1'-1'-1'-r--1'-f--r--l(jPT. HAFAR CONSORTIUMIDate :H-QC-1112-APSReport No.:Subject :AS LAID PIPE TALLY SHEETProjectNo.:Clenl:Shift:ProjectDiameter Pipe :Thk :LocationVesselSignatureSignatureSignatureApproved IWitnessed By.Reviewed /Verified By,Hafar ConsortiumPT. PHEONWJTHIRD PARTYDate :Date :Datemmo'tJ'"Tlox(...1.)-;:-ol.g)_0, co..!.... (f.) IQ)(il