WHEATSTONE LNG FACILITY

FLANGE MANAGEMENT PROGRAM

FORM I: SUMMARY OF QA/QC PROGRAM

THIS DOCUMENT PROVIDES SUMMARY OF QA/QC PROGRAM REQUESTED FOR SUBMISSION WITH BID

New front sheet required

EXHIBIT “C” – QUANTITIES, PRICING AND DATA Package Title: Flange Management
Form I – Summary of QA/QC Program Program Request for Proposal No. 25658-540-YK195-PZ00-00001
 ITP No. TBA
INSPECTION AND TEST PLAN
Wheatstone Project Rev. No. 00 - Original Issue

LNG Plant Flange Management Services ITP Handover Classification (Generic/Specific/Not Applicable)
Page 1 of 4
Unit / AREA BUILDING NO, SHELTER NO, SUBSTATION NO ETC. DESCRIPTION BARCODE

NA Wheatstone Project LNG Plant, Onslow Provision of Joint Integrity Assurance including Structured Training and Flange Management Services
Activity
No. Method of Verification
Nature & Extent of Inspection Acceptance Criteria Responsible Person
Activity Description Controlled Document FMC Bolting Report Ref. No.
/ Test (Inspection/Test Requirements) Contractor Owner at Location
Subcontractor Subcontractor

Successful completion of Training and

Assessment according to allocated role or
TRAINING duty:- Training Plan and Curriculum for
SS [PM] Questionnaire Test Paper (Theory)
Training of the 3rd Party Bolting Verification/Witnessing of Flanged Joint Assembly and
1.0 Subcontractor Training - Theory and Practical training course Tightening HT JE [JIE] Training /Assessment records (Practical)
JI Trainer (JIE) FDMS - Unique ID issued
(Assembly and Tightening Personnel) - Theory Assessment Ref.H14-CVX-APC-EXE-008
- Simulated Practical Assessment
- Work Place Assessment

- Personnel ID - Cards ID cards of trained and assessed personnel

Training Plan and Curriculum for
- Safety Helmet Sticker with ID/Skill SS [PM] Training register of qualified personnel
1.1 TRAINING Verification - Register of qualified personnel, Flanged Joint Assembly and I JE [JIE] according to defined skills and capability,
Review of Training Records Tightening
each individual mechanical jointing JI Trainer (JIE) indicated on ID Card and safety hat sticker
performance record. Ref.H14-CVX-APC-EXE-008 FDMS

- Check status of pipework

- Status of pre-works
JOINT IDENTIFICATION (NDT/Hydro-test, flushing, drying, FMC Inspection Application Form Bolting Subcontractor Flange Inspection Test Record [FITR]
1.2 Verification I HR
Joint Selection - for inspection and assembly visual inspection have been signed Ref.H14-CVX-APC-FRM-001 Supervisor/Superintendent & FDMS
off as necessary)
- Completeness of Work-pack

- Check status of joint Identification Tagging and Status

1.3 JOINT IDENTIFICATION Visual Check/Verification - Correct identification on tag Control of Flanged Joints I HR JE [JIE] Flange Inspection Test Record [FITR]
Unique Tag No. for each assembly JI [JII] Joint Tag & FDMS
- Correct joint no. as per FITR and ISO H14-CVX-APC-EXE-006

- Lateral Alignment as per Specification

- Parallel Alignment as per Specification
- Correct alignment of Pipe supports near
to Joint Assy.
Flanged Joint Preparation and Flange Inspection Test Record [FITR]
1.4 JOINT PREPARATION Verification - Ensure any clamp type supports are loose Assembly I HI JE [JIE] &
Alignment of Flange Faces to enable p/work to move freely. JI [JII]
H14-CVX-APC-EXE-005 FDMS
- No stress on mating flange joints.
- Stud bolts must move freely in all bolt
holes of applicable flange assembly.
- Internal Pipe Cleanliness Check

- Surface finish is within Specification

- Check surface cleanliness,
JOINT PREPARATION - Flange surface is degreased
Preparation of Flanges prior to Boltworking - Preservation/Protective Coating Removal
Flanged Joint Preparation and Flange Inspection Test Record [FITR]
1.5 activities Visual Check - Free of defects, nicks or burrs & corrosion Assembly I HI JE [JIE] &
- Flange area under nut seating area JI [JII]
H14-CVX-APC-EXE-005 FDMS
[Incl. Flange Joints that are deemed Critical must be clean and undamaged & free
(Compressor, Pump, Tank Nozzle connections )] from Paint.
- Pipework Internal Cleanliness ; seeds dirt
QRM etc.
 ITP No. TBA
INSPECTION AND TEST PLAN
Wheatstone Project Rev. No. 00 - Original Issue

LNG Plant Flange Management Services ITP Handover Classification (Generic/Specific/Not Applicable)
Page 2 of 4
Unit / AREA BUILDING NO, SHELTER NO, SUBSTATION NO ETC. DESCRIPTION BARCODE

NA Wheatstone Project LNG Plant, Onslow Provision of Joint Integrity Assurance including Structured Training and Flange Management Services
Activity
No. Method of Verification
Nature & Extent of Inspection Acceptance Criteria Responsible Person
Activity Description Controlled Document FMC Bolting Report Ref. No.
/ Test (Inspection/Test Requirements) Contractor Owner at Location
Subcontractor Subcontractor

- Surface finish is within Specification

- Check surface cleanliness
- Flange Surface is degreased
- Preservation/Protective Coating Removed
JOINT PREPARATION - Free of defects, nicks or burrs & corrosion Flanged Joint Preparation and JE [JIE] Flange Inspection Test Record [FITR]
1.6 Visual Check/Verification Assembly I HI &
Rectification of Damaged Flange Face(s) - Flange area under nut seating area H14-CVX-APC-EXE-005 JI [JII] FDMS
must be clean and undamaged & free
from Paint.
- Pipework Internal Cleanliness ; seeds dirt
QRM etc.

All Materials detailed on Flange Inspection Test Flanged Joint Preparation and SS [PM] Flange Inspection Test Record [FITR]
MATERIAL VERIFICATION
1.7 Technical Integrity Verification Record [FITR] match Isometric BOM. Ensure latest Assembly R HR JE [JIE] &
ISO Revision H14-CVX-APC-EXE-005 JI [JII] FDMS

- Correct Gasket as per ISO, type/size/class &

material
- Brand new, unused, clean and undamaged Flanged Joint Preparation and Flange Inspection Test Record [FITR]
1.8 MATERIAL VERIFICATION Visual Check/Verification - No gasket compound or grease on gasket I HI JE [JIE]
Gasket Assembly JI [JII] &
surface H14-CVX-APC-EXE-005 FDMS

- Manufacturer Procedure followed

for preparation, assembly, tightening
including manufacturer supplied bolt loads
to be used if applicable
- Brand new, unused, clean and undamaged
MATERIAL VERIFICATION - No gasket compound or grease on gasket Flanged Joint Preparation and JE [JIE] Flange Inspection Test Record [FITR]
1.9 Visual Check/Verification surface Assembly I HI &
Insulation Gasket JI [JII]
- No conducting path exists for the two H14-CVX-APC-EXE-005 FDMS
mating flanges

- Bolt Diameter and Length to be as

Isometric BOM
- Material Grade of Bolts and Nuts be as
Isometric BOM
MATERIAL VERIFICATION - Correct Colour Coding of Bolts and Nuts Flanged Joint Preparation and JE [JIE] Flange Inspection Test Record [FITR]
1.10 Visual Check/Verification where applicable Assembly I HI &
Bolts and Nuts JI [JII]
- Corrosion free H14-CVX-APC-EXE-005 FDMS
- Undamaged Bolts and Nuts
- Identification markings to be visible and
all in same orientation after assembly
- Thread protrusion as per specification

MATERIAL VERIFICATION Apply Project Specification Lubricant to Bolt Threads Flanged Joint Preparation and Bolting Subcontractor JE Flange Inspection Test Record [FITR]
1.11 Thread Lubrication Visual check/verification and the Nut Bearing Face (Lubrication shall be site Assembly I HI [JIE] &
(Before assembly) specific) H14-CVX-APC-EXE-005 JI [JII] FDMS
 ITP No. TBA
INSPECTION AND TEST PLAN
Wheatstone Project Rev. No. 00 - Original Issue

LNG Plant Flange Management Services ITP Handover Classification (Generic/Specific/Not Applicable)
Page 3 of 4
Unit / AREA BUILDING NO, SHELTER NO, SUBSTATION NO ETC. DESCRIPTION BARCODE

NA Wheatstone Project LNG Plant, Onslow Provision of Joint Integrity Assurance including Structured Training and Flange Management Services
Activity
No. Method of Verification
Nature & Extent of Inspection Acceptance Criteria Responsible Person
Activity Description Controlled Document FMC Bolting Report Ref. No.
/ Test (Inspection/Test Requirements) Contractor Owner at Location
Subcontractor Subcontractor

- Check the Serial No. of Equipment

- Condition of Equipment Bolting Subcontractor Equipment Calibration Register
Controlled Torquing and Tensioning
JOINT ASSEMBLY AND TIGHTENING - Calibration / Verification Label on Supervisor/Superintendent Calibration Certificate
1.12 Calibration of Equipment Verification Equipment of Flanged Bolts R HR JE [JIE] Calibration Sticker
H14-CVX-APC-EXE-004
- Validity of Calibration / Verification Date JI [JII] Verification Sticker
- Equipment Calibration Register

- Qualification of Personnel. Personnel

Identification verified (Photo ID, Hat
Badge)
- Assembly Status, all components are as
listed on Isometric BOM and verified
- FITR has complete and correct information
JOINT ASSEMBLY AND TIGHTENING - Equipment selected will fit Joint/Flange Controlled Torquing and Tensioning Flange Inspection Test Record [FITR]
1.13 Bolt Torquing Visual Check/Verification orientation of Flanged Bolts T HI JE [JIE] &
Manual and Hydraulic Torque Equipment - Applicable Torque Values are followed in H14-CVX-APC-EXE-004 JI [JII] FDMS
stages (25%, 50%, 75%, 100% sequential and
rotational according to Project specification
- Thread protrusion on both sides to match
Project Specification
- Correct Joint Alignment after tightening.
- Joint Tag fitted and FITR completed
- Leak Test (Site Specific)

Controlled Torquing and Tensioning

JOINT ASSEMBLY AND TIGHTENING A light tap with hammer on the flat of the nut will Bolting Subcontractor
1.14 Visual Check/Verification of Flanged Bolts T T Good Practice
Tap Test produce a high pitched 'RING" Technician
H14-CVX-APC-EXE-004

- Qualification of Personnel. Personnel

Identification verified (Photo ID, Hat
Badge)
- Assembly Status, all components are as
listed on Isometric BOM and verified
- FITR has complete and correct information
- Equipment selected will fit Joint/Flange
orientation
JOINT ASSEMBLY AND TIGHTENING - Applicable Tension Pump Pressure(s) are Controlled Torquing and Tensioning JE [JIE] Flange Inspection Test Record [FITR]
1.15 Visual Check/Verification followed according to FITR of Flanged Bolts T HI &
Hydraulic Bolt Tensioning JI [JII]
- Thread protrusion on side to be tightened H14-CVX-APC-EXE-004 FDMS
is at least equal to bolt Diameter
(i.e. 2"Φ =2" Protrusion before any
tightening has taken place.)
- Thread protrusion on opposite flange to be
as project specification after tightening
- Correct Joint Alignment after tightening
- Joint Tag fitted and FITR completed
- Leak Test (Site Specific)
 ITP No. TBA
INSPECTION AND TEST PLAN
Wheatstone Project Rev. No. 00 - Original Issue

LNG Plant Flange Management Services ITP Handover Classification (Generic/Specific/Not Applicable)
Page 4 of 4
Unit / AREA BUILDING NO, SHELTER NO, SUBSTATION NO ETC. DESCRIPTION BARCODE

NA Wheatstone Project LNG Plant, Onslow Provision of Joint Integrity Assurance including Structured Training and Flange Management Services
Activity
No. Method of Verification
Nature & Extent of Inspection Acceptance Criteria Responsible Person
Activity Description Controlled Document FMC Bolting Report Ref. No.
/ Test (Inspection/Test Requirements) Contractor Owner at Location
Subcontractor Subcontractor

- 'A'(First pass) pressure should be equal to

Controlled Torquing and Tensioning
1.16 JOINT ASSEMBLY AND TIGHTENING Visual Check/Verification or greater than 'B'(Second pass)pressure of Flanged Bolts T HI Bolting Subcontractor n/a
Break Loose & Tap Test - A light tap with hammer on the flat of the Technician
H14-CVX-APC-EXE-004
nut will produce a high pitched 'RING"

Check to see if permit required All interventions must follow FMC

JOINT ASSEMBLY AND TIGHTENING Controlled Torquing and Tensioning
1.17 Breaking of Assembled and Tightened Joint Visual Check/Verification No pressure in line of Flanged Bolts HI I I Bolting Subcontractor procedures.
New controlled bolt tightening tag and full repeat of Technician NO TAG ON JOINT = NO FMP HAS TAKEN
Assembly H14-CVX-APC-EXE-004
process PLACE

- Permanent Tag Fitted according to Project Identification Tagging and Status Flange Inspection Test Record [FITR]
JOINT ASSEMBLY AND TIGHTENING JE [JIE]
1.18 Final Documentation Verification Specification Control of Flanged Joints R JI [JII] Joint Tag, FDMS Reports, Module,
- Completion of documents H14-CVX-APC-EXE-006 System/Subsystem/Test Pack/OS Joints

Definitions
Hold points are defined as critical steps and activities, whereby Subcontractor is obligated to advise Contractor Quality Representative at least ten (10) working days (unless otherwise stated in the Subcontract) in advance of the operation so that it may be witnessed. Subcontractor shall not proceed with work
H
past the hold point without witness by the Contractor Quality Representative, except by prior written agreement from Contractor.

Witness points are defined as critical steps and activities, whereby Subcontractor is obligated to advise Contractor Quality Representative at least ten (10) working days (unless otherwise stated in the Subcontract) in advance of the operation so that it may be witnessed. With prior concurrence from Contractor,
W Subcontractor may proceed with work past the witness point if Contractor Quality Representative cannot attend. In the event Contractor Quality Representative defers a witness point, the next same operation shall be witnessed. Results of Subcontractor inspection/testing shall be available to Contractor Quality
Representative for review/verification.
R Review is designated as “R”. Review is the act of verifying that documentation is in compliance with project requirements.
I Inspect is designated as “I”. Inspection is the act of verifying (such as, examining, measuring, observing, reviewing, recording, etc.) activities are in conformance with project requirements.
T Test is designated as “T”. Testing is the act of verifying (such as, Compaction, NDE, Hydrostatic, Megger, etc.) to pre-defined values that activities are in compliance with project requirements.
Note: Hold and Witness points are identified as HR, HI, HT, WR, WI, and WT on the Inspection and Test Plan. R, I, and T may be indicated by themselves, as appropriate, on the ITP, if no Hold or Witness Point is identified.

FDMS Flange Data Management System

FITR Flange Inspection Test Record
FMC Flange Management Contractor - Hydratight
FMP Flange Management Process
SS FMC Site Supervisor/Project Manager
JE FMC Joint Engineer/Joint Integrity Engineer
JI FMC Joint Inspector/Joint integrity Inspector