RUMAILA PROJECT

INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL

FABRICATION

DOCUMENT NUMBER

0000RP-C-G0-G000-QA-ITP-0007
th
DATE:- 18 August 2018

Rev Description Originator Review Project Date

Approval

Sharath Krishna Stephen Keegan Tim Johnson

B01 Issued for use 18th August 2018
Parayitham Steve Wright John Farrell
Digitally signed by Stephen

Sharath TIMOTHY
E Keegan Digitally signed by TIMOTHY
Stephen
Digitally signed by Sharath Krishna,
Parayitham DN: cn=Stephen E Keegan, JOHNSTON
DN: cn=Sharath Krishna, Parayitham, o=Operations,
Krishna,
DN: cn=TIMOTHY JOHNSTON,

JOHNSTO
o=ROO, ou=ROO OPS Engineering ou=Engineering Services,

E Keegan
Services,
email=stephen.keegan@ro o=ROO OPS, ou=ENG,
email=Sharath.Parayitham@roobasra
email=timothy.johnston@roo
Parayitham .com, c=IQ obasra.com, c=IQ
Date: 2018.08.18 10:13:12 +03'00' Date: 2018.08.18 09:47:49 basra.com, c=US
+03'00'
N Date: 2018.08.18 14:46:43
+03'00'

This document is the property of Rumaila Project. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

REVISION DESCRIPTION SHEET

Rev. Para. Reason for Revision

B01 Issued for use

Hold No. Para. Description of Hold

0000RP-C-G0-G000-QA-ITP-0007 Rev B01 18th August 2018 Page 2 of 14

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RUMAILA PROJECT
INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

CONTENTS

1.0 DEFINITIONS & ABBREVIATIONS.................................................................................... 4

2.0 INSPECTION & TEST PLAN .............................................................................................. 5

0000RP-C-G0-G000-QA-ITP-0007 Rev B01 18th August 2018 Page 3 of 14

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RUMAILA PROJECT
INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

1.0 DEFINITIONS & ABBREVI ATIONS

ROO Rumaila Operating organisation.

The party which carries out all or part of the described work and service. The CONTRACTOR may undertake all or part of the duties of the
CONTRACTOR CONTRACTOR.
WORK Shall mean all and any of the works, services and materials required to be provided by the CONTRACTOR.

MUST / SHALL A mandatory requirement.

SHOULD A preferred requirement.

MAY One possible course of action.

DOCUMENT This shall include both text documents.

RFI Request for Inspection.

Hold, a mandatory activity that SHALL not proceed to the next step until formal verification has been completed or documented and consent
H
has been given by ROO or its appointed TPI.
Witness, an activity requiring witness by ROO or its appointed TPI and signing work release. CONTRACTOR may proceed with the next
W scheduled activity, should ROO or its appointed TPI not be available at the time notified on the RFI.
Surveillance, a point where ROO or its appointed TPI, MAY carry out surveillance of work in progress and or associated documentation. This
S SHALL be carried out on an unscheduled basis without prior notification and amendment to the schedule.
R Review, a document or activity that requires review and approval by ROO or its appointed TPI.
C Certification, specific and appropriate certification for inclusion in the handover dossiers that requires verification by ROO or its appointed TPI.

GENERAL NOTE:-

CONTRACTOR shall provide a project schedule after order placement and prior to commencement of any activities. CONTRACTOR SHALL
notify ROO or its appointed TPI of any inspections by RFI based on the agreed ITP intervention points. Excluding hold points, all activities
SHALL proceed based on the agreed schedule and failure to attend by ROO or its appointed TPI intervention points according to the approved
ITP SHALL be deemed as approval to waiver this requirement.

0000RP-C-G0-G000-QA-ITP-0007 Rev B01 18th August 2018 Page 4 of 14

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RUMAILA PROJECT
INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

2.0 INSPECTION & TEST PLAN

0000RP-C-G0-G000-QA-ITP-0007 Rev B01 18th August 2018 Page 5 of 14

This document is the property of Rumaila Project. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

QUALITY INSPECTION & TEST PLAN

LEGEND:
DESCRIPTION OF WORK: Structural Steel Fabrication H - Hold, W - Witness, S - Surveillance, R - Review, A - Approval, C - Certification

ITEM ACCEPTANCE VERIFYING RESPONSIBILITY

ACTIVITY VERIFICATION
CRITERIA DOCUMENT
CONTRACTOR ROO

1.1 Review and Approval of 1) Revision of AFC Drawing 1) AWS D1.1 1) AFC Drawings H R/A
Fabrication Drawings 2) Drawings issued for construction 2) AISC 360-10 Register

1.2 Review & Approval of 1) PQR verification, as run welding 1) ROO Specification for 1) Approved H R/A
PQR / WPS sheets, NDT, Mechanical Test Structural Steel Material, PQR/WPS
Reports, MTCs, Calibration Fabrication and Erection 2) Approved
Certificates, Specification 101591PF-C- PQR/WPS
2) WPS-Essential Variables/ G0-G000-ST-SPC-1001, Register
Supporting PQR Section 5
2) AWS D1.1 Sections 3 or 4
1.3 Welder Qualification 1) WQT witness, NDT, MTCs, 1) ROO Specification for 1) Approved Welder H/C R/A
Testing Certificates & Calibration Certificates Structural Steel Material, Certificates /
Document

Cards Approval 2) Welder Certificates / Cards- Fabrication and Erection

Approval

Welder Cards
Essential Variables-Ranges Specification 101591PF-C- 2) Approved Welder
1. 0

G0-G000-ST-SPC-1001, Qualification
Section 5 Register
2) AWS D1.1 Section 4
1.4 NDE Procedures & NDE 1) NDE Procedures 1) ROO Specification for 1) Approved NDE H/C R/A
Personnel Qualification 2) NDE Personnel Qualifications Structural Steel Material, Procedures
Approval Fabrication and Erection 2) Approved NDE
Specification 101591PF-C- Personnel
G0-G000-ST-SPC-1001,
Section 5
2) AWS D1.1 Section 6
1.5 Inspection & Calibration of 1) Verification of Calibration 1) ROO Calibration / 1) Tools & H/C R
Tools and Equipment’s Certificates Verification Procedure Equipment
2) Cross check of Certificates 0000BF-C-G0-G000-QA- Calibration
against Tools & Equipment PRO-0008 Certification
Calibration Register 2) AWS D1.1 Register

0000RP-C-G0-G000-QA-ITP-0007 Rev B01 18th August 2018 Page 6 of 14

This document is the property of Rumaila Project. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

QUALITY INSPECTION & TEST PLAN

LEGEND:
DESCRIPTION OF WORK: Structural Steel Fabrication H - Hold, W - Witness, S - Surveillance, R - Review, A - Approval, C - Certification

ITEM ACCEPTANCE VERIFYING RESPONSIBILITY

ACTIVITY VERIFICATION
CRITERIA DOCUMENT
CONTRACTOR ROO

1.6 Material Inspection & 1) Contractor Method statement and 1) ROO Material control 1) Approved Material H R/A
Handling Procedure ITP Procedure for Shutdown Inspection &
Approval (TAR) and Construction Handling
Work activities. 000RP-C- Procedure
G0-G000-PM-PRO-0005
Section-3
1.7 Consumable Control & 1) Compliance to ROO Specification 1) ROO Specification for 1) Approved H R/A
Document

Handling Procedures for Process & Utility Piping Structural Steel Material, Consumable
Approval

Approval Welding 0000BF-C-G0-G000-QA- Fabrication and Erection Control & handling

1. 0

SPC-0001 Specification 101591PF-C- Procedure

G0-G000-ST-SPC-1001,
Section 5
2) AWS D1.1
1.8 Structural Steel Painting 1) Compliance to ROO Specification 1) ROO Specification for 1) Approved H R/A
Procedure for Painting 0000RP-C-G0-G000- Painting 0000RP-C-G0- Painting / Coating
ML-SPC-0002 G000-ML-SPC-0002 Procedure

2.1 Verification of Welding 1) Calibration of Clamp Meters/ 1) ROO Calibration / 1) Calibration H/C R
Calibration &

Machines, Equipment and Digital Thermometer / Verification Procedure Certificates

Validation

inspection tools condition, Arc Monitor / Baking / Holding 0000BF-C-G0-G000-QA- 2) Plant & Equipment
check valid calibration Ovens. PRO-0008 List
2.0

certificate 2) Verification of Welding and

PWHT Machine Calibration
3) Verification of NDT Equipment
Calibration

0000RP-C-G0-G000-QA-ITP-0007 Rev B01 18th August 2018 Page 7 of 14

This document is the property of Rumaila Project. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

QUALITY INSPECTION & TEST PLAN

LEGEND:
DESCRIPTION OF WORK: Structural Steel Fabrication H - Hold, W - Witness, S - Surveillance, R - Review, A - Approval, C - Certification

ITEM ACCEPTANCE VERIFYING RESPONSIBILITY

ACTIVITY VERIFICATION
CRITERIA DOCUMENT
CONTRACTOR ROO

3.1 Material Receipt 1) Inspection of Structural Items 1) ROO Specification for 1) Material Issue H S
Inspection such as Plates, Shapes, Structural Steel Material, Ticket 0000RP-C-
Fasteners etc. on arrival at site Fabrication and Erection G0-G000-MH-
(appearance, coating check, Specification 101591PF-C- TPL-0001
Incoming Material

traceability, quantity, G0-G000-ST-SPC-1001, 2) Material Receiving

dimensions, etc.) Section 4 Report 0000RP-C-
Inspection

2) Material Grade Verification 2) ROO Specification for G0-G000-MH-

Materials traceability & TPL-0002
3.0

certification 0000BF-C-G0- 3) MTCs

G000-QA-PRO-0003 Clause
9.2.2 and Appendix 1
3) ROO Material control
Procedure for TAR and
Construction Work activities
0000RP-C-G0-G000-PM-
PRO-0005

0000RP-C-G0-G000-QA-ITP-0007 Rev B01 18th August 2018 Page 8 of 14

This document is the property of Rumaila Project. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

QUALITY INSPECTION & TEST PLAN

LEGEND:
DESCRIPTION OF WORK: Structural Steel Fabrication H - Hold, W - Witness, S - Surveillance, R - Review, A - Approval, C - Certification

ITEM ACCEPTANCE VERIFYING RESPONSIBILITY

ACTIVITY VERIFICATION
CRITERIA DOCUMENT
CONTRACTOR ROO

Material Traceability / 1) Verification of Heat No, Markings 1) ROO Specification for 1) Material Issue H/C R
Control of material against MTC Structural Steel Material, Ticket 0000RP-C-
2) Transferring of Heat numbers on Fabrication and Erection G0-G000-MH-
3.2 cut sections Specification 101591PF-C- TPL-0001
3) Visual Inspection for mechanical G0-G000-ST-SPC-1001, 2) MTCs
Incoming Material

damage Section 4
Inspection

2) ROO Specification for

Materials traceability &
3.0

Certification 0000BF-C-G0-
G000-QA-PRO-0003
Clause 9.2.2 and
Appendix 1
3) ROO Material control
Procedure for TAR and
Construction Work activities
0000RP-C-G0-G000-PM-
PRO-0005
4.1 Control, handling & 1) Correct Consumables as per 1) ROO Specification for 1) Consumable H/C S
storage of Welding approved WPS Structural Steel Material, Register/Log
Consumable

Consumables 2) Storage and handling conditions Fabrication and Erection 2) Consumable

3) Consumable Batch Test Specification 101591PF-C- Batch Test
Control

Certificates G0-G000-ST-SPC-1001, Certificates

4.0

4) Review Consumable issued and Section 5 3) Calibration

returned log 2) Manufacturers Certificates –
Recommendations Ovens / Quivers
3) AWS D1.1 Section 5
4) Approved WPS

0000RP-C-G0-G000-QA-ITP-0007 Rev B01 18th August 2018 Page 9 of 14

This document is the property of Rumaila Project. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

QUALITY INSPECTION & TEST PLAN

LEGEND:
DESCRIPTION OF WORK: Structural Steel Fabrication H - Hold, W - Witness, S - Surveillance, R - Review, A - Approval, C - Certification

ITEM ACCEPTANCE VERIFYING RESPONSIBILITY

ACTIVITY VERIFICATION
CRITERIA DOCUMENT
CONTRACTOR ROO

5.1 Welding environment and 1) Adequate protection for the 1) ROO Specification for 1) Inspection H S
weather limitations environmental Conditions check Structural Steel Material, Surveillance Log
(Visual inspection) Fabrication and Erection
Specification 101591PF-C-
G0-G000-ST-SPC-1001,
Section 5
2) AWS D1.1 Section 5
3) Approved WPS

5.2 Weld bevel preparation, 1) Weld bevel check and 1) ROO Specification for 1) Inspection H S
Joint & cleanliness freedom of surface contaminants
2) Joint cleanliness Structural Steel Material, Surveillance Log
3) Weather protection Fabrication and Erection
Installation &

Specification 101591PF-C-
Welding

G0-G000-ST-SPC-1001,
5.0

Section 5
2) AWS D1.1
3) Approved WPS

5.3 Fit-Up, Alignment & 1) Joint configuration check 1) ROO Specification for 1) Inspection H S
Dimension Check 2) Joint fit up alignment check Structural Steel Material, Surveillance Log
3) Dimensional check Fabrication and Erection
4) Adjacent weld proximity Specification 101591PF-C-
distance check G0-G000-ST-SPC-1001,
5) Tack Welding & Welder ID card Section 5
verification 2) AWS D1.1
3) Approved WPS
4) AFC Drawings

0000RP-C-G0-G000-QA-ITP-0007 Rev B01 18th August 2018 Page 10 of 14

This document is the property of Rumaila Project. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

QUALITY INSPECTION & TEST PLAN

LEGEND:
DESCRIPTION OF WORK: Structural Steel Fabrication H - Hold, W - Witness, S - Surveillance, R - Review, A - Approval, C - Certification

ITEM ACCEPTANCE VERIFYING RESPONSIBILITY

ACTIVITY VERIFICATION
CRITERIA DOCUMENT
CONTRACTOR ROO

5.4 Joint Identification 1) WPS number recorded on joint 1) ROO Specification for 1) Visual Inspection H S
2) Joint number Structural Steel Material, Report
3) Welder ID Fabrication and Erection
4) Date of welding Specification 101591PF-C-
G0-G000-ST-SPC-1001,
Section 5
2) Approved WPS
3) Welder ID card & WQT
5.5 WPS & WQT verification 1) Approved WPS available at work 1) Approved WPS 1) PQR H S
face 2) Welder ID card 2) WQT Certificate
2) WPS suitable for task
3) Welder ID check, suitable for the
Installation &

Task
Welding

5.6 Pre-heat & Inter pass 1) Digital Thermometer or 1) Approved WPS 1) Inspection H S
5.0

Temperature verification Temperature Indicating crayon 2) AWS D1.1 Section 5 Surveillance Log
Check
5.7 Welding parameters 1) Clamp Meter check 1) Approved WPS 1) Inspection H S
verification 2) Run out length time 2) AWS D1.1 Surveillance Log
3) Time between passes
4) Speed of travel
5) Calculation of arc energy
5.8 Visual Inspection 1) Visual inspection for surface 1) ROO Specification for 1) Visual Inspection H S
defects or mechanical damage Structural Steel Material, Report
2) Weld Identification (Joint No, Fabrication and Erection
WPS, Welder No, Weld Date) Specification 101591PF-C-
G0-G000-ST-SPC-1001,
Section 5
2) AWS D1.1 Section 5

0000RP-C-G0-G000-QA-ITP-0007 Rev B01 18th August 2018 Page 11 of 14

This document is the property of Rumaila Project. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

QUALITY INSPECTION & TEST PLAN

LEGEND:
DESCRIPTION OF WORK: Structural Steel Fabrication H - Hold, W - Witness, S - Surveillance, R - Review, A - Approval, C - Certification

ITEM ACCEPTANCE VERIFYING RESPONSIBILITY

ACTIVITY VERIFICATION
CRITERIA DOCUMENT
CONTRACTOR ROO

5.9 NDE Inspection 1) Use of Approved Procedure / 1) ROO Specification for 1) NDT Report H R/
(UT,RT,PT/MT) Technique and Approved Structural Steel Material, 2) Monthly Repair W for Film
- Full Penetration Welds Personnel Fabrication and Erection Statistics Interpretation
- Fillet Welds 2) NDE requirements check Specification 101591PF-C- (applying
- Splice Joints 3) Progressive sampling per G0-G000-ST-SPC-1001, progressive
- Nodes Welder is being applied Section 5 sampling
- Pad Eyes* 2) AWS D1.1 Section 6
requirements)
- Lifting Attachments*
(*Before and After Load
Test, as applicable)
5.10 Welds Repair, excavation, 1) Defect is accurately removed 1) ROO Specification for 1) Visual & NDT H W
removal of defect and 2) Repeat of verification step item Structural Steel Material, Report
Installation &

welding 4.1 Fabrication and Erection 2) CONTRACTOR

Welding

Specification 101591PF-C- Repair Statistics

5.0

G0-G000-ST-SPC-1001,
Section 5
2) AWS D1.1 Section 5
5.11 Final Visual and 1) Dimensions are within 1) ROO Specification for 1) Dimensional H S
Dimensional Inspection permissible tolerances specified Structural Steel Material, Report
2) Verticality check Fabrication and Erection
3) Straightness check Specification 101591PF-C-
4) Flatness check G0-G000-ST-SPC-1001,
5) Squareness / Diagonal check Section 5
6) Welds appearance and 2) AWS D1.1 Section 5
Cleanliness 3) AFC Drawings
7) Piece Marking of each
Ship Loose item

0000RP-C-G0-G000-QA-ITP-0007 Rev B01 18th August 2018 Page 12 of 14

This document is the property of Rumaila Project. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

QUALITY INSPECTION & TEST PLAN

LEGEND:
DESCRIPTION OF WORK: Structural Steel Fabrication H - Hold, W - Witness, S - Surveillance, R - Review, A - Approval, C - Certification

ITEM ACCEPTANCE VERIFYING RESPONSIBILITY

ACTIVITY VERIFICATION
CRITERIA DOCUMENT
CONTRACTOR ROO

6.1 Trial Assembly 1) Assembly check 1) ROO Specification for 1) Inspection Report H H
- alignment of members Structural Steel Material,
Trial Assembly and Final Inspection

- matching of bolt holes Fabrication and Erection

- orientation Specification 101591PF-C-
Before Painting / Coating

- level and any out-of-plumbness G0-G000-ST-SPC-1001,

- ample clearance for bolt Section 5
tightening 2) AFC Drawings
- ship loose items trial fitted
6.0

6.2 Weld Summary Review 1) Weld Map, NDT summary 1) ROO Specification for 1) Weld Summary H R
Review and check of all Structural Steel Material, Sheet
associated ITR’s Fabrication and Erection 2) NDT Clearance
Specification 101591PF-C- Certificate
G0-G000-ST-SPC-1001,
Section 5
2) AFC Drawings
3) NDT Extent

7.1 Painting / Galvanising of 1) Visual Inspection of painting / 1) ROO Specification for 1) Painting H H
Structural Steel Members galvanising Painting 0000RP-C-G0- Inspection Report
( Refer separate ITP) 2) DFT Measurement G000-ML-SPC-0002
Galvanising
Painting /

3) Repair of painting / galvanising 2) ROO Specification for

(If any) Structural Steel Material,
7.0

4) Piece marking of each member Fabrication and Erection

for Identification / traceability Specification 101591PF-C-
G0-G000-ST-SPC-1001,
Section 6

0000RP-C-G0-G000-QA-ITP-0007 Rev B01 18th August 2018 Page 13 of 14

This document is the property of Rumaila Project. It must not be stored, reproduced or disclosed to others without written authorisation from the Company
RUMAILA PROJECT
INSPECTION TEST PLAN (ITP) - STRUCTURAL STEEL FABRICATION

QUALITY INSPECTION & TEST PLAN

LEGEND:
DESCRIPTION OF WORK: Structural Steel Fabrication H - Hold, W - Witness, S - Surveillance, R - Review, A - Approval, C - Certification

ITEM ACCEPTANCE VERIFYING RESPONSIBILITY

ACTIVITY VERIFICATION
CRITERIA DOCUMENT
CONTRACTOR ROO

8.1 Final Release of 1) Check all Fabrication, Painting / 1) ROO Specification for 1) Inspection H H
Fabricated Structures / Galvanising works are completed Structural Steel Material, Release Note
Structural Members 2) All items are inspected, Fabrication and Erection 2) Sign-off ITP
NDE tested, QC Documentation Specification 101591PF-C-
Final Release

is reviewed and accepted, items G0-G000-ST-SPC-1001,

are trial assembled and verified Section 5
3) No outstanding NCRs, 2) AFC Drawings
8.0

Observations, Corrective Actions,

Punch Lists
4) Spares, Ship Loose items are
properly tagged, secured

0000RP-C-G0-G000-QA-ITP-0007 Rev B01 18th August 2018 Page 14 of 14

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