Inspection and test Plan

INSPECTION AND TESTING PLAN ( ITP )

2/28

ITP FOR FABRICATION OF MISCELLANEOUS STRUCTURAL STEEL WORKS

CONTRACTOR'S VERIFICATION STAMP PURSUANT TO SPECIAL CONDITION 6, WE SKY ORYX JOINT VENTURE, VERIFY THAT THIS SUBMITTAL SATISFIES ALL REQUIREMENTS OF THE CONTRACT, WITH THE EXCEPTION OF THE FOLLOWING CLARIFICATIONS/ PROPOSALS ACCEPTED BY THE ENGINEER; CONTRACTOR'S PROJECT MANAGER;

M. HORIKAWA PRINT NAME

SIGNATURE

DATE DOCUMENT REVIEW STATUS

STATUS 1: WORK MAY PROCEED. STATUS 2: REVISE & RESUBMIT.WORK MAY PROCEED SUBJECT TO INCORPORATION OF COMMENTS INDICATED . STATUS 3: REVISE & RESUBMIT. WORK MAY PROCEED. STATUS 4: REVIEW NOT REQUIRED. WORK MAY PROCEED. PERMISSION TO PROCEED SHALL NOT CONSTITUTE ACCEPTANCE OR APPROVAL OF DESIGN DETAILS, CALCULATIONS, ANALYSES, TEST METHODS, OR MATERIALS DEVELOPED OR SELECTED BY CONTRACTOR AND SHALL NOT RELIEVE CONTRACTOR FROM FULL COMPLIANCE WITH THE CONTRACT TECHNICAL SPECIFICATIONS AND DRAWINGS.

Overseas Bechtel, Inc.

Date

Document No:25045-A1126-18-ITP-S-027

Rev.No 02

Prepared Date

Description

QA/QC Syed Kausar

Checked QA/QC Struct Engg Cond.Mgr. Mgr.

FET Mgr.

Approved Project Manager

3/29

NDIA New Doha International Airpoet Project

INSPECTION AND TEST PLAN FOR FABRICATION OF MISCELLANEOUS STRUCTURAL STEEL WORKS Contract No.:

Contract Title: Passenger Terminal Complex CCP-18 Reference Procedure/Method Statements/Specs. : Spec. 05120, 05060.

25045-000FC1-maht-00018

Discipline: Structural Steel Activity

Controlling

Activity Description

No.:

1.2

2 2.1

Issue date:09-02-2009

QAP No.25145-A1000-18-GQA-S-001 Rev.2,

Acceptance Criteria

Document

1.0 1.1

Frequency

ITP No.

Rev. no : 2

25045-A1126-18-ITP-S-027

Page: 1 of 6

Verifying Documents

Inspection* SOJV

OBI

TPIA (BOI)

H

H

H

R

H

H

H

R

SSI/C

TPIA (NDT)

Document Review • • • • • • •

Project Quality Assurance Plan (PQP) Method Statement Inspection and TestMethod Statement Plan (ITP) Shop drawings Material Submittals WPS, PQR&WQT NDT (TPIA) Procedures

• Fabrication Drawings

Meterials-Steel Framing (ASTM A572, ASTM A36) Paint Material Inspection

• Primer Paint

Inspection H-Hold Point : Written notification required. Contractor may not proceed beyond this point without written confirmation of the Engineer

• Project Specifications • Exhibit-F • Exhibit-B

• Project Specifications

• • • •

Before Work Commencement

Before Work Commencement

Spec-05120/Clause 2.1 Spec-05120 Each Supplier submittal Delivery Manufacturer product data, Safety Data & application procedure

W - Witness : Written notification required but Contractor may not proceed if OBI do not attend

As oer OBI Status code 1, 2 and 4

Fabrication Drawing acceptance to SOJV

ASTM, drawings, 05120

SOJV-QP-10-02/X-01

SOJV-QP-10-02/X-01

MRR, Drawings

H

H

R

R

D.O. (SOJVMRR-014-01 rev 1 & x-004) H

S - Surveillance : No notification required but activity may be subjected to OBI Surveillance/ Monitoring

H

R

R - Review : Record/ Document review

SR

4/29



Contract Title: Passenger Terminal Complex CCP-18 Reference Procedure/Method Statements/Specs. : Spec 05120, 05060.

25045-000FC1-maht-00018

Discipline: Structural Activity


No.: 2.2

3 3.1

4 4.1

Controlling

ITP No.

Issue date ;

QAP No.25145-A1000-18-GQA-S-001 Rev.0,

Frequency

Acceptance Criteria

Document Welding Consumables

• SMAN • FCAW • SAW Calibration • Equipments Calibration • Measuring Instrument • NDT Testing Equipments

Rev. no : 2

25045-A1126-18-ITP-S-027

Verifying Documents

• Spec-05120 Part2.1, • 05060, part 2.1 • Supplier submittal

Each Delivery

• Calibration Procedure

As per manufacturer/ calibration agency recommendations.

ASME Section ll, Part C/ AWS D 1.1, Section 5.3

Page: 2 of 6

D.O & Batch Certificate / Electrode log Register

• ISO10012-1:1992, Part 1 - Metrological conformation system for measuring equipment. • For NDT Awa D1.1 & ASME BPVC Section V

• Calibration certificates • Equipments Calibrationlog

Dimensions tolerance shall be as per • AISC Specification for Structural steel Building Part 16, Chapter M,M2,2 • Fabrication Tolerances ± 6 mm. for AESS. • Fabrication Tolerances are as per AISC for Non- AESS.

Material identification and tracesbility / Inspection Request (25045-A1000-18-ITRS-002& 001)

Inspection* SSI/C

TPIA (NDT)

H

H

H

SOJV

OBI

TPIA (BOI)

H

R

SR

H

S/R

W

W

S

SR

Fabrication Marking and Cutting


• Spec-05120 Part2.1,2.5c, 2.5.A.2, 2.5 I • Approved shop Drawings

100%



H


5/28




25045-000FC1-maht-00018



No.:

4.2

4.3

4.4

Controlling

Frequency

ITP No.

Issue date ;

QAP No.25145-A1000-18-GQA-S-001 Rev.0,

Acceptance Criteria

Document

Fit-up

Welding Process

Welding Repair

• Spec -05120, Part 2.6.B • Approved shop Drawings

• Spec-05120, Part 2.6 & 05060 Part 3.5 • Production Drawings

100%

• Production Drawings

• Repairs local surface imperfection depth below 1/16 inch or less • Repair by welding where required • Test on repair portion


Page: 3 of 6 Verifying Documents

100%


Rev. no : 2

25045-A1126-18-ITP-S-027

• AWS code for Weld joint preparation • Marking the high strength steel as per ASTM A/A6 M. • Camber if requied by IFC • AWS D1.1 • Complicance to production Drawing

• Approved WPS & PQR • AWS D1.1 • APProved TPIA to review and certify weld procedures and all welder qualifications • By grinding to smooth contour with a curvature of less than 1/2 inch (13 mm) in either direction. • To ensure that defects have been temoved prior to depositing any weld metal, examine prepared areas by DPT.

Weld Visual Inspection Report / Inspection Request (25045-A1000-18ITR-S-003&001) Weld Visual Inspection Report / Inspection Request (25045-A1000-18-ITRS-003&001) Report/ Inspection Report (25045-A1000-18ITR-S-003&001) (NDT TPIA- Reports)


Inspection* SOJV

OBI

TPIA (BOI)

H

H

S

SR

H

H

S

SR

W

S

SR

SSI/C

H

TPIA (NDT)

H


6/29




25045-000FC1-maht-00018



No.: WELDING TESTING Visual inspection of Welding

5.2

Liquid Penetration test for Back gauging of CP Welds

5.4

Frequency

Issue date ;

• UT on CP Welds • UT on 38 mm and thicker plate subject throung thickness weld shrinkage strain. • MPI on Fillet Welds • MPI on Partial penetration Welds


• Spec -05060 Part 3.2 C • Drawings

Spec -05120, Part 2.9

• Spec-05060, Part 3.2,3.5 & 05120 part 2.9 • Drawings

• Spec-05060, Part 3.5J • Drawings

Weld Visual for Surface holes, cracks, Undercut, Confirming to AWS D 1.1 2004 Section (6.9), Table 6.1

Page: 4 of 6

Verifying

Acceptance Criteria

Documents

100%

Rev. no : 2

QAP No.25145-A1000-18-GQA-S-001 Rev.0,

Document

5 5.1

5.3

Controlling

ITP No. 25045-A1126-18-ITP-S-027

Weld Visual Inspection Report (25045-A1000-18ITR-S-004) (ITPA Endorsement on Report)

Inspection* SSI/C

TPIA (NDT)

SOJV

OBI

TPIA (BOI)

H

W

W

S

SR

H

H

W

S

SR

• AWS D1.1 - 2004 Section (6.10)

Visual

• AWS D1.1 - 2004 • Section (6.13) • ASTM E 164

UT Report (TPIA -Report) & Weld map

H

H

W

S

SR

• Web- Flange • AWS D1.1 - 2004 connection 10%,ii) 10% Section (6.10) Beam and Girder • ASTM E 709 connection where they connection using a clip angle, otherwise 100% • All other connection s-100%

MPI Report (TPIA-Report) & Weld map

H

H

W

S

SR

As needed

100%




7/28




25045-000FC1-maht-00018



No.: 5.5

6.0 6.1

7.0 7.1

Controlling

Frequency

ITP No.

Issue date ;

QAP No.25145-A1000-18-GQA-S-001 Rev.0,

Acceptance Criteria

Document • RT on CP Welds

Final Inspection (Fabrication) • Final Inspection • Visual Inspection • Dimensional check

Sand blasting and Primer Painting Surface Preparation by Shot / Grit Blasting


• Spec-05120 part 2.9 E • Drawings • NDT Procedure • Spec-05060 Part 3.2 & 3.2, 05120 Part 2.5, 2.6.B • Approved shop Drawings

• Spec-05120, part 2.7 • For AESS-Spec-09805 part 3.2.A.1

Before Painting

Each Fabricated component inspection


Rt Re[prt (TPIA-Report & Weld) map

Check for dimension, tolerance, orientation, depth, camber, holes positions, distortion, straightness, Erection marks, etc & confirming to AISC "Code of Standards Practice for steel Buildings Section 6,6.4. Weld visual for surface holes, cracks, Undercut, Confirming to AWS D 1.12004 Section 6.9, Table 6.1 • As per SSpc-sp 14/ NACE No.8 • For AESS confirming with SSPC SP-6

Page: 5 of 6

Verifying Documents

25%

Rev. no : 2

25045-A1126-18-ITP-S-027

Inspection* SSI/C

TPIA (NDT)

SOJV

OBI

TPIA (BOI)

H

H

W

S

SR

Dimension Reports (25045-A1000-18ITR-S-005) (TPIA Endorsement on all fabrication Records)

H

H

S

SR

Paint Report (25045-A1000-18ITR-S-006)

H

W

S

SR



8/28




25045-000FC1-maht-00018



No.: 7.2

8.0

Controlling

Frequency

ITP No.

Issue date ;

QAP No.25145-A1000-18-GQA-S-001 Rev.0,

Acceptance Criteria

Document Primer Paint Application & Inspection

• Spec-05120, part 2.3,2.7 • For AESS-Spec-09805 part 2.3

Check for Surface cleaning, Atmosphere conditions (Temperatures & Humidity), recommended maerials, Dry Film Thickness (DFT not less than 38μ) and confirming with Manufacturer's recommendations. • For AESS primer DFT (76μ ± 12.7 μ) • Keep steel members off ground and spaced using pallets, dunnage, or other supports and spacers.

Page: 6 of 6

Verifying Documents

Each Batch random inspection

Rev. no : 2

25045-A1126-18-ITP-S-027

Inspection* SSI/C

TPIA (NDT)

SOJV

OBI

TPIA (BOI)

W

S

SR

Paint report (DFT) (25045-A1000-18ITR-S-006)

H

Final Inspection (Before Packing )





9/28

INSPECTION REQUEST INSPECTION REQUEST NUMBER:

DATE:

CONTRACT NO:

REPORT NO:

CONTRACTOR NAME:

DRAWING NO:

AREA / LOCATION / SUBJECT :

TYPE OF INSPECTION MATERIAL

FIT UP

WELDING

NDT

PAINTING

SURVEY

FINAL INSPECTION

OTHER

DATE & TIME INSPECTION REQUIRED: CONTRATOR :

DATE & TIME :

RECEVIED BY :

DATE & TIME :

REPLY

Approved

Approved as noted

Not Approved

SUB CON QC REP:

DATE: ( PRINT NAME AND SIGN )

SUB CONTRACTOR QC REP:

DATE: ( PRINT NAME AND SIGN )

OBI REP:

DATE: WITNESS & REVIEW

ONLY REVIEW

( PRINT NAME AND SIGN )

Document No: 25045-A1126-18-ITR-S-001

10/28

Material Receiving Report

11/28

MATERIAL RECEIVING REPORT (RAW STEEL MATERIALS) CONTRACT NO. CP - 18 CONTRACTOR NAME : SIAM STEEL INTERNATIONAL PLC. PROJECT : NEW DOHA INTERNATIONAL AIRPORT AREA : LOCATION : SIAM STEEL BANGNA FACTORY STORAGE AREA : SIAM STEEL BANGNA FACTORY YARD Weight Material Item No. Qty. Manufacturer Heat No. (kgs.) Specification Description

DATE : REPORT NO. : SHEET NO. : Mill Test Date Certificate No. Received

Delivery Order No.

REMARKS : CONTRACTOR QC REPRESENTATIVE :

DATE :

________________________________________________________________ (PRINT NAME AND SIGN)

SOJV QC REPRESENTATIVE :

DATE :


OBI REPRESENTATIVE :

DATE :

__________________________________________________ (PRINT NAME AND SIGN)

WITHNESS & REVIEW

ONLY REVIEW Document No. : 25045-A1126-18-ITR-S-001,ForM a

12/28

Marking, Cutting and Drilling (Material Identification and Traceability)

13/28

MATERIAL IDENTIFICATION AND TRACEABILITY REPORT INSPECTION REQUEST NO.:

DATE :

REPORT NO. :

CONTRACT NO. CP - 18

CONTRACTOR NAME : SIAM STEEL INTERNATIONAL PLC.

SHEET NO. :

PROJECT : NEW DOHA INTERNATIONAL AIRPORT

AREA :

LOCATION : SIAM STEEL BANGNA FACTORY

PIECE MARK : Item Part No./Mark No.

STRUCTURE TYPE : Material Specification

Description

Qty.

DRAWING NO.: Heat No.

Mill Test Certificate No.

CONTRACTOR QC REPRESENTATIVE :

DATE :

_________________________________________________________________________ (PRINT NAME AND SIGN)


DATE :



DATE :

_________________________________________________________ (PRINT NAME AND SIGN)

WITHNESS & REVIEW

ONLY REVIEW Document No. : 25045-18-ITR-S-002

Marking/ Cutting

14/28

Fit-Up Inspection

15/28

FIT- UP INSPECTION REPORT (WELD GROOVE) INSPECTION REQUESTNO.:

DATE :


REPORT NO. :


SHEET NO. :


AREA :

PIECE MARK :


STRUCTURE TYPE :

DRAWING NO. :

WELD JOINT KEYPLAN :

(SEE ATTACHED SHEETS)

LEGEND: F = FILLTE WELD

Joint No. Root Gap

Root Face

Groove Angle

P = PARTIAL PENETRATION WELD

Remark

Joint No.

Root Gap

C = COMPLETE PENETRATION WELD

Root Face


Groove Angle

DATE :

__________________________________________________________ (PRINT NAME AND SIGN)


DATE :



DATE :

______________________________ (PRINT NAME AND SIGN)

WITNESS &REVIEW

ONLY REVIEW Document No. :25045-A1126-18-ITR-S-003

Remark

16/28

FIT- UP INSPECTION REPORT (WELD GROOVE) INSPECTION REQUESTNO.:

DATE :


REPORT NO. :


SHEET NO. :


AREA :

PIECE MARK :


STRUCTURE TYPE :

DRAWING NO.

WELD JOINT KEYPLAN :

(SEE ATTACHED SHEETS)

LEGEND: F = FILLTE WELD

PIECE MARK

DRAWING NO.

P = PARTIAL PENETRATION WELD

REV.

Joint No.

Root Gap

C = COMPLETE PENETRATION WELD

Root Face


Groove Angle

Remark

DATE :



DATE :



DATE :


WITNESS &REVIEW

ONLY REVIEW Document No. :25045-A1126-18-ITR-S-003,Form b

17/28

Weld Visual Inspection (VT)

18/28

19/28

E

20/28

WELD VISUAL INSPECTION REPORT INSPECTION REQUESTNO.:

DATE :


REPORT NO. :


SHEET NO. :


AREA :

PIECE MARK :


STRUCTURE TYPE :

MATERIAL SPECIFICATION:

DRAWING NO. : Joint No.

WPS No.

Welding Process

Welder Id No.

Marking / Cutting Report No.

Fit-Up Report No.

Visual

VASUAL INSPECTION SUMMARY (As per AWS D1.1/D1.1M:2006 Sectuib 6.9, Tavle 6.1): Item No.

Inspection Category

Result

Item No.

Inspection Category

Result

OTHER REMARKS (IF ANY): Refer to attached weld joint keyplan


DATE :



DATE :



DATE :


WITNESS &REVIEW

ONLY REVIEW Document No. : 25045-A1126-18-ITR-S-004

21/28

Final Inspection

22/28

FINAL INSPECTION REPORT (VISUAL INSPECTION & SUMMARY OF INSPECTION REPORTS) INSPECTION REQUEST NO.:

DATE :

CONTRACT NO.: CP-18

REPORT NO. :


SHEET NO. :


AREA :

PIECE MARK :


STRUCTURE TYPE:

DRAWING No.:

MATERIAL SPECIFICATION: ASTM A572 Grade 50

INSPECTION REPORTS SUMMARY

Description

ITP Activity No.

Inspection Report No.

INSPECTION RESULT:

OTHER REMARKS (IF ANY):


DATE :


TPIA REPRESENTATIVE

DATE :



DATE :



DATE :


WITNESS &REVIEW


23/28

FINAL INSPECTION REPORT (VISUAL INSPECTION & SUMMARY OF INSPECTION REPORTS) INSPECTION REQUEST NO.:

DATE :

CONTRACT NO.: CP-18

REPORT NO. :


SHEET NO. :


AREA :

PIECE MARK :


STRUCTURE TYPE:

DRAWING No.:

MATERIAL SPECIFICATION: ASTM A572 Grade 50

Non-Destructive Examination (NDE) Report Summary Ultrasonic Testing (UT)

Radiographic Testing (RT)

Magnetic Particle Testing (MT)

Document No. : 25045-A1126-18-ITR-S-005, form b

24/28

Dimensional Inspection (Pre-Fit up)

25/28

DIMENSIONAL INSPECTION REPORT (SINGLE PRODUCT) INSPECTION REQUEST NO.:

DATE :



REPORT NO. :


AREA :

SHEET NO. :

STRUCTURE TYPE:

DRAWING NO.: L1

PIEXE MARK

L2

L3


L4

L5

H1

H2

H3

H4

e1

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

e2

B1

B2

B3

B4

B5

B6

B7

B8

B9

B10

B11

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

4-6ARCH1

B12

B13

B14

B15

B16

B17

B18

B19

B20

B21

B22

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

B24

B25

B26

B27

B28

B29

B30

B31

B32

B33

DD

B23 E

DD

B34

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

DD

E

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

E

(mm) (mm) (mm)

DD

B35 E

DD

(mm) (mm) (mm)

LEGEND:

SUBCONTRACTOR QC REPRESENTATIVE

DATE :



DATE :



DATE :


WITHNESS & REVIEW

(mm)

ONLY REVIEW Document No. : 25045-A1126-18-ITR-S-005,Form C

E (mm)

26/28

Painting Inspection

27/28

PAINTING INSPECTION REPORT INSPECTION REQUEST NO.:

DATE :

REPORT NO.:



SHEET NO.:


AREA :


PIECE MARK :

STRUCTURE TYPE :

Surface Preparation: Sa 2.5

No. of Coats:

Paint Specification: 25045-a1100-18-ssd-s-xxxx

Required DFT: 76 microns

Paint Material:

Spot No.

Primer Coat DFT (microns) Gage Readings Average 1st 2nd 3rd

Spot No.

DRAWING NO.: Blasting & Painting Date: ๐ Ambient Te,perature ( C)

Relative Humidity (%): Primer Coat DFT (microns) Gage Readings Average 1st 2nd 3rd

Weather : ๐ Steel Temperature ( C)

Spot No. 1st

Dew Point (๐C) Primer Coat DFT (microns) Gage Readings 2nd 3rd

OTHER REMARKS (IF ANY): Note: Refer to Sheet 3 of 3 for DFT Spot Measuring Keyplan.


DATE :

____________________________________________________________________________ (PRINT NAME AND SIGN)


DATE :

_____________________________________________________________________________ (PRINT NAME AND SIGN)


DATE :

________________________________________________________________ WITHNESS & (PRINT NAME AND SIGN)

REVIEW


Average

28/28

PAINTING INSPECTION REPORT INSPECTION REQUEST NO.:

DATE :

REPORT NO.:



SHEET NO.:


AREA :


PIECE MARK :

STRUCTURE TYPE :

Surface Preparation: Sa 2.5

No. of Coats: One (1)

Paint Specification: 25045-a1100-18-ssd-s-xxx

Required DFT: 76 microns

Paint Material:

Item No.

Drawing No.

Piece Mark

Rev.

DRAWING NO.: Blasting & Painting Date: Ambient Te,perature (๐C)

Weather : Steel Temperature (๐C)

Relative Humidity (%): Primer Coat DFT (microns) Gage Readings Spot No. Average 1st 2nd 3rd


Dew Point (๐C) Average DFT (microns)

Inspection Result

DATE :

____________________________________________________________________________ (PRINT NAME AND SIGN)


DATE :

_____________________________________________________________________________ (PRINT NAME AND SIGN)


DATE :


WITHNESS & REVIEW

ONLY REVIEW Document No. : 25045-A1126-18-ITR-S-006,form b

Inspection and test Plan

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