Duqm Refinery Project

EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

INSPECTION AND TEST REPORT Rev.0

INSPECTION REPORT Page : 22 Pages
REPORT NO: 2037-PL-PL-0058-IR-T-015 PO NO : 2037-PL-PL-0058-C.O-1 Dated 31.01.2019
VENDOR : FTV Proclad LLC LOCATION: Techno Park, Jebel Ali, Dubai , U.A.E.
PROJECT NO: Duqm Refinery EPC Package 2 – Utilities DATE OF INSPECTION or Period Of Inspection: 08 to 10.12.2019,
& Off sites 16.12.2019 & 17.12.2019
CONTRACTOR PROJECT/JOB NO. /PURCHASE ORDER NO.: 2037-PL-PL-0058-C.O-1 Dated 31.01.2019
INSPECTION NOTIFICATION NO (if any) : 014 Rev.04 Dated 25.11.2019 & 015 Rev. 1 Dt.- 16.12.2019

DESCRIPTION OF PRODUCT
Hot Induction Bends – 10” x 7.09 mm Pipe- 90 Deg. 5D
Hot Induction Bends – 10” x 7.09 mm Pipe- 20 Deg. 5D
Item Description:
Hot Induction Bends – 10” x 7.09 mm Pipe- 5.83 Deg. 5D

PO Item No: PO Line Item # 23- 10”, 30-10”, 66-10”

PO Line Item # 23- 27 Nos out of 54 Nos PO Qty.
Qty: PO Line Item # 30- 02 Nos out of 03 Nos PO Qty.
PO Line Item # 66- 01 No out of 01 No PO Qty.
SP-PL-HIB-023 (10”- FTDS19009-23-25 to 30, FTDS19009-23-32 to 35, FTDS19009-23-27 to
50, FTDS19009-23-52 to 54 / Heat No- 179908 )
Tag No:
SP-PL-HIB-030 (10”- FTDS19009-30-1, FTDS19009-30-2/ Heat No- 179908)
SP-PL-HIB-066 (10”- FTDS19009-74-1/ Heat No- 179908)
TYPE OF INSPECTION: DURING MANUFACTURE/ PRIOR TO SHIPMENT/ RECEIPT:
Reference Documents:
Drawing No.: DRP001-OUF-2037-PL-PL-0058-G54-0001, Rev B1 Code : 4
P&ID No.: NA Code : NA
Data Sheet: DRP001-OUF-DSH-Y-650SPI-029, Rev B1 Code : NA
ITP: DRP001-OUF-2037-PL-PL-0058-Q93-0001, Rev O3 Code : 3
Procedure No.: DRP001-OUF-2037-PL-PL-0058-P40-0002, Rev O3 Code : 4
(INDICATE TYPE)

REQUIRED INSPECTION AS PER ITP Hold Witness

INSPECTION/ TEST RESULT: Acceptable Not Acceptable

Continuation Sheet Yes No

NCR ISSUED DURING INSPECTION : Yes No

PURCHASE ORDER STATUS: Completed Not Completed

NEXT VISIT: Required Not Required

INSPECTION PERFORMED BY :

CONTRACTOR INSPECTOR :

NAME : NITIN SAMPATE

 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

DEPT : QC

SIGNATURE:

DATE: 17.12.2019

INSPECTION REPORT

REPORT NO : 2037-PL-PL-0058-IR-T-015

DRP001-OUF-2037-PL-PL-0058-P40-0001-O1 – Heat Treatment Procedure - Code 3

DRP001-OUF-2037-PL-PL-0058 -P80-0001 - NDE Procedures- REV O3 – Code 3
DRP001-OUF-MR-Y-650-007, Rev P1- Purchase Requisition for Hot Induction Bends
DRP001-OUF-SPE-Y-650-023, Rev B1- Specification for Hot Induction Bends
REFERENCE DOCUMENTS DRP001-OUF-DSH-Y-650SPI-025, Rev B2- Data Sheet for Line Pipe Material
& SPECIFICATION : DRP001-OUF-SPE-Y-650-004, Rev B3- Specification for Line Pipe Material
DRP001-OUF-2037-PL-PL-0058 -T97-0001, Rev O1- Procedure for Handling, Storage, Packing,
Preservation & delivery of Hot Induction Bends.
DRP001-OUF-SPE-N-000-006, Rev A1- Packing, Marking, Preservation & Shipping procedure.

PRODUCTION BEND :
PO Line Item No # 23 - 10” x 7.09 mm Pipe- 90 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS Sr. No. as mentioned in description of product / Heat No- 179908- Qty-
second Lot of 27 Nos.

&

PRODUCTION BEND :
PO Line Item No # 30 - 10” x 7.09 mm Pipe- 20 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS19009-30-1 & 2 / Heat No- 179908- Qty- first Lot of 02 Nos.

&

DOCUMENTATION : PRODUCTION BEND :

PO Line Item No # 66 - 10” x 7.09 mm Pipe- 5.83 Deg. 5D Bend- API 5L GR X60 PSL2- Tan
Length 410 mm (1.5 D)- FTDS19009-74-1/ Heat No- 179908- Qty- first Lot of 01 No.

Below documents reviewed for above productions bends.

• Mother pipe visual/ dimension & wall thickness inspection report.

• Visual & dimension inspection report of MPQT bend.
• Surface Hardness of MPQT bend.
• Magnetic Particle Inspection report.
• Ultrasonic test report.
• Ultrasonic Wall Thickness Measurement report.
• Heat Treatment (Quenching & Tempering) chart/ report.
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

PRODUCTION BEND :
PO Line Item No # 23 - 10” x 7.09 mm Pipe- 90 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS Sr. No. as mentioned in description of product / Heat No- 179908- Qty-
second Lot of 27 Nos.

&

PRODUCTION BEND :
PO Line Item No # 30 - 10” x 7.09 mm Pipe- 20 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS19009-30-1 & 2 / Heat No- 179908- Qty- first Lot of 02 Nos.

VISUAL INSPECTION &

PRODUCTION BEND :
PO Line Item No # 66 - 10” x 7.09 mm Pipe- 5.83 Deg. 5D Bend- API 5L GR X60 PSL2- Tan
Length 410 mm (1.5 D)- FTDS19009-74-1/ Heat No- 179908- Qty- first Lot of 01 No.

 Visual inspection of above production bends carried out after blast cleaning to ensure
surface is free of defects like surface notches, surface marks, laminations, cracks,
mechanical damage etc. Visual inspection of bend found satisfactory.
 Heat number, Bend size, Thk, Angle, Radius, Proclad Id number found marked on pipe by
low stress stamping.

PRODUCTION BEND :
PO Line Item No # 23 - 10” x 7.09 mm Pipe- 90 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS Sr. No. as mentioned in description of product / Heat No- 179908- Qty-
second Lot of 27 Nos.

&

PRODUCTION BEND :
PO Line Item No # 30 - 10” x 7.09 mm Pipe- 20 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS19009-30-1 & 2 / Heat No- 179908- Qty- first Lot of 02 Nos.

&

PRODUCTION BEND :
DIMENSONAL INSPECTION PO Line Item No # 66 - 10” x 7.09 mm Pipe- 5.83 Deg. 5D Bend- API 5L GR X60 PSL2- Tan
Length 410 mm (1.5 D)- FTDS19009-74-1/ Heat No- 179908- Qty- first Lot of 01 No.

 Dimension inspection of above 7 (5+1+1) Nos production bend carried out as per approved
drawing and following parameters verified.
 Bend layout, Bend OD, Tangent Length, Bend ends Ovality, Bend body ovality, Tan length,
Bend Radius, Bend Angle, Bevel Edge angle, bevel Root face, bevel end Squareness, &
wall thickness measurements. All these parameters found in line with drawing.
 Drift Test- Gauge passing test witnessed and found gauge passed through.
 Wall thickness witnessed for above one 5 no’s production bends.
 Wall thickness check carried out with calibrated ultrasonic gauge. Calibration ensured on
step wedge block prior to start of test.
 Wall thickness readings found within acceptance limit as per MPS and drawing.
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

PRODUCTION BEND :
PO Line Item No # 23 - 10” x 7.09 mm Pipe- 90 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS Sr. No. as mentioned in description of product / Heat No- 179908- Qty-
second Lot of 27 Nos.

&

PRODUCTION BEND :
PO Line Item No # 30 - 10” x 7.09 mm Pipe- 20 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS19009-30-1 & 2 / Heat No- 179908- Qty- first Lot of 02 Nos.

HARDNESS TEST : &

PRODUCTION BEND :
PO Line Item No # 66 - 10” x 7.09 mm Pipe- 5.83 Deg. 5D Bend- API 5L GR X60 PSL2- Tan
Length 410 mm (1.5 D)- FTDS19009-74-1/ Heat No- 179908- Qty- first Lot of 01 No.

 Hardness test randomly witnessed on production bends.

 Hardness test carried out with calibrated MIC-10 hardness tester. Calibration ensured on
block prior to start of test.
 Hardness reading found within acceptance limit as per MPS.

PRODUCTION BEND :
PO Line Item No # 23 - 10” x 7.09 mm Pipe- 90 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS Sr. No. as mentioned in description of product / Heat No- 179908- Qty-
second Lot of 27 Nos.

&

PRODUCTION BEND :
PO Line Item No # 30 - 10” x 7.09 mm Pipe- 20 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS19009-30-1 & 2 / Heat No- 179908- Qty- first Lot of 02 Nos.

&

NDE: PRODUCTION BEND :

PO Line Item No # 66 - 10” x 7.09 mm Pipe- 5.83 Deg. 5D Bend- API 5L GR X60 PSL2- Tan
Length 410 mm (1.5 D)- FTDS19009-74-1/ Heat No- 179908- Qty- first Lot of 01 No.

 MPI: Magnetic particle test monitored on randomly selected for dimensional inspection
production bends. AC Yoke calibration and lifting capacity verified prior to start of test
and found satisfactory. MPI witnessed on 100 % surface of MPQT bend. NO relevant
indication observed during the test, MPI test found satisfactory.

 UT: Ultrasonic test randomly witnessed on production bends. UT machine range

calibration & sensitivity calibration verified on calibration block & DAC block prior to
start of test and found satisfactory. UT test was carried out by using Normal probe for full
body scanning including tangent ends and angle probe of 45 & 60 degree for scanning of
extrados portion. UT test found satisfactory.
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

PRODUCTION BEND :
PO Line Item No # 23 - 10” x 7.09 mm Pipe- 90 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS Sr. No. as mentioned in description of product / Heat No- 179908- Qty-
second Lot of 27 Nos.

&

PRODUCTION BEND :
PO Line Item No # 30 - 10” x 7.09 mm Pipe- 20 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS19009-30-1 & 2 / Heat No- 179908- Qty- first Lot of 02 Nos.

&

PRODUCTION BEND :
MARKING, PACKING & PO Line Item No # 66 - 10” x 7.09 mm Pipe- 5.83 Deg. 5D Bend- API 5L GR X60 PSL2- Tan
PRESERVATION : Length 410 mm (1.5 D)- FTDS19009-74-1/ Heat No- 179908- Qty- first Lot of 01 No.

 Marking details witnessed on bends and found in line with marking identification details
provided in approved MPS. Marking of bends has been performed using low stress punch
stamping.
 Temporary rust preventive rust inhibitor CRC SP-400 has been applied on external surface
of pipe body including bevel ends. Validity of rust inhibitor verified and found within
validity.
 Bevels ends of bends have been protected by plastic bevel ends caps.
 Bends are suitably kept on pallets and wooden stoppers are provided on either side of
bends to stop the bends movements during transit.
 Bends are suitably tied-up by plastic strap to hold them with wooden pallet.
 Finally bends are fully covered with plastic polythene cover.
 Packing list & shipping document verified. Same needs to be attached on each pallet.

PRODUCTION BEND :
PO Line Item No # 23 - 10” x 7.09 mm Pipe- 90 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS Sr. No. as mentioned in description of product / Heat No- 179908- Qty-
second Lot of 27 Nos.

&

PRODUCTION BEND :
PO Line Item No # 30 - 10” x 7.09 mm Pipe- 20 Deg. 5D Bend- API 5L GR X60 PSL2- Tan Length
410 mm (1.5 D)- FTDS19009-30-1 & 2 / Heat No- 179908- Qty- first Lot of 02 Nos.
LAB TEST WITNESS
&

PRODUCTION BEND :
PO Line Item No # 66 - 10” x 7.09 mm Pipe- 5.83 Deg. 5D Bend- API 5L GR X60 PSL2- Tan
Length 410 mm (1.5 D)- FTDS19009-74-1/ Heat No- 179908- Qty- first Lot of 01 No.

1) Mechanical Test- Longitudinal & Transverse Tensile Test

• Before testing witnessed actual mother pipe sample piece identified at Lab storage for
verification of identification and to ensure correctness of samples.
• Above MPQT, bend mechanical test witnessed at Lab Lonestar, Dubai.
• Sample locations were marked/ signed as per sketch provided in MPS- Figure 1.
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

• Lab reference identification number verified on samples as per sample location & details
provided in MPS- Table 1.
• Tensile test UTM machine calibration verified & found within validity.
• Tensile test witnessed along with Duqm TPIA, Proclad TPIA, & Proclad QC. Test results found
meeting the requirement specified in MPS.

2)Transverse CVN Impact Test

• Above MPQT bend Transverse Impact test witnessed at Lab Lonestar, Dubai.
• Sample locations were marked/ signed as per sketch provided in MPS- Figure 1.
• Lab reference identification number verified on samples as per sample location & details
provided in MPS- Table 1.
• Impact test machine calibration verified & found within validity.
• Impact test witnessed along with Duqm TPIA, Proclad TPIA, & Proclad QC. Test results found
meeting the requirement specified in MPS.

3) Through thickness hardness Test

• Above MPQT bend through thickness hardness Test witnessed at Lab Lonestar.
• Sample locations were marked/ signed as per sketch provided in MPS- Figure 1.
• Lab reference identification number verified on samples as per sample location & details
provided in MPS- Table 1.
• Hardness tester machine calibration verified & found within validity.
• Through thickness hardness test witnessed along with Duqm TPIA, Proclad TPIA, & Proclad QC.
Test results found meeting the requirement specified in MPS.

4) Metallurgical Section-Micro Grain-Size Examination Test

• Above MPQT bend micro grain size examination test witnessed at Lab Lonestar for tangent 1,
tangent 2, intrados, extrados.
• Sample locations were marked/ signed as per sketch provided in MPS- Figure 1.
• Lab reference identification number verified on samples as per sample location & details
provided in MPS- Table 1.
• Machine calibration verified & found within validity.
• Test witnessed along with Duqm TPIA, Proclad TPIA, & Proclad QC. Test results found meeting
the requirement specified in MPS.

INSPECTION RESULTS : Acceptable

AREA OF CONCERN NIL

NCR STATUS (if any) NIL

ANNEXURE (If any)

Check List Yes No
MTC Yes No
Test Reports Yes No
Packing List Yes No
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

INSEPCTION PERFORMED BY :

CONTRACTOR INSPECTOR:

NAME Nitin D Sampate

DEPARTMENT: QC

SIGNATURE:

DATE 17.12.2019
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

Photos

Visual & Dimensional Inspection

 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

Thickness check
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

Hardness test
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

NDE Test (MPT & UT)

 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

Lab Test
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

Marking Identification
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

Packing & Preservation

 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267
 Duqm Refinery Project
EPC Package 2 –
Utilities
Contract No.: CNT-1100-1000-007 and Offsites Project No.: JI-2037/SO0267

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