MOS-0570-5685619-00 Combined

Test Package For
Replacement of Corroded Piping segments of AIR-221019001(With

LP Steam Jacketed Line) for 221-J-0001B Based on IREP-22-00663
Test Package Number: KBR-TP-0570-5685619

TEST PACKAGE NO. KBR-TP-0570-5685619
MOCC / WORK ORDER .No 5685619
INSPECTION REPORT IREP-22-00663
EFFECTIVE DATE: 10-Apr-2022
TITLE:
TABLE OF CONTENTS
1. Test Package Flow Chart……………………………………………
2. Inspection Reports or MOCC…………………….…………………………
3. Method of Statement……..…
4. Drawings & weld maps…………..
5. Daily welding reports (NDE Reports & Material MTC’s)………………...
6. Post Weld Heat Treatment Reports…………………………..………….
7. Hydro Test Reports………………………………………………………….
8. Flanged Connection Torque Record……………………………………
9. Painting Reports……………………………………………………………..
10. Insulation Report If Applicable……………………………………………..
11. Punch List………………………………………………………………
12. Inspection original comments……………………………………………....

TEST PACKAGE NO. TITLE: Replacement of Corroded Piping segments of
AIR-221019001(With LP Steam Jacketed Line) for 221-
KBR-TP-0570-5685619 Rev 00
J-0001B Based on IREP-22-00663
TEST PACKAGE FLOW CHART

TEST PACKAGE
PREPARATION &
REVIEW for
KBR-AY QA/QC KBR-AY QA/QC MANAGER
REVIEW OF TEST PACKAGE

BY SATORP
SATORP MAINTENANCE SATORP INSPECTION
JOINT PREAPRATION,
FABRICATION,WELDING,
OF THE JOINTS KBR-AY MAINTENANCE KBR-AY QA/QC
AS PER THE PROCEDURE;
N.D.T & PUNCH LIST
INSPECT THE WELD JOINTS

WITNESS BY SATORP
KBR-AY QA/QC SATORP INSPECTION
FINAL PRESSURE TESTING

KBR-AY MAINTENANCE KBR-AY QA/QC SATORP INSPECTION / OPERATION *
REINSTATEMENT
BOLTING & TORQUING
KBR-AY MAINTENANCE KBR-AY QA/QC SATORP MAINTENANCE
PAINTING
KBR-AY MAINTENANCE KBR-AY QA/QC SATORP OPERATION
INSULATION
KBR-AY MAINTENANCE KBR-AY QA/QC SATORP OPERATION
* Service test will be signed by Satorp Operations.


TITLE:
Method of Statement Rev 00
SCOPE
Fabrication, testing, coating of jacketed spools and replace the existing corroded spools as per
IREP-22-00663 and further instruction from Inspection based on visual or penetrant inspection
of flanges and other existing components
Note: Slip on flanges of Jacketed piping should be as per JERES-L-315 requirements
AREA
Area -3, UNIT- 221
REFERENCE DRAWINGS
ISO NO : ID-AIR-22109001-08,09,10
P & ID NO : 221-PID-0021-020
LINE CLASS : 101CS1J (10” Jacket pipe), 101CS4V (8” Process pipe)
WELDING PROCEDURE
WPS No: 1-1-A-21-1 Rev.00 ER 70S-2 + E 7018 8” Process & 10 “Jacket pipe
WPS No: 1-8-A-21-3-A Rev.00 ER NiCr-3 - SS Reinforcement Plate /SS Baffle
WPS-No: 1-1-A-2-2 Rev No 08. ER 70S2 1” Jumper line, Baffle
MATERIAL DESCRIPTION
Base material is Carbon Steel (A 106 Gr B, A234-WPB, A105N) for Jacket pipe -101CS1J.
Base material is Carbon Steel (A 106 Gr B, A234-WPB, A105N) for process pipe -101CS4V
WELD MAP
As attached
Page 1 of 8

TITLE:
Abbreviations.
(SB-Shop Butt, SF-Shop Fillet, SE-Shop External Attachment, SBR-Shop Branch, SS-Shop Socket)
Suffix P – Welding to Process Line
Suffix J – Welding to Jacket Line
Page 2 of 8

TITLE:
FABRICATION & WELDING OF PROCESS PIPE – 8” CS -A106-B
1. Obtain necessary permits and actual site measurements to be followed prior to start of
fabrication.
2. MTC for all new materials to be verified and submitted to Satorp prior to start of job
3. If any re use of non defective components from existing spool shall be verified and accepted
by Satorp Inspection followed by cut surface Penetrant test
4. First complete the fabrication of process pipe as per actual site dimensions with new/ re-
usable material and same specifications of attached isometric material list.
5. Flow conveyor baffle plate and reinforcing plate(A240-316L / A 106 Gr.B) as per attached
drawing dimensions to be welded at ‘SE’ locations of weld map, prior to flange welding.
Page 3 of 8

TITLE:
6. Jacket pipe 10” to be kept installed without fit up prior to welding of Reducing Slip-On
Flanges (10”x8”, A105N, Cl 150,Max 125 AARH) to Process pipe
7. GTAW+SMAW welding will be performed for ‘SB&SF’(excluding SF-9P) joints of weld map
with ER 70S-2 + E 7018 based on the approved WPS 1-1-A-21-1 Rev.00 parameters through
company approved welder
8. GTAW welding will be performed for ‘SE’ joint of weld map (for baffle plate/CS Reinforcement
plate - intermittent weld as per diagram of JERES-L-315), SF-9P,all SBR and SS joints with
ER 70S-2 based on the approved WPS 1-1-A-2-2 Rev No 08 parameters through company
approved welder
9. GTAW welding will be performed for ‘SE’ joint of weld map (for SS Reinforcement plate-
intermittent weld as per diagram of JERES-L-315) with ER NiCr-3 based on the approved
WPS 1-8-A-21-3-A Rev.00 parameters through company approved welder
(SE-8P1, SE-17P1, SE-28P1,SE-39P,SE-39P1 – Belongs to Dissimilar weld. Item number
24&25 of BOM Reinforcement Plate of SS 316L weld with A106-B Process pipe)
10. Visual inspection and 10% radiography to be completed for the final butt welds (process pipe)
11. 100% DPT to be performed for all completed Fillet joints (Pipe to Flange)
12. Perform hydro test at 11.62 bars for 30 minutes of process pipe (8”) to check the integrity of
system, prior to jacket pipe fit up and welding
Joint & Weld Details- Process Pipe

Joint No Size Weld Type Components Electrode /Filler
SF-1P 8" Fillet weld Red SORF Flange-8"Pipe ER 70S-2& E7018
SBR-3P 3/4" Branch weld Half Coupling-8"Pipe ER 70S-2
SS-3P1 3/4" Socket weld Half Coupling-3/4"Pipe ER 70S-2
SE-8P Baffle Fillet stitch SS/CS plate -3/4" Pipe ERNicr-3
SE-8P1 Reinforce SS Fillet stitch SS 316 plate- 3/4" Pipe ERNicr-3
SF-9P 3/4" Fillet weld Red SORF Flange-3/4"Pipe ER 70S-2
SB-11P 8" Butt weld Cross Tee -8" Pipe ER 70S-2& E7018
SE-17P Baffle Fillet weld SS/CS plate -8" Pipe ERNicr-3
Page 4 of 8

TITLE:
SE-17P1 Reinforce SS Fillet weld SS 316 plate- 8" Pipe ERNicr-3
FABRICATION & WELDING OF JACKET PIPE – 10” CS – A 106 Gr.B
13. After acceptance hydro test of process pipe, proceed with fit up and welding of jacket pipe
with new/re-usable material and same specifications of attached isometric material list.
14. MTC for all new materials to be verified and submitted to Satorp prior to start of job
15. If any re use of non-defective components from existing spool shall be verified and accepted
by Satorp Inspection followed by cut surface Penetrant test
16. GTAW+SMAW welding will be performed for ‘SB&SF’ joints (Excluding SB-6J&SB-7J) and
Support (SE-27J&SE-32J) of weld map with ER 70S-2 + E 7018 based on the approved
WPS 1-1-A-21-1 Rev.00 parameters through company approved welder
17. GTAW welding will be performed for ‘SBR’ & ‘SS’ and (SB-6J, SB-7J,SF-9J) joints of weld
map with ER 70S-2 based on the approved WPS 1-1-A-2-2 Rev No 08. parameters through
company approved welder
Page 5 of 8

TITLE:
(All SBR, SS Joints belongs to 1” interconnecting jump over of jacket line. Existing line will
verify with PT for re -usability or new material according to BOM item 17 to 20)
18. Visual inspection to be completed on all completed welds.
19. 100% DPT to be performed on all Fillet Welds, socket welds and branch welds
20. Perform hydro test at 10.64 bars for 30 minutes of jacket pipe (10”) to check the integrity of
system.
21. Painting system M will be performed after Hydrotest acceptance of jacket piping
Joint & Weld details - Jacket Pipe

Joint No Size Weld Type Components Electrode /Filler
SF-1J 10" Fillet weld Red SORF Flange-10"Pipe ER 70S-2& E7018
SBR-2J 1" Branch weld Sockolet - 10" Pipe ER 70S-2
SS-2J1 1" Socket weld Sockolet- 1" Pipe ER 70S-2
SBR-3J 3" Branch weld 3"Pipe -10"pipe ER 70S-2
SF-4J 10" Fillet weld CS RF Pad -10"pipe ER 70S-2& E7018
SF-5J 3" Fillet weld CS RF Pad -3"pipe ER 70S-2& E7018
SB-6J 3" Butt Weld Con-Reducer -3"Pipe ER 70S-2
SB-7J 2" Butt Weld Con-Reducer -2"Pipe ER 70S-2
SBR-8J 1/2" Branch weld Sockolet - 2" Pipe ER 70S-2
SS-8J1 1/2" Socket weld Sockolet - 1/2" Pipe ER 70S-2
SF-9J 2" Fillet weld Red SORF Flange-2"Pipe ER 70S-2
SS-10J1 1" Socket weld Sockolet - 1" Pipe ER 70S-2
SB-11J 10" Butt weld Cross Tee -10" Pipe ER 70S-2& E7018
SB-11J1 Cross tee segment Butt weld 10" Cross tee segments ER 70S-2& E7018
Page 6 of 8

TITLE:
SE-27J Support Fillet weld Support - 10"Pipe ER 70S-2& E7018
SS-28J1 1" Sockolet weld Sockolet - 1" Pipe ER 70S-2
SE-32J Support Fillet weld Support - 10"Pipe ER 70S-2& E7018
Page 7 of 8

TITLE:
HYDRO TEST
1. 11.62 bars for 30 minutes of process pipe (8”)
2. 10.64 bars for 30 minutes of jacket pipe (10”)
PAINTING REQUIREMENTS:
System – M, complying with JERES-H-001 and company procedures on jacket pipe.
INSULATION
Thk 50 mm Complying with JERES-N-001 and company procedures.
Page 8 of 8

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Test Package For

Replacement of Corroded Piping segments of AIR-221019001(With

Test Package Number: KBR-TP-0570-5685619

1. Test Package Flow Chart……………………………………………

2. Inspection Reports or MOCC…………………….…………………………

4. Drawings & weld maps…………..

5. Daily welding reports (NDE Reports & Material MTC’s)………………...

6. Post Weld Heat Treatment Reports…………………………..………….

7. Hydro Test Reports………………………………………………………….

8. Flanged Connection Torque Record……………………………………

10. Insulation Report If Applicable……………………………………………..

11. Punch List………………………………………………………………

12. Inspection original comments……………………………………………....

TEST PACKAGE FLOW CHART

REVIEW OF TEST PACKAGE

INSPECT THE WELD JOINTS

FINAL PRESSURE TESTING

* Service test will be signed by Satorp Operations.

Replacement of Corroded Piping segments of AIR-221019001(With

Note: Slip on flanges of Jacketed piping should be as per JERES-L-315 requirements

Area -3, UNIT- 221

WPS No: 1-8-A-21-3-A Rev.00 ER NiCr-3 - SS Reinforcement Plate /SS Baffle

WPS-No: 1-1-A-2-2 Rev No 08. ER 70S2 1” Jumper line, Baffle

Replacement of Corroded Piping segments of AIR-221019001(With

Suffix P – Welding to Process Line

Suffix J – Welding to Jacket Line

Replacement of Corroded Piping segments of AIR-221019001(With

FABRICATION & WELDING OF PROCESS PIPE – 8” CS -A106-B

Replacement of Corroded Piping segments of AIR-221019001(With

Joint & Weld Details- Process Pipe

Replacement of Corroded Piping segments of AIR-221019001(With

FABRICATION & WELDING OF JACKET PIPE – 10” CS – A 106 Gr.B

Replacement of Corroded Piping segments of AIR-221019001(With

Joint & Weld details - Jacket Pipe

Replacement of Corroded Piping segments of AIR-221019001(With

Replacement of Corroded Piping segments of AIR-221019001(With

1. 11.62 bars for 30 minutes of process pipe (8”)

2. 10.64 bars for 30 minutes of jacket pipe (10”)

System – M, complying with JERES-H-001 and company procedures on jacket pipe.

Thk 50 mm Complying with JERES-N-001 and company procedures.

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