SOMATM SA PILING PROJECT

Pipe Manufacturer Logo Customer Logo

&

0 24.02.2022 Issued for Reviewed M.GEL M.GEL A.TOH

Rev. Date Description Prepared Checked Reviewed Customer Approval

Document Title : Inspection and Test Plan - SAWH-Spiral Welded Pile Production

Document No : ERC-ITP-22-11-1

General Project Information

 Customer SOMATM

Project Name -

Oil or Gas
Prod.
Onshore Offshore Sour Water Pilling
Form
Pipe Type Service Service Service

- - - - X CFCHS
Quantity -
Length Quantity ID OD
Item Size (mm) Steel Grade Tolerance
(m) (PCS) Coating Coating
(m)
Scope
1800,0
1 Ø610 x 25,0 S355JR 30,0 60,0 Bare Bare
±0,6%

Manufacturing Spec.1-BS EN 10219-1:2006

Standards or Specs Spec.2-BS EN 10219-2:2019

Standard Annexes -

Coating
BARE
Standards or Specs

Lining
BARE
Standards or Specs

ABREVIATION LIST:

AUT Automatic Ultrasonic Test

ASME American Society of Mechanical Engineers
CFCHS Cold Formed Circular Hollow Section
HAZ Heat Affected Zone
HRC Hot Rolled Coil
ID Inside Diameter
MUT Manual Ultrasonic Test
MPQT Manufacturing Procedure Qualification Test
MTC Mill Test Certificate
NDT Non Destructive Test
N.A. Not Applicable
OD Outside Diameter
PQR Procedure Qualification Record
SAWH Sub Merged Arc Welding Helically
TDC Technical Delivery Condition
UT Ultrasonic Test
W.T. Wall Thickness
WPS Welding Procedure Specification
 Date  24.02.2022
INSPECTION AND TEST PLAN - PILING PROJECT
Rev  0
Document No ERC-ITP-22-11-1 PILE PRODUCTION Page No  4 / 12
Method of
Sampling
Description of Inspection /Test Acceptance Criteria Controlling Performed Quality Verification
NO size/type
Activity Requirements Checking Method Document By frequency Record Erciyas Client

1.0 Incoming HRC and Welding Consumable Control

Incoming
Mechanical, chemical, dimensional
Mechanical, chemical, dimensional Inspection Quality,
1.1 HRC Order properties shall be acc. to Incoming Each coil Purchase H R
properties, Procedure Purchasing
Inspection Procedure. order
TA-016

Welding Consumable Mechanical, chemical, dimensional Purchase Planning, Each

1.2 Consumable standards ASME Certificate Purchase H R
Order properties, order purchasing delivery
order

Each coil,
Heat basis Incoming
Damage, Marking, Mechanical, Incoming
HRC Receipt & Visual inspection Quality, (mechanical Ins.
1.3 Chemical properties, Ins. Report H R
Storage Supplier material certificate 2.2 or 3.1. Planning and Report
Dimensional control & Coil list
chemical & Coil list
tests)

Welding Incoming Incoming

Visual inspection, Quality,
1.4 consumables Receipt Damage, Marking control Inspection Each heat / Inspection H R
Supplier material certificate 2.2 or 3.1 Planning
& Storage Report Batch Report

Legend : R : Document Review; W : Witness point; I : Inspection Points; T : Test Points ; H : Mandatory Hold Point for Inspection / Test, M : Monitoring
Erciyas QA / QC TPI Representative Client
Name :
Date / Signature
ITP-001-R0
 Date  24.02.2022
INSPECTION AND TEST PLAN - PILING PROJECT
Rev  0
Document No ERC-ITP-22-11-1 PILE PRODUCTION Page No  5 / 12
Method of
Sampling
Description of Inspection /Test Acceptance Criteria Controlling Performed Quality Verification
NO size/type
Activity Requirements Checking Method Document By frequency Record Erciyas Client

2.0 Forming, Seam and Repair Welding & NDT Validation

Quality management of welding to be executed 3834-2 Starting of

2.1 Quality Management Quality Management review QA Certificate H R
according to DS/EN ISO 3834-2 Certificate Production

Seam Welding Production Each welder

2.2 Qualification control Qualified according to ISO 14732 WPQR Certificate H R
Operator /Quality operator

Repair Welding Production

2.3 Qualification control Qualified according to ISO 9606-1 WPQR Each welder Certificate H R
Operator /Quality

Personnel shall be certified as Level II acc. to ISO NDT Each

2.4 NDT Operator Qualification control Quality Certificates H R
11484 Certificates technician

Production
2.5 Forming Visual and dimension control Checking of OD Production Each Pipe N.A. H -
Plan

3.0 Pipe Manufacturing

Legend : R : Document Review; W : Witness point; I : Inspection Points; T : Test Points ; H : Mandatory Hold Point for Inspection / Test, M : Monitoring
Erciyas QA / QC TPI Representative Client
Name :
Date / Signature
ITP-001-R0
 Date  24.02.2022
INSPECTION AND TEST PLAN - PILING PROJECT
Rev  0
Document No ERC-ITP-22-11-1 PILE PRODUCTION Page No  6 / 12
Method of
Sampling
Description of Inspection /Test Acceptance Criteria Controlling Performed Quality Verification
NO size/type
Activity Requirements Checking Method Document By frequency Record Erciyas Client

Accepted Coil
3.1 In feed coil Heat & coil number control Identification control Production Each Coil N.A. H -
List
Accepted
Welding consumable Each heat /
3.2 Heat / batch number control Identification control Welding Production N.A. H -
use Batch
consumables
Butt welds, used to join lengths of strip/plate
together in the spiral submerged arc weld
process, shall be permitted, provided that the Spec. 1 Shift
3.3 Skelp-end-weld Welding parameters control Production Each pipe H R
butt weld is tested to the same type of item 9.4.3 Report
procedure and meets the same acceptance level
as the main weld seam.
After any
Visual check for machining quality, Production Shift
3.4 Edge Milling WPS Parameter control Production change of H R
bevel angle & root face plan Report
beveling tools
Production
3.5 Forming Visual and dimension control Checking of OD Production Each Pipe N.A. H -
Plan
Amp, voltage, speed, shall be within
the ranges of the specified parameters in WPS First pipe of
production. Shift Report,
according to EN 15609 or ASME Sec. IX
Inside and Outside Quality Continuously Mechanical
3.6 Welding parameters control PQR, Mechanical tests (tensile, bending, charpy, WPS&PQR H R
Automatic SAWH Production from dials on Test
hardness 350 HV10) conducted after welding. the welding Reports
PQR shall be according to EN 15614 or ASME equipment
Sec. IX.

Legend : R : Document Review; W : Witness point; I : Inspection Points; T : Test Points ; H : Mandatory Hold Point for Inspection / Test, M : Monitoring
Erciyas QA / QC TPI Representative Client
Name :
Date / Signature
ITP-001-R0
 Date  24.02.2022
INSPECTION AND TEST PLAN - PILING PROJECT
Rev  0
Document No ERC-ITP-22-11-1 PILE PRODUCTION Page No  7 / 12
Method of
Sampling
Description of Inspection /Test Acceptance Criteria Controlling Performed Quality Verification
NO size/type
Activity Requirements Checking Method Document By frequency Record Erciyas Client

Jointer welding PQR shall be according to

EN 15614 or ASME Section IX.
VT – 100% acc. to ISO 5817 Class C
MPI - Min. 10% acc. to ISO 23277 Level 3x
UT –Min. 10% acc. to ISO 11666 Rate 3 EN ISO Quality Shift
3.7 Splice welding (If needed) Each Joint H W/R
All welds must be visually inspected for 17635 Production Report
superficial porousness and cracks. Any
errors need to be eliminated by gutting the
existing weld and re-welding the area of
the faulty weld.
4.0 Automatic Online Ultrasonic Test
The calibration shall be checked two times per ISO 10893-11 Each Shift
Control of calibration Quality H R
shift. 7.3.1 Calibration report

For Weld Metal:

Acceptance criteria: ISO 10893-11 U4/U4H
4.1 AUT Weld & HAZ Minimum Coverage : 100%
ISO 10893-11
& Shift
Inspection For HAZ: Quality Each Pipe H R
ISO 10893-8 report
Acceptance criteria : ISO 10893-8
Acceptance level : U3
Minimum Coverage : 100% (25 mm from each
side of the weld)
5.0 Length Cutting
Customer Shift
5.1 Length Cutting Pipe Length Tolerances: ±500 mm Production Each Pipe H R
Requirement report

Legend : R : Document Review; W : Witness point; I : Inspection Points; T : Test Points ; H : Mandatory Hold Point for Inspection / Test, M : Monitoring
Erciyas QA / QC TPI Representative Client
Name :
Date / Signature
ITP-001-R0
 Date  24.02.2022
INSPECTION AND TEST PLAN - PILING PROJECT
Rev  0
Document No ERC-ITP-22-11-1 PILE PRODUCTION Page No  8 / 12
Method of
Sampling
Description of Inspection /Test Acceptance Criteria Controlling Performed Quality Verification
NO size/type
Activity Requirements Checking Method Document By frequency Record Erciyas Client

6.0 First Visual Inspection (Immediately after production)

Surface defects may be removed by the
manufacturer by grinding, provided that the Spec.1 Quality
6.1 Surface Inspection Visual control Each Pipe N.A. I -
thickness of the hollow section after the repair is Item 6.9.1 Production
not less than the minimum permissible thickness

Any visible imperfection on the internal and

Erciyas Quality
6.2 Weld Inspection Visual and dimensional control external on the weld is considered unacceptable Each Pipe N.A. I -
Requirement Production
and shall be dressed out by grinding.

7.0 Traceability (Immediately after production)

Inside of Pipe at both sides the barcode contain

the following information; Traceability
7.1 Traceability Pipe identification and Sticker control  Nominal Diameter Instruction Production Each Pipe N.A. I -
 Wall Thickness (TA-06-02)
 Pipe Number

8.0 Sampling of test coupon

Lot test samples shall be cut as a ring from the Laboratory Quality, Acc. to this Laboratory
8.1 Sampling Sample geometry control H R
pipe. Records Production ITP Records

Legend : R : Document Review; W : Witness point; I : Inspection Points; T : Test Points ; H : Mandatory Hold Point for Inspection / Test, M : Monitoring
Erciyas QA / QC TPI Representative Client
Name :
Date / Signature
ITP-001-R0
 Date  24.02.2022
INSPECTION AND TEST PLAN - PILING PROJECT
Rev  0
Document No ERC-ITP-22-11-1 PILE PRODUCTION Page No  9 / 12
Method of
Sampling
Description of Inspection /Test Acceptance Criteria Controlling Performed Quality Verification
NO size/type
Activity Requirements Checking Method Document By frequency Record Erciyas Client

9.0 Pipe End Preparation & Lifting Hole Dimension

Plain end for top and bottom of the pile;
 Angle 90o (-5/+5o)
 Squareness: Max. 3 mm
Erciyas req.
Each pipe
Bevel geometry & Carrying Hole dimension For all pipes, Inside and outside weld bead shall & Shift
9.1 Pipe End Preparation Production both end of I R
control be grinded as 50±10 mm. Spec.1 report
pipe
Item 6.9.2
For splice welding, the one end of each pipes
shall be beveled. (If needed)

10.0 Visual and Dimensional Inspection

At Pipe Ends: %1, min.±0,5 mm max.±10 mm
Visual and Dimensional Pipe End and Min. (mm) Nom. (mm) Max. (mm) Spec.2 Each Shift
10.1 Outside Diameter Quality H R
Inspection Pipe Body Table 2 pipe ends report
604,0 610,0 616,0

- Ur Max.; % 2
Visual and Dimensional dmax−dmin Spec.2 Shift
10.2 Out of roundness Pipe End Ur= Quality Each Pipe H R
Inspection dnom Table 2 report

±10 % with a maximum of ± 2 mm

Min. (mm) Nom. (mm) Max. (mm)

Visual and Dimensional Spec 2 Each both Shift
10.3 Wall Thickness 23 25 27 Quality H R
Inspection Table 2 pipe ends report
Measurement shall be applied by micro meter or
UT Thickness equipment.

Legend : R : Document Review; W : Witness point; I : Inspection Points; T : Test Points ; H : Mandatory Hold Point for Inspection / Test, M : Monitoring
Erciyas QA / QC TPI Representative Client
Name :
Date / Signature
ITP-001-R0
 Date  24.02.2022
INSPECTION AND TEST PLAN - PILING PROJECT
Rev  0
Document No ERC-ITP-22-11-1 PILE PRODUCTION Page No  10 / 12
Method of
Sampling
Description of Inspection /Test Acceptance Criteria Controlling Performed Quality Verification
NO size/type
Activity Requirements Checking Method Document By frequency Record Erciyas Client

Visual and Dimensional Customer 1 per 4 hour Shift

10.4 Straightness Max. 20 mm but aim shall be 9 mm Quality H R
Inspection Requirement operating shift report

Spec.2 1 times per Shift

Inner weld height Max. 4,8 mm Quality H R
Table 5 shift report
Visual and Dimensional Weld geometry,
10.5
Inspection Macro Examination
Spec.2 1 times per Shift
Outer weld height Max. 4,8 mm Quality H R
Table 5 shift report

Visual and Dimensional 1 times per Shift

10.6 Peaking Max. 6 mm Erciyas Req. Quality H R
Inspection shift report

Visual and Dimensional 1 times per Shift

10.7 Radial Offset (Hi-Low) Max. 5 mm Erciyas Req. Quality H R
Inspection shift report

11.0 Destructive Tests

Sampling Preparation: EN ISO 14284
Test Method: ASTM E 415
Elements Max (%) Elements Max (%)
EN 10025-2 1 per every Test
11.1 Destructive Tests Chemical composition C 0,27 S 0,045 Quality H R
Table 3 & 5 75 ton Report
Si 0,60 N 0,014
Mn 1,70 Cu 0,60
P 0,045 CEV 0,45

Test Standard: ISO 6892-1

Min.(MPa)
Rt(0,5) 345 EN 10025-2 1 per every Test
11.2 Destructive Tests Transverse Tensile test – Base material Quality H R
Table 6 75 ton Report
Rm 470-630
Elg. % 20%

Legend : R : Document Review; W : Witness point; I : Inspection Points; T : Test Points ; H : Mandatory Hold Point for Inspection / Test, M : Monitoring
Erciyas QA / QC TPI Representative Client
Name :
Date / Signature
ITP-001-R0
 Date  24.02.2022
INSPECTION AND TEST PLAN - PILING PROJECT
Rev  0
Document No ERC-ITP-22-11-1 PILE PRODUCTION Page No  11 / 12
Method of
Sampling
Description of Inspection /Test Acceptance Criteria Controlling Performed Quality Verification
NO size/type
Activity Requirements Checking Method Document By frequency Record Erciyas Client

Test Standard: ASTM A370

Min.(MPa) EN 10025-2 1 per every Test
11.3 Destructive Tests Transverse Tensile test – Weld material Quality H R
Table 6 75 ton Report
Rm 470

12.0 Final Marking

Stencil marking include followings shall be

applied at one end of the pile.
 ERCIYAS
 EN 10219
 610 x 25 mm
Spec.1
12.1 Marking Outside marking on one end  S355JR SAWH PRD/QAC Each Pipe N.A. H -
Item 10
 Pipe No : .............
 Pipe Length :…….

The marking starts 300 mm from the side of

the pipe end

12.2 Marking Outside marking ERCIYAS name marks at the middle of pipe. - PRD/QAC Each Pipe N.A. H -

13.0 Documents

Legend : R : Document Review; W : Witness point; I : Inspection Points; T : Test Points ; H : Mandatory Hold Point for Inspection / Test, M : Monitoring
Erciyas QA / QC TPI Representative Client
Name :
Date / Signature
ITP-001-R0
 Date  24.02.2022
INSPECTION AND TEST PLAN - PILING PROJECT
Rev  0
Document No ERC-ITP-22-11-1 PILE PRODUCTION Page No  12 / 12
Method of
Sampling
Description of Inspection /Test Acceptance Criteria Controlling Performed Quality Verification
NO size/type
Activity Requirements Checking Method Document By frequency Record Erciyas Client

This file includes, as a minimum;

Erciyas
Before transportation manufacturer -Inspection Test Certificate EN 10204-3.1 Requirement
create an end-of- manufacture file. MTC,
13.1 Final Release -The packing list. & Quality Each Item H R
Retention of records shall be at least 5 Packing list
-NDT Test Reports Customer
years.
Requirement
-Lab. Test Reports

Legend : R : Document Review; W : Witness point; I : Inspection Points; T : Test Points ; H : Mandatory Hold Point for Inspection / Test, M : Monitoring
Erciyas QA / QC TPI Representative Client
Name :
Date / Signature
ITP-001-R0