ZapSib-2 Project

Ethylene Cracker Unit (ECU)

Linde Project No.: 3110ATH2 Inspection Report

Linde Project Code: TOBOLSK_02 INS-0012DI3630-20171213
Page 1 of 12

COVER SHEET
LINDE Project No.: K-01-3110ATH2 Supplier: John Zink Hamworthy
LINDE Project Code: TOBOLSK_02 Supplier's Ref. No.:
LINDE P.O. No.: 0012DI3630 Manufacturer: Metalfab Middle East FZ LLC
Subject of P.O.: Flare Package Manufacturer's Ref. No.:
Dimensional Inspection / Trial
Place of Visit: Metalfab Middle East FZ LLC
Subject of Inspection: Assembly of Flares
RAKIA Free Zone, Al Jazeera Al
Date of Visit: 28th Dec 17 and 02nd Jan 18 Hamra, Ras Al Khaimah, UAE

Participants Kalyan.Rajagopal – LEME (Quality Inspector) Akhtar Ansari / Shahabudeen– QA/QC METALFAB
(name, Tarek – Behalf of JohnZink
company/department)

Linde Inspector Internal External

Quality Control Inspection
Functional Inspection

Summary 1. Packing Inspection on Tag No.: 27-FL-2001 (Sour Gas Flare) Sections SR 2 to SR 15 – Found acceptable
2. Trail assembly Inspection on Tag No.: 27-FL-2002 10” Acetylene riser Sections AR 1 to AR 15 – Found
acceptable
3. Reports review and signed

Problems New Existing None Not checked

Technical
Schedule weeks weeks

Actions Release for further processing Further inspection required

Partial release for further processing Cost unit LINDE ENGINEERING (proposal to PM)
Stop of production Cost unit supplier / manufacturer (proposal to PM)

Any inspection or release by LINDE does in no way dispense the supplier / manufacturer from his obligations of the P.O.

Kalyan.Rajagopal – LEME U.A.E January 3, 2018

Date, acknowledgement of supplier / manufacturer Date, signature of inspector on behalf of LINDE ENGINEERING

Distribution Lead Inspector InEx Coordinator Supplier

EQR Expediter Manufacturer
Discipline Lead Engineer PPM PC Buyer
QA/QC Lead Engineer PM Other:

Restricted – distribution outside of The Linde Group only with confidentiality agreement.
The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.
Form: &AZ-T-PE 2080 (EN), Issue 01 dated 22.05.2015
 ZapSib-2 Project
Ethylene Cracker Unit (ECU)

Linde Project No.: 3110ATH2 Inspection Report

Linde Project Code: TOBOLSK_02 INS-0012DI3630-20171213
Page 2 of 12

BASIS SHEET
Description of Components

LINDE Item ID / P.O. Pos. / Tag No. Manufacturer's Serial No. Subject of P.O.

Tag No.: 27-FL-2001 24” Sour Gas Riser MFLP00389-A250.03 Rev 02 SOUR GAS RISER FOR FIXED FLARE H=170 M

Tag No.: 27-FL-2002 - 10” Acetylene Riser MFLP00389-A250.02 Rev 02 ACETYLENE RISER FOR FIXED FLARE H=170 M

Inspection Documents

List of Attachments (LoA) Doc. No.: &AA-2000-B-GE 1960 (EN) Issue: 7

General Legal and Quality Requirements Doc. No.: Issue:

Technical Data Sheet Doc. No.: Issue:

0012DI3630 2720 B-ZA 1400 (EN) REV 2./
0012DI3630 2720 B-ZE 1700.001 (EN)
REV.3 /
GA Drawings Doc. No.: 0012DI3630 2720 B-ZE 1500.001 /REV 3. Issue: 2 /3 / 3

Technical Purchase Specification Doc. No.: Issue:

LINDE Standard (LS) Doc. No.: Issue:

Inspection and Test Plan (ITP) Doc. No.: Issue:

Doc. No.: Issue:

Inspection Check List – &AZ-T-PC 10xx (EN)

To be used mandatorily. No distribution outside of The Linde Group. For internal purpose only.

Pressure Vessels / Reactors Tubular Heat Exchangers Plate Fin Heat Exchangers
Pressure Swing Adsorbers Columns / Column Trays / Internals Rotating Equipment / Compressors
Flat Bottom Tanks Spherical Storage Tanks Non-Pressure Vessel
Coil (Strip) Steel Structures and Shells Forgings, Discs and Rings
Dished Heads Internals: Wire Mesh, Perforated Plate, Expanded Metal, Knitted Wire Mesh
Flanges Pipes and Fittings Valves / Safety Valves & Rupture Discs
Skids and Units Vacuum-Insulated Piping Painting / Coating
Other: No CL for this kind of PU available

Restricted – distribution outside of The Linde Group only with confidentiality agreement.
Form: &AZ-T-PE 2080 (EN), Issue 01 dated 22.05.2015
 ZapSib-2 Project
Ethylene Cracker Unit (ECU)

Linde Project No.: 3110ATH2 Inspection Report

Linde Project Code: TOBOLSK_02 INS-0012DI3630-20171213
Page 3 of 12

RESULT SHEET
No. Item 1) Description Key 2)

1 27-FL-2001 SR 2 to Visual inspection done, Paint coating system verified , Degree marking verified , Insulation cleats 1
SR 15 verified , Field weld Bevel preparation verified , Linde packing list verified

2 27-FL-2002 AR 1 to Visual inspection done , Paint coating system verified , Degree marking verified , Insulation cleats 1
AR 15 verified , Field weld Bevel preparation verified , Bottom Section AR 1 North Direction mark
verified , , Linde packing list verified
3 Reports Signed reports attached

10

11

12

END OF REPORT

1)
Tag or ID no. of item, or material description.
2)
Key 1 accepted as it is
2 accepted after remedy during inspection
3 to be remedied (to be copied into PUNCH LIST below stipulating name of responsible party/person and due date)
info only for information, e.g. further details about technical aspects or inspection activities carried out

Restricted – distribution outside of The Linde Group only with confidentiality agreement.
Form: &AZ-T-PE 2080 (EN), Issue 01 dated 22.05.2015
 ZapSib-2 Project
Ethylene Cracker Unit (ECU)

Linde Project No.: 3110ATH2 Inspection Report

Linde Project Code: TOBOLSK_02 INS-0012DI3630-20171213
Page 4 of 12

PHOTOGRAPHS

Fig. 1: Packing Inspection on Tag No. 27-FL-2001 SR2 to SR15 Fig. 2: Packing Inspection on Tag No. 27-FL-2001 SR2 to SR15

Fig. 3: Packing Inspection on Tag No. 27-FL-2001 SR2 to SR15 Fig. 4: Packing Inspection on Tag No. 27-FL-2001 SR2 to SR15

Fig. 5: Packing Inspection on Tag No. 27-FL-2001 SR2 to SR15 Fig. 6: Packing Inspection on Tag No. 27-FL-2001 SR2 to SR15

Restricted – distribution outside of The Linde Group only with confidentiality agreement.
Form: &AZ-T-PE 2080 (EN), Issue 01 dated 22.05.2015
 ZapSib-2 Project
Ethylene Cracker Unit (ECU)

Linde Project No.: 3110ATH2 Inspection Report

Linde Project Code: TOBOLSK_02 INS-0012DI3630-20171213
Page 5 of 12

PHOTOGRAPHS

Fig. 7: Packing Inspection on Tag No. 27-FL-2002 AR1 to AR15 Fig. 8: Packing Inspection on Tag No. 27-FL-2002 AR1 to AR15

Fig. 9: Packing Inspection on Tag No. 27-FL-2002 AR1 to AR15 Fig. 10: Packing Inspection on Tag No. 27-FL-2002 AR1 to AR15

Fig. 11: Packing Inspection on Tag No. 27-FL-2002 AR1 to AR15 Fig. 12: Packing Inspection on Tag No. 27-FL-2002 AR1 to AR15

Restricted – distribution outside of The Linde Group only with confidentiality agreement.
Form: &AZ-T-PE 2080 (EN), Issue 01 dated 22.05.2015
 ZapSib-2 Project
Ethylene Cracker Unit (ECU)

Linde Project No.: 3110ATH2 Inspection Report

Linde Project Code: TOBOLSK_02 INS-0012DI3630-20171213
Page 6 of 12

PUNCH LIST
Punch Point 2) Close-out
No. Item 1)
Description Action by Due date Description of Corrective Action taken Accepted by 3) Date

1 27-FL-2002 – Riser W.r.to the Linde LE approved the 0012DI3630 2720 John Zink 7 Dec 2017 Need to change the all RT reports to latest version Random Inspection done and 10
AR-1 to AR-15 T-SV 1400.009 (EN) /Metal Fab w.r.to the Linde LE approved Radiography found satisfactory -CLOSE December
METALFAB using the old format in Radiography procedure 2017
reports

2 27-FL-2002 – Riser Visual Inspection need to offer after cleaning John Zink 5 Dec 2017 John Zink inspector will do the Visual Inspection Random Inspection done and 7
AR-1 to AR-15 /Metal Fab and same will offer to Linde LE in next visits. found satisfactory -CLOSE December
2017

3 27-FL-2003 – Guide supports and Anchor supports welded on the John Zink 12 Dec 2017 Need to provide the Linde / John Zink acceptance
Process Riser PR-15 Shell Circumference Seam weld /Metal Fab documents
to PR-10
4 27-FL-2003 – Field Weld Preparation Not found satisfactory John Zink 10 Dec 2017 Need to offer the same to Linde on next Inspection Verified and found acceptable 10 Dec
Process Riser PR-15 /Metal Fab visit -CLOSE 2017
to PR-10
5 27-FL-2003 – Material summary sheet not ready John Zink 10 Dec 2017 Need to offer the same to Linde on next Inspection Verified and found acceptable 13 Dec
Process Riser PR-15 /Metal Fab visit -CLOSE 2017
to PR-10
6 27-FL-2003 – W.r.to the Linde LE approved the 0012DI3630 2720 John Zink 12 Dec 2017 Need to change the all RT reports to latest version Verified and found acceptable 13 Dec
Process Riser 15 to T-SV 1400.009 (EN) /Metal Fab w.r.to the Linde LE approved Radiography -CLOSE 2017
PR-10 METALFAB using the old format in Radiography procedure
reports

1)
Tag or ID no. of item, or material description. For bulk material, reference to the notification for inspection (NFI) may be used.
2)
Topics labeled with key 3 in the RESULT SHEET above are to be copied into the PUNCH LIST stipulating name of responsible party/person and due date.
3)
On behalf of Linde Engineering.

Restricted – distribution outside of The Linde Group only with confidentiality agreement.
Form: &AZ-T-PE 2080 (EN), Issue 01 dated 22.05.2015
 ZapSib-2 Project
Ethylene Cracker Unit (ECU)

Linde Project No.: 3110ATH2 Inspection Report

Linde Project Code: TOBOLSK_02 INS-0012DI3630-20171213
Page 7 of 12

PUNCH LIST
Punch Point 2) Close-out
No. Item 1)
Description Action by Due date Description of Corrective Action taken Accepted by 3) Date

7 Drawings for
Insulation cleats
(Valid for all flare
tag)
All the sections required insulation cleats as per John Zink 18 Dec 2017 John Zink to update the fabrication drawing and Under progress on Progress
Linde LS 151-02 , /Metal Fab update to Metalfab for fabrication and same to riser
Shear leg required for all bottom sections install in sections prior to start Coating activities Completed on 28 Dec 2017
required as per foundation drawings Acetylene Riser and Sour
risers – found acceptable

8 PMI verification
(Valid for all SS flare
ITEM TAG)
9 Al Built Drawings
(Valid for all flare
item tag)
Raw materials are done, Welds are balance John Zink 26 Dec 2017 100% witnessed by Johnzink TPI . Reports need Under progress
/Metal Fab to forward Linde review & acceptance
During my trial assembly inspection 27-FL-2003 - John Zink 26 Dec 2017 Johnzink /Metalfab to update the actuals in as
80” process riser individual Sections length are /Metal Fab built drawing and ensure that overall length of
not as per shop fabrication drawings But all section to be verified within limit. Linde to
attachments are fixed as per the drawing verify the overall length.
elevations.

1)
Tag or ID no. of item, or material description. For bulk material, reference to the notification for inspection (NFI) may be used.
2)
Topics labeled with key 3 in the RESULT SHEET above are to be copied into the PUNCH LIST stipulating name of responsible party/person and due date.
3)
On behalf of Linde Engineering.

Restricted – distribution outside of The Linde Group only with confidentiality agreement.
Form: &AZ-T-PE 2080 (EN), Issue 01 dated 22.05.2015
 ZapSib-2 Project
Ethylene Cracker Unit (ECU)

Linde Project No.: 3110ATH2 Inspection Report

Linde Project Code: TOBOLSK_02 INS-0012DI3630-20171213
Page 8 of 12

PUNCH LIST
Punch Point 2) Close-out
No. Item 1)
Description Action by Due date Description of Corrective Action taken Accepted by 3) Date

10 Weld overlap (valid Guide supports and Anchor supports are Welded
for all flare) with on the Cir. Seam & long seam welds ,
Johnzink /Metalfab informed the followed the
B31.3 acceptance criteria and suggested the
solution.
John Zink 13 Dec 2017 JohnZink/Metalfab suggested solution:
/Metal Fab 1. All flare riser design code is ASME B 31.3 and
TR CU 10 therefore other Not applicable code
stated in detail drawing to be removed. In any
case we have all code listed in GA drawing.
2. In Technical passport of flare ITEM TAG, we
have separate chapter for individual
components like flare riser in that John Zink will
specifically write “design code ASME B31.3 and
acceptance criteria for welding seam as per
ASME code”. Therefore, being a non pressure
part this will not be problem to get RTN.

1)
Tag or ID no. of item, or material description. For bulk material, reference to the notification for inspection (NFI) may be used.
2)
Topics labeled with key 3 in the RESULT SHEET above are to be copied into the PUNCH LIST stipulating name of responsible party/person and due date.
3)
On behalf of Linde Engineering.

Restricted – distribution outside of The Linde Group only with confidentiality agreement.
Form: &AZ-T-PE 2080 (EN), Issue 01 dated 22.05.2015
 ZapSib-2 Project
Ethylene Cracker Unit (ECU)

Linde Project No.: 3110ATH2 Inspection Report

Linde Project Code: TOBOLSK_02 INS-0012DI3630-20171213
Page 9 of 12

PUNCH LIST
Punch Point 2) Close-out
No. Item 1)
Description Action by Due date Description of Corrective Action taken Accepted by 3) Date

11 Misalignment at C/S SIBBUR inspector highlighted the mismatch on John Zink 13 Dec 2017 JohnZink/Metalfab suggested solution: 13 Dec
weld joint weld joints ( It’s non-conformance of requirement /Metal Fab 2017
SA 03-005-07). 1. All flare riser design code is ASME B 31.3 and
TR CU 10 therefore other Not applicable code
Johnzink /Metalfab informed the followed the
stated in detail drawing to be removed. In any
B31.3 acceptance criteria and suggested the
case we have all code listed in GA drawing.
solution.
2. In Technical passport of flare ITEM TAG, we
have separate chapter for individual
components like flare riser in that John Zink will
specifically write “design code ASME B31.3 and
acceptance criteria for welding seam as per
ASME code ”. Therefore being a non pressure
part this will not be problem to get RTN.

12 Base plate anchor Johnzink / Metalfab using the old revision John Zink 21 Dec 2017 Johnzink to provide the latest Linde approved Completed verified – Found 28 Dec
bolt hole size (REV. 01) for the fabrication of 90” Sour flare /Metal Fab to Metalfab and same will offer to Linde for acceptable 2017
gas riser (KO Drum SR1 ), Required Holes size is witness.
(27-FL-2001)
diameter 56 mm , actual observed 36 mm.
Need to change & follow the latest issued
drawing MFLP00389-A280 Rev 02.

1)
Tag or ID no. of item, or material description. For bulk material, reference to the notification for inspection (NFI) may be used.
2)
Topics labeled with key 3 in the RESULT SHEET above are to be copied into the PUNCH LIST stipulating name of responsible party/person and due date.
3)
On behalf of Linde Engineering.

Restricted – distribution outside of The Linde Group only with confidentiality agreement.
Form: &AZ-T-PE 2080 (EN), Issue 01 dated 22.05.2015
 ZapSib-2 Project
Ethylene Cracker Unit (ECU)

Linde Project No.: 3110ATH2 Inspection Report

Linde Project Code: TOBOLSK_02 INS-0012DI3630-20171213
Page 10 of 12

PUNCH LIST
Punch Point 2) Close-out
No. Item 1)
Description Action by Due date Description of Corrective Action taken Accepted by 3) Date

13 Drawings for All the sections required insulation cleats as per John Zink 18 Dec 2017 John Zink to update the fabrication drawing and Completed verified – Found 28 Dec
Insulation cleats (27- Linde LS 151-02 , /Metal Fab update to Metalfab for fabrication and same to acceptable 2017
FL-2002, Valid for all Shear leg required for all bottom sections install in sections prior to start Coating activities
flare) required as per foundation drawings

14 Shear lug at base Shear lug at foundation base plate as per drawing John Zink 18 Dec 2017 John Zink to update the fabrication drawing and Completed verified – Found 28 Dec
plate (MFL00389-A-210 REV 1/C-ZA 1400.001) shall be /Metal Fab update to Metalfab for fabrication and same to acceptable 2017
(27-FL-2002, Valid attached. be installed at base plate.
for all flare)
15 Name plate bracket Name plate bracket for valid for all riser’s is not John Zink 18 Dec 2017 John Zink to update the fabrication drawing and Completed verified – Found 28 Dec
attached. /Metal Fab update to Metalfab for fabrication and same to acceptable 2017
(27-FL-2002, Valid
for all flare) be installed at base plate.

16 Bevel Protection and
Un-coating for field
weld joints (27-FL-
2002, Valid for all
flare)
Supplier need to provide the written for each John Zink 26 Dec 2017 Corrosion protection applied in 40 mm Field Completed verified – Found 02 Jan
items Field Weld ( FW ) bevel protection packing /Metal Fab Weld ( FW ) bevels acceptable 2018
and to provide suitable corrosion protection
during transit period of shipment like Rust
Preventive Coat (easily remove at site)

1)
Tag or ID no. of item, or material description. For bulk material, reference to the notification for inspection (NFI) may be used.
2)
Topics labeled with key 3 in the RESULT SHEET above are to be copied into the PUNCH LIST stipulating name of responsible party/person and due date.
3)
On behalf of Linde Engineering.

Restricted – distribution outside of The Linde Group only with confidentiality agreement.
Form: &AZ-T-PE 2080 (EN), Issue 01 dated 22.05.2015
 ZapSib-2 Project
Ethylene Cracker Unit (ECU)

Linde Project No.: 3110ATH2 Inspection Report

Linde Project Code: TOBOLSK_02 INS-0012DI3630-20171213
Page 11 of 12

PUNCH LIST
Punch Point 2) Close-out
No. Item 1)
Description Action by Due date Description of Corrective Action taken Accepted by 3) Date

17 Painting adhesion As per painting specification LS-2301 requires John Zink 26 Dec 2017 Completed verified – Found 02 Jan
test Adhesion Test to be performed. /Metal Fab acceptable 2018
As per T-SS 2301 ID 6.1, .".. Quality control shall be
(27-FL-2002, Valid
done by experienced and qualified personnel
for all flare)
(DIN-CERTCO, NACE, FROSIO or equivalent). " Pls
check with manufacturer. If METALFAB/DANEM is
qualified for that then no need for painting
manufacturer.
- In any case FORM 1-"Corrosion Protection by
Manufacturer" shall be filled by manufacturer and
signed.

18 Assembly match
mark (27-FL-2027-
FL-2002, Valid for all
flare 03)
19 North marking-base
plate (27-FL-2002,
Valid for all flare)
20 Hand grip and safety
rung for manhole
(27-FL-2002-KOD)
Metal fab to perform the assembly match John Zink 18 Dec 2017 JohnZink to confirm and same to be offered in Completed verified – Found 02 Jan
marking tag after painting for erection /Metal Fab next Linde visit. acceptable 2018
identification at site.
North Marking shall be marked on base plate. John Zink 18 Dec 2017 JohnZink to confirm and same to be offered in Completed verified – Found 02 Jan
/Metal Fab next Linde visit. acceptable 2018
Metal fab to attach Hand grip at EL+5.1 (Qty 1) John Zink
and safety rung at EL+3.9 (Qty 1)and EL+3.6 /Metal Fab
(Qty 1) at Manhole (A01) orientation.
Fabrication drawing to be updated in as built

1)
Tag or ID no. of item, or material description. For bulk material, reference to the notification for inspection (NFI) may be used.
2)
Topics labeled with key 3 in the RESULT SHEET above are to be copied into the PUNCH LIST stipulating name of responsible party/person and due date.
3)
On behalf of Linde Engineering.

Restricted – distribution outside of The Linde Group only with confidentiality agreement.
Form: &AZ-T-PE 2080 (EN), Issue 01 dated 22.05.2015
 ZapSib-2 Project
Ethylene Cracker Unit (ECU)

Linde Project No.: 3110ATH2 Inspection Report

Linde Project Code: TOBOLSK_02 INS-0012DI3630-20171213
Page 12 of 12

PUNCH LIST
Punch Point 2) Close-out
No. Item 1)
Description Action by Due date Description of Corrective Action taken Accepted by 3) Date

21 KOD-DRUM Platform Information of platform cleats + ladder cleats on John Zink

Cleats KOD-skirt to be informed to DANEM since /Metal Fab
DANEM is fabricating platform in order to perfect
matching of respective parts.

END OF PUNCH LIST

1)
Tag or ID no. of item, or material description. For bulk material, reference to the notification for inspection (NFI) may be used.
2)
Topics labeled with key 3 in the RESULT SHEET above are to be copied into the PUNCH LIST stipulating name of responsible party/person and due date.
3)
On behalf of Linde Engineering.

Restricted – distribution outside of The Linde Group only with confidentiality agreement.
Form: &AZ-T-PE 2080 (EN), Issue 01 dated 22.05.2015