IQWQ-CE1092-QPQAC-00-0004 - 0 -QUALITY CONTROL PROCEDURE FOR FIELD FEBRICATED TANKS罐安装质量控制程序 PDF

IQWQ-CE1092-QPQAC-00-0004 QUALITY CONTROL PROCEDURE FOR FIELD FEBRICATED TANKS 16-Apr-2017
TABLE OF CONTENTS
1.0 PURPOSE ............................................................................................................................................. 1
2.0 SCOPE .................................................................................................................................................. 1
3.0 REFERENCES ...................................................................................................................................... 1
4.0 QUALIFICATIONS ................................................................................................................................ 1
5.0 RESPONSIBILITIES ............................................................................................................................. 1
6.0 PROCEDURE ........................................................................................................................................ 2
6.1 Foundation Surveying ............................................................................................................ 2
6.2 Foundation Construction ........................................................................................................ 2
6.3 Review and Approval of Welding Procedure ......................................................................... 2
6.4 Review and Approval of NDE Procedures ............................................................................. 2
6.5 Dimension Checks of Tank .................................................................................................... 2
6.6 Completed tank Inspection ..................................................................................................... 2
6.7 Witness Testing of Tank ......................................................................................................... 2
6.8 Inspection of Tested Tank Prior to Closing ............................................................................ 3
7.0 INSPECTION FORMS ........................................................................................................................... 3
ATTACHMENTS
Attachment A :
1 - Tank Elevation Tolerances Record
2 - Inspection Record Field Erected Tank
3 - Tank Plate Dimensional Control Record Field Erected Tank
4 - Water Filling And Settlement Record Field Erected Tank
5 - Tank Leak Test Record
6 - Surveillance Report
7 - Tank Test Report
8 - Inspect Tested Tank Prior To Closing Record
1.0 PURPOSE
This procedure covers the proper control of inspection, testing and documentation requirements for
installation activities for field fabricated tanks for WEST QURNA 1 PRODUCED WATER
TREATMENT PROJECT (109).
2.0 SCOPE
This procedure defines the inspection, testing and documentation requirements for installation
activities for field fabricated tanks.
3.0 REFERENCES
ASME IX Welding And Brazing Qualifications
AWS D 1.1 Structural Welding Code - Steel
API 650 Welded Tanks for Oil Storage
API 653 Tank Inspection, Repair, Alteration and Reconstruction (If applicable)
ASME Sect. V Non Destructive Examination
ASME Sect. II Part C Welding Rods, Electrodes and Filler Metal
4.0 QUALIFICATIONS
All Mechanical Engineer/Inspectors should have at least five years’ working experience with
applicable industry codes and conducting inspections during construction and fabrication in the
petrochemical industry. Less experience may be considered with documented formal education or
technical training.
5.0 RESPONSIBILITIES
Construction manager is overall responsible for the execution of all inspection, testing and
documentation requirements for installation activities for field fabricated tank. Welding supervisors
and foreman are responsible for day to day activities.
Site QA/QC Manager is responsible for the implementation of this procedure and of all quality related
activities including the management of non-conformities.
FREQUENCY OF
ACTIVITY RESPONSIBILITY DOCUMENTATION
ACTIVITY
Verify foundation
Construction Engineer Survey Field Books Prior to start of erection
surveying
Inspect foundation
Contractor Form: F02201 Prior to start of erection
construction
Review and approve
Approval from Company Prior to start of welding
contractor's welding Welding Engineering
Welding Engineering activities
procedures
Review and approve
Approval from Company Prior to start of NDE
contractor's NDE Company NDE Level III
Level III activities
procedures
Check dimensions of tank Form: F74103Q Form: Periodically during life
Contractor
shell F02201 of activity
CPECC Page 1 of 3 Rev. 0

Surveillance of weld and Site Quality Manager/ Daily during life of

Form: F02201
NDE activities. Contractor activity
Check Tank Elevation is Site Quality Manager/
Form: F74101Q Each tank
within tolerances Contractor
Inspect completed tank Site Quality Manager/
construction Contractor
Water filling and Site Quality Manager/
Settlement inspection Contractor
Site Quality Manager/
Witness leak testing Forms: F74105Q Each tank
Contractor
WQI Quality
MC Final Acceptance M02R Each Tagged Tank
Representative
Inspect tested tank prior
Commissioning Rep. Form: M02B Each tank
to closing
6.0 PROCEDURE
6.1 Foundation Surveying
Verify that the foundation surveying is complete
6.2 Foundation Construction
Verify the foundation construction is complete and released for the tank erection. For subcontracted
work ensure the erector has accepted the foundation prior to start of tank erection activities.
6.3 Review and Approval of Welding Procedure
Verify the welding procedures have been reviewed and approved by the Quality Manager or his
representative .
6.4 Review and Approval of NDE Procedures
Verify the NDE Procedures have been reviewed and approved by the Company.
6.5 Dimension Checks of Tank
Monitor the in-process fabrication activities. Utilize Form F74102Q to document the dimension
checks.
Verify the first course shell plates have been surveyed for levelness, circularity, and plumbness prior
to setting the second course. Contractor must submit the results immediately after each survey has
been completed.
6.6 Completed tank Inspection
Verify that a final survey has been performed of the erected dimensions of the tank after all roof
framing has been installed.
Verify the tolerances for plumbness of roof columns and stilling wells, tank nozzles and modules are
within those established by the specification.
6.7 Witness Testing of Tank
Witness the hydrostatic test on the completed tank in accordance with the project specifications and
applicable code requirements.

Check the settlement and rebound of the foundation during and after the hydro-test using Form
F74101Q. Excessive settlement data shall be referred immediately to the Site Engineering Manager.
Obtain a copy of the tank test for inclusion in the permanent file.
6.8 Inspection of Tested Tank Prior to Closing
Inspect the tested tank prior to closing, including final cleanup. Document the approval to close the
tank using Form M02B (Static Commissioning Activity)., Complete Mechanical Completion Check
Record M02R and include with Turnover Package.
Verify that a nameplate according to code and the Manufacturer's Certification Letter and the as-built
data has been provided as required by the specifications.
7.0 INSPECTION FORMS
Quality Control Forms:
000 509 F74101Q - Tank Elevation Tolerances Record
000 509 F74102Q - Inspect completed tank construction
000 509 F74103Q - Check dimensions of tank shell
000 509 F74104Q - Water Filling And Settlement Inspection
000 509 F74105Q - Witness leak testing
000 509 F02201 - Inspect Foundation Construction Report
M02R – Mc Final Acceptance Record
M02B - Inspect Tested Tank Prior To Closing Record

Attachment A
1 - Tank Elevation Tolerances Record
2 - Inspect completed tank construction Record
3 - Check dimensions of tank shell
4 - Water Filling And Settlement Record Field Erected Tank
5 - Tank Leak Test Record
6 - Inspect Foundation Construction Report
7 - Mc Final Acceptance Record
8 - Inspect Tested Tank Prior To Closing Record
CPECC Att – A (9 Pages) Rev. 0

West Qurna I 000 509F74101Q

Contract: Serial No.
Project Location: Basra, Iraq Rev. No.
QUALITY CHECKSHEET - TANK ELEVATION TOLERANCES RECORD
Tag Description Tag No.
Contract No. System No
Contractor Sub-System No.
Drawing Reference Location
0+00 1+00 2+00 3+00 4+00 5+00 6+00 7+00 8+00

Note: Show vertical scale and units. STATUS
TANK FOUNDATION DESIGN ELEV.____________________________ FOUNDATION DESIGN CROWN ELEV._______________________________________
INSTRUCTIONS
TANK FOUNDATION TOLERANCE Senior Field Engineer
Foundation elevation tolerances in accordance with applicable specifications and drawings. Foundation elevation tolerances checked and accepted
Establish tank foundation tolerances and obtain tank fabricator acceptance before the start of tank erection. Starting at North Centerline
with Station 0+00, and moving clockwise, establish stations at approximately half-sheet intervals around the tank. Do this by Date Area Superintendent Date
establishing the tank shell outline on the foundation and marking off the half-sheet intervals. Take level readings at each station and
record on this form. Unless otherwise specified by the contract, the initial tolerance of foundations shall be in accordance with API-650 Fabricator's Representative Date
This exhibit may also be used to record shell and roof elevation tolerances, as well as settlement data, during and after signature
of the Fabricator's Representative
CPECC Att – A (Pages 1 of 9) Rev. 0

West Qurna I 000 509 F74102Q

Contract: Serial No…………
Project Location: Basra, Iraq Rev. No…………..
QUALITY CHECKSHEET INSPECT COMPLETED TANK CONSTRUCTION RECORD
Contract No. System No.
West Qurna I
Subject Contractor
Quality Rep
1.0 Inspection-Bottom
1.1 Bottom annular plates level.
2.0 Inspection-Shell
2.1 Shell diameter checked at bottom, mid-height, top.
2.2 Shell height checked.
2.3 Shell banding checked. /Shell peaking checked
2.4 Wind girder erection checked
2.5 Location nozzle’s, manhole and stairway checked.
3.0 Inspection-Roof
3.1 Support columns for roof in place and plumb
3.2 Roof fittings locations checked.
3.3 Roof seals installed and checked.
3.4 Stairway and ladder locations checked
3.5 Fire extinguishing systems installed and checked.
3.6 Internal spray and distributor piping and fittings checked
4.0 Testing
4.1 Hydrotest water quality and temperature checked.
4.2 Operation of vents and liquid gauges checked
4.3 Tank cleaned.
4.4 Corner weld tested.
4.5 Bottom seams vacuum tested
5.0 Arrangement
5.1 Foundation correct
5.2 Dimension in accordance with design data
5.3 Peaking/banding/Verticality & Roundness
5.4 Nozzle Sizing, orientation & standouts
5.5 Bottom drain location correct
5.6 Arrangement traceability weld maps accepted
5.7 Temporary attachments removed
6.0 Testing
6.1 All NDE completed and verified
6.2 Floor Vacuum Test
6.3 Nozzle reinforcing pad air test
6.4 Fixed roof tightness test
6.5 Hydrostatic Test
6.6 Settlement under hydrotest recorded


QUALITY CHECKSHEET INSPECT COMPLETED TANK CONSTRUCTION RECORD
West Qurna I
Subject Contractor
Quality Rep
7.0 Attachments
7.1 Ladders & platforms installed correctly
7.2 Foam piping installed (where applicable)
7.3 Sprinkler system installed (where applicable)
7.4 Breather valves/Air vents installed
7.5 Level gauges/ stilling wells installed
7.6 Earthing
8.0 Surface Protection
8.1 Internal coatings
8.2 External coatings
9.0 Final Acceptance
9.1 Tank calibration carried out
9.2 Nameplate data correct
9.3 Tank cleaned out & ready for closure
9.4 QC documentation reviewed & accepted
9.5 Closure certificate signed
Remarks:-
Contractor West Qurna I Quality Representative

Name: Name:
Signature: Signature:
Date: Date:


QUALITY CHECKSHEET CHECK DIMENSIONS OF TANK SHELL
Type of Tank: Diameter ft Height: ft Volume: ft
Dimension check ( ) Roundness (HP) ( ) Peaking/Banding(HP) ( ) Verticality(HP)
for:
No. Weld / Tolerance Difference Acceptable No. Weld / Tolerance Difference Acceptable
Plate Plate
No. No.
Remarks:-

Name: Name:
Date: Date:


QUALITY CHECKSHEET WATER FILLING AND SETTLEMENT INSPECTION
Type of Tank: Diameter: ft Height: ft Volume: ft
Water Filling
Time Holding
No Increment Height Rate Remarks
From To Time
1 ft ft .hrs
2 ft ft .hrs
3 ft ft .hrs
4 Full ft ft .hrs
Section to be checked (degrees )

No. Stage
0 - 45 45 - 90 90 - 135 135 - 180 180 - 225 225 - 270 270 - 315 215 - 360 Remarks
1 Before Fill HP
2
3
4 Full HP
5 Empty HP
Remarks:-

Name: Name:
Date: Date:


QUALITY CHECKSHEET WITNESS LEAK TESTING
Type of Tank: Diameter: ft Height: ft Volume: ft
Leak Test for: ( ) Vacuum Box (HP) ( ) Oil (HP) ( ) Air (HP)
Test Area / Test Area /
No. Test Date Result No. Test Date Result
Portion Portion

Name: Name:
Date: Date:

West Qurna I 000 509 F02201

INSPECT FOUNDATION CONSTRUCTION REPORT
Completed Work
Location Subcontractor/Activity Date Report No.
□ Yes □ No
Inspection Checklist, Specification, Or Drawing Used As Reference:
__________________________________________________________________________________________
__________________________________________________________________________________________
RESULTS: Follow-up Required  Satisfactory 
Description Of Item/Work Inspected/Observed:
__________________________________________________________________________________________________
__________________________________________________________________________________________________
__________________________________________________________________________________________________
Observations/Deficiency:______________________________________________________________________________
__________________________________________________________________________________________________
__________________________________________________________________________________________________
__________________________________________________________________________________________________
__________________________________________________________________________________________________
_________________________________________________________________________________________________
Surveillance Personnel/Date Site Quality Manger/Date
Person Notified Of Deficiency _______________________________________________________________________

Name Title
Recommended Corrective Action:

__________________________________________________________________________________________________
__________________________________________________________________________________________________
__________________________________________________________________________________________________
__________________________________________________________________________________________________
_________________________________________________________________________________________________
Corrective Actions Implemented/Accepted

:_________________________________________________________________________________________________
__________________________________________________________________________________________________
__________________________________________________________________________________________________
__________________________________________________________________________________________________
_______________________________________________________________________________________________
________________________________________________________________________________________________
Surveillance Personnel/Date Site Quality Manger/Date

West Qurna I M02R . . .

QUALITY CHECKSHEET MC FINAL ACCEPTANCE RECORD
CONFIRM/VERIFY OK N/A P/L
1.PRESSURE SAFETY VALVES INSTALLED ACCORDING TO DRAWINGS & SPECIFICATIONS □ □ □
2. ALL PIPE WORK INSTALLED ACCORDING TO DRAWINGS & SPECIFICATIONS □ □ □
3. INSTRUMENTATION /ELECTRICAL INSTALLED IN ACCORDANCE WITH DRAWINGS/SPECIFICATIONS
/MANUFACTURERS INSTRUCTIONS □ □ □
4. ACCESS TO VALVES/INSTRUMENTATION ACCEPTABLE □ □ □
5. MANHOLES SEALED IN ACCORDANCE TO DRAWINGS & SPECIFICATIONS □ □ □
6. ALL INSULATION CORRECT ACCORDING TO DRAWINGS & SPECIFICATIONS □ □ □
7. HYDROSTATIC TESTING IN ACCORDANCE WITH SPECIFICATIONS AND PROCEDURE □ □ □
8. PNEUMATIC TESTING IN ACCORDANCE WITH SPECIFICATIONS AND PROCEDURE □ □ □
9. TANK DRYING AND CLEANING COMPLETE TO SPECIFICATIONS □ □ □
10. ALL CHECKS SET OUT IN INSPECTION & TEST PLAN COMPLETE AND ALL RECORDS & REPORTS AGREED AND
SIGNED BY ALL PARTIES □ □ □
11. NITROGEN PURGING COMPLETE TO SPECIFICATION □ □ □
12. ALL SCAFFOLDING REMOVED FROM TANK AND INTER-SPACE □ □ □
13. ALL PUNCH ITEMS CLEARED AND VERIFIED BY CLIENT □ □ □
14. PRESERVATION INTACT □ □ □
15. COMMISSIONING / OPERATIONS TO COMPLETE INTERNAL INSPECTION AND WITNESS FINAL CLOSURE □ □ □
16. BOTTOM - VACUUM TEST NUMBERS □ □ □
17. FITTINGS - AIR TEST NUMBERS □ □ □
18. ROOF - VACUUM TEST NUMBERS □ □ □
19. SHELL - HYDROSTATIC TEST NUMBERS □ □ □
TEST PRESSURE □_/_□ / PSI / BAR
PRESSURE
AMBIENT TEMPERATURE OC / OF
TEST
TEST DURATION MIN.

TEST MEDIUM AIR,WATER, N2
GAUGE
COMMENTS:
OUTSTANDING PUNCH LIST ATTACHED? YES □ NO □

Name: Name:
Date: Date:

West Qurna I M02B . . .

QUALITY CHECKSHEET INSPECT TESTED TANK PRIOR TO CLOSING RECORD
THIS CERTIFICATE VERIFIES THAT THAT THE EQUIPMENT (TAGGED ITEM) IDENTIFIED ABOVE WHICH IS:
• A STAND ALONE PLANT ITEM OR
• AN INTEGRAL SUB-PART (DELETE AS APPLICABLE)
OF THE MAIN EQUIPMENT PLANT ITEM SITUATED AT OR WITHIN THE ABOVE SYSTEM HAS NOW BEEN FULLY INSTALLED AND HAS BEEN
INSPECTED BY THE DESIGNATED CONTRACTOR, OPERATIONS AND INSPECTING AGENCY REPRESENTATIVE WHERE NECESSARY AND IS
CONFIRMED AS BEING
IN ACCORDANCE WITH THE RELEVANT DESIGN DOCUMENTS AND CONSTRUCTION DRAWINGS.
IT IS FURTHER CONFIRMED THAT ALL INTERNAL PARTS AND SUB-ASSEMBLIES ASSOCIATED / APPLICABLE TO THIS EQUIPMENT HAVE BEEN
INSTALLED IN ACCORDANCE WITH DRAWINGS AND THAT ALL OUTSTANDING ITEMS ON THE ABOVE VESSEL / TANK PUNCHLIST WHICH
REQUIRE INTERNAL ACCESS HAVE BEEN COMPLETED.
THE VESSEL / TANK MANWAYS MAY NOW BE CLOSED.
Contractor SC West Qurna I SC Representative
Name Name
Signature Signature
Date Date

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IQWQ-CE1092-QPQAC-00-0004 QUALITY CONTROL PROCEDURE FOR FIELD FEBRICATED TANKS 16-Apr-2017

ASME IX Welding And Brazing Qualifications

AWS D 1.1 Structural Welding Code - Steel

API 650 Welded Tanks for Oil Storage

ASME Sect. V Non Destructive Examination

ASME Sect. II Part C Welding Rods, Electrodes and Filler Metal

CPECC Page 1 of 3 Rev. 0

Surveillance of weld and Site Quality Manager/ Daily during life of

6.1 Foundation Surveying

Verify that the foundation surveying is complete

6.2 Foundation Construction

6.3 Review and Approval of Welding Procedure

6.4 Review and Approval of NDE Procedures

6.5 Dimension Checks of Tank

6.6 Completed tank Inspection

6.7 Witness Testing of Tank

CPECC Page 2 of 3 Rev. 0

6.8 Inspection of Tested Tank Prior to Closing

7.0 INSPECTION FORMS

Quality Control Forms:

000 509 F74101Q - Tank Elevation Tolerances Record

000 509 F74102Q - Inspect completed tank construction

000 509 F74103Q - Check dimensions of tank shell

000 509 F74104Q - Water Filling And Settlement Inspection

000 509 F74105Q - Witness leak testing

000 509 F02201 - Inspect Foundation Construction Report

M02R – Mc Final Acceptance Record

M02B - Inspect Tested Tank Prior To Closing Record

CPECC Page 3 of 3 Rev. 0

1 - Tank Elevation Tolerances Record

2 - Inspect completed tank construction Record

3 - Check dimensions of tank shell

4 - Water Filling And Settlement Record Field Erected Tank

5 - Tank Leak Test Record

6 - Inspect Foundation Construction Report

7 - Mc Final Acceptance Record

8 - Inspect Tested Tank Prior To Closing Record

CPECC Att – A (9 Pages) Rev. 0

West Qurna I 000 509F74101Q

0+00 1+00 2+00 3+00 4+00 5+00 6+00 7+00 8+00

TANK FOUNDATION DESIGN ELEV.____________________________ FOUNDATION DESIGN CROWN ELEV._______________________________________

TANK FOUNDATION TOLERANCE Senior Field Engineer

CPECC Att – A (Pages 1 of 9) Rev. 0

West Qurna I 000 509 F74102Q

CPECC Att – A (Pages 2 of 9) Rev. 0

West Qurna I 000 509 F74102Q

Contractor West Qurna I Quality Representative

CPECC Att – A (Pages 3 of 9) Rev. 0

West Qurna I 000 509 F74103Q

Contractor West Qurna I Quality Representative

CPECC Att – A (Pages 4 of 9) Rev. 0

West Qurna I 000 509 F74104Q

Section to be checked (degrees )

Contractor West Qurna I Quality Representative

CPECC Att – A (Pages 5 of 9) Rev. 0

West Qurna I 000 509 F74105Q

Contractor West Qurna I Quality Representative

CPECC Att – A (Pages 6 of 9) Rev. 0

West Qurna I 000 509 F02201

Person Notified Of Deficiency _______________________________________________________________________

Recommended Corrective Action:

Corrective Actions Implemented/Accepted

CPECC Att – A (Pages 7 of 9) Rev. 0

TANK FOUNDATION DESIGN ELEV. FOUNDATION DESIGN CROWN ELEV.___________