23115_A Field Inspection and Test Plan - Umbrella Roof Tanks .PDF

516-RB-E-23115

NEW GC-16 IN WEST KUWAIT Sh. 2 of 13

Rev. A

KOC Contract No. 44930 Document Title:

Field Inspection and Test Plan - Umbrella Roof Tanks

COMPANY DOC No.

SAIPEM PROJECT NO. 032114 AGC Contract No.

GC-16/SC/GC-16/003

CBI EASTERN ANSTALT

VENDOR DOC No. 180581-000-WS-PL-00002

No. Description of Activity Controlling Procedure/Doc. Specification Acceptance Criteria QA/QC Record to be used to

verify Compliance Inspection Point Comments/

Remarks Sub Contractor Contractor Company

Data File : 23115_A.pdf

A ITEMS REQUIRED PRIOR TO TANK CONSTRUCTION

01

Pre Inspection Meeting to ensure all project documents are in place prior to start

Customer Inspection Requirement

Approved ITP Cover Sheet

I H

02

Review of ITP with contractors site inspection

API 650 Contract Documents Approved ITP Cover Sheet

I H W

03

Review Contract Drawings Approved Design Calculation, 516-RB-E-23009, 23018,

23027, 23035, 23043, 23051, 23059

Approved Design Calculation, 516-RB-E-23009, 23018, 23027, 23035, 23043, 23051,

23059

Issued For construction (IFC) Drawings

R R/A R

04

Procurement of materials, if sent direct to site, material inspection and review Certified Test Report (CTR) as required

IFC Drawings, CMS-720-00-PL-61010, 516-RB-E-23113 (Project Quality

Plan)

IFC Drawings

Material inspection reports and CTRs

R R R

05

Quality Assurance system Project Quality Plan, RB-E-23113

RB-E-23113 RB-E-23113

I R R

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06

General welding Procedure specification Welding Procedure Specification (WPS) General Repair Procedure (GRP), Weld Map, Storage and Care of Welding Consumable, Plate Clean-up Procedure. Field Performance Qualification Test Procedure for Welders & Welding Operators Telebrineller Hardness Test

516-RB-E-23134, 23135, 23136, 23137, 23138 (GWPS SMAW, SAW, GMAW & FCAW, GTAW, EGW) 516-RB-E-23139 (WPS- E6010), 516-RB-E-23140 (WPS- E7018), 516-RB-E-23141 (WPS-ER70s-3/E7018), 516-RB-E-23142 (WPS-EM12K), 516-RB-E-23143 (WPS-EM13K), 516-RB-E-23144 (WPS-EG72T-1), 516-RB-E-23145 (WPS-E71T-1), 516-RB-E-23146 (WPS-E309L), 516-RB-E-23152 (GRP-MW) 516-RB-E-23123 (WM-DRT 516-RB-E-23148 (WMCP) 516-RB-E-23151 (PCUP) 516-RB-E-23150 (WPQT)

516-RB-E-23153 (BHN-1)

API 650 ASME Section IX, 516-GA-E-60902

GWPS & WPS

R R/A R

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07

Nondestructive examination Procedures: Radiography Examination Magnetic Particle Exam. Liquid Penetrant Exam. Visual Inspection Procedure. Leak Testing Procedure Ultrasonic Test Procedure Tank Hydro testing Method Statement

516-RB-E-23128 (RT65, RT5, RT31.3) 516-RB-E-23124 (MT65, MT5Y, MT5YW, MT31.3) 516-RB-E-23125 (PT65, PT5S, PT5W, PT31.3) 516-RB-E-23126 (VI65, VI5, VT5, VI31.3, VT31.3) 516-RB-E-23127 (SFT5V, LTOP, SFT5C, SFT5D, SFT5R) 516-RB-E-23133 (UTLP) 516-RB-E-23108

API 650, ASME Sec V, 516-GA-E-60902

CMS-830-15-FM-48023, 48019, 48021, 48018, 48024.

R R/A R

08 Welder performance qualification and test

ASME IX 516-GA-E-60902

ASME IX Use Qualification forms specified in 516-RB-E-23150

I H R

09 NDE Technician qualification CB&I Written Practice to

ASNT TC-1A

CB&I Written Practice to ASNT TC-1A

Certification WL30 or CMS-830-15-FM-46001 I R/A R

10 Foundation Acceptance: API 650 IFC Drawings API 650

IFC Drawings CMS-830-17-FM-00004 I R

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B FIELD FABRICATION OF BOTTOM & ROOF SKETCH PLATES, IF ANY 01 Cut sketch plates (Check dimension before

cutting)

IFC Drawings IFC drawing CMS-720-01-FM-00410/ In process records I W S

02 Fabrication records IFC Drawing IFC Drawing CMS-720-01-FM-00410 I R S

C FABRICATION OF STAIRWAY AND PLATFORM etc. (If any) 01 Dimensional check IFC Drawing IFC Drawing CMS-720-01-FM-00410/

In process records I W S

02 Visually inspect completed welds 516-RB-E-23126 (VI5, VT5, VI65)

API 650, 516-RB-E-23126 (VI65)

CMS-830-15-FM-48024 I W S

D BUTT-WELDED ANNULAR PLATES 01 Visually inspect fit-up and completed weld.

516-RB-E-23126 (VI5, VT5,

VI65)

API 650, 516-RB-E-23126 (VI65)

CMS-830-15-FM-48024 I W S

02 Vacuum box test completed welds at 3 to 5 psi

516-RB-E-23127 (SFT5V) API 650, 516-RB-E-23127 (SFT5V)

CMS-830-15-FM-48018 I W S

03 Radiograph examine as per RT schedule

516-RB-E-23128 (RT65, RT5) API 650, 516-RB-E-23128 ( RT65)

CMS-830-15-FM-48023 I R S

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04 Record welder identification Record Drawing

N/A Record Drawing I R S

E TANK BOTTOM WELDS & SUMPS 01 Check that sump has been shop tested by

supplier, if not perform leak test

516-RB-E-23127 (LTOP) API 650, 516-RB-E-23127 (LTOP)

CMS-830-15-FM-48018 I R S

02 Visually inspect fit up, completed welds & bottom plates (for potential defects and leaks)

516-RB-E-23126 (VI5, VT5, VI65)

API 650, 516-RB-E-23126 (VI65)

CMS-830-15-FM-48024 I W S


516-RB-E-23127 (SFT5V) API 650, 516-RB-E-23127 (SFT5V)

CMS-830-15-FM-48018 I W S

05 Record welder identification

Record Drawing N/A Record Drawing I R S

F SHELL TO BOTTOM (Corner weld) 01 Visually inspect initial weld pass inside or

outside.

516-RB-E-23126 (VI5, VT5, VI65)

API 650, 516-RB-E-23126 (VI65)

CMS-830-15-FM-48024 I W S

02 Leak Test by oil penetrant method or vacuum box @ 3 to 5 psi the inside fillet initial pass before welding the second side.

516-RB-E-23127 (SFT5V, LTOP)

API 650, 516-RB-E-23127 (SFT5V, LTOP)

CMS-830-15-FM-48018

I W S

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03 Visually inspect completed inside and outside welds

516-RB-E-23126 (VI5, VT5, VI65)

API 650, 516-RB-E-23126 (VI65)

CMS-830-15-FM-48024 I W S

04 When welded outside first or when both sides are welded automatically at the same time, vacuum box @ 3 to 5 psi the inside fillet weld.

516-RB-E-23127(SFT5V) API 650, 516-RB-E-23127( SFT5V)

CMS-830-15-FM-48018

I W S

05 Record welder identification Record Drawing N/A Record Drawing I R S G SHELL BUTT WELDS OF VERTICAL AND HORIZONTAL JOINTS 01 Visually inspect shell plate edges for

lamination (If not performed in the shop).

516-RB-E-23126 ( VI65), API 650

516-RB-E-23126 ( VI65),API 650

CMS-830-15-FM-48024 H H S

02 If any lamination is detected above, UT examines to determine extent (N/A if not required).

516-RB-E-23133 (UTL65) 516-RB-E-23133 (UTL65)

CMS-830-15-FM-48021

I W S

03 Visually inspect fit up & completed welds

516-RB-E-23126(VI5, VT5, VI65)

API 650, 516-RB-E-23126( VI65)

CMS-830-15-FM-48024 I W S

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04 Radiograph examine as per RT Schedule

516-RB-E-23128 (RT65, RT5)

API 650, 516-RB-E-23128 (RT65)

CMS-830-15-FM-48023 I W S

05 WM random hardness Test of welds deposited by automatic (EGW and SAW) process (For Tank 016-D-001, 002, 003, 004)

516-RA-E-20122 Note 32 & 516-RB-E-23153 (BHN-1)

516-RB-E-23153 (BHN-1) (Max

248HV10)

CMS-830-15-FM-55002 I

W S

06 Dimensional check (Plumbness, Roundness & Peaking/banding)

516-RB-E-23126(VI5, VT5, VI65)

API 650, 516-RB-E-23126(VI65)

CMS-830-15-FM-48024 W W S

07 Record Welder ID

Record Drawing ASME IX Record Drawing W R S

H FITING PENETRATING THE TANK SHELL 01 Visually inspect shell plate cut-out edges for

lamination (If not performed in the shop).

516-RB-E-23126 ,API 650 516-RB-E-23126 ,API 650

CMS-830-15-FM-48024 H H S

02 If any lamination is detected above, UT examines to determine extent (N/A if not required).

516-RB-E-23133 (UTL65) 516-RB-E-23133 (UTL650

CMS-830-15-FM-48021

I W S

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03 Visually inspect completed weld on all fittings penetrating the tank shell attaching the reinforcement plate (if any) and the inside and outside surface of welds between the fitting neck, shell & the reinforcing plate.

516-RB-E-23126(VI5, VT5, VI65)

API 650, 516-RB-E-23126(VI65)

CMS-830-15-FM-48024

I W S

04 Magnetic Particle examine completed welds on all fittings penetrating the tank shell attaching the reinforcement plate (if any) and the inside and outside surface of the welds between the fitting neck, shell and the reinforcing plate.

516-RB-E-23124(MT5Y, MT5YW, MT65)

API 650, 516-RB-E-23124( MT65)

CMS-830-15-FM-48019

I W+R S

05 Magnetic Particle examine reinforcement pad plate welds that intersect a shell weld for a distance of 6 (150mm) on each side of the intersection and the butt weld for a distance of 2 (50mm) beyond the pad weld. Note: RT to be carried out for Shell joint which have intersecting openings &RF pads 100 % over welding length 3 times the diameter of the opening. Specific approval From AGC to be Obtained for Any shell joints which have intersecting openings & RF pads

516-RB-E-23124(MT5Y, MT5YW, MT65)

API 650, 516-RB-E-23124( MT65)

CMS-830-15-FM-48019

I W+R S

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06 Air pressure solution film test reinforcing pad plate and neck to shell weld at 15 psig maximum.

516-RB-E-23127(SFT5R) API 650, 516-RB-E-23127(SFT5R)

CMS-830-15-FM-48018

I W /S

07 Visually inspect nozzle (if any) after welding for the following: a) Projection from outside of the shell to

extreme face of flange b) Elevation & angular location c) Flange tilt in any plane, measured on the

flange face. d) Flange bolt hole for proper orientation

516-RB-E-23126(VI5, VT5, VI65)

API 650, 516-RB-E-23126(VI65)

CMS-830-15-FM-48024

I W S

08 Visually inspect manholes (if any) after welding for the following: a) Projection from outside of the shell to

extreme face of flange b) Elevation & angular location c) Flange tilt in any plane, measured on the

flange face.

516-RB-E-23126(VI5, VT5, VI65)

API 650, 516-RB-E-23126(VI65)

CMS-830-15-FM-48024

I W S

09 100% Radiograph the butt weld around the periphery of all thickened insert plate of a nozzle or manhole, if any.

516-RB-E-23128 (RT65, RT5) API 650, 516-RB-E-23128 (RT65)

CMS-830-15-FM-48023

I R S

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J PERMANENT AND TEMPORARY ATTACHMENT TO SHELL 01 Visually inspect welds joining permanent

attachment and all temporary weld areas after the surface has been restored to a smooth contour prior to hydrotest.

516-RB-E-23126(VI5, VT5, VI65)

API 650, 516-RB-E-23126(VI65)

CMS-830-15-FM-48024

I W S

02 Visually inspect butt welds to be covered by attachments after they are ground flush but prior to being covered.

516-RB-E-23126(VI5, VT5, VI65)

API 650, 516-RB-E-23126(VI65)

CMS-830-15-FM-48024 I W S

03 For shell plates group IV VI material, MT or PT examine all permanent attachment weld areas prior to hydrotest. (N/A to A283-C material)

516-RB-E-23124 (MT5Y, MT5YW, MT65), 516-RB-E-23125 ( PT5S, PT5W, PT65)

API 650, 516-RB-E-23124 (MT65), 516-RB-E-23125 (PT65)

CMS-830-15-FM-48019/021 I W S

04 For any group IV VI material, MT or PT examine all temporary attachment weld areas on pressure shell (after restored to smooth contour). N/A to A283-C Material.

516-RB-E-23124 (MT5Y, MT5YW, MT65), 516-RB-E-23125 ( PT5S, PT5W, PT65)

API 650, 516-RB-E-23124 (MT65), 516-RB-E-23125 ( PT65)

CMS-830-15-FM-48019/021 I W S

K FIXED ROOF 01 Visually inspect fit up & completed welds

516-RB-E-23126(VI5, VT5,

VI65) API 650, 516-RB-E-

23126(VI65) CMS-830-15-FM-48024 I W S


516-RB-E-23127(SFT5V) API 650, 516-RB-E-23127(SFT5V)

CMS-830-15-FM-48018 I W S

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L FILLET WELD SPACING IN BOTTOM WELDS OR FIXED ROOF WELDS, If any 01 For bottom, floating or fixed roof fillet lap

welds that are closer than 6 (152mm) to the attachment fillet weld of a patch or pad plate without opening, MT examine these welds within 6 (152mm) limit after completion of both welds.

516-RB-E-23124 (MT5Y, MT5YW, MT65)

API 650, 516-RB-E-23124 (MT65)

CMS-830-15-FM-48019

I W S

M FOAM & DELUGE SYSTEM, if any 01 Visually inspect fit up & completed welds

516-RB-E-23126(VI5, VT5,

VI65), IFC Drawing API 650, 516-RB-E-

23126(VI65) CMS-830-15-FM-48024 I W S

02 Perform hydro test 516-RB-E-23108 API 650 180581-Hydro W H S N HYDRO TEST 01 Final visually inspect entire bottom shell and

roof prior to test 516-RB-E-23126(VI5, VT5,

VI65) API 650, 516-RB-E-

23126(VI65) CMS-830-15-FM-48024 I W S

02 Verify all the QC documents to ensure completeness prior to testing And release for hydro test.

Inspection & Test Plan Signed off inspection reports as per ITP

Signed off reports and Release for Hydro test H H S

03 Hydro test 516-RB-E-23108( Tank Hydro test Method Statement )

API 650 180581-Hydro H H S

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04 Vacuum box test completed Shell welds above test water level at 3 to 5 Psi or Air pressure solution film test at design pressure.

516-RB-E-23127(SFT5V, SFT5D)

API 650, 516-RB-E-23127( SFT5V,

SFT5D)

CMS-830-15-FM-48018

I W S

05 Inspect the shell, including the fitting and lower piping, for leak and sign of distress. If any leak appear, lower the water level about 1 Ft. below the leak, make repair and retest. If any distress is found, immediately start to drain the tank and contact the construction office.

516-RB-E-23108( Tank Hydro test Method Statement )

API 650

180581-Hydro

I W W/S

06 Settlement Check 516-RB-E-23108( Tank Hydro test Method Statement )

API 650 CMS-830-17-FM-00004 I W+R W+R P TANK CALIBRATION 01 Tank Calibration.

Third party Procedure API 2550 Third Party Report R R R

Inspection Point

H : Hold Point - A designated stopping place during test or inspection, and the dated signature or initial of the appropriate individuals is required before further work can be performed

W : Witness Point - Witness of the designated personnel. If the specified party is not present, the work may continue. W/S : Spot Witness - Spot witness of the designated personnel. If the specified party is not present, the work may continue. R : Review Point - Review of documents, drawings or records for the works. No formal notification is required. I : Inspection Point - Perform the activity of test or inspection. No formal notification is required.