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Abbreviations
ASME American Society of Mechanical Engineers PGCC Petrol and Gas Construction Company
ASTM American Society for Testing Materials QP Qatar Petroleum
API American Petroleum Institute AI Authorized Inspector
AWS American Welding Society F.R Pad Reinforcement Pad
C Eq. Carbon Equivalent TDC Technical Delivery Condition
CS Carbon Steel
DFT Dry Film Thickness
LPI Liquid Penetrant Inspection Applicable Standards
MTO Material Take-off
MPT Magnetic Particle Test API 650 Tank Design Specification
MTC Mill Test Certificate ASTM A240 SS316 SS Material Specification
MDD Manufacturer’s Data Dossier ASME Sec II, Part c Specification for Welding Rods, Electrodes and Filler Metals
MCN Material control Number ASME Sec V Non-Destructive Examination
NACE National Association of Corrosion Engineers ASME Sec VIII, Div.1 Rules for Construction of Pressure Vessels
NCR Non-conformance and Resolution Report ASME Sec IX Qualification Standard for welding procedures and welders
NDT Non Destructive Testing ASME B16.5 Standards of Pipes and Fittings
NDE Non Destructive Examination ASME Sec X Fiber-Reinforced Plastic Pressure Vessels
PO Purchase order SNT-TC-1A Guidelines to NDT Personnel Qualification and certification
PWPS Proposed Welding Procedure Specification
QC Quality Control
RT Radiography Testing
SS Stainless Steel
TPI Third Party Inspection Agency
TQ Technical Query
UT Ultrasonic Testing
WPS Welding Procedure Specification
WPQR Welder Performance Qualification Record
WFT Wet Film Thickness
QUALITY CONTROL PLAN
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1.0 Design
1.1 Design review & Meeting all the Clients P.O Data Clients P.O Data PGCC’s Design Design Manager
Design Calculation Requirements of Sheet Sheet Calculation /Design Engineer
Clients P.O
1.2 Preparation of Compliance with Clients P.O Data Clients P.O Data PGCC Design Manager
Engineering drawing design conditions, Sheet Sheet Drawing /Design Engineer
and detail drawings. Client Specification
& Data Sheet
2.0 Material Purchase
2.1 Material Requisition Technical and Drawing, Matching Drawing, Material Design Engineer,
Quality Technical Delivery Clients spec & Requisition Draftsman
Requirements as Conditions(TDC) Technical delivery
per conditions.
Contract/Drawings
2.2 Purchase Order Purchasing Data Buying enquiry Vendors offer match Purchase Purchaser, Project
Complete and offer from with the order Engineer &
vendor, client requirements, technical Operation Manager
approval vendor Substitutions offered Query
list are approved by TEPQ Requests (in
case of
substitutions)
3.0 Material Control
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3.1 Material list of PGCC Material Size Mill test Material controller &
procured Materials identification, certificates, Material QC
(Shell plates, bottom test cert. as per Dimensional Inspector
plates, top plates, API 650 inspection
pipes, fittings, etc..) for pressure part report if
required &
NDT Report (If
applicable)
3.2 Dished Heads
3.3 Material Storage Clearly identified, Mill TC, Stores Identification marking -- Material Controller
MCN, PO# and Records traceability to MTC & QC Inspector
Stored/ Segregated
to prevent
contamination and
damage
3.4 Material issue Issue against Material Issue Slip Issue against Material Material Controller,
authorization only authorization only requisition Supervisor
issue Slip Project Engineer
3.5 Internal Installation Dimension, trial Sub-vendors Sub-Vendors Drawing Sub- Sub-contractors &
items (, assembly at floor, drawing & Doc# & Doc# contractors’ Project Engineer.
MTC Review inspection
reports
3.6 Anodes As per client PO
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4..0 Welding control
4.1 Welding Procedure Covers full range of Meets WPS Welding Engineer
Specification (WPS) parameters, API 650 API 650
processes and Drawing & job requirements and job
meets CODE specific WPS range
requirements
4.2 Welder Qualification Covers full range of API 65 Welder Welding Engineer
records (WPQR) parameters and Qualification
process to be certificates
welded
4.3 Weld Map
4.4 Welding Size ,Batch No & PG/WC/001,ASME Consumable Welding Engineer
Consumables Test Certification. Sec. II part C & GS Batch
API 650 for S. steel EP PVV 611 Certificates
material
consumables; and
3.1B for all other
material
consumables
5.0 NDE Testing /Procedure
5.1 NDE Testing
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5.1.1 NDE Procedures Covers full range of API 650 GS EP Meets CODE QC Manager/QC
parameters and PVV… requirements and Engineer
processes and covers job range
meets CODE
requirements
5.1.2 NDE Personal Covers all methods ASNT Meets CODE NDE QC Manager/QC
Qualification of NDE applicable to requirements and personnel Engineer
the degree of covers job range Qualification
competence Certificates
required
5.2 Procedures
5.2.1 QC Procedures Covers Full Range of Meets API 650 Meets API 650 QC Manager/QC
parameters requirements and Engineer
covers job range
6.0 Manufacturing Of 4903F
6.1 Prefabrication
Activities(Sheet,
Nozzles and Saddles)
6.1.1 Identification, As per drawing Drawing, API 650 Drawing, API 650 & Inspection Supervisor & QC H R R R
marking, cutting and dimensions within (UW-31), Request & Inspector
weld preparation of tolerances. Material
shell plates. Summary
sheet.
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6.1.2 Fit up of shell long As per drawing API 650. API 650 Inspection Supervisor & QC H W W S
seams along with dimensions within report Inspector.
Production Test tolerances.
Coupon (2 Coupons
for each WPS)
6.1.3 Mechanical test on As per concern Concern WPS & API 650 & GS EP PVV Lab Test Project Engineer & H H S H
one two Production PQR’s mechanical PQR. 211 Rev: 06 Report QC Welding
Test Coupon. characteristics. Inspector
6.1.4 100% weld visual All relevant drawing Drawing API 650, API 650, GS EP PVV Inspection Supervisor & QC H S S S
And dimension dim. GS EP PVV 611 611 Rev: 06 & Request (Form Inspector
inspection on Shell Rev: 06 & MG/NDE/VT/)006 no MSF 012)
and manhole long MG/NDE/VT/006
seams joints.
6.1.5 Fit-up and Welding Welding per WPS WPS, list of API 650 & GS EP PVV Weld Visual Supervisor & QC H S S S
WPS and Qualified and Qualified qualified and 211 Rev: 06 Request (Form Inspector
welders welders. approved Weld no MSF 012)
Map.
6.1.6 Flush Grinding of Smooth merging of Drawing Drawing Inspection Supervisor & QC H S S S
Inside Welding surface with shell Request (Form Inspector
Penetration. surface. no MSF 012)
6.1.7 10% RT on Shell long Absence of Internal PG/NDE/RT/004 API 650, RT Report Level II Inspector, QC H R R R
seam joints. defects. API 650, GS EP PG/NDE/RT/004, GS (Form No Inspector
PVV 211 Rev: 06 EP PVV 211 Rev:06 & MSF/014)
& GS EP PVV 611 GS EP PVV 611 Rev:06
Rev:06
6.1.8 100% RT on Manhole Absence of Internal PG/NDE/RT/00 API 650, RT Report Level II Inspector, QC H R R R
long seam joints. defects. API 650 PG/NDE/RT/00 Inspector
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6.1.10 Identification, As per drawing Drawing, Drawing, Inspection Supervisor & QC H R R R
marking & cutting dimensions within API API 650 Request & Inspector
and weld preparation tolerances. Material
of nozzle neck, flange Summary
& fittings. sheet
6.1.11 Manhole nozzle and As per drawing API 650 Drawing, API 650 Inspection Supervisor & QC H S S S
other Nozzle neck dimensions within request Inspector
with W.N flange fit up tolerances.
(for all nozzle)
6.1.12 Welding of Manhole Welding per WPS WPS, list of API 650 Weld Visual Supervisor & QC H S S S
nozzle and other and Qualified qualified welders Request Inspector
nozzle neck with welders. and approved
flange. Weld Map.
6.1.13 100% visual Absence of defects Drawing API 650, Drawing API 650 Inspection Supervisor & QC H S S S
inspection on & all relevant & PG/NDE/VT/00 & PG/NDE/VT/00 Request Inspector
Manhole nozzle neck drawing dim.
and other Nozzle
neck with Flange
welds.
6.1.14 Flush Grinding of Smooth merging of Drawing Drawing Inspection Supervisor & QC H S S S
Inside Welding surfaces Request Inspector
Penetration
6.1.15 10% RT on Nozzle Absence of Internal PG/NDE/RT/00, API 650, RT Report Level II Inspector, QC H R R R
with flange for above defects. API 650, PG/NDE/RT/00, Inspector
NPS 10 on circular
seam joints.
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6.2.16 Closing Seam Fit Up As per drawing Drawing, API 650 Drawing, API 650 Inspection Supervisor & QC H W W R
dimensions within Report Inspector
tolerances
6.2.17 Welding & Closing Welding per WPS WPS, list of API 650 Weld Visual Supervisor & QC H S S S
Seam and Qualified qualified welder Request Inspector
Welders sand approved
weld map
6.2.18 Weld Visual Weld Quality to Drawing, API 650 Drawing, API 650 & Inspection Supervisor & QC H S S S
Inspection 100% meet Code & PG/NDE/VT/00 PG/NDE/VT/00 Request Inspector
requirement
6.2.19 10% Radiography for Absence of internal PG/NDE/RT/00, API 650, RT Report Level II Inspector, QC H R R R
Circular seam welding defects API 650 PG/NDE/RT/00 Inspector
6.2.20 Spot RT on all Long Absence of Internal PG/NDE/RT/00, API 650, RT Report Level II Inspector, QC H R R R
seam and circular defects API 650 PG/NDE/RT/00 Inspector
seam intersecting
location. (100% "T"
section/ "+" Section
6.2.21 100% MPT on all Weld Quality to PG/NDE/MT/00 API 650, MPT Report Level II Inspector H W R R
Category "D" Joints meet Code API 650 PG/NDE/MT/00
Requirement
6.2.22 Pneumatic testing of Integrity of welds Proc# Proc# PG/PRTST/00 Inspection QC Inspector H W R R
R.F. pad Nozzles at and leak PG/PRTST/00 Report
1.0 Barg
6.3 External Attachment
6.3.1 Fit up of saddle As per drawing WPS, list of API 650 Weld Visual Supervisor & QC H S S S
support with Vessel dimensions qualified welders Request Inspector
and approved
weld map
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6.3.2 Welding of saddle Welding per WPS WPS, list of API 650 Weld Visual Supervisor & QC H S S S
support with Vessel and Qualified qualified welders Request Inspector
Welders and approved
weld map
6.3.3 100% Visual Absence of Defects Drawing API 650 Drawing API 650 & Weld History Level II Inspector/ H S S S
Inspection & PG/NDE/VT/00 PG/NDE/VT/00 Sheet QC Inspector
6.3.4 Fit up lifting lugs, Ad per drawing WPS, list of API 650 Weld Visual Supervisor & QC H S S S
Name plate bracket, dimensions qualified welders Request Inspector
external attachment and approved
and internal weld map
attachment
6.3.5 Welding of lifting Welding per WPS WPS ,list of API 650 Weld Visual Supervisor & QC H S S S
lugs, Name Plate and Qualified qualified welders Request Inspector
bracket, External & Welders and approved
Internal attachment weld map
6.3.6 100% Visual Absence of defects Drawing, ASME Drawing, API 650 & Weld History Level II Inspector/QC H S S S
Inspection of external Section V Article 9 PG/NDE/VT/00 Sheet Inspector
& Internal &
Attachment PG/NDE/VT/006
6.3.7 100% U.T. and MPT Absence of Internal ASME Section V, API 650, UT Report Level II Inspector/QC H W R R
on lifting lug welding defects PG/NDE/UT/00 & PG/NDE/UT/00 & Inspector
PG/NDE/MT/00 PG/NDE/MT/00
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6.3.8 100% MPT on all Absence of defects PG/NDE/MT/00 API 650, Appendix 6, MPT Report Level II Inspector/QC H W R R
external attachments ASME Sec V PG/NDE/MT/00 Inspector
welds with Pressure Article 7
Parts, Arc Strikes and
temporary
attachments removal
area
7.0 Final Dimensional, Visual Inspection and preparation for Hydro-Test
7.1 Flush Grinding of All Smooth merging of Drawing Drawing Inspection Supervisor & QC H S S S
Inside Welding surfaces Request Inspector
Penetration
7.2 Final Dimensional, Dimension Check, Drawing API 650 Drawing API 650 & all Weld History QC Inspector H W W W
Visual Inspection Free of visual defect related NCRs closed, Sheet/
before internal Trial and distortion all hot work Dimensional
assembly completed Inspection
Report
7.3 Trial assembly Dimension, Drawing Drawing Inspection Project Engineer/QC H W S S
internals Location, Report Inspector
Orientation
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7.4 Weighing of Vessel Final Weight of Drawing Horizontal lifting and Inspection Project Engineer/QC H W W W
vessel with full weight within design Report Inspector
internal limits and hook load
arrangements specified
7.5 Dismantling of all Removal of all Drawing Drawing - Project Engineer H - - -
internal items and internal
insulated parts attachments
8 Pressure Test for 4903F
8.1 Hydro test @required The integrity of API 650& Proc# Shall not be any leak Pressure Test Supervisor & QC H H H H
pressure in Vertical vessel PG/PRTEST/00 @ test pressure Report Inspector
position.
8.2 Draining of hydro test Proper venting, Proc# Proc# PG/PRTEST/00 - Project H S S S
water complete draining. PG/PRTEST/00 Engineer/Supervisor/
QC Inspector
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9 Final Dimensional Inspection
9.1 Dimensional Dimensional Check Drawing, API 650 Drawing API 650 Weld History QC Inspector H W R R
inspection after the Sheet/
completion of Hydro Dimensional
test Inspection
Report
10 Fixing of ASME Name
Plate & Signing of
MDR
10.1 Name Plate Code As per Drawing Drawing & API Drawing & API 650 Name Plate/ QC Inspector & AI H - H R
Stamping 650 Photograph
10.2 Name Plate As Per Drawing Drawing API 650 Drawing API 650 - QC Inspector & AI H - H R
attachment vessel
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10.3 Manufacturer's Data Prepared per API 650 & as Built API 650 Manufacturer' Quality Engineer & H R H R
Report requirement of API Dimensions s Data Report AI
650
11.0 Release Note
11.1 Acceptance, Contractual Drawing, API 650 Drawing, API 650 Final Quality manager H H H H
Inspection and requirements Acceptance/
Release Note fulfilled Release Note
12.0 As Built Dossier
12.1 As Built Dossier and All Required Tests Contractual Contractual Manufacturer Quality manager H H H H
Records completed, all NCRs requirement requirement and API Data Dossier
closed out, all 650 (MDD)
required
documentation
collated