pcp mmc qac fqp ug 010022

PROJECT STORAGE TANK'S FOR PENGERANG COGEN POWER PLANT DOC. NO AK/QA/FQP/015C/009-001

OWNER PETRONAS RAPID REV. NO 1

DISCIPLINE DATE 27 AUG 2015

1.0 Pre Fabrication

1.1

1.2 Test plate welding-Check the test coupon preparation

1.3 Visual Inspection- To do the completed weldment visual inspection

1.4

AKRA ENGINEERING SDN BHD

FIELD QUALITY PLAN

TANK FABRICATION & ERECTION

ITEM

NO.ACTIVITY

REFERENCE /

ACCEPTANCE CRITERIAVERIFYING DOCUMENTS

STAGE/

FREQUENCY

INSPECTION POINTS

REVISION

Approved WPS &

ASME SEC IXWelder Qualification List Before Start Work H, R, V

AKRA MMCES CLIENT

ASME SEC IX WPS Before Start Work R

Non Destructive Examination - Radiographic testingASME SEC IX

Radiography Test report & After Visual I, V

Approved WPS &

ASME SEC IXVisual Inspection Report

After test coupon

weldedH, R, V

To review all Welding Procedure Specification (WPS) and Procedure

Qualification Records (PQR)

1.4

-To check the internal defect of weldment

2.0 Material Control

2.1

2.2

3.0 Tank Fabrication Works

3.1 Bottom Plate & Annular Plate

3.2 Shell Plate

3.3 Roof Plate

3.4 Nozzle, Manhole, Reinforcement Pad and Sump

3.5 Roof Structure & Truss

4.0 Foundation Inspection

4.1 Levelness and Flatness

Non Destructive Examination - Radiographic testingASME SEC IX

Radiography Test report &

Qualified Welder List

After Visual

InspectionI, V

- Visual Inspection to ensure the material are in good condition as per

Welding Consumables

Approved WPS Material Inspection Report &

Electrode issue formsBefore welding I, R, V

Material Receiving Inspection of Bottom Plates, Annular Plate,Shell

Plate, Roof Plate & Stural MaterialAFC Drawing, Mill Certificate

& Delivery Order (DO)

Material Inspection Report&

Mill Certificates

Upon receiving

materialI, R, V

- To perform dimensional check after marking

AFC Drawing & Approved

Fabrication ProcedureDimensional Report

Before cutting

workI, R, V

- To check the electrode as per specification

- To Maintain the electrode backing register



Before cutting

workI, R, V



Fabrication Procedure

Dimensional Report, Fit up,

Visual & NDT

Before cutting

workI, R, V




Before cutting

workI, R, V

- To perform dimensional check after marking and welding

AFC Drawing, API 650 Foundation Levelness Report Before laying

annular plateI, R, V



Fabrication Procedure

Dimensional Report, Fit up,

Visual & NDT

Before cutting

work and after

welding

I, R, V

- To check levelness and flatness on final surface of tank foundation

Page 1 of 8

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FIELD QUALITY PLAN


ITEM

NO.ACTIVITY

REFERENCE /


STAGE/

FREQUENCY

INSPECTION POINTS

REVISIONAKRA MMCES CLIENT

4.2 Orientataion Marking

5.0 Tank Erection Works

5.1 Material

- Material Identification

52 Annular Plate

5.2.1

- To check tank centre, 0, 90,180, 270 orientations

Fit-up InspectionWelding Summary Sheet

Before/After

plate layingI, R, V

AFC Drawing, API 650Checking at site and Survey

Record

Before tank

erectionI, R, V

MVR & Material Identification

Record

5.2.2

5.2.3

5.2.4

5.2.5

5.3 Bottom Plate & Centre Sump

5.3.1

5.3.2

5.3.3

Welding Summary Sheetplate laying

I, R, V

AFC Drawing, Approved

WPS, Approved Erection

Procedure & API 650

- To check start point for annular plate laying & fit-up inspection

Weld MonitoringMonitoring at site

During welding

worksS

- To do the daily monitoring of welding work at site

Visual InspectionWelding Summary Sheet

After completion

of weldingI, R, V

After Visual

InspectionH, W, R, V

- To do the completed weldment visual inspection

Non Destructive Examination - Ultrasonic testingAFC Drawing, Approved

WPS, Approved NDT

Procedure & API 650

Ultrasonic Test reportAfter Visual

InspectionH, I, R, V

- To do the leak test on all annular plate weld joints

Before/After

plate layingI, R, V


Visual InspectionVisual Report

After completion

of weldingI, R, V


During welding

worksS



Procedure & API 650

- To check orientation of 1st bottom plate laying- To check lapping of bottom plate to bottom plate & annular plate


- To check the Internal Shell plate to head lapping - To check the Centre sump installation as per AFC drawings

Fit-up Inspection

Fit up Report

- To do the 50% of total radial annular plate weld joints

Vacuum Box testing AFC Drawing, Approved

Erection Procedure & API 650 Vacuum Box Test report

Page 2 of 8





FIELD QUALITY PLAN


ITEM

NO.ACTIVITY

REFERENCE /


STAGE/

FREQUENCY

INSPECTION POINTS


5.3.4

5.4 Shell Plate

5.4.1

5.4.2



After Visual


S

- To check orientation of 1st shell plate installation

- To check the joint preparations

- To check the joint misalignment

- To do the leak test on all bottom plate weld joints

Fit-up Inspection

Fit up Report

After complete

installation of

shell plate course

by course

H, I, R, V

AFC Drawing, Approved Weld MonitoringMonitoring at site

During welding 5.4.2

5.4.3

5.4.4

5.4.5

5.4.6

5.4.7

5.4.8

S

Before & After

weldingH, I, R, V


Oil Penetrant testingOil Penetrant Test Report

1st layer weld on

annular plate to

shell plate

H, I, R, V



Procedure & API 650 - To do the daily monitoring of welding work at siteVisual Inspection

Visual ReportAfter completion

of weldingI, R, V


During welding

works

- To check the shell plate joint curvature

Non Destructive Examination - Dye Penetrant TestingAFC Drawing, Approved

WPS, Approved NDT

Procedure & API 650

DPT ReportAfter Visual

InspectionW, V

Local deviation check - Peaking & BandingPeaking & Banding Report

Before & After

weldingH, I, R, V


Erection Procedure & API 650

- To check levelness after 1st course erection- To check the roundness after 1st course erection- To check the plumbness before and after every course erection

Levelness , Plumbness & RoundnessLevelness , Plumbness

& Roundness Report

-To check the surface defect of shell to annular plate external weldment

Non Destructive Examination - Radiography testingAFC Drawing, Approved

WPS, Approved NDT

Procedure & API 650

Radiography Test reportAfter Visual

InspectionV

-To check the internal defect of weldment on shell plate weld joints

- To detect leakage on internal weldment of annular plate to shell plate

Page 3 of 8





FIELD QUALITY PLAN


ITEM

NO.ACTIVITY

REFERENCE /


STAGE/

FREQUENCY

INSPECTION POINTS


5.5 Top Angle

5.5.1

5.5.2

5.5.3

During welding

worksS


Visual Inspection



Procedure & API 650

Fit-up InspectionFit up Report Before welding I, R, V

- To check fitup of inspection of top angle to 8th course shell plate


5.5.3

5.5.4

5.6 Shell Nozzle, Manhole, Reinforcement Pad & Repad to Shell

5.6.1

5.6.2

5.6.3

5.6.4

5.6.5

Visual Inspection



Procedure & API 650

After completion

of weldingI, R, V

- To check surrface defect of weld top angle To shell plate & top angle to

top angle.

Orientation Check Fit up Nozzle & Manhole

ReportBefore welding I, R, V



Procedure & API 650

During welding

worksS


- To check the orientation of nozzle installation as per AFC drawingFit-up Inspection

Fit up Nozzle & Manhole

ReportBefore welding I, R, V- To check the nozzle installation as per AFC drawings


Visual Inspection Approved WPS, Approved


Visual Nozzle & manhole

Report

After completion

of weldingI, R, V


-To check the surface defect of shell to annular plate external weldment

Non Destructive Examination - Magnetic Particle / Dye Penetrant Testing After Visual

InspectionW, V


NDT -MT/DPT

Visual Report

NDT Report

- To check the surface defect of weld nozzle neck To shell plate &

manhole neck To shell plate & reinforcement pad To shell


WPS, Approved NDT

Procedure & API 650

DPT Report

Weld MonitoringApproved WPS Monitoring at site

Page 4 of 8





FIELD QUALITY PLAN


ITEM

NO.ACTIVITY

REFERENCE /


STAGE/

FREQUENCY

INSPECTION POINTS


5.6.6 API 650

5.7 Roof Structure & Truss

5.7.1

5.7.2


Air leak test- Reinforcement PadAir Leak Test report

After Visual


- To detect leakage on weldment using soap solution




Procedure & API 650

- To check the truss bracket attached to shell installation


During welding

worksS

5.7.3

5.7.4

5.8 Roof Plate

5.8.1

5.8.2

5.8.3

5.8.4



Bolt tightening check AFC Drawing, Approved

Erection Procedure & API 650 Bolt Tightening Report

Before laying

Roof PlateW, R, V

Procedure & API 650


After completion

of weldingI, R, V

-To check all the bolt joint have been fully tightened

works

- To check lapping of roof plate to roof plate & crown plate


During welding

worksS






After Visual

InspectionH, 'W, V



Procedure & API 650


After completion

of weldingI, R, V

- To do the leak test on all roof plate weld joints

Page 5 of 8





FIELD QUALITY PLAN


ITEM

NO.ACTIVITY

REFERENCE /


STAGE/

FREQUENCY

INSPECTION POINTS


5.9 Roof Nozzle & Manhole

5.9.1

5.9.2

5.9.3

Orientation Check Nozzle & Manhole Fit up

ReportBefore welding I, R, V

Fit-up InspectionNozzle & Manhole Fit up

ReportBefore welding I, R, V- To check the nozzle installation as per AFC drawings



During welding

worksS



Procedure & API 650

- To check the orientation of nozzle installation as per AFC drawing

5.9.4

5.9.5

5.10 Permanent Bracket to Shell

5.10.1

5.10.2

5.10.3

5.10.4

5.10.5

- To check the orientation as per AFC drawing

Monitoring at siteworks

S



After completion

of weldingI, R, V


Orientation Check AFC Drawing, Approved

Erection Procedure & API 650 Fit up Report Before welding I, R, V

Non Destructive Examination - Dye Penetrant TestingAFC Drawing, Approved


Procedure & API 650

DPT ReportAfter Visual

InspectionW, V


Visual InspectionVisual Inspection Report

After completion

of weldingI, R, V

- To check the installation as per AFC drawings- To check the joint preparations


During welding

worksS




Procedure & API 650


-To check the surface defect of shell attachment external weldmentNon Destructive Examination - Dye Penetrant Testing AFC Drawing, Approved NDT

Procedure & API 650 DPT Report

After Visual

InspectionW, V

Page 6 of 8





FIELD QUALITY PLAN


ITEM

NO.ACTIVITY

REFERENCE /


STAGE/

FREQUENCY

INSPECTION POINTS


6.0 Tank Hydrotesting

6.1 Pretest check list

6.2 Internal Bottom Plate Settlement

6.3 Water Filling & Discharging

6.4

- To measure at max.3m interval on diametrical line across the tank

Pre Test Check List Before water

fillingI, R, V

- To ensure all the tank attachment welds are completed

Monitoring at site During

hydrostatic testW

Tank Bottom settlement

Report

Before

hydrostatic testH, I, R, V


- To check filling & discharging rate as per API 650

- To ensure roof nozzle & manhole in open positionVisual Inspection & observation

Visual Check at site During

H6.4

6.5

7.0 Tank Painting Works

7.1 Paint Material

7.2 Surface preparation

- After the tank has been emptied

Material Inspection Report &

Paint Batch Certificate

Upon receiving

materialI, R, V



Settlement reading shall be taken as below mentioned intervals- Before start hydostatic test- With tank filled with 25% test height- With tank filled with 50% test height- With tank filled with 75% test height- With tank filled with 100% test height

- To do the visual check & observation on weldments for any leaksTank settlement Monitoring - Before, during & after hydrostatic test

Tank settlement Report &

Hydrostatic test report

Before , During &

After hydrostatic

test

Visual Inspection & observationVisual Check at site

During

hydrostatic test

- To ensure the surface cleanliness of plate & weld profile as per

Manufacturer data or specification

- To ensure approved paint material used as per specification

Blasting & Painting Report Before start

paintingI, R, V

H, I, R, V

H

Page 7 of 8





FIELD QUALITY PLAN


ITEM

NO.ACTIVITY

REFERENCE /


STAGE/

FREQUENCY

INSPECTION POINTS


7.3 Steel Temperature & Relative Humidity

7.4

7.5

Blasting & Painting Report Before start

paintingI, R, V

- To do the visual check of blasted surface & DFT checking

Visual Inspection & DFT check

Petronas Technical

Standard,

Manufacturer data and

specification & Approved

Blasting Painting Procedure

- To check Steel Temperature as per Manufacturer data or specification

- To check Relative Humidity as per Manufacturer data or specification

Blasted SurfaceBlasting & Painting Report

After blasting

workI, R, V

7.5

Remarks

I - Inspection R - Generate Record V - Verification of Record W - Witness of Inspection/Test H - Hold on Inspection/Test S - Surveilance/Spot Check

Prepared by : AKRA Reviewed by : AKRA Reviewed & Approved by : MMCES

Name : Khairul Anuar Name : Rosnizam Name :

QA/QC Engineer Project Manager

- To do the visual check of painted surface as per Manufacturer data or

specification

- To carry out the DFT check of painted surface as per Manufacturer data

or specification

Visual Inspection & DFT check

Blasting & Painting Report After painting

worksI, R, V

Page 8 of 8

DOC110915-11092015155145FQP rev.1

pcp mmc qac fqp ug 010022

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