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Teach Yourself Electricity and Electronics

2011-08-16T13:22:00.000+08:00

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CONTROL PANEL (ELECTRICAL ) INSPECTION PROCEDURE

2010-01-11T16:49:00.001+08:00

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*author: theprocedure@engineer.com

WARNING :
POWER SUPPLIES INTO THE PANEL MAYBE GREATER THAN 24VOLTS. CARE MUST BE TAKEN NOT TO TOUCH LIVE PARTS OR CAUSE A SHORT CIRCUIT WITHIN THE PANEL IF WORK IS CARRIED OUT WHILST THE PANEL IS "LIVE".

1. INSPECT EXTERNALLY AND INTERNALLY FOR CORROSION AND DAMAGE.
2. ENSURE THE PANEL IS INTERNALLY CLEAN.
3. CHECK THAT ALL COMPONENTS ARE SECURE AND CARDS ARE SECURELY
CLIPPED IN PLACE.
4. VISUALLY CHECK CONDITION OF INDICATORS , CONTROLLERS
AND ANNUNCIATORS.

5. IF "LAMP TEST" FACILITY IS PROVIDED CHECK THAT LAMPS
    ILLUMINATE CORRECTLY. REPLACE FAULTY LAMPS .
6. VISUALLY CHECK TERMINALS AND CONDITION OF INTERNAL WIRINGS.
7. CHECK CABLE GLANDS FOR TIGHTNESS.
8. IF VENTILLATION FANS ARE FITTED , CHECK THE FANS OPERATE
    CORRECTLY ANY ASSOCIATED AIR FILTERS ARE CLEAN AND
    NOT BLOCKED.

9. CHECK THAT THE PANEL ROOF IS CLEAN AND CLEAR OF
FOREIGN MATERIALS.

10. ENSURE THAT THE DOORS CLOSE CORRECTLY AND LATCH.
11. IF INTERNAL LIGHT FITTINGS ARE PROVIDED CHECK THAT
THESE FITTINGS ARE "ON" WHEN THE DOORS ARE OPEN.

CALIBRATE AIR / GAS ACTUATED BALL VALVE

2010-01-11T16:25:00.001+08:00

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THE FUNCTIONAL TEST MUST BE DONE IN THE PRESENCE AND ASSISTANCE OF OPERATION PERSONNELS.

1) ACTUATOR

a. INSPECT FOR CORROSION AND DAMAGE.

b. CHECK TIGHTNESS OF LOCK NUTS ON STROKE ADJUSTING RODS.

- ENSURE NOT TO CHANGE LENGTH OF STROKE.

c. CHECK THAT THE BREATHER ON THE END OF THE RETURN SPRING CYLINDER IS NOT

BLOCKED.

d. CHECK OPERATION OF ACTUATOR AS FOLLOWS:

NOTE:

BEFORE OPERATING THE ACTUATOR ENSURE THAT THE PROCESS IS NOT IN

OPERATION AND THAT IS IN SAFE TO OPEN AND CLOSE THE BALL VALVE.

i) CHECK THAT THE AIR/GAS PRESSURE LINE TO THE ACTUATOR IS DE-PRESSURISED

AND DISCONNECT AT ACTUATOR.

ii) CONNECT CONTROLLABLE AIR/GAS SUPPLY OF 0 TO 7 BARG TO THE ACTUATOR.

iii) RAISE AND LOWER THE AIR/GAS PRESSURE TO THE ACTUATOR A FEW TIMES. THE

PISTON STROKE STOPS SHOULD PREVENT HAMMERING OF THE VALVE STOPS.

e. IF THE PISTON STOPS REQUIRE ADJUSTMENT PROCEED AS FOLLOWS :

i) ALLOW THE RETURN SPRING TO OPERATE THE VALVE.

ii) CHECK THAT THE VALVE STEM BRACKET JUST MATES WITH THE STOP BY

SCREWING IN THE PISTON STOP ROD UNTIL THE BRACKET.

JUST LIFT OFF THE STOP AND LOCK THE ADJUSTMENT ROD BY LOCK NUT.

iii) APPLY AIR/GAS PRESSURE SLOWLY TO THE CYLINDER AND ALLOW THE VALVE

TO BE DRIVEN FULLY TO OTHER POSITION.

iv) CHECK THAT THE PISTON STOP ROD PREVENTS THE VALVE STOP BRACKET

FROM STRIKING THE STOP SCREW. IF NECESSARY , ADJUST THE STROKE BY THE

ADJUSTMENT ROD LOCATED AT THE END OF THE RETURN SPRING HOUSING.

v) CYCLE THE VALVE OPEN AND CLOSED SEVERAL TIMES TO STABILISE THE

STROKE ADJUSTMENT AND RECHECK THE STROKE.

f. WHILST CARRYING OUT THE ACTUATOR OPERATIONAL CHECKS AS PER ITEM d . IF

THE AIR/GAS ESCAPES FROM THE VENT IN THE SPRING HOUSING WHEN THE PISTON

IS STATIONARY,THE PISTON REQUIRES REPLACEMENT .

g. ENSURE THAT THE LUBRICATOR IS 3/4 FULL OF CLEAN OIL.

h. RECONNECT THE AIR/GAS OPERATING LINE .

i. CHECK FOR AIR/GAS LEAKAGE , WHEN THE SYSTEM IS IN PRODUCTION

2. BALL VALVE
    a. INSPECT FOR CORROSION AND DAMAGE.
    b. CHECK FOR LEAKS AROUND THE VALVE WHILST IN NORMAL OPERATING
        CONDITIONS .
    c. IF THE VALVE IS LEAKING AROUND THE STEM , PROCEED TO TIGHTEN REPLACE
        STEM SEALS.
    d. CONTROL THE VALVE SEAT LEAKAGE , WHEN IT IS CLOSE.
       NOTES:
       i)   RECORD ANY ERROR / FAULTS IN MAINTENANCE SYSTEM.
       ii) ALL THE DEFECTS MUST BE ELIMINATED AND THE VALVE SET IN
            SERVICES ARE FREE OF FAULTS.
       iii) CONSULT THE PRODUCT TECHNICAL MANUAL FOR MORE ADDITIONAL
            INFORMATION.
       iv) LET THE SUPERVISOR KNOW OF ANY ABNORMAL FINDINGS.

MATERIAL IDENTIFICATION AND MARKING PROCEDURE

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1.1 SCOPE

This specification describes the requirement of material identification and marking procedure.

2.0 MATERIAL IDENTIFICATION AND MARKING

2.1 The material identification shall be carried out in order to :-

i) Confirm that the material to be used shall comply with the Mill Certificate.

ii) Identify the individual primary component (i.e. shell plate, roof plate and bottom plate) so that it can be traced back to the Mill Certificate later after shop fabrication. This shall be documented in the Inspection Record.

2.2 The following identification mark shall be used :-

i) Mill marking which consists of heat number, size, plate number, etc. This marking shall be stenciled or stamped on the material by the Mill.

ii) Code marking which consists of tank number, drawing number, part number and serial piece number. The code marking shall correspond to the Mill Certificate as documented in the Inspection Record.

CALIBRATION OF TEST INSPECTION TOOL CONTROL PROCEDURE

2009-12-24T15:39:00.001+08:00

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TABLE OF CONTENTS

1.SCOPE

2.REFERENCES

3.RESPONSIBILITIES

4.PROCEDURE

4.1 CALIBRATION

4.2 REGISTRATION

4.3 DOCUMENTATION

1.0 SCOPE
To provide procedure guidelines for controlling calibration test and inspection tools to be used for inspection at the construction of The EPCC of Two (2) nos. of Storage Tanks.

2.0 REFERENCES
Field Inspection Procedure QA/QC Requirements for Subcontractors Control of Measuring and Test Equipment Specification for Pressure Testing of Piping.

3.0 RESPONSIBILITIES

      3.1 Site Manager Shall be responsible for the full implementation and administration of this procedure
      3.2 QC Manager Shall be responsible for ensuring that all personnel involve are indoctrinated about this procedure.
      3.3 QA Engineer Shall Check and monitor the calibration and registration of testing tools and equipment necessary for the conduct of inspections in accordance with this procedure. Shall record and file all documents pertaining to the calibration certificate and registration of Testing / Inspection Tools.

4.0 PROCEDURE

      4.1 Calibration
          1) Equipment that needs to be calibrated shall be sent to a calibration Agent equipped with laboratory facilities for conduction calibration of inspection and test equipment except for equipment that can be calibrated on site.
          2) All equipment tests shall be designated with a controlled serial number which shall be engraved on the equipment. A calibration label shall be attached to the equipment which shall contain the serial no, registration no. frequency of calibration and date of calibration
          3) Calibration frequency of each equipment shall be subject to change according to the manufacturer’s instruction, frequency of use and adjustments mode during calibration.
          4) The control of deficient measuring and test equipment shall be controlled in accordance with Client requirement.
      4.2 Registration
         All equipment for measuring and testing to be used shall be submitted to the Contractor for registration. The ‘Equipment Calibration Registration Record’ shall be filled up and registry of the necessary information made before submission together with the calibration certificate.
      4.3 Documentation
        Registration of equipment in accordance with the Contractor’s procedure shall be documented using the ‘Equipment Calibration and Registration Record’. The record shall be filed together with calibration certificates and manufacturer’s instructions in a manner for easy filling and retrieval.

REPAIR PROCEDURE FOR TANK

2009-12-20T17:29:00.003+08:00

*note: this is the sample document for the related job only

*author: theprocedure@engineer.com

TABLE OF CONTENTS
1. INTRODUCTION
2. PURPOSE
3. SPECIFICATION
4. APPLICABLE CODE / STANDADR
5. METHOD AND INSPECTION
6. SAFETY
7. REFERENCES & OTHER SUPPORTIVES DOCUMENT - LIST OF WPS & PQR - LIST OF WQT ( WELDER LIST )

REPAIR PROCEDURE
1. INTRODUCTION
This repair procedure is required for grind off and / or perform weld repair on minor defect such as Cluster Porosity, Slug, Under Cut, Arc Strike, Spartter and etc. which have been found during visual inspection and / or found by NDE.

2. PURPOSE
The purpose of this work is as follow: To grind off all the defect, at the defect area base on the report and / or marking area and carry out visual inspection and follow by NDE, examination such as MPI / DPT To perform welding at the defect area after grinding ( surface preparation ) and carry out NDE such as MPI, DPT or RT
3. SPECIFICATION
As per Owner / Client requiment or NDE report.

4. APPLICABLE CODE / STANDARD
The welding and NTD works are to be carried out and in accordance with the following:
i) ASME VIII DIV 1 - UW 42 “Surface Weld Metal Build Up” - Appendix 6 “Method For Magnetic particle Testing” - Appendix 8 “Method For Liquid penetrating Testing”
ii) ASME IX - Welding And Brazing Qualification iii) ASME V - Nondestructive Examination

5. METHOD & INSPECTION
5.1) Mark the defect area to grind off accordingly by appointed inspector and base on NDE (RT, MPI or DPT) report.
5.2) Grind off the defect until meet the sound metal and perform NDE to confirm the has been removed from the respective shell area for welding surface preparation.
5.3) Perform surface preparation before performing weld build up.
5.4) Ensure that area is free from Oil, Grease, Water or any other foreign material
5.5) Proceed weld build up by qualified welder, WPS No as per requiment refer to Welding Qualification. 5.6) Perform NDT upon completion of weld build up on the defect / marking area.
5.7) If the result of NDE is unacceptable remove the defect by grinding and repeat NDE to ensure it is completely removed.
5.8) If the result of NDE is acceptable, carry out the Visual Inspection and request for RT to confirm the weldment are free from and indication / defect.

6. SAFETY
6.1) All condition stated on job safety analysis (JSA) must complied with permit to work (PTW).
6.2) All personal working at job site shall be informed to the safety awareness by attending the safety induction or safety tools box meeting conducted by safety prior to commencing of work.
6.3) Full PPE is ensured whilst working at site.
6.4) Refer to safety requirement.

7. REFERENCES & OTHER SUPPORTIVE DOCUMENT
7.1) WPS & PQR – To be Advice
7.2) WQT List or Welder list – To be Advice

PRESSURE TEST PROCEDURE FOR PIPING SYSTEM

2009-12-20T17:15:00.002+08:00

*note: this is the sample document for the related job only

*author: theprocedure@engineer.com

TABLE OF CONTENTS

1.   SCOPE
2.   REFERENCES
3.   GENERAL REQUIREMENTS
4.   PNEUMATIC TEST
5.   EQUIPMENT FOR HYDROSTATIC TEST
6.   PREPARATION OF THE TEST PACKAGE
7.   LIMITATION, EXCEPTIONS AND EXCLUSIONS
8.   FIELD PREPARATION
9.   PERFORMANCE OF PRESSURE TEST
10. EVALUATION OF TEST RESULTS
11. REPORT / DOCUMENTATION
12. REINSTATEMENT
13. ATTACHMENT 1 (TEST MANIFOLD)

1.0 SCOPE
1.1 This procedure covers the minimum requirements and plans for field pressure test of piping system for

          The EPCC of Two (2) nos additional crude Storage Tanks.

2.0 REFERENCE
   2.1 ANSI / ASME B31.3 - Chemical Plant and Petroleum Refinery Piping

3.0 GENERAL REQUIREMENT
   3.1 All piping lines shall be hydrostatic tested, but however, lines which where indicated in the line list may

be service test.
3.2 All lines which were indicated as a tie-in joint need to do 100% NDT such as RT, MPI or DPT and

carry out the service test.
3.3 The minimum test pressure shall be as specified in each piping Iso drawing or pressure test flow

diagram based on ANSI / ASME B31-3 requirement.
3.4 Test medium shall be fresh water, which clean and free from silt or un dissolved solids of any

description.
3.5 Test medium for austenitic stainless steel piping the water shall not contain more than 30 ppm chloride

10N.
3.6 All the equipment and lines, which are to be tested along with the piping, shall be blanked off or

replaced with temporary spool pieces. Any test along the said item shall be approved by Contractor.
3.7 All pressure gauge and pressure recorder used for the test shall be calibrated and registered in

accordance with Calibration of Test/ Inspection Tools Control Procedure. Each certificate shall be

valid for a period of three (3) months. Pressure gauge shall be selected so that the test pressure of the

system falls between 30% and 75% of the gauge scale range. The following in line items will not be

          subjected to Field Pressure Testing:-
       1) Elements of strainers and filters
       2) Pressure relieving devices such as rupture disc, pressure valves etc.
       3) Locally mounted pressure gauge.
       4) Pressure measuring and regulating items such as flow control valves, turbine meters etc.
       5) Equipment like pumps, hose reels etc.
       6) Lines directly open to the atmosphere such as vents drains, safety valves, discharge etc. (conformation

is required from Contractor)

4.0 PNEUMATIC TESTS
4.1 Pneumatic test may be applied for certain lines and test pressure shall be 110% of design pressure as

specified in each piping Iso drawing and / or pressure test flow diagram as per ANSI / ASME B.31-3

requirement 345.5.4.
4.2 The pressure shall be increased gradually until a gauge pressure which is the lesser of ½ the test

pressure or 25 psi (170kpa) is attained and held for 10 minutes, at which time a preliminary leak check

shall be made with soap solution on all joint. The pressure shall be increased in steps of 25%, 50%

and 75% of the test pressure. At each step the pressure shall be held for sufficient time to allow the

piping to equalize strains. After holding at test pressure for 10 minutes, the pressure shall be reduced

to the design pressure for leakage examination. Leak testing of joints shall be done with soapy water.

Safety precautions shall be taken by placing a safety relief valve on the system under test.
4.3 The set pressure of the relief valve shall be set at a pressure not higher than the test pressure plus the

lesser of 50 psi (340kpa) or 10% of the test pressure

5.0 EQUIPMENT FOR HYDROSTATIC TEST
5.1 Equipment for hydrostatic test shall be properly designed and in good working order and shall be

compatible with the pressure and capacity required during the test.
5.2 The following equipment will be provided in order to conduct the hydrostatic test but not necessarily be

          limited to the following:-
       1) One high volume pump
       2) One portable tank to provide a source of pressurizing water
       3) One hand pump for pressurizing
       4) Pressure gauges and temperature gauges
       5) Pressure recorder
       6) Safety relief valve (only for pneumatic test)
       7) Test manifolds (if required)

6.0 PREPARATION OF TEST PACKAGE
   6.1 Prior to commencement the Field Hydrostatic Test the piping test package shall be prepared and

          submitted to the Client Inspector for review / approval.
   6.2 The following documents will be included in the test package:-
       1) Piping test package certificate
       2) Test block diagrams
       3) Signed off punch list
       4) Signed off Q.C check sheet
       5) Q.C Iso drawing
       6) Pressure Gauge calibration Records (calibration certificates)
   6.3 When the documents in test package are proper and approved by the Contractor. Line check shall be

          made in accordance with approved procedure prior to the test.
   6.4 All welds to be pressure tested shall be free of paint, thermal insulation coating and wrapping.

7.0   LIMITATION, EXCEPTIONS AND EXCLUSIONS
   7.1 Where the test pressure of piping attached to a vessel is the same as or less then the test pressure for the vessel, the piping may be tested with the vessel at the test pressure of the piping.
   7.2 Where the test pressure at the piping exceeds the vessel test pressure and it is not considered

practicable to isolate the piping from vessels, the piping and the vessels may be tested together at the

test pressure of the vessels, when approved by the owner, and provided the test pressure is not less

77% of the piping test pressure. (ASME B 31.3)(337.4.2)
7.3 The equipment or piping which is not subjected to the test shall be blinded off from the piping to be

          tested.

8.0   FIELD PREPARATION
   8.1 When the whole length of system to be tested is completely installed and boundaries are checked by

Subcontractor Q.C
8.2 Test manifold shall be provided in order to supply water to the system, install pressure gauge,

temperature gauge and safety relief valve.
8.3 Pressure gauge shall be provided at two points where one is to be located at highest location in the

system and the other at the manifold.
8.4 All test blanks required for pressure test shall have sufficient thickness to ensure safety during test or

          permanent blinds may be used for the field pressure testing.
   8.5 Prior to commencement of the hydrotest, all hot works shall be completed.

9.0   PERFORMANCE OF HYDROSTATIC
   9.1 All vents and other connections which can serve as pressure test vents, shall be open during filling so

that air can be vented prior to applying test pressure to the system.
9.2 The system shall be filled with fresh water by use of electrical or hand pressurizing pump until the

          intended pressure, slowly and gradually.
   9.3 While the system is being pressured all weld joints will be visually inspected for any leakage.
   9.4 Once attained, the intended test pressure shall be held for a period of 30 minutes minimum or such

time as required for full visual inspection of the system.
9.5 Any joints found leaking during the pressure test shall be retested to the specified test pressure after

repair have been made.
9.6 After hydrostatic testing of the system is completed, all lines and equipment shall be drained

completely. The system shall be vented while draining to avoid vacuum.
9.7 All pressure test must be witness and report to be endorsed by Client rep.

10 EVALUATION OF TEST RESULTS
10.1 If there is no leakage during the test it will be considered as accepted and test report to be

            endorsed by Client.

11   REPORT / DOCUMENTATION
   11.1 After pressure test, the pressure test records and the post-test punch items shall be signed off by

Subcontractor approved by Contractor and endorsed by PPM’s rep. All this documents shall be

           compiled into the Test package.

12   REINSTATEMENT
   12.1 After completion of hydrostatic test, all the system shall be reinstated as per the approved drawings.

WELDING MATERIAL CONTROL PROCEDURE

2009-12-20T16:52:00.002+08:00

*note: this is the sample document for the related job only

*author: theprocedure@engineer.com

TABLE OF CONTENTS

1. SCOPE
2. REFERENCE
3. RESPONSIBILITIES
    3.1 SITE MANAGER
    3.2 QC MANAGER
    3.3 QA ENGINEER
    3.4 QC INSPECTOR
4. WELDING MATERIAL CONTROL

1.0 SCOPE
This procedure shall outline the control of welding materials in welding works for the EPCC of Two (2)

Nos crude Storage Tank

2.0 REFERENCE
1) PTS 64.51.01.31 - STANDARD VERTICAL TANKS ERECTION & TESTING (Section 6.5 –

        Welding Consumables)
   2) IS/D-322 - FIELD INSPECTION & TESTING PROCEDURE
   3) IS/D-310 - MATERIAL CONTROL PROCEDURE
   4) KOBE / ESAB - MANUFACTURE RECOMENDATION

3.0   RESPONSIBILITIES
   3.1 Site Manager
           Shall be responsible for the full implementation of this procedure. He shall assign knowledgeable

           Material Controllers / Welding Foreman who will be able to distinguish all types welding consumables.
   3.2 QC Manager
           Shall be responsible for ensuring that all personnel involved are indoctrinated and shall assign

           personnel to conduct monitoring and audits for compliance to this procedure.
   3.3 QA Engineer
          Shall be responsible for Supervision of Inspection activities, monitoring and documenting

          inspection / monitoring activities.

    3.4 QC Inspector
          Shall inspect welding material control on daily basis and document any deviation from this procedure.

4.0 WELDING MATERIAL CONTROL
   4.1 All welding materials shall be received by the Material Controller / Welding Foreman. He shall check
          welding material condition, damage, material identification and batch / lot / heat / number. All welding
          materials received shall be accompanied by an Inspection Certification form manufacturer or supplier
        . The QA Engineer shall review the manufacturers inspection certificates for compliance to the
          specifications and if acceptable sign and stamp “Issued For Construction”. The certificate shall be
          submitted to contractor for review

   4.2 The Material Controller / Welding Foreman shall check that sufficient quantity is stored in baking /
          holding oven for daily use. The Material Controller / Welding Foreman shall issue as follows:
       1. Issue electrodes by priority,
           a. re-baked electrodes
           b. first baked electrodes
           c. new electrodes
       2. Check size and type of welding material to be issued
       3. Issued maximum quantity of 5kg for each portable oven
       4. For GTAW rods, original containers shall be issued.
            For stainless steels the container or welders quiver shall be clearly
            marked by paint or colored tape with the same color identification as
            given by the consumable manufacturer.
       5. Issue of portable oven marked with Welders no only to respective welders.
       6. Issues of consumables are to be recorded on Consumable Issue Report.

   4.3 The Material Controller / Welding Foreman shall monitor / check his welder’s portable oven (quivers)
          are plugged to power source all the time. At the end of the day, he shall gather all quivers and take to
          the welding material control room.

   4.4 After receiving all portable ovens the Material Controller / Welding Foreman shall place all segregated
           electrodes and place at top portion of baling oven and shall be issued first on the next day. Returned
           electrodes shall be re baked only once. There after they shall disposed of as scrap.

SHOP FABRICATION PROCEDURE

2009-12-17T13:31:00.002+08:00

*note: this is the sample document for the related job only

*author: theprocedure@engineer.com

TABLE OF CONTENTS

1.0 GENERAL
1.1 Scope
1.2 Drawing
1.3 Material
1.4 Welding
1.5 Inspection
1.6 Post Weld Heat Treatment
1.7 Painting

2.0 SHOP FABRICATION
2.1 Shell Plate
2.2 Roof Plate
2.3 Roof Structure
2.4 Top Angle and Stiffener
2.5 Manhole & Nozzle (Unit Fabrication)
2.6 Reinforcing Plate
2.7 Stairway, Ladder & Platform
2.8 Heater piping. (if any)
2.9 Other Accessories

3.0 Dimensional Tolerance
3.1 Shell Plate
3.2 Roof Plate
3.3 Roof Structure
3.4 Top Angle. Stiffener and top Birder
3.5 Nozzle and Manhole

1. GENERAL

1.1 Scope
This specification covers the requirement for shop fabrication of the EPCC of Two (2) nos additional crude Storage Tanks.

1.2 Drawing
All shop fabrication shall be carried out in accordance with WH fabrication drawings.

1.3 Material
All material shall comply with WH drawing and applicable CLIENT specification.

1.4 Welding
To submit all WPS and WQT for review and approved by 3rd Party Inspector (Dosh approved NDT)
All welding shall be carried out in accordance with approved Welding Procedure Specification. (Shop/Site)

1.5 Inspection
Inspection shall be carried out in accordance with Shop Inspection Procedure Specification.

1.6 Post Weld Heat Treatment
Post weld heat treatment shall not be required for this project.

1.7 Painting
Painting at shop shall be carried out in accordance with Painting specification.

2 SHOP FABRICATION

2.1 Shell Plate
Cutting and/or edge preparation shall be done with flame planer or automatic gas cutting and/or automatic beveling machine.
All damage such as pop-outs, deep burn serrations shall be repaired by grinding.
After edge preparation, shell plates shall be cold rolled to the curvature in accordance with fabrication drawings.
The weld edges shall free from oil, dust, scale, water and other foreign materials, then shall be coated with weld able paint.

2.2 Roof Plate
Roof plate shall be marked off in accordance with fabrication drawing and the edge shall be cut with automatic gas cutting for shop fabrication.

2.3 Roof Structure
Rafter, girder and column shall be prefabricated to be ready for erection.

2.4 Top Angle and Stiffener
Top angle and stiffener shall be rolled to suit the curvature of the tank with bending roll machine, then both ends shall be cut and edge prepared.

2.5 Manhole & Nozzle (Unit Fabrication)
Neck plate of manhole shall be cut with automatic gas cutting machine according to the drawing and be cold rolled.
Seam joint shall be welded and then Flange shall be welded to manhole neck.
Nozzle pipe shall be beveled end with pipe cutter or gas cutting machine, and flange shall be welded to nozzle pipe.

2.6 Reinforcing Plate
Reinforcing plate shall be outer periphery cut, opened and beveled with automatic gas cutting machine after marking off then pressed or rolled to suit the tank curvature.

2.7 Stairway, Ladder & Platform
Handrails shall be shaped to the specified curvature with bender.
Treads and platform shall be fabricated to be ready for site erection.

2.8 Heater piping. (if any)
Cutting of pipes may be done either by mechanical or thermal (flame, arch or plasma) means.
For carbon steel, thermal cutting and beveling may be used only if the cut is reasonably smooth and all oxides are removed from the surface.

2.9 Other Accessories
Other accessories shall be fabricated completely in accordance with drawings.

FIELD INSPECTION AND TEST PROCEDURE

2009-12-17T13:05:00.005+08:00

*note: this is the sample document for the related job only

*author: theprocedure@engineer.com

TABLE OF CONTENTS

1. Scope

2. Applicable Code, Standard And Specification

3. General

4. Material Inspection

4.1 Material Receiving Inspection

5. Material Traceability Control

5.1 Extent of Traceability Control

6. Dimensional Inspection

6.1 Foundation Receiving Inspection

6.2 Location Mark Check

6.3 Fit-up Inspection

6.4 Roundness

6.5 Plumbness

6.6 Local Deviation

7. Nondestructive Examination

7.1 Visual Inspection

7.2 NDE Procedure

7.3 Radiographic Examination (RT)

7.4 Liquid Penetrant Examination (PT)

7.5 Vacuum Box Test (VBT)

7.6 Pneumatic Leak Test (LT)

7.7 Repair and Re-examination

8. Hydrostatic Test

8.1 Pre-test Check

8.2 Water Filling

8.3 Settlement Monitoring

8.4 Hydrostatic Test

8.5 Cleaning

8.6 Hydrostatic Test for Heating Coil

9. Fixed Roof Test

10. Paint Inspection

11. Tank Calibration

12. Final Inspection

13. Witness Inspection

14. Manufacturer’s Data Report

1. Scope

This document covers the inspection and test requirements of storage tanks at the construction site specified for the Two (2) nos additional PSR-2 Crude storage tank at Petronas Penapisan Melaka. (PPM)

2. Applicable Code, Standard And Specification

The following standards, code, and specifications have been used as a source of information in the preparation of this document.

API Standard

API 650-9th Ed. 1995 : Welded Steel Tanks for Oil Storage

ASME CODE

ASME SEC. VIII DIV.1 : Rules for Construction of Pressure Vessels

ASME SEC.V : Nondestructive Examination

ASME SEC.IX : Welding and Brazing Qualifications

WH’S SPECIFICATION

: Construction (Erection) Procedure Specicification

: NDT (Non Destructive Procedure)

: Scheme for Water Filling Test and Settlement Measurement

: Quality Plan

3. General

(1) Unless otherwise specified in this specification, inspection and testing shall be performed in accordance with WH’s Quality Plan and applicable codes, standards and PTS.

(2) Field QC personnel shall carefully follow the construction and testing of tanks, and shall make sure that it complies in all details with design, construction, inspection and tests specified by the applicable codes, standards and specification.

4. Material Inspection

4.1 Material Receiving Inspection

Visual inspection of incoming material including the fabricated tank material sent from the shop, shall be made by the field QC personnel to ensure that there is no injurious defect on the surface and cut edges. Check on the identification number of raw material shall be made against material certificates. Check on the erection mark of fabricated tank material shall be made against the corresponding drawings.

5. Material Traceability Control

5.1 Extent of Traceability Control

The following tank components are required to be traceable against the material certificate. The As-built Sketch shall be prepared upon completion of the erection.

a. Shell Plate

Coded marking made at shop can be used to identify the material and be recorded in As-built Sketch. As-build Sketch may be supported by the related material identification records sent from shop.

6. Dimensional Inspection

6.1 Foundation Receiving Inspection

All the stage of receiving tank foundation, the field QC personnel shall review the foundation inspection report. Spot check of actual dimension and bench mark shall be made against the report.

6.2 Location Mark Check

Prior to the primary laying-down or erection of Bottom Plate, Bottom Sketch Plate, Shell Plate, Roof Structures and Roof Plate, the field QC personnel shall check the location marking in accordance with the related orientation drawings. Similarly, prior to make the Nozzle/Manhole opening, the location marking of opening shall be ensured.

6.3 Fit-up Inspection

Weld preparation and dimensional accuracy shall be checked prior to start welding. Butt welds of Shell joints shall be matched accurately and retained in position during welding operation.

Misalignment of Shell weld joint shall not exceed the following tolerance.

a. In completed shell vertical joint

Shell Plate  15.8 mm thk : 1.6 mm

b. In completed shell horizonttal joint

Upper Plate  15.8 mm thk : 1.6 mm

For Bottom Annular butt weld, the tolerances of vertical joints shall be applied.

6.4 Roundness

Prior to commencement of shell to Bottom Sketch plate weld, the tank internal radius shall be measured. The horizontally measured tank radius at 300 mm above the bottom corner weld shall not exceed the following tolerances.

Tank < 12 m diameter : + 13 mm 6.5 Plumbness The first course shell plate shall be checked for plumbness, level and roundness before welding in accordance with WH’s construction procedure to ensure that the tank will be completed within the specified dimensional tolerances. Plumbness of Shell shall be inspected after completion of all Shell welds. The out-of plumbness shall not exceed 1/200 of the total tank height. 6.6 Local Deviation Local deviation shall be inspected, if there is any noticeable distortion after completion of shell weld. The Local deviation shall not exceed the tolerance of 13 mm. 6.7 All nozzle and couplings directly connected with piping shall be at the correct elevations from the surface of bottom plate and radial positions after completion of welding and erection and remain at the following tolerance. Elevation of nozzle : + 10 mm Radial position of nozzle : + 15 mm Nozzle projection : + 10 mm Inclination of flange face : + 0.5°

7. Nondestructive Examination

7.1 Visual Inspection

Regardless any other nondestructive inspection method applied, all the site welds shall be subjected to visual inspection, and meet the requirements of API 650 Sec. 6 para 6.5.

7.2 NDE Procedure

General requirements, examiner’s qualification, equipment and operation procedure of nondestructive examination shall be in accordance with WH Specification : Nondestructive Test Procedure.

7.3 Radiographic Examination (RT)

The following RT shall be performed.

a. Shell vertical / horizontal joints and bottom annular radial joints shall be radiographed in accordance with the requirement of API 650 Sec. 6 para 6.1.

Heating coil butt joints shall be radiographed on spot basis. Minimum 5% butt joints of heating coil welded by each welder shall be fully radiographed.

b. Radiographs shall be judged in accordance with API 650 Sec. 6 para 6.1.5.

c. When a spot radiograph fail to comply with the acceptance standard, additional radiographs shall be taken in accordance with the requirement of API 650 Sec. 6 para 6.1.6.

7.4 Liquid Penetrant Examination (PT)

The following PT shall be performed.

a. The attachment welds of nozzle / manhole welded to shell at site shall be examined by PT.

b. The acceptance standard shall be in accordance with API 650 sec. 6 para 6.4.4.

7.5 Vacuum Box Test (VBT)

The following vacuum box test shall be performed.

a. All Bottom welds, i.e. Bottom-to-Bottom, Sketch Bottom Sketch-to-Bottom Sketch, Bottom Sketch-to-Shell joints, shall be inspected.

b. Any leakage observed by VBT is unacceptable.

7.6 Pneumatic Leak Test (LT)

The following pneumatic leak test shall be performed.

All attachment weld of reinforcement plate on each shell opening welded at site shall be inspected in accordance with API 650 Sec. 5 para 5.3.5. Any leakage observed by LT is unacceptable.

7.7 Repair and Re-examination

When an imperfection is judged to be repaired by welding, repair welding shall be make in accordance with the applicable welding procedure. Repaired are shall be re-examined by the same method originally used.

8. Hydrostatic Test

8.1 Pre-test Check

a. Before filling water into the tank, it shall be ensured that all inspection on Bottom, Shell and Roof including attachment welds shall be completed.

b. Any foreign articles shall not be left in the tank.

8.2 Water Filling

a. The water filling rate shall be decided with consideration given to tank size, pump facilities, water supply available, stability of foundation settlement, and other matter relating to safety.

b. When foundation settlements are negligible or significantly greater than expected settlement, water filling rate may be changed.

c. During the entire filling and emptying operation, roof manhole and/or other openings shall be kept open.

d. During the water filling, the floating roof shall be checked frequently for leaks.

8.3 Settlement Monitoring

a. Settlement reading shall be take at a minimum of 4 points around the base of tank.

b. Settlement reading shall be taken and reported to Contractor at least once a day while the tank is being filled with water and emptied.

8.4 Hydrostatic Test

a. Water shall be filled to the specified test level as WH Spec.

b. After the tank filled to test water level, all welds in the shell, including shell to bottom Sketch Plate welds, shall be visually inspected for water tightness.

c. Water shall be maintained at the test level for minimum of 24 hours after which water may be discharged.

d. Prior to starting the water discharging, ensure that the roof openings are opened.

8.5 Cleaning

a. During and after the tank is emptied, the inside of tank shall be cleaned.

b. All sand, sludge and rubbish on the tank bottom shall be removed.

8.6 Hydrostatic Test for Heating Coil

Heating coil shall be tested hydrostatically at a pressure specified in applicable drawing.

9. Fixed Roof Test

While the tank is maintained at the test water level, welds on the fixed roof shall be pneumatically leak tested. Non-pressure tank roofs shall be tested to pressure not exceeding the weight of the roof plates with compressed air and low-pressure tank roofs shall be tested to a pressure equal to the maximum internal pressure rating. The inaccessible are during hydrostatic test shall be inspected in advance by vacuum box.

10. Paint Inspection

Paint inspection shall cover the following items.

a. paint material check

b. surface preparation check

c. paint application check

d. dry film thickness (DFT) check

e. visual inspection of completed surface

f. pinhole test for tank internal lining

The magnetic pull-off type gauge or fixed probe magnetic flux type gauge shall be used for DFT readings. For each coat of paint, the DFT shall be taken at a frequency of one measurement of every 10 square meters area. Each measurement consists of an average of three gauge readings next to one another. All spot measurements shall not be less that 100% of the specified DFT.

After the final coating has been completed, the field QC personnel shall ensure that the appropriate clean-up is done, and that any abrasions, nicks or scrapes are repaired as required.

11. Tank Calibration

Tank calibration and preparation of gauge table shall be performed by a specialized firm in accordance with internationally accepted method and with local statutory requirements.

12. Final Inspection

Prior to tank box-up, the inside of tank shall be thoroughly ensured clean. Flange surfaces of Nozzle/Manhole shall be carefully inspected for defects which may caused and leakage.

It shall be also ensured that all works required by drawings, specifications and the related inspection and test plan have been thoroughly completed.

13. Witness Inspection

The scope of inspection by Vendor, CONTRACTOR, and OWNER is indicated in Scope of Inspection. The Inspection and Test Plan shall be progressively followed by the inspector throughout site construction.

14. Manufacture’s Data Report (MDR)

The site portion of MDR shall be compiled at site as the construction is progressing. The completed site MDR shall be submitted to CONTRACTOR, while a original copy will be sent to WH home office for retaining. As a minimum, the following inspection records shall be included in the site MDR as per Quality Plan.

a. Inspection Certificate

b. As-built Sketch of Shell Plate

c. Welders Map of Shell and Bottom Plate/WPS & PQR/Welder’s Qualification Records

d. NDE Record of RT, PT, VBT and LT

e. Dimensional Inspection Record of Tank Foundation, Roundness and Plumbness

f. Hydrostatic Test Record including settlement data

g. Roof Test Record

h. Paint Inspection Record

TANK ERECTION PROCEDURE

2009-12-17T12:49:00.001+08:00

*note: this is the sample document for the related job only

*author: theprocedure@engineer.com

TABLE OF CONTENTS

1. SCOPE

2. APPLICABLE CODE

3. FOUNDATION

4. CONSTRUCTION PROCEDURE

4.1. BOTTOM PLATE

4.2. SHELL PLATE

4.3. ROOF STRUCTURE

4.4. ROOF PLATE

4.5. OUTER RAFTER ERECTION PROCEDURE

4.6. WIND PROTECTION OF SHELL PLATE AND ROOF STRUCTURE

4.7. TEST

4.8. CALIBRATION

4.9. ATTACHMENT

1. SCOPE

This specification covers construction (erection) procedure for field erection of Two (2) nos additional crude Storage Tanks.

2. APPLICABLE CODE

a. ASME IX: : Welding & Brazing Qualification

b. B31.3 : Chemical Plant, Petroleum and Refinery piping.

c. ASME V : Non Destructive Testing

d. API650 : Welded Steel Tank for Oil Storage.

e. BS 2654 : Vertical Steel Welded Non-refrigerated Storage Tank with Butt welds for the Petroleum Industry.

f. Client Technical Standard

PTS-20.156A :Standard Tank Vol. 1 – Part 1

PTS-20.156B :Standard Tank Vol. 1 – Part 2

PTS-20.156C :Standard Tank Vol. 2 – Part 3

g. Contractor Specification

: Field Inspection Procedure Specification

: Water Filling Test

: Quality Plan

3. FOUNDATION

The following item of the foundation shall be confirmed and accepted by warga Hikmat QC and Client rep (PPMSB) prior to erection of the tanks.

(Refer to PTS-20.156A – 09.00.00- Foundation)

i. Level and Direction of the foundation

ii. Camber and flatness of foundation surface

4. CONSTRUCTION PROCEDURE

(Refer to PTS-20.156B – 10.00.00 Erection & 10.02.00 Erection Procedure)

4.1 BOTTOM PLATE

(1) Arrangement and welding of the Bottom plate shall conducted as per Bottom Plate Welding Sequence in Attachment 1 and detail procedure as follow;

i. Marking of centre line.

ii. Bottom plate arrangement as per welding sequence and applicable drawing.

iii. Fitting between shell and bottom plate.

(2) Bottom plate shall be welded by back step or skip welding method.

(3) To prevent welding distortion, restraint jigs or reinforcing beams shall be used.

4.2 SHELL PLATE

(1) Prior to erection of shell plate, following marking shall be performed on the bottom plate as shown in Fig. 1 & Fig. 2

i. Marking of radius for shell erection. (The marking shall be larger than the diameter shown in the drawing, considering weld shrinkage of shell plate).

ii. Radius for checking the roundness of shell plate shall be marked.

iii. The marking allotment of 1st course of shell plate shall be carried out.

(2) Level, roundness and verticality shall be inspected after completion of erection of 1st course of shell plate.

(3) Shell plate from second to fifth course and top angle shall be erected.

(4) Welding of shell plate shall be performed from lower course, and vertical joint shall be welded prior to the horizontal joint.

4.2.1 DETAIL ERECTION PROCEDURE OF SHELL PLATE.

The sequence of erection and welding are as follow:

1) Erection of 1st course.

2) Check level, verticality and roundness of 1st course.

3) I) Erection of 2nd course. After completion of erection of second course, the vertical joint of 1st course shall be welded.

ii) Vertical joint of 2nd course shall be aligned.

iii) Local departure, tolerance cut horizontal and vertical shell seams shall be checked.

4) i) Erection of 3rd course. After completion of erection of third course, the vertical joint of 2nd course shall be welded follow by horizontal joint between 1st course and 2nd course.

ii) Local departure, tolerance cut horizontal and vertical shell seams shall be checked.

5) i) Erection of 4th course. After completion of erection of fourth course, the vertical joint of 3rd course shall be welded follow by horizontal joint between 2nd course and 3rd course.

ii) Joint between shell plate and bottom plate shall be welded.

iii) Local departure, tolerance cut horizontal and vertical shell seams shall be checked.

6) i) Erection of 5th course. After completion of erection of fifth course, the vertical joint of 4th and 5th course shall be welded follow by horizontal joint between 3rd and 4th course, and between 4th course to fifth course.

ii) Local departure, tolerance cut horizontal and vertical shell seams shall be checked.

7) i) Installation of top angle. Dimensional shall be checked prior welding the top angle to the top (last) course.

ii) Local departure, tolerance cut horizontal and vertical shell seams shall be checked.

4.3 ROOF STRUCTURE

i. Roof structure shall be assemble on the ground in section or completed depending on size and weight.

ii. Assembled roof structure shall be erected inside the tank after completion of bottom plate and annular plate.

4.4 ROOF PLATE

Roof plate shall be arranged on the roof structure and welding to be carried out according to welding sequence considering the distortion or warping of plates.

4.5 OUTER RAFTER ERECTION PROCEDURE

Roof of outer rafter shall be assemble on the ground in section or completed depending on size and weight. The sequence of assembly are as follow;

1. Assemble the roof plate on the temporary support.

2. Assemble and welding the center ring and center plate complete with stiffener and rib plate.

3. Fit the ring on the roof plate.

4. Install the rafter and girder on the roof plate.

5. Erect the outer rafter on the temporary support after completion of bottom plate and annular plate.

4.6 WIND PROTECTION OF SHELL PLATE AND ROOF STRUCTURE

Shell plate and roof structures shall be protected by heavy wind during the erection using guy wire rope method. A detailed execution procedure and/ or plan including the detailed dimensions of the device shall be prepared and submitted to CLIENT site for approval, prior to commencement of shell construction work.

4.7 TEST

After completion of the entire tank, test shall be performed in accordance with WH FIELD INSPECTION & TEST PROCEDURE SPECIFICATION.

4.8 CALIBRATION

After completion of the required test, the tank shall be calibrated in accordance to WH FIELD INSPECTION & TEST PROCEDURE SPECIFICATION.

4.9 ATTACHMENT:

1. Fig 1 AND Fig 2.

2. Welding Sequence For Bottom Plate.

INSTALL SHOWER

2009-12-16T12:28:00.002+08:00

*note: this is the sample document for the related job only

*author: theprocedure@engineer.com

TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 SCOPE OF WORKS

3.0 SPECIFICATION

4.0 APPLICABLE CODES AND STANDARD

5.0 INSPECTION AND TEST PLAN

6.0 WORK STEP/PROCEDURE

7.0 HYDROSTATIC TESTING

8.0 QUALIFICATIONS

9.0 SAFETY

10.0 REFERENCES & OTHER SUPPORTIVE DOCUMENT

1.0 INTRODUCTION
This procedure outlined the requirement for the fabrication works at piping for Replacement of Diesel Pump at Neu-Pit.

2.0 Scope of Works
The scope of this work is a follows:-

2.1 To replace and fabricate new end spool for Diesel Pump replacement at Neu-Pit.
2.2 To perform blasting and painting for a new end spool.
2.3 To perform NDT i.e Radiography Test (RT) 10% for new end spool .For fillet weld
socket to be Dye Penetrant Test (DPT) 100%.
2.4 To perform installation for that new end spool.
2.5 To carry out the inspection and testing work including Hydrostatic Test.
2.6 To perform Tie-in point.

3.0 Specification.
3.1 Material Specification : (Sample only)

3.2 Welding Specification : (Sample only)

4.0 Applicable Codes & Standards

4.1 Legislative document.

The WORKS to be provides shall comply with requirement of the Factories and
Machinery (FMD) regulation 1967 (Amendments 1991), DOSH Malaysia.

4.2 Quality Assurance – ISO 9001
4.3 Specification & Codes.
4.3.1 ASME/ANSI B 31.3
4.3.2 ASME Section IX
4.3.3 ASME Section V
4.3.4 PTS 30.10.60.18

5.0 Inspection and Test Plan.

5.1 Visual inspection.
5.2 Marking and surface preparation (metal loss area) sizes, dimension and amount
recorded.
5.3 Perform visual & NDT (RT) at marked ar ea prior to start work & 100% on each
welding layer.
5.4 Dimensional check after installation of new end spool.
5.5 Final inspection and testing (HT).

6.0 Work Step/ Procedure.

6.1 All fabrication works will be carried out after completion of material inspection by
Client Representatives.
6.2 Fabrication for new end spool will be carried out at STS worksyop.
6.3 Perform surface preparation. Ensure the surface is free from oil, grease, water or any
other containment material.
6.4 Perform blasting and painting works in worksyop. All pipes, fitting and flange will be
coat by three layers (according to PTS 30.48.00.31-P, Protective Coatings and
Lining). Refer blasting and painting procedure.
6.5 Perform fit-up works, checks for flanges alignment to avoid leaking at flange
connection.
6.6 Perform welding work accordingly by DOSH qualified welder. Refer to Welding
Procedure Specification (WPS).
6.7 After completion of welding work, perform RT for all butt weld joint and DPT for fillet
weld socket at worksyop and site for field joint.(Refer Inspection and Test Plan). All
test shall be witnessed by PEMSB Repr esentatives.
6.8 If the results of RT and DPT found fails, repair the joint accordingly.
6.9 If the result of NDT is satifactory, proceed with next action, which is installation or
tie-in point the spool.
6.10 All welded spool section will be paint in the field after the entire tie-in works finish.
6.11 Perform Hydrostatic Test at new end spool to check any leaking at joint.
A preliminary inspection shall be made during Hydrostatic test at suspected
area. Client Representatives shall indic ate the defect area for next action (repair
work).

7.0 Hydrostatic Testing.

7.1 Following completion of all the above work, hydrostatic test shall be carried out
in the presence of DOSH and Client Inspector.
7.2 Test pressure shall be at 1.5 times the desi gn pressure and holding time shall
be 30 minutes.

8.0 Qualifications.

Welder performing the work shall be DOSH qualified welder and possess valid welder
certificate.

9.0 Safety.

9.1 All condition stated on permit to work and Safe Operating Procedure must be
complied.
9.2 All personnel working on the job site shall be informed of the safety awareness by
attending the safety induction conducted by Client prior to commencing of work.
9.3 Full PPE is ensured whilst working at site.

10.0 References & Other Supportive Document to this procedure:

10.1 CUTTING & WELDING PROCEDURE
10.2 WPS, PQR & WQT
10.3 INSPECTION & TEST PLAN
10.4 RADIOGRAPHY TEST PROCEDURE
10.5 DYE PENETRANT TEST PROCEDURE
10.6 BLASTING AND PAINTING PROCEDURE
10.7 HYDROSTATIC TEST PROCEDURE