QUALITY CONTROL PLAN

Client
Client Ref. No.:
Scope of Work:

Reference No.:
Revision No.:
Date:

QC PLAN FOR FABRICATION & ERECTION

Abbreviations
PGCC
QP
AI
F.R Pad
TDC

Petrol and Gas Construction Company

Qatar Petroleum
Authorized Inspector
Reinforcement Pad
Technical Delivery Condition

Applicable Standards
API 650
ASTM A240 SS316
ASME Sec II, Part c
ASME Sec V
ASME Sec VIII, Div.1
ASME Sec IX
ASME B16.5
ASME Sec X
SNT-TC-1A

1.0

Design

1.1

Design review &

Design
Calculation

Tank Design Specification

SS Material Specification
Specification for Welding Rods, Electrodes and
Filler Metals
Non-Destructive Examination
Rules for Construction of Pressure Vessels
Qualification Standard for welding procedures
and welders
Standards of Pipes and Fittings
Fiber-Reinforced Plastic Pressure Vessels
Guidelines to NDT Personnel Qualification and
certification

Meeting all the

Requirements of
Clients P.O

Clients P.O
Data Sheet

Clients P.O Data

Sheet

PGCCs
Design
Calculation

Design Manager
/Design Engineer

QCP.REF.100.14
00

QUALITY CONTROL PLAN

Client
Client Ref. No.:
Scope of Work:

1.2

Preparation of
Engineering
drawing and
detail drawings.

2.0

Material Purchase

2.1

Material
Requisition

2.2

Purchase Order

3.0

Material Control

3.1

Material list of
PGCC procured
Materials (Shell
plates, bottom

QC PLAN FOR FABRICATION & ERECTION

Compliance with
design
conditions,
Client
Specification &
Data Sheet

Technical and
Quality
Requirements
as per
Contract/Drawin
gs
Purchasing Data
Complete

Material Size
identification,
test cert. as per
API 650

Reference No.:
Revision No.:
Date:

Clients P.O
Data Sheet

Clients P.O Data

Sheet

PGCC
Drawing

Design Manager
/Design Engineer

Drawing,
Technical
Delivery
Conditions(TD
C)

Matching
Drawing, Clients
spec & Technical
delivery
conditions.

Material
Requisition

Design Engineer,
Draftsman

Buying
enquiry and
offer from
vendor, client
approval
vendor list

Vendors offer
match with the
requirements,
Substitutions
offered are
approved by
TEPQ

Purchase
order
technical
Query
Requests
(in case of
substitution
s)

Purchaser,
Project Engineer
& Operation
Manager

Mill test
certificates,
Dimensiona
l inspection

Material
controller &
Material QC
Inspector

QCP.REF.100.14
00

QUALITY CONTROL PLAN

Client
Client Ref. No.:
Scope of Work:

plates, top
plates, pipes,
fittings, etc..)
3.2

Dished Heads

3.3

Material Storage

3.4

Material issue

3.5

Internal
Installation items
(,

3.6

Anodes

Reference No.:
Revision No.:
Date:

QC PLAN FOR FABRICATION & ERECTION

for pressure
part

report if
required &
NDT Report
(If
applicable)

Clearly
identified,
MCN, PO# and
Stored/
Segregated to
prevent
contamination
and damage
Issue against
authorization
only

Mill TC, Stores

Records

Identification
marking
traceability to
MTC

--

Material
Controller &
QCnspector

Material Issue
Slip

Issue against
authorization
only

Material
requisition
issue Slip

Material
Controller,
Supervisor
Project Engineer

Dimension, trial
assembly at
floor,
MTC Review
As per client PO
and da

Sub-vendors
drawing &
Doc#

Sub-Vendors
Drawing & Doc#

Subcontractors
inspection
reports

Sub-contractors
& Project
Engineer.

QCP.REF.100.14
00

QUALITY CONTROL PLAN

Client
Client Ref. No.:
Scope of Work:

4..0

Welding control

4.1

Welding
Procedure
Specification
(WPS)

4.2

Welder
Qualification
records (WPQR)

4.3

Weld Map

4.4

Welding
Consumables

5.0

NDE Testing

Reference No.:
Revision No.:
Date:

QC PLAN FOR FABRICATION & ERECTION

Covers full
range of
parameters,
processes and
meets CODE
requirements
Covers full
range of
parameters and
process to be
welded

Size ,Batch No
& Test
Certification. API
650 for S. steel
material
consumables;
and 3.1B for all
other material
consumables

WPS

Welding
Engineer

API 650, GS EP

Welder
Qualificatio
n
certificates

Welding
Engineer

PG/WC/001,AS
ME Sec. II part
C & GS EP PVV
611

Consumabl
e Batch
Certificates

Welding
Engineer

Meets
API 650
Drawing &
job specific
WPS

/Procedure

API 650
requirements
and job range

QCP.REF.100.14
00

QUALITY CONTROL PLAN

Client
Client Ref. No.:
Scope of Work:

5.1

NDE Testing

5.1.1

NDE Procedures

5.1.2

NDE Personal
Qualification

Reference No.:
Revision No.:
Date:

QC PLAN FOR FABRICATION & ERECTION

Covers full
range of
parameters and
processes and
meets CODE
requirements
Covers all
methods of NDE
applicable to
the degree of
competence
required

API 650 GS EP
PVV

Meets CODE
requirements and
covers job range

PGs Written
practice ASNT

Meets CODE
requirements and
covers job range

Covers Full
Range of
parameters

Meets API 650

requirements
and covers job
range

QC Manager/QC
Engineer

NDE
personnel

QC Manager/QC
Engineer

Qualificatio
n
Certificates

5.2

Procedures

5.2.1

QC Procedures

6.0

Manufacturing Of 4903F

6.1

Prefabrication
Activities(Sheet,
Nozzles and
Saddles)

Meets API 650

QC Manager/QC
Engineer

QCP.REF.100.14
00

QUALITY CONTROL PLAN

Client
Client Ref. No.:
Scope of Work:

Reference No.:
Revision No.:
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QC PLAN FOR FABRICATION & ERECTION

QCP.REF.100.14
00

6.1.1

Identification,
marking, cutting
and weld
preparation of
shell plates.

As per drawing
dimensions
within
tolerances.

Drawing, API
650 (UW-31),

Drawing, API 650

&

Inspection
Request &
Material
Summary
sheet.

Supervisor & QC
Inspector

6.1.2

Fit up of shell
long seams along
with Production
Test Coupon (2
Coupons for each
WPS)

As per drawing
dimensions
within
tolerances.

API 650.

API 650

Inspection
report

Supervisor & QC
Inspector.

6.1.3

Mechanical test
on one two
Production Test
Coupon.
100% weld visual
And dimension
inspection on
Shell and
manhole long
seams joints.
Fit-up and
Welding WPS and
Qualified welders

As per concern
PQRs
mechanical
characteristics.
All relevant
drawing dim.

Concern WPS
& PQR.

API 650 & GS EP

PVV 211 Rev: 06

Lab Test
Report

Project Engineer
& QC Welding
Inspector

Drawing API
650, GS EP
PVV 611 Rev:
06 &
MG/NDE/VT/00
6
WPS, list of
qualified and
approved
Weld Map.
Drawing

API 650, GS EP
PVV 611 Rev: 06
&
MG/NDE/VT/)006

Inspection
Request
(Form no
MSF 012)

Supervisor & QC
Inspector

API 650 & GS EP

PVV 211 Rev: 06

Weld Visual
Request
(Form no
MSF 012)
Inspection
Request
(Form no

Supervisor & QC
Inspector

Supervisor & QC
Inspector

6.1.4

6.1.5

6.1.6

Flush Grinding of
Inside Welding
Penetration.

Welding per
WPS and
Qualified
welders.
Smooth
merging of
surface with

Drawing

QUALITY CONTROL PLAN

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Client Ref. No.:
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QC PLAN FOR FABRICATION & ERECTION

shell surface.
6.1.7

10% RT on Shell
long seam joints.

Absence of
Internal defects.

6.1.8

100% RT on
Manhole long
seam joints.
Identification,
marking &
cutting and weld
preparation of
nozzle neck,
flange & fittings.

Absence of
Internal defects.

Manhole nozzle
and other Nozzle
neck with W.N
flange fit up (for
all nozzle)
Welding of
Manhole nozzle
and other nozzle
neck with flange.

6.1.1
0

6.1.1
1

6.1.1
2

Reference No.:
Revision No.:
Date:

QCP.REF.100.14
00

MSF 012)
PG/NDE/RT/00
4 API 650, GS
EP PVV 211
Rev: 06 & GS
EP PVV 611
Rev:06
PG/NDE/RT/00
API 650

API 650,
PG/NDE/RT/004,
GS EP PVV 211
Rev:06 & GS EP
PVV 611 Rev:06

RT Report
(Form No
MSF/014)

Level II
Inspector, QC
Inspector

API 650,
PG/NDE/RT/00

RT Report

As per drawing
dimensions
within
tolerances.

Drawing,
API

Drawing,
API 650

Inspection
Request &
Material
Summary
sheet

Level II
Inspector, QC
Inspector
Supervisor & QC
Inspector

As per drawing
dimensions
within
tolerances.

API 650

Drawing, API 650

Inspection
request

Supervisor & QC
Inspector

Welding per
WPS and
Qualified
welders.

WPS, list of
qualified
welders and
approved
Weld Map.

API 650

Weld Visual
Request

Supervisor & QC
Inspector

QUALITY CONTROL PLAN

Client
Client Ref. No.:
Scope of Work:

6.1.1
3

Reference No.:
Revision No.:
Date:

QC PLAN FOR FABRICATION & ERECTION

QCP.REF.100.14
00

100% visual
inspection on
Manhole nozzle
neck and other
Nozzle neck with
Flange welds.
Flush Grinding of
Inside Welding
Penetration

Absence of
defects & all
relevant
drawing dim.

Drawing API
650, &
PG/NDE/VT/00

Drawing API 650

& PG/NDE/VT/00

Inspection
Request

Supervisor & QC
Inspector

Smooth
merging of
surfaces

Drawing

Drawing

Inspection
Request

Supervisor & QC
Inspector

Absence of
Internal defects.

PG/NDE/RT/00,
API 650,

API 650,
PG/NDE/RT/00,

RT Report

Level II
Inspector, QC
Inspector

6.2.1
6

10% RT on
Nozzle with
flange for above
NPS 10 on
circular seam
joints.
Closing Seam Fit
Up

Drawing, API
650

Drawing, API 650

Inspection
Report

Supervisor & QC
Inspector

6.2.1
7

Welding &
Closing Seam

As per drawing
dimensions
within
tolerances
Welding per
WPS and
Qualified
Welders

API 650

Weld Visual
Request

Supervisor & QC
Inspector

6.2.1
8

Weld Visual
Inspection 100%

Drawing, API 650

& PG/NDE/VT/00

Inspection
Request

Supervisor & QC
Inspector

6.2.1
9

10% Radiography
for Circular seam

WPS, list of
qualified
welder sand
approved weld
map
Drawing, API
650 &
PG/NDE/VT/00
PG/NDE/RT/00,
API 650

API 650,
PG/NDE/RT/00

RT Report

Level II
Inspector, QC

6.1.1
4
6.1.1
5

Weld Quality to
meet Code
requirement
Absence of
internal defects

QUALITY CONTROL PLAN

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Client Ref. No.:
Scope of Work:

Reference No.:
Revision No.:
Date:

QC PLAN FOR FABRICATION & ERECTION

welding
6.2.2
0

QCP.REF.100.14
00

Inspector

Spot RT on all
Long seam and
circular seam
intersecting
location. (100%
"T" section/ "+"
Section
100% MPT on all
Category "D"
Joints
Pneumatic
testing of R.F.
pad Nozzles at
1.0 Barg
External
Attachment
Fit up of saddle
support with
Vessel

Absence of
Internal defects

PG/NDE/RT/00,
API 650

API 650,
PG/NDE/RT/00

RT Report

Level II
Inspector, QC
Inspector

Weld Quality to
meet Code
Requirement
Integrity of
welds and leak

PG/NDE/MT/00
API 650

API 650,
PG/NDE/MT/00

MPT Report

Level II Inspector

Proc#
PG/PRTST/00

Proc#
PG/PRTST/00

Inspection
Report

QC Inspector

As per drawing
dimensions

API 650

Weld Visual
Request

Supervisor & QC
Inspector

6.3.2

Welding of saddle
support with
Vessel

Welding per
WPS and
Qualified
Welders

API 650

Weld Visual
Request

Supervisor & QC
Inspector

6.3.3

100% Visual
Inspection

Absence of
Defects

WPS, list of
qualified
welders and
approved weld
map
WPS, list of
qualified
welders and
approved weld
map
Drawing API
650 &
PG/NDE/VT/00

Drawing API 650

& PG/NDE/VT/00

Weld
History
Sheet

Level II
Inspector/ QC
Inspector

6.2.2
1
6.2.2
2
6.3
6.3.1

QUALITY CONTROL PLAN

Client
Client Ref. No.:
Scope of Work:

6.3.4

6.3.5

6.3.6

6.3.7

6.3.8

Reference No.:
Revision No.:
Date:

QC PLAN FOR FABRICATION & ERECTION

QCP.REF.100.14
00

Fit up lifting lugs,

Name plate
bracket, external
attachment and
internal
attachment
Welding of lifting
lugs, Name Plate
bracket, External
& Internal
attachment
100% Visual
Inspection of
external &
Internal
Attachment
100% U.T. and
MPT on lifting lug
welding

Ad per drawing
dimensions

WPS, list of
qualified
welders and
approved weld
map

API 650

Weld Visual
Request

Supervisor & QC
Inspector

Welding per
WPS and
Qualified
Welders

API 650

Weld Visual
Request

Supervisor & QC
Inspector

Drawing, API 650

& PG/NDE/VT/00

Weld
History
Sheet

Level II
Inspector/QC
Inspector

API 650,
PG/NDE/UT/00 &
PG/NDE/MT/00

UT Report

Level II
Inspector/QC
Inspector

100% MPT on all

external
attachments
welds with
Pressure Parts,
Arc Strikes and
temporary
attachments
removal area

Absence of
defects

WPS ,list of
qualified
welders and
approved weld
map
Drawing,
ASME Section
V Article 9 &
PG/NDE/VT/00
6
ASME Section
V,
PG/NDE/UT/00
&
PG/NDE/MT/00
PG/NDE/MT/00
ASME Sec V
Article 7

API 650,
Appendix 6,
PG/NDE/MT/00

MPT Report

Level II
Inspector/QC
Inspector

Absence of
defects

Absence of
Internal defects

QUALITY CONTROL PLAN

Client
Client Ref. No.:
Scope of Work:

Reference No.:
Revision No.:
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QC PLAN FOR FABRICATION & ERECTION

QCP.REF.100.14
00

7.0

Final Dimensional, Visual Inspection and preparation for Hydro-Test

7.1

Flush Grinding of
All Inside Welding
Penetration

Smooth
merging of
surfaces

Drawing

Drawing

Inspection
Request

Supervisor & QC
Inspector

7.2

Final
Dimensional,
Visual Inspection
before internal
Trial assembly

Dimension
Check, Free of
visual defect
and distortion

Drawing API
650

Drawing API 650

& all related
NCRs closed, all
hot work
completed

QC Inspector

7.3

Trial assembly
internals

Dimension,
Location,
Orientation

Drawing

Drawing

Weld
History
Sheet/
Dimensiona
l Inspection
Report
Inspection
Report

Project
Engineer/QC
Inspector

7.4

Weighing of
Vessel

Final Weight of
vessel with full
internal
arrangements

Drawing

Horizontal lifting
and weight within
design limits and
hook load
specified

Inspection
Report

Project
Engineer/QC
Inspector

QUALITY CONTROL PLAN

Client
Client Ref. No.:
Scope of Work:

Removal of all
internal
attachments

Reference No.:
Revision No.:
Date:

QC PLAN FOR FABRICATION & ERECTION

7.5

Dismantling of all
internal items
and insulated
parts

Drawing

Pressure Test for 4903F

8.1

Hydro test
@required
pressure in
Vertical position.

The integrity of
vessel

8.2

Draining of hydro
test water

Proper venting,
complete
draining.

Final Dimensional Inspection

QCP.REF.100.14
00

Drawing

Project Engineer

API 650&
Proc#
PG/PRTEST/00

Shall not be any

leak @ test
pressure

Pressure
Test Report

Supervisor & QC
Inspector

Proc#
PG/PRTEST/00

Proc#
PG/PRTEST/00

Project
Engineer/Supervi
sor/ QC
Inspector

QUALITY CONTROL PLAN

Client
Client Ref. No.:
Scope of Work:

9.1

Dimensional
inspection after
the completion of
Hydro test

10

Fixing of ASME
Name Plate &
Signing of MDR

10.1

Reference No.:
Revision No.:
Date:

QC PLAN FOR FABRICATION & ERECTION

QCP.REF.100.14
00

Dimensional
Check

Drawing, API
650

Drawing API 650

Weld
History
Sheet/
Dimensiona
l
Inspection
Report

QC Inspector

Name Plate Code

Stamping

As per Drawing

Drawing & API

650

Drawing & API

650

Name
Plate/
Photograph

QC Inspector &
AI

10.2

Name Plate
attachment
vessel

As Per Drawing

Drawing API
650

Drawing API 650

QC Inspector &
AI

10.3

Manufacturer's
Data Report

Prepared per
requirement of
API 650

API 650 & as

Built
Dimensions

API 650

Manufactur
er's Data
Report

Quality Engineer
& AI

QUALITY CONTROL PLAN

Client
Client Ref. No.:
Scope of Work:

11.0

Release Note

11.1

Acceptance,
Inspection and
Release Note

12.0

As Built Dossier

12.1

As Built Dossier
and Records

Reference No.:
Revision No.:
Date:

QC PLAN FOR FABRICATION & ERECTION

QCP.REF.100.14
00

Contractual
requirements
fulfilled

Drawing, API
650

Drawing, API 650

Final
Acceptance
/ Release
Note

Quality manager

All Required
Tests
completed, all
NCRs closed
out, all required
documentation
collated

Contractual
requirement

Contractual
requirement and
API 650

Manufactur
er Data
Dossier
(MDD)

Quality manager