Prepration of ITP For Storage Tanks Fabrication & Erection

PROJECT 0470-8710-PR-0041
SPECIFIC Rev: O1
PROCEDURE Page: 1 of 27
PREPARATION OF INSPECTION & TEST PLAN – DSN:8026
STORAGE TANKS FABRICATION & ERECTION
AFTON CHEMICAL ASIA PTE LTD
PROJECT LION – PHASE 2
SINGAPORE
PREPARATION OF INSPECTION AND TEST PLAN

FOR STORAGE TANKS FABRICATION &
ERECTION
Rajappan Kelleher Abdul Angela

O1 Issued for Comments 24-Jan-16
Arun Cathal Jabbar Chua
Rev Prepared Checked Approved Quality
Reason For Issue Issue Date
No By By By Review By
CONFIDENTIAL DOCUMENT NO:
PROPRIETARY INFORMATION FOR

0470-8710-PR-0039
FOSTER WHEELER USE ONLY
PROJECT 0470-8710-PR-0041
SPECIFIC Rev: O1
CONTENT
1.0 PURPOSE………………………………………………………......................................... 3
2.0 SCOPE…………………………………………………………......................................... 3
3.0 DEFINITIONS………………………………………………………………………………. 3
4.0 REFFERENCE DOCUMENTS……………………………………………………………... 3
5.0 RESPONSIBILITIES………………………………………………………………………… 5
5.1 Piping and Mechanical Works Contractor…..................................................... 5
5.2 FW………………………………………………………………………………………….5
5.3 Client……………………………………………………………………………………… 5
5.4 Authorized Qualified Engineer……………………………………………………… 5
6.0 PROCEDURES……………………………………………………………………………… 5
6.1 General Overview…………………………………………........................................ 5
6.2 Responsibility Definition……………………………………………………………... 5
6.3 Inspection Forms……………………………………………………………………… 6
6.4 Submission of Inspection Forms……………………………………………………. 7
6.5 NDE Inspection Forms……………………………………………………………….. 7
6.6 System Turnover…………………………………………………………………….…. 7
6.7 Compilation of QC Dossiers…………………………………………………………..8
ATTACHMENT
ATTACHMENT 1 INSPECTION AND TEST PLAN

PROJECT 0470-8710-PR-0041
SPECIFIC Rev: O1
 PURPOSE
The purpose of this procedure is to define Inspection and Test Plan (ITP) requirements
for the Project for Tankage Fabrication and Erection Works.
 SCOPE
This project procedure includes the quality control requirements for the Tankage
Contractor(s) only. This procedure is for both monitoring and ensuring satisfactory
performance at relevant stages of construction whether by Contractor(s) or suppliers,
Foster Wheeler (FW) or by the Client..
 DEFINITIONS
ASNT American Society for Non-destructive Testing.

CSWIP Certification Scheme for Welding and Inspection Personnel.
NDT Non-Destructive Testing.
MPI Magnetic Particle Inspection.
PT Dye Penetrant Testing.
UT Ultrasonic Testing.
RT Radiographic Testing.
PWHT Post Weld Heat Treatment.
PMI Positive Material Identification.
Client (Afton) Afton Chemical Asia Pte Ltd.
FW (FW) Foster Wheeler Asia Pacific Pte Ltd.
QP Qualified Person (Authorize Qualified Engineer).
COW Clerk of Work.
Contractors (S/C) Construction Discipline Contractors working on the Project Site
against a known scope of works.
AFC Approved For Construction (documentation).
ITP Inspection and Test Plan.
NDE Non-Destructive Examination.
WPS Weld Procedure Specification.
PQR Procedure Qualification Record.
IOM Manuals Installation, Operation and Maintenance Manual.
 REFERENCE DOCUMENTS
The following documents include operations, which affect the quality of the plant and
should be referred to in conjunction with this procedure when appropriate:
ASME B31.3 Chemical Plant and Petroleum Refinery Piping.
ASME V Non-destructive Examination.
ASME IX Welding and Brazing Qualifications.
API RP 582 Welding Guidelines for the Chemical, Oil and Gas Industries
API 620 Design and Construction of Large, Welded, Low-Pressure
Storage Tanks.
API 650 Welded Steel Tanks for Oil Storage.
0470-8710-PR-00-0003 Site Quality Plan.
0470-8710-PR-00-0005 Structural Steel Work QC Documentation.
0470-8710-PR-00-0013 Civil Work QC Documentation.
0470-8710-PR-00-0016 Piping Work QC Documentation.

0470-8710-PR-00-0022 Flange & Bolting Assembly Procedure.
PROJECT 0470-8710-PR-0041
SPECIFIC Rev: O1
0470-8710-PR-00-0011 QA QC Instruction To Contractors.

0470-8710-PR-00-0037 Punch List Procedure.
0470-8710-PR-00-0039 System Completion & Turnover Procedure.
0470-8710-PR-00-0021 Welding Control Procedure.
Various Supplier Data Books, Drawings and IOM Manuals.
 RESPONSIBILITIES
1. Storage Tank Fabrication and Erection Works Contractor(s)
The Tankage Works Contractor(s) shall be responsible for preparing an Inspection and
Test Plan strictly in accordance with the requirements of this procedure and for
undertaking the works in accordance with the specific scope of works contract
requisition and documents referenced in Section 4 above and Attachment 1
2. FW
FW shall be responsible for monitoring the Tankage Contractor(s) in the execution of

the contract and for ensuring the Inspection and Test Plan produced by the
Contractor(s) is suitable and appropriate to meet the Project requirements as specified.
FW shall also monitor the adherence by the Contractor(s) to the agreed Inspection and
Test Plan for the work. This does not relieve the Contractor(s) of their responsibilities
under the contract and contract requisition documentation to execute the works per
Section 5.1 above.
3. Client
The Client shall review and monitor FW and the Contractor in the execution of the
agreed Inspection and Test Plan as specified in Attachment 1.
4. Authorize Qualified Engineer
The statutory requirements of the Building Control Act require the appointment of a
Resident Engineer or Clerk of Works.
This Authorize Qualified Engineer or Clerk of Works has duties and responsibilities with
respect to inspection and reporting during execution of the works. The Authorize
Qualified Engineer or Clerk of Works is responsible to the authorities Qualified Persons
/ Professional Engineer to watch, witness the tests, examine materials and examine
and approve workmanship employed. To this end inspection, witness, review and hold
points are to be included within the Contractors ITP.
 PROCEDURES
1. General Overview
Attachment 1 provides guidelines that are generic for the scope of works to be
undertaken as defined by the specific contract and sub-contract requisition. The
Contractor(s) shall provide a work and Project specific Quality Plan and necessary
procedure(s) that define how the quality of the listed activities in Attachment 1 shall be
controlled, specific to the area(s) or element(s) of work being undertaken by them.
PROJECT 0470-8710-PR-0041
SPECIFIC Rev: O1
2. Responsibility Definition
Responsibilities listed in Attachment 1 of this overall Inspection and Test Plan is as

follows:
X: Responsible for implementing the action and verification of the quality of the
final product. This is generally used for the Contractor only.
I: Responsible for inspecting work on surveillance or monitoring basis and signing

for the work.
As inspection and surveillance activities are completed, the QC forms

applicable to the works, generated by the Contractor, will be submitted to FW
Construction Supervisor, (and any other relevant parties specified in the ITP),
for review and sign off. This does not relieve the Contractor of their
responsibilities for undertaking inspection and controlling activities and
hence the quality of the works.
Sign off on the QC form by the FW Construction Supervisor confirms that he

has reviewed the details and data recorded on the QC forms and that these are
in compliance with the Project Specifications.
R: Responsible for reviewing and authorising submissions. This may include pre-
start items such as method statements, welding procedures etc. and post
operation activities e.g. review of construction records or survey reports.
W: Responsible for witnessing and signing for the work.
For FW and any Third Party, attendance at a Witness point activity is

mandatory. When Witness activities have been completed, the works will be
signed for by FW Construction Supervisor, and any Third Party specified in the
ITP, prior to the Contractor moving to the next step. Inspections may be carried
out in conjunction with the Contractor’s staff or as an independent operation at
the FW Construction Supervisor’s discretion.
Client – after receiving advance notification (Request for Inspection) of any

forthcoming activities which they have identified as Witness points on the ITP –
may decide whether or not to inspect the deliverable. Client shall sign for all
inspections and tests that they witness prior to the Contractor moving to the
next step.
Should Client decide to waive attendance at a Witness point, then the activity
may only proceed in the presence of the FW Construction Supervisor who shall
sign for the works prior to the Contractor moving to the next step.
H: Responsible for witnessing and signing work releasing Hold Points. Client, FW
and/or Third Party Inspectors are to be advised by the Contractor of any
forthcoming Hold points (through submission of Request for Inspection
documents).
Hold Points may NOT be waived by identified participants. Work may NOT
proceed beyond these mandatory Hold Points without witness and sign off by
the identified participants.
PROJECT 0470-8710-PR-0041
SPECIFIC Rev: O1
3. Inspection Forms
QC construction certificates / inspection forms have been defined in Attachment 1.

These are available for use by the Contractor (and Lower Tier Sub-Contractors - LTSC)
in undertaking their scope of works. The Contractor(s) own inspection forms may be
submitted to FW for approval for the work(s), providing they meet the minimum content
of those FW certificates and inspection forms already available for use. Where the
Contractor certificate and inspection forms are approved for use, the Contractor shall
substitute the agreed forms for those identified in Attachment 1. Supplementary
Contractor forms may also be added to the list identified.
4. Submission of Inspection Forms
The Contractor shall ensure that QC construction certificates / inspection

documentation and associated documentation for acceptance in those instances where
FW, Client personnel or other Third Party have inspected the works are available
actually at the time of inspection. Such documentation shall be completed in advance
by the Contractor. The Contractor, FW, CLIENT or other Third Party shall clear the QC
construction certificates / inspection documentation at the time of inspection.
5. NDE Inspection Forms
The Contractors nominated NDE Contractor shall complete all NDE examination
certificates and inspection forms.
The completed forms shall be provided to the Tankage Works Contractor for
compilation into the appropriate turnover documentation package, data book or dossier.
6. System Turnover
The Contractor shall compile all necessary QC construction certificates / inspection

forms and associated documentation, per the ITP, on an ongoing basis for all work
being undertaken.
A tank, area, system or line, as defined by FW, shall be subjected to punch listing once
all work has been deemed to be completed by the Contractor.
The Contractor shall offer the area, system or line to FW immediately upon completion
of their last inspection, for FW punch listing. The Client shall be invited to participate in
such punch list activities by FW.
A consolidated System Punch List of outstanding items shall be agreed between the
Contractor, FW and the Client, including a categorisation of outstanding items.
Where outstanding or punch list items are identified as Category “A” on the
Consolidated System Punch List, the Contractor shall rectify all outstanding items and
have them verified by FW and the Client prior to System Turnover acceptance.
Category “B” items can be completed after System Turnover but before Start-up of the
Facility.
Category "C" items are required before Acceptance of the Facility.
All QC construction certificates / inspection forms and associated documentation that

was prepared by the Contractor shall be included within their turnover documentation
PROJECT 0470-8710-PR-0041
SPECIFIC Rev: O1
package. Upon acceptance (or otherwise) of this turnover documentation package by

FW, the Contractor shall be informed of the same in writing
Acceptance of System Turnover shall not preclude the Contractor(s) in completing

outstanding punch list items work. Once all punch list items work has been completed,
within the agreed timescale, the Contractor(s) shall sign off the completed items on the
consolidated System Punch List for verification by FW and the Client.
7. Compilation of QC Documentation
The original copies of any Test Packs are archived by the FW Turnover Engineer at
reinstatement per the FW Document. “Storage Tank Work QC Documentation.”
The Construction Contractor shall compile tank plate and isometric weld maps QC
dossiers on an ongoing basis for all work being undertaken. A separate QC Dossier is
required for each tank. This shall include, but not be limited to:
 Original weld map / “As built”.
 Original QC and NDE reports.
The tank plate and piping weld map QC Dossiers, as prepared by the Contractor, shall
be presented to FW for acceptance immediately following acceptance of all inspections
by FW and the Client and before any tanks are tested.
ATTACHMENT
ATTACHEMENT 1 – inspection and Test Plan

PROJECT ATTACHMENT-1 0470-8710-PR-00-0041
SPECIFIC Rev: O1
DSN NO:8026
PREPARATION OF INSPECTION & TEST PLAN – STORAGE TANKS FABRICATION & ERECTION
RESPONSIBILITY
CONTROL DOCS REPORT FORM/
PROCEDURE
ITEM ACTIVITY Acceptance CHECKLIST Qualification Note S/C FW QP CLI COMMENTS
REQUIRED
Criteria NUMBER EN
T
1. DESIGN DOCUMENTS
1.1 Review Work scope. Contract Requisition Review work scope and X See Contract requisition and
and associated accept contract. associated Tankage Data
documents and Sheets.
drawings.
1.2 Review FW drawings / X

documents and Equipment
List.
1.3 Review Supplier and Vendor Contract Requisition. X

Drawings / Documents and
Equipment details.
1.4 Prepare Detailed Fabrication Contract Requisition Contractor Fabrication, NDE, Shop fabrication not to X H/R Structural steel fabrication to
Drawings, Cut-Sheets, and associated Coating, Galvanising and commence until the include pipe supporting
Welding Sequence Map for documents / drawings Painting and Erection detailed drawings are elements, units, racks and
Bottom Plate, Shell & Roof, See Section 4 for Procedures. submitted / accepted by structures.
NDE Maps, Element listed specifications. FW.
Drawings based on
calculations.
1.5 Prepare and issue a detailed Contract Requisition. Commence work after FW X R
schedule for detail design, approval.
material control, fabrication,
erection and NDE activities.
1.6 Prepare Inspection and Test This document. Contractor Inspection and Test Agreed Contractor X H/R Note requirements for PE to
Plan. Plan. Inspection and Test Plan. witness certain activities.
1.7 Contract kick-off meeting. Contract Requisition Notes of meeting. X X

and associated
documents and
drawings.
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DSN NO:8026

PROCEDURE
ITEM ACTIVITY Acceptance CHECKLIST Qualification Note RESPONSIBILITY COMMENTS
REQUIRED
Criteria NUMBER
1.8 Sample Signatures. Sample signature of S-HDS 3290- X I Sample signatures

Contractor personnel Authorize list/document to be included
who inspect / sign Signatories List. within final Turnover dossiers.
inspection
certificates / QC
documentation.
2. DOCUMENTS REQUIRING APPROVAL
2.1 Submission of applicable As-built foundation Contractor Procedures to cover X H/R Note requirements for working
Tankage Works Procedures surveys. the following activities: in an operational plant close to
for Fabrication, Installation,  Mechanical Design existing live buried services.
Erection, Welding Sequence  Material
Map for Bottom Plate, Shell procurement and control Note restricted areas for plate
& Roof, where required procedure lay down
Testing Works / Procedure(s)  Material marking
to cater for works within the procedures Transportation and logistic
Contract Requisition  Material cutting and routes for materials and
initial plate / section equipment required.
fabrication procedures
 Setting out and For piping fabrication and
benchmark datum and from inspection works see procedure
existing structure dimensions -Piping Work QC
Documentation.
 Existing and new
Foundation Inspection
For structural steel fabrication
 Care of the works
and inspection works see
 Calibration procedure no. -Structural Steel
procedures. Work QC Documentation.
 Temporary works to
assist permanent installation.
 Disposal works.
 Welding Sequence
Map for Bottom Plate, Shell
& Roof,
2.1  Tank roof / plates,
Cont piping and supports, welding,
fabrication, NDT, installation,
Hydro-testing, flushing and
drying procedures.
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DSN NO:8026

PROCEDURE
REQUIRED
Criteria NUMBER
 Steelwork, structure
and support modification,
fabrication, erection and
modularisation procedures
 Painting / repair
procedures for shop and field
works.
 Insulation Works
 Lifting / rigging
studies / transportation
procedures.
 Grouting / bit-sand
repairs for tank bases.
 Cathodic Protection,
earthing and grounding.
2.2 Preparation and submission SHES Procedures. Method Statements and Job Method Statements, X H/R
of applicable Mechanical CLIENT Procedures. Safety and Environmental JSEA’s and Permits for all
Erection and Installation Contract Requisition. Analysis and associated project activities to be submitted
Works Method Statements, documentation. before performing work.
Task Risk Assessments, These are a safety
Work Packs and Job Safety requirement to ensure safe
and Environmental Analysis practises and not to be
(JSEA) and Client Permits. inspected as part quality
control activities.
2.3 Weld Procedure ASME IX Contractor Submission of Weld WPINDEX-Welding Procedures and X H/R
Specifications -Welding Procedures, Procedure Specifications and Procedure Index & qualifications (technique
-General Specification Weld Procedure Qualification TESTREC- Welder and personnel executing
for Welding, Records. Approval Test the works) to be reviewed
API RP 582, Record. and approved prior to
API 620, performing any welding or
API 650, Non-Destructive
0470-8710-PR-00- Examination activities.
0021- Welding Control
Procedure confirms
control of welding,
welders, NDE, etc.
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DSN NO:8026

PROCEDURE
REQUIRED
Criteria NUMBER
2.4 Welder Qualification Test. ASME IX, Contractor procedures required. FW3414-Summary X I
-Welding Procedures, Piping materials for welder of Approved Welders
& 0470-8710-PR-00- tests to be free-issued from &FW3417-
0021 Welding Control FW. Tank plate requirements to Welder Approval Test
Procedure. be supplied by Contractor. Certificate.
2.5 Dye Penetrant Test ASME V & Contractor Dye Penetrant X H/R
Procedure (If Applicable). -0470-8710-PR-00- Procedure.
0021 Welding Control
Procedure
2.6 Radiographic Test ASME V & Contractor Radiographic X H/R

Procedure. 0470-8710-PR-00- Procedure.
Procedure
2.7 Magnetic Particle Inspection ASME V & Contractor Magnetic Particle X H/R
Procedure. 0470-8710-PR-00- Inspection Procedure.
Procedure
2.8 Ultrasonic Test Procedure. ASME V & Contractor Ultrasonic Test X H/R
0470-8710-PR-00- Procedure.
Procedure
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DSN NO:8026

PROCEDURE
REQUIRED
Criteria NUMBER
edures and qualifications (technique and personnel executing the works) to be reviewed and approved prior to
2.9 Post Weld Heat Treatment Welding Procedures & Contractor Post Weld Heat
Procedure. PWHT procedure for Treatment Procedure.
Equipments.
performing any welding or Non-Destructive Examination activities

SPECIFIC Rev: O1
DSN NO:8026

PROCEDURE
REQUIRED
Criteria NUMBER
2.10 Positive Material Positive Material Contractor Positive Material X H/R

Identification Procedure (If Identification. Identification Procedure.
Applicable).
2.11 Hardness and Ferrite Testing Additional Contractor Hardness Testing

Procedure (If Applicable). Requirements for Procedure.
Materials.
2.11 Non Destructive Examination Appropriate ASNT, Contractor Fabrication and Approved NDE X H/R Technician certificates to be
(NDE) Operator CSWIP or PCN NDE / NDT Procedures. Operator Register. provided for RT, UT, MT, DP,
Qualifications. Qualifications, PMI and Hardness testing
ASME V, activities prior to any NDE or
General Specification testing.
for Welding,- Welding
Control Procedure &
Contract Requisition.
2.11 Blasting, Painting, Coating Coating Systems for Contractor Blasting, Painting, FW3456-Painting Approval by FW before X R
and Galvanising Procedures. Structures and Coating and Galvanising Completion Report. work commences.
Equipment. Procedure. & FW3461-Paint
Acceptance Report.
2.12 Transportation and Lifting Equipment List, Contractors specific list of lifting FW to approve prior to lifts X H/R Transportation routes from site
Studies. tankage data Sheets and rigging studies to be commencing. access points, or jetties (if
& Equipments Lift by developed. To include plate agreed) to be included.
Cranes. movements.
3. INSPECTION MEASUREMENT & TEST EQUIPMENT
3.1 Calibration Control. 0470-8710-PR-00- Contractor Calibration All inspection, X R Calibration status to be
0021 Procedure. measurement and test identified on equipment. Out of
Welding Control equipment to be calibrated. calibration equipment to be
Procedure, Welding Certificates to be available removed from use. To include
Procedure, for review prior to work DFT measurement and
API 620, API 650. commencing. atmospheric measurement
instruments.
4. WELDING & NON-DESTRUCTIVE TESTING OPERATIONS

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PROCEDURE
REQUIRED
Criteria NUMBER
4.1 Storage of Welding 0470-8710-PR-00- Contractor segregation and X I Carbon and Stainless Steel
consumables. 0021 storage of welding rods. Issue material segregation for
Welding Control and return of unused fabrication, consumables and
Procedure. consumables. testing mediums.
4.2 Calibration of ovens. 0470-8710-PR-00- Contractor Consumable Control Oven temperatures to be X I Oven temperature gauges to be
0021 Procedure. checked and recorded checked against thermometer.
Welding Control daily. Ovens to be calibrated.
Procedure.
4.3 Issue of consumables. 0470-8710-PR-00- Segregation and storage of rods Only the appropriate X I Issue log to be maintained
0021 in original containers, in quantity of consumables to showing welder and quantity.
Welding Control accordance with the supplier be issued to welders that Returns to be recorded.
Procedure. recommendation. can be used in one shift.
4.4 Control of consumable 0470-8710-PR-00- Contractor Baking oven as per Quivers to be heated. X I No quivers to be left open
quivers. 0021 supplier recommendation or Temperatures to be during welding operations.
Welding Control instructions and weld procedure maintained within quivers.
Procedure. specification.
4.5 Weld Procedure 0470-8710-PR-00- Contractors fabrication and FW3414-Summary X I

Specifications. 0021 construction procedures for of Approved
Welding Control shop and field activities. Welders.
Procedure, Approved
WPS
Welding Procedure
&.
4.6 Welder performance. Individual welder daily Construction Procedures for FW3407 Logging welder's ID's to X R Contractor shall submit
and weekly weld maps. FW3409-D-Daily welds. individual welder's
performance record Welders performance daily for NDE
&0470-8710-PR-00- Performance selection.
0021 Record& W-Welders
Welding Control Weekly Performance
Procedure. Record.
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PROCEDURE
REQUIRED
Criteria NUMBER
4.7 Weld reports, Weld tests, API 620 / 650 Contractor Construction FW3407-Weld X R Completed NDE packs to be
Weld inspection summary -General Specification Procedures for Weld Sequence, Inspection Summary submitted to FW and approved
sheet. for Welding, –0470- Weld Maps and NDE Maps. Sheet. prior to any hydro testing.
8710-PR-00-0021
Welding Control
Procedure,
Contract requisition,
Mechanical Tests.
4.8 Request for Inspection. API 620 / 650 & 0470- See also Master Daily FW3408-Request for X R
8710-PR-00-0021 Inspection Log. NDE / PWHT /
Welding Control Inspection.
Procedure.
4.9 Visual Inspection of Welds. ASME V, Contractor Fabrication and FW3460-Visual X I

API 620 / 650, NDE / NDT Procedures. Examination Report.
Contract requisition &
0470-8710-PR-00-
Procedure
4.10 MT examination of Welds. ASME V, Contractor Fabrication and FW3411-MT / PT X R

API 620 / 650, NDE / NDT Procedures. Report.
0470-8710-PR-00-
Procedure.
4.11 PT examination of Welds. ASME V , Contractor Fabrication and FW3411-MT / PT X R

API 620 / 650, NDE / NDT Procedures. Report.
0470-8710-PR-00-
Procedure.
4.12 RT examination of Welds. ASME V , Contractor Fabrication and FW3410-RT Report. X R Notification of RT and RT
API 620 / 650, NDE / NDT Procedures. Control Chart to be completed.
Welding Control
Procedure.
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PROCEDURE
REQUIRED
Criteria NUMBER
4.13 UT examination of Welds. ASME V , Contractor Fabrication and FW3412-UT Report. X R
API 620 / 650, NDE / NDT Procedures.
0470-8710-PR-00-
Procedure
4.14 PMI examination. -Positive Material Contractor Fabrication and FW3415-Weld-PMI X W

Identification, NDE / NDT Procedures. Report &
ASME V , FW3415-Valve PMI
API 620 / 650, Report.
0470-8710-PR-00-
Procedure.
4.15 Posts weld heat treatment Welding Procedure, Contractor Fabrication and FW3413-PWHT X W
and hardness testing. PWHT procedure for Construction Procedures. Report,FW3416-
equipment, , API 620 / Hardness Test
650, Contract Report &FW3418-
requisition & 0470- Ferrite Test Report.
8710-PR-00-0021
Welding Control
Procedure
5. MATERIALS (CONTRACTOR SUPPLIED).
5.1 Assessment of suppliers. Contract Requisition. Contractor Procurement or Contractor to assess X R Suppliers to operate a Quality
Material Control Procedure. suppliers to ensure Management System meeting
technical requirements are ISO 9000 requirements.
met and to the appropriate Certification not essential.
quality level.
5.2 Material Approval and Contract Requisition. Contractor Procurement or X Purchase orders to be
subsequent Purchase Order Material Control Procedure. maintained. PMI required as per
placement. Positive Material Identification
(IF Applicable).
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PROCEDURE
REQUIRED
Criteria NUMBER
5.3 Material Certificates. Project Specification Contractor Procurement or Review prior to work X R Ensure compliance to project
Purchase Order Material Control Procedure. starting. requirements. Accompanying
Contract Requisition. certification to be checked and
included in data dossiers /
book.
5.4 Impact Test Results. See Material Contractor Procurement or Review prior to work X R Ensure compliance to project
Certification. Material Control Procedure. starting. requirements.
Accompanying certification to
be checked and included in
data dossiers / book.
5.5 Inspection of purchased Purchase Order Any item not complying with All purchased items to be X R Materials to confirm to the
items (receiving inspection Mill Certification specification will be inspected against the Contract requisition and tank
by Contractor at Contractors Supplier marking and quarantined. requirements of the data sheets.
works and prior delivery to coding purchase order.
site). Packing Lists, Purchased items without
Inspection of Release Notice or Rejection Accompanying certification appropriate certification to be
Equipment and Notice Per Inspection of to be checked and included rejected and quarantined.
Materials. Positive Equipment and Materials. in data book discrepancy
Material Identification, reports. No material to be released for
Atmospheric Storage use until appropriate
Tanks & certification is available.
API 620 / 650.
5.6 Material Preservation and 0470-8710-PR-00- Contractor Procedures from X I Maintenance log to be
Maintenance. 0026 Material receipt to Turnover. maintained by Contractor
Preservation & throughout duration of Contract
Maintenance from Contractor procurement to
Procedure. system Turnover.
Pipe and fittings to be kept

internally clean.
Flange and valve faces to be

protected against damage and
corrosion.
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PROCEDURE
REQUIRED
Criteria NUMBER
6. SITE SURVEY
6.1 Acceptance of the site. Contract Requisition. Contractor to take pre- Survey report. Excavation not to X I Note survey only show “live”
Site surveys, construction survey commence until Contractor cables, others may be
drawings and details photographs prior starting to reviews survey reports and disconnected, but still buried.
of existing confirm condition of facilities at checks reports of existing
underground services handover. CLIENT to confirm buried and underground
information. location of Operational services.
Blinds with Contractor
fabrication, Installation and
Removal.
6.2 Temporary works during Contractors drawings, Underground Set temporary benchmarks X I Temporary pipe supports for
construction. documents and procedures. Services / Drainage and datum points. new and existing facilities.
Inspection.
7. SITE INSPECTIONS
7.1 Foundation Acceptance and AFC layout drawings Contractor Fabrication and FW3344-Civil Works Check elevation and X W Install tank settlement plates;
install tank settlement plate. 0470-8710-PR-00- Construction Procedures Foundation Release coordinates. perform surveys at start of
0039 System Record. construction, prior to and after
Completion & test.
Turnover Procedure
7.2 Plate Cleanliness. Contract Requisition. Contractor Fabrication and Visual inspection X I
Construction Procedures
7.3 Record Tank Levels. Layout drawing. Contractor Fabrication and FW3599Record of Commence work after FW X W
Construction Procedures. Levels, Cardinal approval
Points, Orientation
and Dimensions.
7.4 Check plate dimensions Radical Vertical Contractor Fabrication and X I

Distortion Construction Procedures
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PROCEDURE
REQUIRED
Criteria NUMBER
7.5 Plate damage during Discrepancy report. Contractor Fabrication and Repair prior to work X I FW to witness repairs and any
transportation. Construction Procedures. commencement. NDE works.
8. BOTTOM PLATES
8.1 Tank Foundations / Leak Contract Requisition, Contractor Fabrication, FW3344-Civil Works X I Cathodic Protection system
detection. -Tank Foundations & Construction and Electrical Foundation Release design and installation
-Cathodic Protection. Testing Procedures. Record & confirmation.
FW3880Earthing
Test Report.
8.2 Bottom / annular plate Contract Requisition. Contractor Fabrication and FW3456-Painting Commence work after FW X I (H) FW to witness coating condition
inspection of protective Construction Procedures. Completion Report. approval (where required) prior laying on
coating of lower (underside) to the foundation.
surface (where required).
8.3 Bottom plate and draw off AFC layout drawings Contractor Fabrication and FW4049-Tank X I
sump laying arrangement. API 620 / 650 Construction Procedures. Bottom Plate Level
Check.
8.4 Visual inspection of fit-up API 620 / 650 Contractor Fabrication and FW3460-Visual Review joint alignment and X I For welding, PWHT, PMI and
conditions, root gap, Construction Procedures. Examination Report. dimensions prior to starting NDE see Section 4.
bevelling, joint alignment and full weld.
dimensioning.
8.5 Bottom / annular plate API 620 / 650 Contractor Fabrication and FW3460-Visual Satisfactory inspection - X W
intermittent welds. Construction Procedures. Examination Report proceed work.
& FW3411-MT / PT
Report.
SPECIFIC Rev: O1
DSN NO:8026

PROCEDURE
REQUIRED
Criteria NUMBER
8.6 Plates overlap width. AFC layout drawings Contractor Fabrication and Tank Bottom Contractor specification. X I
API 620 / 650 Construction Procedures. Inspection Test
Chart & FW3600-
Bottom / Roof
Annular Butt Weld
Numbers.
8.7 Bottom plate weld and sump NDE report & Vacuum Contractor Fabrication and FW3407-Weld Satisfactory welding X R/W
draw off completion. Box Tests. Construction Procedures. Inspection Summary Sequence and records.
Sheet, FW3410-RT
Report & -FW3411-
MT / PT Report.
9. SHELL PLATES
9.1 Tank ID Marking. AFC layout drawings. Contractor Fabrication and FW4053-Shell Base Commence work after FW X H/W
Construction Procedures. Roundness Report. approval.
9.2 Adjust first course shell AFC layout drawings Contractor Fabrication and FW3604-Site Record X I Visual and dimensions checks
plates for roundness and API 620 / 650 Construction Procedures. Test Numbers, on-going.
anchor bolt pick-up (where FW3606-Shell Welds
required). Visual / NDT &
FW4053- Shell Base
Roundness Report.
9.3 All courses / strakes check AFC layout drawings Contractor Fabrication and FW3604-Tank Shell X I Visual and dimensions checks
level, verticality, peaking and API 620 / 650 Construction Procedures. Vertical and Radial on-going.
banding. API 620 / 650 Checks &FW4051-
Shell Peaking and
Banding Report.
9.4 All courses / strakes check AFC layout drawings Contractor Fabrication and FW4052-Shell X I Visual and dimensions checks
level, roundness and API 620 / 650 Construction Procedures. Plumbness Report. on-going.
plumbness. API 620 / 650
9.5 Wind girder, intermediate AFC layout drawings Contractor Fabrication and FW3608-Storage X I
wind girder, curb angles and API 620 / 650 Construction Procedures. Tank Miscellaneous
top angles and stiffeners. API 620 / 650 Inspections.
SPECIFIC Rev: O1
DSN NO:8026

PROCEDURE
REQUIRED
Criteria NUMBER
10. ROOF PLATES
10.1 Lifting Operations. Equipment Lifts by Contractor rigging studies / Cranes and lifting X I Crane test certification to be
Cranes. method statements / Permit to equipment to be inspected current and available for
Work / SOC approval for by FW. Crane operators to inspection.
working close to existing / live be appropriately qualified.
facilities.
10.2 Arrangement and installation Approved for Contractor Fabrication and Bottom / Roof X I
of roof plates & deck plates Construction layout Construction Procedures. Annular Butt Weld
decks. drawings. Numbers & Storage
Tank Miscellaneous
Inspections.
11. ACCESSORIES
11.1 Stairways, platforms, rolling AFC layout drawings Contractor Fabrication and FW3608-Storage X I Orientation Check for
ladders, vent support, vessel Supplier drawings Construction Procedures. Tank Miscellaneous attachments and access points.
trims, vessel clips, fire Inspections.
suppressant connections,
etc.
11.2 Man ways and nozzles AFC layout drawings Contractor Fabrication and FW4048-Tank X W All Man ways and Nozzle
reinforcing or compensation AFC layout drawings Construction Procedures. Appurtenance on Roof & Shell openings
pads. API 620 / 650 Orientation & must be Verified and sign
API 620 / 650. FW5016- off on Dimensional Check at
Reinforcement Pad actual location Marking
Test Report. before Cutting of Openings
is carried out.
11.3 Pipework systems, fire / AFC layout drawings X I

foam systems, roof drainage. & for Fire Systems.
11.4 Relief Valve installation and AFC layout drawings. Contractor Fabrication and FW3425-Safety X I Relief valve test by Instrument
inspection. Construction Procedures. Relief Valves – Contractor. Relief.
-Vents for Fixed Roof Installation Report.
Vent installation. Atmospheric Storage
Tanks.
SPECIFIC Rev: O1
DSN NO:8026

PROCEDURE
REQUIRED
Criteria NUMBER
11.5 Installation and testing of Contract Requisition. Contractor Fabrication, FW3376-Cable Electrical RE to witness X W Note that mechanical protection
grounding / earthing cables Electrical installation / Construction and Electrical Trench Backfilling lightning protection testing is required where earthing cable
and rods / protection. earthing drawings. Testing Procedures. Record,FW3380- activities. stubs up adjacent to plinths
Earthing Test Report and/or foundations.
& Lightning
Protection Report.
12. INSPECTIONS
12.1 Test Plan Inspections per the Contractor Procedures. WITNESS ITP approval by FW & X H/R Note requirements for RE
agreed Contractor Master Daily CLIENT. inspections, typically against
Inspection and Test Inspection Log. fire systems / lightning
Plan. protection.
12.2 Welding and NDE Report. Welding and NDE Contractor Fabrication, NDE / FW4091-Tank Shell X R Weld and NDE maps for plates
Report Complete. NDT and Construction Welding and NDE and pipe required.
Procedures Summary Sheet.
12.3 Certification against visual QC Documentation Contractor Fabrication, NDE / FW4057-Tank X R

inspection of unit. Complete. NDT and Construction Installation Check
Procedures. List.
12.4 Jig scars for all areas Visual inspection. Contractor Fabrication and FW3460-Visual X I
removed. Construction Procedure. Examination Report
&FW3607- Visual /
Crack Detection
Scar Area: Pre-
Hydrotest.
13. TESTING
13.1 Pre-test inspection. Inspection and Test Contractor Construction and FW4092-Tank X R
Plan. Testing Procedures. Completion Ready
for Test.
SPECIFIC Rev: O1
DSN NO:8026

PROCEDURE
REQUIRED
Criteria NUMBER
13.2 NDE records complete. NDE and Welding Contractor Fabrication, NDE / Welding and NDE FW acceptance and X H
completed and NDT and Construction reports clearance of welding and
cleared. Procedures. FW4091-Tank Shell NDE documents.
Welding and NDE
Summary Sheet.
13.3 Pre-hydro-test inspection. AFC layout drawings. Contractor Construction and FW3608-Storage Inspection prior to hydro- X W Review tank drainage / water
Testing Procedures. Tank Miscellaneous test discharge location.
Inspections
.FW3607-Visual /
Crack Detection
Scar Area: Pre-
Hydrotest.
13.4 Settlement datum points. AFC layout drawings. Contractor Fabrication and FW3599-Record of X I Datum reviewed prior test. See
Construction Procedures. Levels, Cardinal Section 8.1
Points, Orientation
and Dimensions.
13.5 Hydro-test preparation. Method statement, Construction and Testing FW4050-Tank Task FW witness at holding X W/I Monitor settlement. Confirm
Task Safety, Procedures and Test Packs. Water Filling Chart & times and periodically filling and holding periods with
Assessment and FW3609-Storage during filling operations. CLIENT.
JSEAs, Testing schedules against fill Tank Hydrostatic Any settlement for those tanks
API 620, API 650 & point locations and available Test. using foundations from
liquid volumes. disinvested facilities, details to
Note any inhibitors / water be discussed with CLIENT.
quality.
13.6 Empty. Settlement Check. Contractor Construction and FW4054-Tank Review any settlement. X W Note initial levels prior start of
Testing Procedures. Foundation test. See Section 8.1.
Settlement Report.
13.7 Half full. Settlement Check. Contractor Construction and FW4054-Tank Review any settlement. X W
Testing Procedures. Foundation
Settlement Report &
FW3610-Record of
Level During Water
Test.
SPECIFIC Rev: O1
DSN NO:8026

PROCEDURE
REQUIRED
Criteria NUMBER
13.8 Full. Settlement Check. Contractor Construction and FW4054-Tank Review any settlement. X W
Testing Procedures Foundation
Settlement Report &
FW3610-Record of
Level During Water
Test..
13.9 24 hour full. Settlement Check. Contractor Construction and FW4054-Tank Review any settlement. X W
Testing Procedures. Foundation
Settlement Report &
FW3610-Record of
Level During Water
Test.
13.10 Leak test. Atmospheric Hydro- Contractor Construction and FW3610-Record of X W

test. Testing Procedures. Level During Water
Test & FW3609-
Storage Tank
Hydrostatic
Inspection.
13.11 Vacuum test. Vacuum 0.02 MPa (g) Contractor Construction and FW3602-Tank X W
or 3psig. Testing Procedures. Bottom Vacuum
Test.
13.12 Oil penetrant test. API 620 / 650 Contractor Construction and FW3608-Storage X W
Testing Procedures. Tank Miscellaneous
Inspections
&FW3609-Storage
Tank Hydrostatic
Inspection.
13.12 Reinforcing or compensation 0.103 MPa(g) / 15psig Contractor Construction and FW4048-Tank X W .
pads. using compressed air. Testing Procedures. Appurtenances
Orientation &
FW5016-
Reinforcement Pad
Test Report.
SPECIFIC Rev: O1
DSN NO:8026

PROCEDURE
REQUIRED
Criteria NUMBER
13.13 Pipework Pre-test, Test and Method Statement. Contractor Construction and FW3419-Pipework X W Standard piping certification to
Post Testing activities. Testing Procedure. Pre-Test Check List, be used. Test packs required.
FW8711-Pipig Test NDE clearance per Section 4.
See also 0470-8710-PR-0012 Pack Specification
Piping Work QC Documentation and Test Report & Prior Certification of Statutory
& 0470-8710-PR-0015 Pipingg FW3422-Pipework Completion (CSC) all fixed
Testpack Coordination Post Test Check foam / water spray / monitors
Procedures. List. for the tanks / tank farm to be
completed and foam bladder
tank / lines to be painted and
stencilled accordingly.
The RE/RI to inspect.
13.14 Flushing and cleaning of tank Method Statement, Contractor Construction and FW3426-Flushing X W Clean pipework/completed tank
and pipework. Field Erection & pipe Testing Procedures. Check List & Test post testing activities.
Cleanliness Pack Post Test
Procedure. Drying Certificate.
13.15 Tank strapping. Contract Requisition. Contractor Construction and X I

& 0470-8710-PR-00- Testing Procedures.
0039 System
Completion &
Turnover Procedure
14. DEFECTS
14.1 Repair of defects. Approved procedures, Contractor Fabrication, Erection FW3607-Visual / X W Type of examination dependent
qualifications, and Examination / Testing Crack Detection on repair.
specifications, procedures. Scar Area: Pre-
method statements, Hydrotest & FW3419
etc. -Pipework Pre-Test
Check List.
14.2 Defects repair – Defects Report. Contractor Fabrication, FW3410-RT Report, Defect repaired. X W Record of all elements that are
examination. Construction and Erection FW3411- MT Report, subject to repair / defects to be
procedures. FW3412- UT-Report collated into As-Built Dossier.
& FW3606-Shell
Welds (Visual /
NDT).
SPECIFIC Rev: O1
DSN NO:8026

PROCEDURE
REQUIRED
Criteria NUMBER
15. PAINTING, COATINGS, COATING AND WRAPPING TOUCH-UP / REPAIRS
15.1 Surface preparation and -Colour Coating Contractor preparation, FW3461-Paint Measure and record X I To include Tank Identification
application. System for Structure/ blasting, painting, coating, Acceptance Report. achieved surface profile. Tag Numbers.
Equipments -Colour inspection, repair procedures.
Identification for
Storage Tanks.
SP-93-1.
15.2 Measurement of temperature -Colour Coating Contractor preparation, FW3461-Paint Daily monitoring of X I Daily records to be maintained
and humidity levels. System for Structure/ blasting, painting, coating, Acceptance Report. temperature and humidity of morning and afternoon
Equipments Colour inspection, repair procedures. levels. atmospheric conditions.
Identification for
Storage Tanks. SP-
93-1.
15.3 Coating system inspection. -Colour Coating Contractor preparation, FW3461-Paint Dry film thickness X I
System for Structure/ blasting, painting, coating, Acceptance Report. measurement of primer,
Equipments -Colour inspection, repair procedures. intermediate and top coats.
Identification for
Storage Tanks. SP-
93-1.
15.4 Galvanising application, Contract Requisition. Contractor hot dip galvanising FW3461-Paint Thickness of galvanise X I Visual inspection of galvanising
inspection and repair. procedures. Acceptance Report. repairs to be randomly finish quality.
Galvanising repair procedures examined.
15.5 Coating and Paint Colour Coating Contractor coating / wrapping FW3461-Paint X I/R
Completion. System for Structure/ procedure from supplier and Acceptance Report.
Equipments & Colour applied in accordance with
Identification for supplier recommendations.
Storage Tanks. SP- Holiday Detection examination
93-1. to supplier or CLIENT voltages
16. VENDOR SERVICE REPRESENTATIVE AND SUPPLIERS REQUIREMENTS
16.1 Vendor Specific Vendor Procedures. Vendor Standard(s) X W Works to be completed in

Requirements. where required. accordance with vendor
requirements. Vendor to sign off
completion QC certificate(s) if
applicable.
SPECIFIC Rev: O1
DSN NO:8026

PROCEDURE
REQUIRED
Criteria NUMBER
17. SYSTEM COMPLETION
17.1 Construction and final punch Contract Requisition. FW3291- X X X Punch List items transmitted to
lists. Construction Punch FW Turnover Engineer to
List. produce Consolidated System
Punch List.
17.2 Consolidated System Punch Consolidated System Category "A" must be X X X .

List issued. Punch List completed before System
0470-8710-PR-00- Turnover.
Contractor clears and signs 0039 Category “B” items can be
off items which are verified System Completion & completed after System
and countersigned by FW Turnover Procedure. Turnover but before Start-
and CLIENT. up of the Facility.
Category "C" items can be
completed after Start-up,
but are required before
Acceptance of the Facility.
17.3 Copy of System Turnover 0470-8710-PR- System Turnover Note Category “B” and “C” X X X Contractor continues to clear
Notice issued to Contractor. 0028System Notice. items must be completed and sign off any outstanding
Completion & under Client permit to work Category “B” and “C” items
Turnover Procedure. system. which are verified and
countersigned by FW and
CLIENT
17.4 Prepare site QC dossier and Contract Requisition, FW to review turnover X R Vendor QC certificates and
submit to FW. 0470-8710-PR-00- documentation package. procedures to be incorporated
0039 within QC Dossier.
-System Completion
& Turnover
Procedure, 0470-
8710-PR-00-0021
Welding Control
Procedure.
17.5 Prepare red-line "as-builts" FW approved FW to review. X R

and submit to FW for modifications in
acceptance. writing.

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PROJECT 0470-8710-PR-0041

AFTON CHEMICAL ASIA PTE LTD

PROJECT LION – PHASE 2

PREPARATION OF INSPECTION AND TEST PLAN

Rajappan Kelleher Abdul Angela

CONFIDENTIAL DOCUMENT NO:

PROPRIETARY INFORMATION FOR

4.0 REFFERENCE DOCUMENTS……………………………………………………………... 3

5.1 Piping and Mechanical Works Contractor…..................................................... 5

5.4 Authorized Qualified Engineer……………………………………………………… 5

6.1 General Overview…………………………………………........................................ 5

6.2 Responsibility Definition……………………………………………………………... 5

6.3 Inspection Forms……………………………………………………………………… 6

6.4 Submission of Inspection Forms……………………………………………………. 7

6.5 NDE Inspection Forms……………………………………………………………….. 7

6.6 System Turnover…………………………………………………………………….…. 7

6.7 Compilation of QC Dossiers…………………………………………………………..8

ATTACHMENT 1 INSPECTION AND TEST PLAN

ASNT American Society for Non-destructive Testing.

0470-8710-PR-00-0016 Piping Work QC Documentation.

0470-8710-PR-00-0011 QA QC Instruction To Contractors.

1. Storage Tank Fabrication and Erection Works Contractor(s)

FW shall be responsible for monitoring the Tankage Contractor(s) in the execution of

4. Authorize Qualified Engineer

Responsibilities listed in Attachment 1 of this overall Inspection and Test Plan is as

I: Responsible for inspecting work on surveillance or monitoring basis and signing

As inspection and surveillance activities are completed, the QC forms

Sign off on the QC form by the FW Construction Supervisor confirms that he

W: Responsible for witnessing and signing for the work.

For FW and any Third Party, attendance at a Witness point activity is

Client – after receiving advance notification (Request for Inspection) of any

QC construction certificates / inspection forms have been defined in Attachment 1.

4. Submission of Inspection Forms

The Contractor shall ensure that QC construction certificates / inspection

5. NDE Inspection Forms

The Contractor shall compile all necessary QC construction certificates / inspection

Category "C" items are required before Acceptance of the Facility.

All QC construction certificates / inspection forms and associated documentation that

package. Upon acceptance (or otherwise) of this turnover documentation package by

Acceptance of System Turnover shall not preclude the Contractor(s) in completing

ATTACHEMENT 1 – inspection and Test Plan

1.2 Review FW drawings / X

1.3 Review Supplier and Vendor Contract Requisition. X

1.7 Contract kick-off meeting. Contract Requisition Notes of meeting. X X

CONTROL DOCS REPORT FORM/

1.8 Sample Signatures. Sample signature of S-HDS 3290- X I Sample signatures

2. DOCUMENTS REQUIRING APPROVAL

CONTROL DOCS REPORT FORM/

CONTROL DOCS REPORT FORM/

2.6 Radiographic Test ASME V & Contractor Radiographic X H/R

CONTROL DOCS REPORT FORM/

performing any welding or Non-Destructive Examination activities

CONTROL DOCS REPORT FORM/

2.10 Positive Material Positive Material Contractor Positive Material X H/R

2.11 Hardness and Ferrite Testing Additional Contractor Hardness Testing

3. INSPECTION MEASUREMENT & TEST EQUIPMENT

4. WELDING & NON-DESTRUCTIVE TESTING OPERATIONS

CONTROL DOCS REPORT FORM/

4.5 Weld Procedure 0470-8710-PR-00- Contractors fabrication and FW3414-Summary X I

CONTROL DOCS REPORT FORM/

4.9 Visual Inspection of Welds. ASME V, Contractor Fabrication and FW3460-Visual X I

4.10 MT examination of Welds. ASME V, Contractor Fabrication and FW3411-MT / PT X R

4.11 PT examination of Welds. ASME V , Contractor Fabrication and FW3411-MT / PT X R