QUALITY ASSURANCE PLAN FOR CONSTRUCTION OF STORAGE TANKS

CUSTOMER :
CONTRACTOR :
PROJECT
:
SL.
NO.

DESCRIPTION OF ITEMS

DATE
QAP NO.
PAGE
CHARACTERISTICS TO
BE CHECKED

CAT

:
:
:

TYPE/METHOD
OF CHECK

EXTENT OF
CHECK

REFERENCE
DOCUMENTS

ACCEPTANCE
STANDARDS

FORMAT OF
RECORDS

AGENCY
P
W

V
1,2

REMARKS

MATERIAL IDENTIFICATION
1.

2.

3.

Plate for tanks, nozzle neck 10" and

above and structurals

Pipes for nozzle

Flanges for nozzles

Pipe fittings

Bolts, nuts for nozzle flanges &

structurals

1 Physical, chemical
properties, heat
treatment.

Physical &
Chemical Tests.

As per
Specification

APPD DRGS/
DATA SHEET

IS 2062 GR. B,C

& GR. A for
structurals SA
370

MILL TC

3/1

2 Dimensions and
surface quality

Meas. & Visual

100%

APPD DRGS/
DATA SHEET

ASTM A 6,A20

IR

3 Lamination free

Visual, UT/MPT (if

reqd.)

All edges

API 650

ASME Sec. VII

Div. I

MFTRS TC &
IR

1 Physical, chemical
properties, heat
treatment

Physical &
Chemical Tests

As per
specification

APPD DRGS/
DATA SHEET

A 106GR B/C,
API 5L Gr. B

MFTRS TC

1*

2 Dimensions and
surface quality

Meas. & Visual

100%

APPD DRGS/
DATA SHEET

ANSI B
36.10/API 5L

IR

1 Physical, chemical
properties, heat
treatment

Physical &
Chemical Test

As per
specification

APPD DRGS/
DATA SHEET

ASTM A 105 & A

181

MILL TC

3/1

1,2

2 Dimensions & surface

quality

Meas. & Visual

100%

APPD DRGS/
DATA SHEET

ANSI B 16.5

IR

1,2

1 Physical, chemical
properties, heat
treatment
2 Dimensions & surface
quality

Physical &
Chemical Tests

As per
specification

APPD DRGS/
DATA SHEET

As per WO/
ASME SA 234

MFTRS TC

3/1

Meas. & Visual

100%

APPD DRGS/
DATA SHEET

ANSI B 16.9

IR

1 Physical, chemical
properties, heat
treatment

Physical &
Chemical Tests

As per
specification

APPD DRGS/
DATA SHEET

ASTM A 193 &

194/ IS 1367
C. L. 4.4.6

MFTRS TC

3/2

2,1

2 Dimensions & surface

quality

Meas. & Visual

100%

APPD DRGS/
DATA SHEET

ANSI B 1.1/B
1.2/ B 18.2.2

IR

For IOC supplied

material

Not reqd. for

structurals.
1,2

*If specified in WO

IOC to witness 10%

random meas &
100% visual.

SL.
NO.

6.

DESCRIPTION OF ITEMS

IN PROCESS:
Welding procedure specification
proposed

CHARACTERISTICS TO
BE CHECKED

CAT

TYPE/METHOD
OF CHECK

EXTENT OF
CHECK

REFERENCE
DOCUMENTS

ACCEPTANCE
STANDARDS

FORMAT OF
RECORDS

AGENCY
P
W

Correctness

Scrutiny

100%

WPS

WPS-ASME
SEC. IX

WPS

Welding procedure qualification

test and record

Desired property of
welding, establishing
correctness of
welding variables

Physical &
Chemical Tests

100%

WPS

ASME SEC
IX

ASME WPS &

PQR Formats

1,2

Welders Performance
Qualification

Ability of welders to
make sound weld

Radiography

100%

WPQ

ASME SEC IX

ASME WPQ
format

1,2

Plate cutting for bottom, shell &

roof

Dimensions,
checking diagonal &
squaring

Meas. & Visual

100%

Cutting Layout
Plan

APPD. DRGS.

IR

10

Rolling of Plates

Dimensions &
Shape

Meas./ Visual

100%

APPD. DRGS.

APPD. DRGS.

IR

11

Fittments of weld joints

Alignment, Edge
preparation, root
gap, cleanliness
along seam

CR

Visual, Meas,
Plumpness

100%

APPD. DRGS.

APPD. DRGS.

IR

2,1

12

Root run after back gauging of

Butt weld joints

Free of flaw

Visual

100%

API 650

API 650

IR

2,1

13

Finished Butt weld joints

1 Smoothness and
Reinforcement
2 Internal Flaws

Visual

100%

API 650

API 650

IR

2,1

CR

Radiography

API 650 & WO

2/3

2,1

Meas/Plump

API 650

ASME Sec. VIII

Div. I, UW-51b
API 650

IR

3 Peaking/ Banding/
Circularity

API 650 &

WO
100%

IR

2,1

1 Lay out, Edge Prepn

2 Welding

M
M

Visual
Visual, Vacuum
Test, Pneumatic
Test

100%
100%

API 650
API 650

API 650
API 650

IR
IR

2
2

2,1
2,1

14

All Lap Joints of Bottom Plates

REMARKS

To be checked
and approved by
IOC before tests.

SL.
NO.

DESCRIPTION OF ITEMS

15

Bottom plates sand blasting

underside painting

16

Nozzle to flange & nozzle to

shell

17

RF Pad/ Nozzle to Shell

18
19

CHARACTERISTICS TO
BE CHECKED

TYPE/METHOD
OF CHECK

EXTENT OF
CHECK

REFERENCE
DOCUMENTS

ACCEPTANCE
STANDARDS

FORMAT OF
RECORDS

AGENCY
P
W

1,2

M
M

DFT, Elcometer
Visual, Plumb,
Meas

100 %
100%

WO
APPD. DRGS/
API 650

Painting Spec.
API 650/
APPD. DRGS

IR
IR

2
2

1,2
1,2

Leak tightness

Pneumatic soap
suds

100%

API 650

API 650

IR

1,2

Shell to Annular plate

1 Weld soundness
2 Leak tightness

M
M

Visual/ Meas.
Penetrant/

100 %
100%

APPD DRGS
API 650

API 650
API 650

IR
IR

2
2

1,2
1,2

Deck plate lap joints

1 Fitment, dimensions
Slope
2 Weld Soundness

Visual/ Meas.

100%

APPD DRGS

API 650

IR

1,2

Visual/
Penetrant

100%

API 650

API 650

IR

1,2

1 Fitment / Dimension
2 Welding

M
M

Visual & Meas

LPT/Pneumatic

100%
100 %

APPD DRGS
API 650

API 650
API 650

IR
IR

2
2

1,2
1,2

Dimensions &
Welding
Alignment,
Dimension, Weld
soundness

Visual & Meas.

100%

API 650

IR

1,2

Visual /Meas.

100%

APPD DRGS/
API 650
APPD DRGS

API 650

IR

1,2

1 Cleanliness/ Surface
Profile
2 Coating thickness
Dimension,
Orientation of
nozzle, projection,
elevation, fittment

CAT

Visual / Meas.

100%

WO

Painting Spec.

IR

20

Rim bulk head compartment

21

Splice joints of rafters/columns

22

Appurtenances, leg supports

fabricated appurtenances

23

Central Sump

1 Fitment
2 Weld soundness

M
M

Visual / Meas.
DPT/ & Visual

100%
100%

APPD. DRGS.
API 650

API 650
API 650

IR
IR

2
2

1,2
1,2

24

Piping for fire water/foam system

1 Layout & fitment

2 Welding quality

M
M

Visual, Meas.
Root DPT &
Final welding
Visual

100%
100%

APPD. DRGS.
APPD. DRGS.

APPD. DRGS.
APPD. DRGS.

IR
IR

2
1

1,2
1,2

REMARKS

10% of DPT shall

be witness by 1

SL.
NO.

DESCRIPTION OF ITEMS

25

Inspection prior to release for

hydro-test, Inside/Outside
welding surface, External
Internal attachment

26

CHARACTERISTICS TO
BE CHECKED

CAT

TYPE/METHOD
OF CHECK

EXTENT OF
CHECK

REFERENCE
DOCUMENTS

ACCEPTANCE
STANDARDS

FORMAT OF
RECORDS

AGENCY

Completeness,
cleanliness, overall
dimension,
plumpness
orientation,
radiography etc.

CR

Visual, Random
Meas.,
Verification of all
records

100%

APPD. DRGS,
DATA SHEET

APPD. DRGS.
DATA SHEET,
API 650

IR

Final inspection during hydrotest

Leak tightness
verticality

CR
M

Hydrotest
Plump

100%
Every 30

APPD. DRGS
APPD. DRGS

API 650
API 650

IR
IR

2
2

1,2
1,2

27

Final assembly

Settlement

Meas.

Every 30

APPD. DRGS

IR

1,2

28

Buoyancy test, Floatation test,

Deck puncture test

Smooth Floatation
leak tightness

CR
M

Hydrotest
Submersion
Measurement

100%
100%

APPD. DRGS
API 650

OISD 129/ BS
3659
API 650
API 650

IR
IR

2
2

1,2
1,2

29

Rain water test

Deck

CR

Water filling on
deck

100%

API 650 Spec.

API 650 Spec.

IR

1,2

30

Calibration

Capacity wrt Filling

height

Meas. &
Certification

100%

APPD. DRGS
IS 2007/2008

IS 2007/2008

Cali. Chart

1,2

31

Cleaning

Cleaning external &

internal after
hydrotest

Visual

100%

Technical
Specification

Technical
Specification

IR

2,1

32

Painting/ Stamping

1 Surface Preparation
2 Surface Finish
3 Coating Thickness

M
M
M

Visual
Mech. Gauge
Elco. Meter

100 %
Random
Random

Approved
Procedure

Approved
Procedure

IR

2,1

33

QA & QC Documentation

Overall quality, Data

Keeping

Review of all
TC, IR for
previous stages

100%

Technical
Specifiation

Technical
Specifications
& applicable
codes

IR

REMARKS
V

SL.
NO.

34

DESCRIPTION OF ITEMS

STANDARD BOUGHT-OUT
ITEMS
Gauge hatch

35

Sprinkler nozzle/ Foam maker

36

Foam seal & Accessories

37

P
W
V
H

Flame arrestor/ Breather valve

PERFORMED BY
WITNESSED BY
VERIFIED & REVIEWED BY
HOLD TILL CLEARED BY 1

CHARACTERISTICS TO
BE CHECKED

CAT

TYPE/METHOD
OF CHECK

EXTENT OF
CHECK

REFERENCE
DOCUMENTS

ACCEPTANCE
STANDARDS

FORMAT OF
RECORDS

AGENCY
P
W

AS PER
SPEC.
APPD. DRGS.
APPD. DRGS.
DATA SHEET

As per spec.
APPD. DRGS

MFTRS TC

3,2

1,2

APPD. DRGS.
DATA
SHEETS

MFTRS TC

3,2

1,2

1 Physical & Chemical

Properties

Physical,
Chemical Tests

Random

2 Dimension

Visual & Meas.

100%

Physical &
Chemical Tests

Random

APPD. DRGS
& SPEC.

APPD. DRGS
& Spec.

MFTRS TC

3,2

1,2

1 Physical & Chemical

Properties

Physical &
Chemical Tests

Random

APPD. DRGS
& SPEC.

APPD. DRGS
& Spec.

MFTRSTC

2 Dimension

Meas. & Visual

100%

APPD. DRGS
& SPEC.

APPD. DRGS
& Spec.

MFTRS TC

3,2

1,2

1 Physical & Chemical

Properties

Physical &
Chemical Tests

Random

APPD. DRGS
& SPEC.

APPD. DRGS
& Spec.

MFTRSTC

2 Dimension

Meas., Visual

100%

APPD. DRGS
& SPEC.

APPD. DRGS
& Spec.

IR

Dimension &
Surface Quality

1. HPCL AUTHORISED REPRESENTATIVE

2. VENDOR QC
3. SUB AGENCY/ SUB VENDOR (IF APPLICABLE & APPROVED)

CR : CRITICAL
M : MAJOR
IR : INSPECTION RECORD TO BE MAINTENED BY STS
MEAS. : MEASUREMENT

Remarks