Shop Fabrication Welding & Painting Procedure 22-07 Rev-2

Project Number 2200016412
Dammam Water Improvement Project South Strategic &

Distribution Networks and Reservoirs – Project 3
Al-Yamama Company for Trading & Contracting (AYC)
ILF Consulting Engineers
METHOD STATEMENT
OF
SHOP FABRICATION, WELDING & PAINTING
PROCEDURE
Date: 06/NOV/2023
Version: 2
Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501)

Document History
Issue Status
&  Issued for Review/Approval  Issued for use
Description
Reviewed Approved
Prepared
Document Ref. Rev Issue Date by by Project
by
Supervising Manager
Contractor Consultant
2200016406- 1 28/October/2023 M.A Baig
D3-AYC-
010GEN-MEC-
MS-04501
2200016406- 2 06/November/2023 M.A Baig

D3-AYC-
010GEN-MEC-
MS-04501
Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 2 of 18

LIST OF CONTENTS
1. Introduction...............................................................................................4.
2. Scope & Purpose......................................................................................4.
3. References................................................................................................4.
4. Abbreviations...........................................................................................4.
5. Responsibilities.....................................................................................5 to 6.
6. Material Identification & Traceability.......................................................7.
7. Fabrication-Raw Material........................................................................7.
8. Shop Fabrication Process..........................................................................7 to 14.
9. Type of Tank components....................................................................14 to 17.
10. Packing & Transportation........................................................................18.
11. Safety......................................................................................................18.
12. Attachment ………………………………………………………….......18.

1. Introduction
This document intended to describe the Shop work activities of tanks component of field erected tanks,
Above Activities shall be performed at Metscco own Facility Situated at Riyadh, 2nd industrial area &
Jeddah, Kingdom of Saudi Arabia.
2. Scope and Purpose
This procedure provides guidelines and safe requirements for shop fabrication, welding & Painting of field
assembled storage tanks in general. In addition to that, document is to follow proper methodology
to achieve the activities in sequence of fabrication, welding & painting with best suited method, good
workmanship and in accordance with the specifications, enables proper erection/installation of the storage
tank. No work shall be started prior to approval of method statement/procedure and ITP
all method statements and procedures shall conform to NWC specifications along with applicableinternational
standards.
SL.NO Mfr. Tag No. Description Type Location QTY Capacity

Nominal-
METSCCO TK# 440,441,442) Field Assembled vertical cylindrical water Fixed,Aluminium Dammam 49774
1 3
(CLIENT TK#1,2,3) storage tanks.(50mØ *25m Ht.) Dome roof. KSA Maximum-
48498
3. Reference
th

API 650 13 Edition.

PARTICULAR SPECIFICATION- DAMMAM- PROJECT 3 |<September 2018>.

PMF-012-QUA-121_02 Quality Requirements for Construction Contractors & Design
Consultants.
 ASME section IX.
 WQIP-D3-ILF-T-00218—Inspection test plan for shop works of tanks.
 2200016406-D3-AYC-010GEN-MEC-PR-04501---Steel Tanks WPS/PQR and weld map.
 2200016406-D3-AYC-010GEN-MEC-PR-04502---Steel Tanks Penetrating oil test procedure.
 2200016406-D3-AYC-010GEN-MEC-PR-04503---Steel Tank ; RF Pad Air (Pneumatic) Testing Procedure.
 2200016406-D3-AYC-010GEN-MEC-PR-04505---Steel Tanks; Liquid Penetrant Test (PT) Procedure.
 2200016406-D3-AYC-010GEN-MEC-PR-04506---Steel Tanks; Magnetic Particle Test (MT) Procedure.
 2200016406-D3-AYC-010GEN-MEC-PR-04507---Steel Tanks; Radiographic Test (RT) Procedure.
 2200016406-D3-AYC-010GEN-MEC-PR-04508---Steel Tank: Weld Repair Procedure.
 2200016406-D3-AYC-010GEN-MEC-PR-04509---Steel Tanks; Shop / In-Furnace PWHT Procedure
REV:2
4. ABBREVATIONS.
ISO - International Organization for Standardization
TPI - Third Party Inspector

NDT - Non-Destructive Testing
Contractor - Al-Yamama Company for Trading & Contracting (AYC)
Consultant - ILF Consulting Engineers (ILF)
Client - National Water Company (NWC)
ITP - Inspection & Test Plan
QC - Quality Control
RFI - Request For Inspection
MRIR - Material Receiving Inspection Report
5. Responsibilities
General
 Metscco are responsible for performing fabrication works.

 Complete prefabrication of tank components for site assembly shall be done
at Metscco manufacturing facility except sub vendor scope items.
 Galvanizing /FBE coating for steel structure, handrails, grating & pipes shall
be done by sub vendor as per approved IFC drawing & Painting specification.
Key personnel
Quality Manager
 The assigned QC manager shall meet the requirements stipulated in PMF-012-QUA-121_02

Quality Requirements for Construction Contractors & Design Consultants.
 The Quality Manager shall assign QC Engineer/Inspector to prepare the Inspection

and Test Plan, Test Procedures and other documents that may be contractually
required.
 The quality Manager shall review and approve the Inspection and Test Plan,
Test Procedures and other documents that may be contractually required.
 The Quality Manager shall supervise and randomly review the reports prepared by the
QC Engineers/Inspectors to ensure that the Project requirements are met.
QC Inspector
 The assigned QC manager shall meet the requirements stipulated in PMF-012-QUA-121_02

Quality Requirements for Construction Contractors & Design Consultants.
 The assigned QC Engineer/Inspector shall review the JO construction drawings,
specifications, ITP and other related documents to familiarize, with the requirements,
before starting work, at shop or at field site.

 He shall perform routine surveillance of the work-in-progress to monitor and ensure that
the Project requirements, especially those in the ITP are implemented.
 Upon completion of the desired inspection or test, prepare an Inspection or Test Report,
on the appropriate form/document, as stated in the “Verifying Documents” column of the
ITP and sign-off the same, if Engineer/TPI is involved- have it reviewed and signed by the
Engineer/TPI representative.
Production Manager
 Manages activities and supervises employees involved in the departmental operations. Assures the
process, production requirements and product quality expectations and customer needs are met.
 Provides direction and leadership to the departmental team to achieve high quality, productivity
and safety standards.
 Ensures compliance with production schedules, process quality, efficiency standards, budget,
inventory and data reporting.
 Assign work/ responsibility to the Production engineers.
 Plan the material to be delivered considering the priority, readiness of material for
delivery, requirement at site, and instruct the Production engineer to arrange the same.
 Ensure the compliance of ISO system, Project specification & procedures.
 Review & signing of PWHT chart prior to submit QC Engineer.
Production Engineer
 Depending on the Fabrication Activities required for fabricating a specific item/component,

Select & Assign a Group. And assign the work to Supervisor/ Foreman/Group Leader/with all
necessary instructions needed to accomplish the work activity.
 When the task is completed as per the requirements and arrange for the required Inspectionand
Testing to be carried out, by raising a RFI /verbally notifying the assigned QC E/Inspector.
 Study the welding requirements from the ref. drawing and weld map. Ensure that the applicable
WPS and qualified Welder/Welding Operator are available to perform the desired weld. If not
available arrange for the qualification of the desired.
 Maintain an updated “List of WPS/PQR”, “List of Qualified Welders/Welding Operators”.
 Review the Production Supervisor’s request for equipment and/or material and accordingly
coordinate with department head and desired dept. to raise a Purchase Request.

6. Material Identification & Traceability
 Material shall confirm to NWC Spec PARTICULAR SPECIFICATION- DAMMAM-

PROJECT 3 |<September 2018> para 1.5 or the Approved Drawings.
 After receipt of raw material, warehouse/storekeeper shall verify the material and forward
the Material Receiving Inspection Report (MRIR) for inspection and acceptance.
 The Storekeeper and the Material Receiving Inspector should be responsible for checking
the received materials and delivery note and test certificates.
 Storing of materials shall be the responsibility of the Storekeeper.
 Bolts, nuts, and gaskets shall be checked as per purchase order and verify size, grade
requirements.
 Quality inspectors will inspect the raw materials and verify the heat number & material
specifications with Material Testing Certificate (MTC).
 On acceptance, the raw materials will be released for production use. And store keeper shall
be issued material up on request from respective persons.
 The Production Supervisor/Foreman shall be responsible for arranging the item number and
punch the material heat number on each piece of plates, fitting or any other component of the
tank.as minimum item part mark, material grade and heat number.
 Any material not conforming with the material grade specification shall be kept and stored
separately, also log shall be maintained for unused/Rejected material.
 All Receiving material subjected to witness; review & Surveillance followed as per ITP.
 The material received shall be subject to inspection by the third-party inspector as per approved
ITP.
7. Fabrication –Raw Materials
 Main raw materials to be used for tank fabrication are plates, pipes, flanges, fittings,
structural etc.
 All materials must be clearly identified & provided with legible MTC.
 Material must comply with all requirements of applicable codes and specifications.
8. Shop Fabrication process
General - Components of tanks to be fabricated at shop.
Different components of the tank as applicable to different types of tanks are prefabricated with the
best suited process for fabrication. Shop activities include but not limited to marking, cutting, beveling
(Edge preparation) rolling, fit up, welding, PWHT, blasting, coating, packing & delivery.

Each piece of plates, fittings or any other component of tankage system shall be clearly identified by
marking heat no, Part mark, Job/tank number on the part by using hard punching system.
(letter/number punch & Marking Machine). All marking shall be properly visible with easy access.
Main components of the tank to be fabricated at shop are annular plate, bottom plate, shell plate,
nozzles &structural etc.
Welding
 The Field fabrication shop welding shall be performed in accordance with the req approved
Welding procedure specification (WPS). The welder and welding operator shall be qualified in
accordance with welder & welding operator's performance qualification procedure. Welding shall
be in accordance with API650, Section9. Welder and welding operators shall be qualified in
accordance with Section IX of the ASME code and NWC Specification.
 All welding procedure and welding performance qualification records shall be made available
to the TPI for review.
 Oil, moisture, rust scale, or other foreign matter shall be removed from the weld surface. Each
weld pass shall be thoroughly cleaned and all slag or foreign matter removed before next pass.
 All tack welds shall be made by qualified welders.
 All weld joints shall be marked for identification by a weld number and symbol (as shown in
weld map).
 All tack welds shall be made using a qualified welder.
 Any tacks that are to be incorporated in the final weld shall be properly cleaned.
 Each weld joint shall be marked with joint number with welder number.
 Weld joint geometry, alignment, and root opening are in accordance specified WPS
requirements.
 Weld preparation cleanliness is in accordance with specified WPS requirements.
 The weld filler material used is in accordance with specified WPS requirements

Non-Destructive testing
 All required Nondestructive Examination (NDE) shall be performed in accordance with

inspection procedure that are in complete compliance with API 650/ASME Sec V.
 All Nondestructive examinations including Magnetic particle and liquid penetrant examination
shall be performed by certified personnel.
 NDE shall be performed on tank components, as per approved ITP & Drawings
 All applicable NDT Procedures shall be approved prior to any concerned activity by ILF/NWC.
 All NDT personnel will be approved before any activity by ILF/NWC.
Painting /coating
 Coating shall confirm to PARTICULAR SPECIFICATION- DAMMAM- PROJECT 3

|<September 2018> Para 1.17 or approved Painting Specification
 Protective coating shall be applied in accordance with surface

preparation and painting specifications.
 After blasting, salt contamination test will be performed. REV:2
 Test the substrate for the chloride content. Residual chloride shall not exceed 40 mg/m² for external
coatings and 20 mg/m² for internal coatings.
 For the Nozzle gasket contact surface shall be properly protected from blasting and shall not be
coated or painted.
 All safety requirements shall be followed as per the details mentioned in the Paint Manufacturers
Safety Data Sheet (MSDS).
 Mixing and application procedures shall be as per the manufacture data sheet.
 Galvanizing/FBE coating shall be performed by approved sub-contractor (If required).
 Coating materials shall be stored in well-ventilated containers at storage temperatures as

recommended in the Manufacturers data sheet.
 Coatings which have exceeded the shelf life shall be set aside and not to be used.
 Abrasive shall be kept dry and clean.
 Color code to be followed as per painting specification.
 All personnel shall be used Proper Protective Equipment (PPE).
 Ensure the following environmental conditions shall fulfill before painting.

WORK METHODOLOGY FOR SURFACE PREPRATION & PAINTING
Pre-Blasting Surface Examination.
After the surface is ready for surface preparation, the blasting foreman shall inform the QC
Inspector of the intended time of abrasive blasting. The QC Inspector shall examine the
surface to be painted before abrasive blasting and decide if the substrate requires solvent or
detergent cleaning before abrasive blasting.
Abrasive blasting shall be carried out only when the steel surface temperature is at least 3 0 C
above the Dew point.
Prior to blasting, rough welds and cut-offs shall be ground to a small radius, and weld spatter
shall be removed. In general, all surfaces shall be free of all grease, scales, welding flux,
spatter, oil or other extraneous matter.
Equipment Examination (Blotter Test)
The compressed air supply shall be free of oil, moisture and contamination. As a minimum,
the Painting Supervisor shall check and approve the air quality at the start and at mid-point of
each 8-hour period. This shall be determined as follows:
The blast system shall be operated for at least 5 minutes under actual field conditions at the
specified pressure prior to making the blotter test.
A proper sized dehumidifier can be connected downstream of the compressor during periods
of high relative humidity to improved moisture removal from the air stream.
Attached a piece of blotter or absorbent paper to a clip board, then hold it approximately 45-
60 cm in front of the blast nozzle during air flow only, with a nozzle pressure of 388 kPa (50
psig) for approximately one minute. Satisfactory results shall be no water or oil
contamination on the blotter.
The semi-automatic/Manual blasting machine shall be equipped with dead man handle button.
Abrasives.
Steel Shot/Steel grit or similar abrasive material shall be used to achieve required surface profile &
cleanliness.
The QC Inspector shall examine and ensure that the abrasive being intended to be used is in
compliance with the specification requirements and that it is stored properly.
Surface Preparation.
The Material shall be blasted using steel grit (PR058)/Steel Shot (WS-330) in Manual/Automatic
blasting machine. the abrasive material for each machine is recycled automatically. The dust, rust or

any foreign particle get separated automatically with help dust collector/separator attached to the
Automatic/manual blasting machine. The operator shall maintain the quantity of abrasive to be used.
The material shall be blasted according to the required profile.
Post Surface Preparation Examination.
After the surface preparation is complete and the surface is made ready for painting, the QC
Inspector at the location shall be notified to perform the inspection, by the concerned
Painting Supervisor. As a minimum, the QC Inspector shall examine and ensure that, the
spent abrasive shall be removed from cleaned external surface by dry brushing and blowing
down with clean, dry compressed air.
The surface cleanliness and surface profile (anchor pattern) is meeting or exceeding the
requirements, using a surface profile comparator/profile measurement (Testex tape).
Tank components
After the surface preparation is complete and the surface is made ready for painting, the QC
Inspector at the location shall be notified to perform the inspection, by the concerned
Painting Supervisor. The QC painting Inspector shall examine the tank components by
accessible area to ensure the surface cleanliness and surface profile, Make ensure that surface
profile meeting or exceeding the requirement and also make ensure that spent abrasive shall
be removed from cleaned internal surface by blowing down with clean, dry compressed air.
After blasting, test the substrate for the chloride content. Residual chloride shall not exceed
40 mg/m² for external coatings and 20 mg/m² for internal coatings.
REV:2
The quality of level defined have been selected so as to be roughly equivalent to those defined
in the internationally recognized standard. This equivalence may be expressed as follows:
BS SSPC SIS 05 95 00
First Quality White metal SA 3
Second Quality Near-white SA 2.5
Third Quality Commercial SA 2
 Sa 3 (First quality) – The entire surface shall show blast-cleaning pattern and shall be
clean bare steel completely free from any contamination or discoloration. Areas that
appeared shadowed solely because of differences in the blast-cleaning pattern or structure
of steel shall be classed as clean steel.
 Sa 2.5 (Second quality) – The entire surface shall show blast cleaning pattern and shall be
completely free from contamination by oil, grease, dirt or other matter, except that
tightly- bonded residues of mill scale or rust shall be permissible up to the following
limits:
a. For the whole surface. An average of not more than 5% of the surface shall not be
visible from any mill scale or rust. At least 95% of the surface shall be clean bare steel.
b. For any single square of 25 mm side. Not more than 10% of the square would be
visible from any mill scale or rust.
Note: There are no simple precise means of measuring these characteristics but the first can
be estimate from the appearance of the surface and the second can generally be controlled
within broad limits by the choice of blast cleaning procedure, and notably of the type of
grade of abrasive.
The surface roughness (profile) achieved for each qualities of finish depends mainly upon
the type of steel, its condition before blast-cleaning and type and grade of abrasive used. The
abrasive can be classified as metallic and non-metallic.
The application of at least the first coat of paint or non-metallic coating should follow with at least
possible delay and in any case before visible deterioration has occurred as compared with freshly
blasted-cleaned area.
Pre-Painting Examination
Paint Storage
Prior to painting is started the Painting Supervisor shall examine and ensure the following as a
minimum: Paints and thinners shall be stored in well-ventilated buildings/Container at a temperature
as recommended in the Manufacture data sheet . Paints shall not be used from a container which
shows signs of leakage.
Paints which have exceeded the shelf life given in the Data Sheet shall be set aside and not used.
Paint (Mixing) Preparation
The Painting Supervisor/Foreman shall examine and ensure that the paint is mixed properly and
homogenously. Paints which have gelled shall not be used.
Paint Application
Prior & during the paint application the QC Inspector at the location shall monitor the weather and
surface conditions. As a general rule, painting shall not be performed during adverse conditions.
Even if the weather seems fit for painting there will be condensation if the
temperature of the substrate is at or below the dew point. To compensate for the fluctuations the
temperature of the surface should be at least a few degrees above the dew point during painting and
drying. 3°C is often quoted as safe.
In confined spaces it may be necessary to remove solvent vapors or water vapors by providing an
adequate amount of fresh air constantly during application and drying, both for reasons of safety and
health and to assist evaporation.
Keep the paint at room temperature when applying during winter. If not, the paint will require
excessive thinning leading to an increased risk of sagging. The viscosity in any paint will increase if the
temperature decreases. Check and monitor the wet film thickness (WFT) for the paint coat being
applied.

Post Painting Examination
After the paint application and drying is complete and the surface is made ready for application of the
subsequent coat and inspection, the QC Inspector at the location shall be notified to perform the
inspection, by the concerned production personnel.
As a minimum, the QC Inspector shall examine and ensure that, the painted surface is free of visual
paint defects and the required dry film thickness (DFT) is achieved. Also ensure that the paint coat is
properly dried prior to application of the subsequent coat and properly cured before permitting to
putting the internal coating in service. Prepare the “Painting Inspection Report” with all details and
have it reviewed/verified by the Client Inspector.
Acceptance Criteria
The acceptance criteria for acceptance/rejection of Painting DFT shall be as defined in the Paint
Manufacturer’s Data Sheets / as recommended by Paint manufacture and as detailed in the applicable
painting specification.
REPAIR PROCEDURE FOR PAINTING DEFECTS.
Repair procedure as specified in Data sheet shall be followed to repair coating.

After repairs have been made, the repaired area shall be blended smoothly into the surrounding area coating
and re-examined by same examination and test method and by all methods that were originally required for
the affected coating.
Repair Method for immersion coatings.

 cover areas adjacent to defects with heavy duty textile or fabric adhesive tape before commencing
repair or patch up.
 Clean defective area by solvent or detergent wash.
 For area less than 0.1 m2 grind to a rough metal surface using at least an 80-grit disc sander
alternatively, spot blast to bare steel. Feather edge the coating at least 50 mm beyond bare metal. to
the original specification except that the first coat of a multi coat system shall be thinned
 For area greater than 0.1 m2 blast clean to obtain the metal surface pre-treatment originally specified.
Feather edge the coating at least 50 mm beyond bare metal.
 Remove dust and debris by brush.
 Apply coating by brush for less area less than 0.1 m2and by spray for area greater than 0.1m to the
original specification except that the first coat of a multi-coat system shall be thinned.
Repair Method for Atmospheric coatings.
 Follow the surface preparation and application requirements in the applicable painting specification
and the manufactures technical data sheet.
BRUSH APPLICATION (if the internal surfaces are accessible)
 All weld lines, edges, bolts, nuts and rivets should be given brush applied stripe coat prior to all
coating application.
 Brush application should be done on small areas for touch up and for site application.
 Maximum brush size used should be 125 mm.

Inspection/Testing
 The Engineers or TPI Inspectors shall have free access to the work at all times. They have the
right to inspect the fabrication at any stage and to reject material or workmanship which is not
confirmed to the specified requirements.
 Inspection shall be offered as per approved ITP & requirement.
9. Types of Tank Components

Annular plates
 The annular plates are cut to size as per approved shop fabrication drawings.
 CNC cutting machine with oxyacetylene cutting tip will be used for plate cutting. Beveling
or edge preparation is done according to the weld joint design as per approved Drawing.
 Blasting and painting of annular plates will be carried out at shop facility in accordance
with approved procedures and painting specification.
 The Bottom plates are blasted in automatic shop blasting machine and the shop paint.
 Airless spray-painting machines shall be used to do the painting.
 Once the paint is dried the plates are piled up one on top of the other with wooden packings
in between. After making Bundles, it shall be wrapped with plastic sheet which enable
proper handling & protection of the plates.
 Upon inspection release annular plates shall be delivered to site.
Cleanout door assembly
 The cleanout door assembly parts (sole plate, insert plate, pad plate, flange and cover)are
cut by CNC machine. Beveling or edge preparation is done with portable beveling
machines using mechanical cutters.
 The beveled surface is grinded to give the smooth finish.

 The contact surface of the cleanout door flange and cover is machined to make the contact
surface area fully intact with each other.
 The welded assembly shall be post weld heat treated at shop

Bottom (Rectangular and sketch plates)
 The bottom plate includes the rectangular plate and sketch plates.
 Identification Marking shall be done on all the bottom plates and shall have the following as
minimum:
a) Item Mark number (Project No., Tank No., Part Mark No.)
b) Material Grade
c) Heat Number or heat code
 Mill Cut rectangular plates are used if the bottom plate weld is a lap joint.
 However, if the joint is butt joint all the rectangular plates are squared and beveled.
 The entire sketch the plates are cut to shape as per the approved shop drawings.
 The plates are blasted in automatic shop blasting machine and the shop paint is
applied as per Approved painting specification.
 Cutting burrs shall be removed by grinding operation. When the edges of plates are cut with a
torch, the resulting surface shall be uniform, smooth, and free from scale and slag before
performing any Painting.
 QC Inspector shall verify the marking for identification and perform inspection.
Nozzles and Manholes
 Nozzle & Manhole neck shall be made either from Pipe or plate.
 Pipe to be cut a desired dimension as per drawing and flange/ fittings shall befit &
weld as per approved procedure & Drawing.
 Neck to be made from plate, shall be cut plate as per drawing /cutting schedule, beveled
& rolled in to required dimension prior to welding. Fabricated Necks shall be used to fit
flanges/fittings as per drawing to make nozzles and manhole.
 Shell and roof nozzles are fabricated at shop.
 Shell and roof manhole will be fabricated, assembles and welded as a unit ready for site
erection.
 Welding shall be performed as per WPS requirements.
 QC Inspector shall perform the weld visual inspection as per the Procedure.
 Inspection reports shall be made for all the inspection activities.

 Identification marking shall be transferred on reinforcement plates, shell manhole
and nozzle neck formed with plates and pipes.
 The flange type (either SORF or WNRF, OR SOFF, OR WNFF) and the ratings (150 or 300) shall
be checked and verified as per drawing requirements.
 Pipe spools are fabricated from a number of raw pipes and pipe fittings (eg elbows,
flanges, tees, etc.)
 Raw pipes are cut to the required sizes and moved with pipe fittings to a fitting table.
 The pipe spool will be prefabricated as per approved drawing.
 where some of the components are fitted together (i.e temporarily connected).The resulting
sub-assembly (part of the final pipe spool) continues with welding operations (i.e permanent
connected) before it comes back to the fitting table and gets fitted with other spool
components. REV:2
Draw-off Sump.
 The sump plates shall be cut as per the drawing requirements.

 Heat number shall be marked on the sump.
 Rolling operation shall be carried out and fit-up of the vertical seam completed.
 Welding operation shall be carried out on the vertical & Horizontal joint.
 Work Instruction shall be used for welding activities for Welding/NDT inspection.
 After completion of the 1st side welding and after back-gouging, Dye Penetrant
Test shall be carried out prior to the second side welding.
 PT shall be performed by NDT Technician who is certified to Level II.
 QC Inspector shall perform the test as per approved ITP.
 Inspection reports shall be made for all the Inspection Activities.
Shell plates
 Shell plates are cut/squared either in profile cutting machine or CNC cutting machine.
 Edge preparation is done as per shell vertical and horizontal joint design.
 The plates are rolled to tank diameter before being delivered to site.
 Rolling operation shall be done as per Work Instruction. QC Inspector shall verify
the rolling radius using the required radius template.

 For shell plates which required PWHT all the shell fittings (Nozzles. Manholes Etc.)
are fitted and welded at shop.
 PWHT for clean door assembly or prefabricated nozzle assemblies shall be done asper
approved fabrication ITP at shop.
 Shell and roof manhole will be fabricated, assembles and welded as a unit ready for
site erection.
 PWHT for welded shell and nozzles assembly will be done at the shop.
Tank Accessories
 Wind girder is either fabricated from rolled angle or from steel plates, in case steel
platesare used the cutting, beveling and welding is done as per the requirement.
 Most of the fabrication and welding platforms, ladders, staircase is done to have
minimum welding work at site.
 It is fabricated in segments so that it can be easily assembled at site.

 If the ladders and platforms to be galvanized it is subcontracted to the approved
galvanizing companies.
 All the spares which are to be assembled at site are sent with proper markings punched on it.
 QC Inspector shall check the visual and dimensional inspection.
 Inspection reports shall be made for all the inspection activities.
Aluminum Dome Roof & Roof Accessories
The fabrication of Aluminum dome roof & roof accessories (to be made in
aluminum) shall be performed by Approved Subcontractor on their facility and to
be delivered to site for installation.

10 Packing & Transportation
 On completion of final shop clearance, all necessary repairs or modification shall

becompleted & documented prior to shipment.
 All the plate/material shall be transported in truck or trailer and shall not be dragged.
 All rolled shell plates shall be packed properly to retain the shape and shall be
handled carefully to avoid damage during transit.
 The contractor shall be responsible for transportation of material fabricated in his

workshop orworksite.
 Production Engineer will ensure that the tanks nozzles and manholes are covered as per the project
requirements.
 The Production Engineer will also ensure that suitable saddles (if required) are used for
transportation.
 Delivery advice will be prepared by Production Engineer and given to Trailer Driver.
 QC Inspector will ensure that only items inspected and accepted are loaded on trailers as
mentioned in the Delivery advice.
 After confirming the items loaded on the trailer, the Qc inspector will sign the
Delivery advice.
11 Safety
 Tested & certified Lifting equipment’s should be used for lifting and shifting Purpose.
 Safety Precautions should be followed during fabrication and Delivery.
 Welding cables and power cables is to be laid properly as per IE rules

and local state Govt. rules.
 Proper housekeeping and clean condition shall be maintained in the

fabrication shop as per the requirement.
12 Attachment
 APPENDIX A
 APPENDIX B
 PAINTING SPECFICATION (METS-P-2207-01 REV:1)

APPENDIX A
INSPECTION & TESTING PLAN -

SHOP
Title Reference Rev. Pages

Inspection and Test Plan for Shop Works WQIP-D3-ILF-T-00218 V2 1 of 16
Inspection and Test Plan for Shop works of Water
‫خطة الفحص واالختبار ألعمال الورشة لخزانات المياه‬
Tanks
Ref No.: WQIP-D3-ILF-T-00218 Issue No.: V2 Date: 11/5/2023
CRITERIA ACCEPTANCE ‫المعا ي ر المقب ولة‬ Inspection Type
ACTIVITY DESCRIPTION RESPONSIBILITY Frequency of Test / Inspection Verification Documents
SN Reference Documents Acceptance Limits Tolerance METSCCO AYC/ILF/NWC/TPI
‫النشاط‬ ‫المسؤولية‬ ‫ الفحص‬/ ‫معدل التكرا ر لإلختبار‬ ‫الت وثيقات المطل وبة لفحص‬
‫الوثائق المرجعية‬ ‫حدود القب ول والرفض‬ ‫السماحية‬ ‫ال م قا و ل‬ ‫اإلستشاري‬
1.0 Shop QA/QC Documentation Review & Acceptance/Approval.
Reference Drawing + API 650, 13 Ed. +

Review & Acceptance of Inspection & Test
1.1 QA/QC Mechanical Before Fabrication Starts. NWC Patricular Specification - Dammam Engrneer/Client Approval - Accepted ITP. H R
Plans (ITP) for Shop Works of Water Tanks - Project 3l<September 2018>
Review & Acceptance of Inspection & Test Reference Drawing +

1.2 QA/QC Mechanical Before Fabrication Starts. Engrneer/Client Approval - Accepted ITP. H R
Plans (ITP) for Aluminum Dome Roof Works API 650, 13 Ed. Annex-G.
API 650, 13 Ed. + AMSE Sec. IX + NWC

Review & Acceptance of WPS/PQR and
1.3 QA/QC Mechanical Before Welding Starts. Patricular Specification - Dammam - Engrneer/Client Approval - Accepted WPS/PQR. H R
Weld Map (foe Reference) Project 3l<September 2018> para 1.23
1.4 Quality Procedures' Review & Acceptance.
API 650, 13 Ed. + NWC Patricular API 650, 13 Ed. + NWC Patricular
1.4.1 RF Pads' Air Test Procedure. QA/QC Mechanical Before Start of Air Test. Specification - Dammam - Project Specification - Dammam - Project - Approved Test Procedure H R
3l<September 2018> 3l<September 2018>
1.4.2 Penettraing Oil Test Procedure. QA/QC Mechanical Before Start of Hydro Test. Specification - Dammam - Project Specification - Dammam - Project - Approved Test Procedure H R
3l<September 2018> 3l<September 2018>
1.5 NDT Procedures' Review & Acceptance.
API 650, 13 Ed. + ASME Sev. V + NWC API 650, 13 Ed. + ASME Sev. V + NWC
1.5.1 Magnetic Particle Test (MT) Procedure QA/QC Mechanical Before Start of MT. Patricular Specification - Dammam - Patricular Specification - Dammam - - Approved NDT Procedure H R
Project 3l<September 2018> Project 3l<September 2018>
1.5.2 Liquid Penetrant Test (PT) Procedure QA/QC Mechanical Before Start of PT. Patricular Specification - Dammam - Patricular Specification - Dammam - - Approved NDT Procedure H R
1.5.3 Radiographic Test(RT) Procedure QA/QC Mechanical Before Start of RT. Patricular Specification - Dammam - Patricular Specification - Dammam - - Approved NDT Procedure H R
1.6 Quality Personnel Qualification Review & Acceptance.
Before Start of Fabrication/Welding API 650, 13 Ed. + NWC Spec PMF-01- API 650, 13 Ed. + NWC Spec PMF-01-
1.6.1 QC Inspector: Mechanical/Welding QA/QC Mechanical - CV + Qualification Records H R
Activities. QUA-121_02 QUA-121_02
API 650, 13 Ed. + NWC Spec PMF-01- API 650, 13 Ed. + NWC Spec PMF-01-
1.6.2 QC Inspector: Painting/Coating QA/QC Mechanical Before Start of Painting Activitiess. - CV + Qualification Records H R
QUA-121_02 QUA-121_02
1.6.3 NDT Technician: MT QA/QC Mechanical Before Start of the NDT. - CV + Qualification Records H R
QUA-121_02 QUA-121_02
1.6.4 NDT Technician: PT QA/QC Mechanical Before Start of the NDT. - CV + Qualification Records H R
QUA-121_02 QUA-121_02
1.6.5 NDT Technician: RT QA/QC Mechanical Before Start of the NDT. - CV + Qualification Records H R
QUA-121_02 QUA-121_02
2.0 Material Receiving Inspection at Workshop

Plates/Structural Shapes, Pipes & Forging, Before to release for Fabrication Correlation of ID Markings and API 650, 13 Ed. +
2.1 QCI -Material MTC to EN10204.3.1 MRIR + MTR/MTC H W
Flanges, Bolting & Gaskets. use. Certification with applicable specs. Relevant Material Specs. + NWC
(for Pressure Parts) &
+ NWC Patricular Specification - Patricular Specification - Dammam -
EN 10204.2.2 (for
2.2 Welding Electrodes, Welding Wires & Flux. QCI -Material Before to release for Welding use. Dammam - Project 3l<September Project 3l<September 2018> para MRIR + Batch Certificates H S
Others)
2018> para 1.5 1.5
All dates to be entered in format: dd/mm/yyyy

WQIP-D3-ILF-T-00218 V2 ITP for Shop Works 1 of 5
Correlation of Markings & PO. + P.O. + Product Data Sheet + NWC
NWC Patricular Specification - - Patricular Specification - Dammam No Leaks or damage to
2.3 Abrasives, Paints & Thinners. QCI -Material Before to release for Painting use. MRIR + Batch Certificates H
Dammam - Project 3l<September Project 3l<September2018> para cans.
S
2018> para 1.16 1.16
3.0 In-Process Fabrication, Welding, PWHT & NDE at Workshop.
3.1 Bottom Plates:

Annular Plates;
As per Reference
3.1.1 Examine Dimensjons, Cutting & Edge QCI - Mechanical/Welding Before Painting. MFIR H S
Drawing
Preparation. Part Mark Identification.
Correlation with applicable Drawing Correlation with applicable Drawing
Sketch Plates;
+ API 650, 13 Ed. + NWC Patricular + API 650, 13 Ed. + NWC Patricular As per Reference
3.1.2 Examine Dimensions, Cutting & Edge QCI - Mechanical/Welding Before Painting. MFIR H S
Specification - Dammam - Project Specification - Dammam - Project Drawing
3l<September 2018> section 1 3l<September 2018> section 1
Rectangular Plates;
Rectangular Plates shall
3.1.3 Examine Dimensions, Cutting & Edge QCI - Mechanical/Welding Before Painting. MFIR H S
be as Mill Cut.
Preparation.Part Mark Identification.
3.2 Draw-Off Sump:
Outlet/Draw-Off Sump Plates;

As per Reference
3.2.1 Examine Dimensions, Cutting & Edge QCI - Mechanical/Welding Before Welding. MFIR H S
Drawing
Preparation.Part Mark Identification. Reference Drawing + Reference Drawing +
Draw-Off Sump Neck Plates;
API 650, 13 Ed. + NWC Patricular API 650, 13 Ed. + NWC Patricular As per Reference
3.2.2 Examine As-Rooled Dimensions, QCI - Mechanical/Welding Before Welding. MFIR + JFR H S
Specification - Dammam - Project Specification - Dammam - Project Drawing
w/Template for Conformity.
3l<September 2018> section 1 3l<September 2018> section 1
Draw-Off Sump Assembly; As per Reference
3.2.3 QCI - Mechanical/Welding Before Welding. JFR H S
Examine Fit-up Diemnsions before Welding. Drawing
API 650 Sec. 8.5 + NWC Patricular API 650 Sec. 8.5 + NWC Patricular
Post Welding Visual Examination of Draw-
3.2.4 QCI - Welding Before NDT Examination Specification - Dammam - Project Specification - Dammam - Project As per API 650 Sec. 8.5 RFI + WIR H W
Off Sump Assembly.
3l<September 2018> para 1.23 3l<September 2018> para 1.23
ASME Sec. V + MT Procedure + ASME Sec. V + MT Procedure +
NDE:
MT on all Welds, After welding prior to QCI - Welding + NWC Patricular Specification - NWC Patricular Specification -
3.2.5 Before Painting MT shall be done by MT Report H W
Blasting/Painting. NDT Technician Dammam - Project 3l<September Dammam - Project 3l<September
Subcontractor
2018> section 1 2018> Section 1
3.3 Shell Plates:
Plates Visual & Dimensional Examination;

Reference Drawing + Reference Drawing + As per Reference
3.3.1 Length/Width/Diagonal, Cutting Edge QCI - Mechanical/Welding Before Rolling. MFIR H W
API 650, 13 Ed. + NWC Patricular API 650, 13 Ed. + NWC Patricular Drawing
Specification - Dammam - Project Specification - Dammam - Project
Examine Rolled Shape; 3l<September 2018> section 1 3l<September 2018> section 1 As per Reference
3.3.2 QCI - Mechanical/Welding Before Painting MFIR H W
Diemnsion w/Templates for Conformity. Drawing
Nozzles and Manholes (Shell), Including
3.4
Spools:
Parts' Visual & Dimensional Examination;
Examine Dimensions, Cutting & Edge As per Reference
3.4.1 QCI - Mechanical/Welding Before Rolling (as applicable). MFIR H S
Preparation.Part Mark Identification. Reference Drawing + Reference Drawing + Drawing
For Manholes/Nozzles w/ Plate Neck and Specification - Dammam - Project Specification - Dammam - Project
RF Pad; 3l<September 2018> section 1 3l<September 2018> section 1 As per Reference
3.4.2 QCI - Mechanical/Welding Before Welding. MFIR H S
Examine Rolled Shape Dimensions w/ Drawing
Template for Conformity after Rolling.
Reference Drawing + API 650, 13 Reference Drawing + API 650, 13
Assembly Fit-up, Alignment, Tack Welds; Ed. + Weld Map + NWC Patricular Ed. + Weld Map + NWC Patricular As per Reference
3.4.3 QCI - Mechanical/Welding Before Welding. JFR H S
Visual & Dimensional Examination. Specification - Dammam - Project Specification - Dammam - Project Drawing
API 650 Sec. 8.5 + NWC Patricular API 650 Sec. 8.5 + NWC Patricular
Post Welding Visual & Dimensional
3.4.4 QCI - Welding Before NDT Examination Specification - Dammam - Project Specification - Dammam - Project API 650 Sec. 8.5 RFI + WIR H W
Examination.

100% PT or MT of all Welds, prior to QCI - Welding + As per PT/MT

3.4.5 Before Painting PT/MT Procedure PT/MT Procedure PT/MT Report H W
Painting. NDT Technician Procedure
100% RT for Shell Manholes/Nozzles' Neck;
QCI - Welding + As per ASME Sec. V +
3.4.6 (Fabricated from Plates) Longitudinal Joint Before Painting ASME Sec. V + RT Procedure ASME Sec. V + RT Procedure RT Films + Report H W
NDT Technician RT Procedure
Welds.
3.5 Cleanout Doors & Pre-assembled Shell Plates w/ Nozzles/Manholes.
Reference Drawing + API 650, 13

Shell Nozzles & Manholes Lay-out;
Ed. + NWC Patricular Specification - Reference Drawing + As per Reference
3.5.1 Orientation & elevation marking before QCI - Mechanical/Welding Before Fit-up/Welding. RFI + NOIR H S
Dammam - Project 3l<September API 650, 13 Ed. Para 7.5.6 & 7.5.7 Drawing
cutting the opening. 2018> section 1
Shell Nozzles & Manholes and Cleanout Reference Drawing + API 650, 13 Reference Drawing + API 650, 13
Door Installation; Ed. + NWC Patricular Specification - Ed. 7.5.6 & 7.5.7 + NWC Patricular As per Reference
3.5.2 QCI - Mechanical/Welding Before Welding. RFI + JFR H S
Fit-up, Plumb-ness, orientation, elevation, Dammam - Project 3l<September Specification - Dammam - Project Drawing
projection. 2018>para 1.9 3l<September 2018> para 1.9
Shell to Nozzles/Manholes & Cleanout As per Reference
QCI - Welding + Before Welding of Succeeding
3.5.3 Door Welds' VT & MT; Drawing + API 650 13 RFI + WIR + MT Report H S
NDT Technician Welds. Reference Drawing +
After Root Pass. Ed.
Reference Drawing + API 650, 13 API 650, 13 Ed. Para 7.5.8.11 &
QCI - Welding + Before Welding of Succeeding Ed. + Weld Map + NWC Patricular 7.2.3.6 + Weld Map+ NWC
3.5.4 Door Welds' VT & MT; Drawing + API 650 13 RFI + WIR + MT Report H W
NDT Technician Welds. Specification - Dammam - Project Patricular Specification - Dammam -
After every ½" weld deposit. Ed.
3l<September 2018> para 1.23 Project 3l<September 2018> para
QCI - Welding + 1.23
3.5.5 Door Welds' VT & MT; Before RF Pads Test. Drawing + API 650 13 RFI + WIR + MT Report H W
NDT Technician
After completion before PWHT (SR). Ed.
Pre-assembled Shell Plate & Cleanout Door
RF Pads' Air Test; Reference Drawing + API 650, 13
3.5.6 QCI - Mechanical/Welding Before PWHT. RF Pad's Air Test Procedure No Leaks. RFI + ATR H S
After welding completion before PWHT Ed. Para 7.3.4
(SR)
Pre-assembled Shell Plate & Cleanout Door

As per PWHT
PWHT (Stress Relieving); API 650, 13 Ed. Para 5.7.4.3 + PWHT API 650, 13 Ed. Para 5.7.4.3 + PWHT
3.5.7 QCI - PWHT Before Painting Procedure + API 650 13 PWHT Certificate H S
Monitoring of the cycle & review of PWHT Procedure Procedure +
Ed.
Chart.
Shell to Nozzles/Manholes & Cleanout Reference Drawing + As per Reference

QCI - Welding + Reference Drawing +
3.5.8 Door Welds' VT & MT; Before Painting API 650, 13 Ed. 7.2.3.7 + Drawing + API 650 13 RFI + WIR + MT Report H W
NDT Technician API 650, 13 Ed. + Weld Map.
After PWHT (SR) before painting. Weld Map. Ed.
3.6 Accessories; Top Tension Ring, Spiral Stair, Wind Girders, Supports, Earthing Lugs, Name Plate Brackets, etc.
Parts' Visual & Dimensional Examination; Reference Drawing + API 650, 13

As per Reference
Examine Dimensions, Cutting & Edge Ed.+ NWC Patricular Specification -
3.6.1 QCI - Mechanical/Welding Before Welding Reference Drawing + API 650, 13 Ed. Drawing + MFIR H S
Preparation.Part Mark Identification. Dammam - Project 3l<September
API 650, 13 Ed.
2018> para 1.10
As per Reference
Assembly Fit-up, Alignment, Tack Welds;
3.6.2 QCI - Mechanical/Welding Before Welding Reference Drawing + API 650, 13 Drawing + JFR H S
Visual & Dimensional Examination.
Reference Drawing + Ed. + Weld Map + + NWC Patricular API 650, 13 Ed.
API 650, 13 Ed. + Weld Map. Specification - Dammam - Project As per Reference
Post Welding Visual & Dimensional
3.6.3 QCI - Mechanical/Welding Before Painting. 3l<September 2018> para 1.10 Drawing + WIR H S
Examination.
API 650, 13 Ed.
4.0 Shop Painting/Coating.
4.1 Surface Preparation:
Pre-Blast Checks;
a) Abrasive Type & Storage
4.1.1 QCI - Painting Before Painting H W
b) Surface condition. (Salt Contamination As per Paint
check, if required). Paint Manufacturer Data Sheet & Paint Manufacturer Data Sheet & Manufacturer Data

Equipment; Approved Painting Specification + Approved Painting Specification + Sheet + Painting

a) Compressed Air Supply Blotter Test. Painting Procedure + NWC Painting Procedure + NWC Specification + Paint Free from Oil, Moisture &
4.1.2 QCI - Painting Before Painting H S
b) Operational "Deadman" Remote Patricular Specification - Dammam - Patricular Specification - Dammam - Procedure + NWC Contamination.
Control Used. Project 3l<September 2018> para Project 3l<September 2018> para Patricular Specification -
1.17 1.17 Dammam - Project
Post Blast Examination;
3l<September 2018>
Cleaning- Spent Abrasive Removal.
4.1.3 QCI - Painting Before Painting RFI + PIR & Press-O-Film H W
Examine Surface Cleanliness & Profile.
Salt contamination test.
4.2 Painting:
Pre-Painting Checks; As per Paint
4.2.1 Paint/Thinners Condition & Storage. QCI - Painting Before Painting Manufacturer Data Painting Log H S
Substrate Conditions & Paint Mixing. Paint Manufacturer Data Sheet & Sheet + Painting
+ Approved Painting Specification
During Painting Checks; Approved Painting Specification + + Specification + Paint
- NWC Patricular Specification
4.2.2 Wet Film Coating Thickness Reading & re- QCI - Painting Every Succeeding Coat. NWC Patricular Specification - Procedure+ NWC Painting Log H S
Dammam - Project 3l<September
coating intervals. Dammam - Project 3l<September Patricular Specification -
>para 1.17 2018
Post Painting Examination; 2018> para 1.17 Dammam - Project
After Succeeding Coat
4.2.3 Dry Film Thickness reading & Visual QCI - Painting 3l<September 2018> RFI + PIR H W
(as applicable) para 1.17
Examination.
4.3 Galvanizing:
Visual & DFT Examination of Galvanied Reference Drawing + Reference Drawing + Galvaning shall be done
4.3.1 QCI - Painting Before Delivery. Galvanizing Certificates. H W
Parts / Components (as applicable). ASTM A 123 ASTM A 123 by Subcontractor.
4.4 FBE Coating:

Visual & DFT Examination of FBE coated
Reference Drawing + Reference Drawing + FBE shall be done by
4.4.1 Parts / Components (as applicable) upon QCI - Painting Before Delivery. FBE Certificates / Reports. H W
FBE Coating Specs. / Procedure. FBE Coating Specs. / Procedure. Subcontractor.
receipt at shop.
5.0 Fianl Shop Inspection and Shipping Release.

TPI Shall witness and
review the IRB before
shipment for each
Reference Drawing + API 650, 13 ITP + Reference Drawing + API 650,
Verification of Records (IRB); batch.
Ed. + NWC Patricular Specification - 13 Ed. + NWC Patricular
5.1 Ensure that all Shop Inspection & Testing QCI - Mechanical Before Delivery. All the Fabrication and Release Note and/or FIR. H W
Dammam - Project 3l<September Specification - Dammam - Project
requirements are successfully completed. Workshop reports as
2018> section 1 3l<September 2018> section 1
approved ITP shall be
review and endorse by
TPI
Verification of Shipping Protection; NWC Patricular Specification - NWC Patricular Specification -
5.2 Check Shipping Preparation & Protection QCI - Mechanical --- Dammam - Project 3l<September Dammam - Project 3l<September --- Delivery Advice H W
to be Adequate. 2018> section 1 2018> section 1
Notes:
- Network Water for Speification Technical to refers Specification Technical ‫مرجعية الموا صفات الي موا صفات مشروعات المياه‬
- activities all for Surveillance is Manager Project NWC ‫ مراقبة جميع األنشطة‬- ‫مدير المشروع شركة المياه ل وطنية‬
‫ وعلى المقاول‬،‫ ما دق يتطلب أن يق وم المقاول بتطبيق إجراءات تحكم غير وا ردة في النموذج‬.‫هذا النموذج‬. - form. the to added be must measures additional These form. this on listed not measures control other implement to need may Contractor The form. this on stated items the cover minimum, a as must, measure control quality These '‫إجراءات التحكم في الجودة الوا ردة في النموذج أعاله يجب أن تغطي البنود الورادة في‬
‫دإ راج هذه اإلجراءات اإلضافية‬
- METSCCO Shall use the their internal QMS form for reporting the reulst at Workshop.

MRIR = Material Receiving Inspection Report

RFI = Request for Inspection
MFIR = Material Fabrication and Inspection Report
Hold = H ‫استالم‬
NOIR = Nozzle Orientation Inspection Report
Witness = W ‫الشاهد‬
Forms: JFR = Joint Fitup Report Inspection Type:
R = Review ‫المراجعة‬
WIR = Welding Inspection Report
ATR = Air test Report Surveillance = S ‫المراقبة‬
PIR = Painting Inspection Report
FIR = Final Inspection Report

DAMMAM Water Improvement Project Page: 1 of 1
West/South Distribution Network & Reservoir Project 3 Form: 2207/F101, Rev. 0. Dated: 28/08/2023
Owner: Engineer: Contractor: Manufacturer:
MRIR No.:
MATERIAL RECEIVING INSPECTION REPORT (MRIR)
MRIR Date:
PO No.: Supplier: JO No.: 22-07

Items Description Quantity Traceability Inspection Findings Results
S.#
Incl. Original Marking Ord Rec Bal (Heat/Lot #) Dimensions Damages Documents Acc./Rej./Hold
Attachments to the MRIR: Inspector’s Comments/Remarks:
Inspection Authority Sign-off:

Prepared By: METSCCO Reviewed By: AL YAMAMA Reviewed By: Reviewed By: NWC
QCI: Materials
Distribution List: Original – QA/QC Dept., e-copies to Stores, Purchase, Production, Finance, Client’s Witnessing Inspector/s.
West/South Distribution Network & Reservoir Project Form: 2207/F102, Rev. 0. Dated: 28/08/2023
3
RFI No.:
REQUEST FOR INSPECTION (RFI)
Ref. ITP No.:
Mfr. Eq. No.: Ref. Dwg. No.:
Request Date: JO No.: 22-07
Location: Date & Time: Contact Personnel:
ITP A. No. Description of Inspection/Test Requested
Requested By:
Production or Construction
Personnel In-Charge of Execution
METSCCO QC Inspector Comments:

Checked Findings Result
# (List the Checks point/s) (Evaluation against Acceptance Criteria) (Acc. /Rej.)
If Rej., NCR No.
.
Attachments to the RFI: Inspector’/s Comments/Remarks:

Inspected By: METSCCO Reviewed By: AL YAMAMA Reviewed By: Reviewed By: NWC
Discipline QC Inspector
Distribution List: Original – QA/QC Dept., e-copies to Production, Planning, Client’s Witnessing Inspector/s.
MFIR No.:
MATERIAL TRACEABILITY & FABRICATION INSPECTION
REPORT (MFIR) MFIR Date:
Mfr. Eq. No.: Ref. Dwg. No.: Item: JO No.: 22-07

Material Traceability Dimensions (L/W/T/H,etc) Other Results
Part Mark Specs. Heat No. Ref. MRIR # Required Actual/Measured Findings Acc./Rej./Hold
Attachments to the MFIR: Inspector’s Comments/Remarks:

QCI: Mechanical/Welding
NOIR No.:
NOZZLE ORIENTATION INSPECTION REPORT (NOIR)
NOIR Date:
Mfr. Eq. No.: Ref. Dwg. No.: Item: JO No.: 22-07

Nozzle Location Marking Required Actual Marking Results
Dwg. # Nozzle ID Elevation Orientation Radius Elevation Orientation Radius
(Shell / Roof) Acc./Rej./Hold
Attachments to the NOIR: Inspector’s Comments/Remarks:

JFR No.:
JOINT FIT-UP INSPECTION REPORT (JFR)
JFR Date:
Mfr. Eq. No.: Item: JO No.: 22-07

For butt Joints For fillet Joints
Joint No. Root Gap (Max ±1.5mm) Tack Weld Results
Ref. Dwg. No. Mismatch Gap
(Ref. Weld Map)
Required Actual
Visual Acc./Rej./Hold
(Max ±1.5mm) (Max 2mm)
Attachments to the JFR: Inspector’s Comments/Remarks:

Distribution List: Original – QA/QC Dept., e-copies to Production, Client’s Witnessing Inspector/s.
WIR No.:
WELDING INSPECTION REPORT (WIR)
WIR Date:

Mat’l. Welder Post Weld NDT Tick the Applicable NDT Results
Dwg. Joint No. Thk. J.Fit-up WPS No. No. VT Required? PT MT RT VB PO Air Acc./Rej./Hold
Attachments to the WIR: Inspector’s Comments/Remarks:

ATR No.:
RF PADS AIR TEST REPORT (ATR)
ATR Date:

Nozzle Test Pressure (psi) Holding Time (min.) Pressure Gage Results
Dwg. No. Test Findings
No. Required Actual Required Actual ID No. Cal. Due Acc./Rej./Hold
Attachments to the ATR: Inspector’s Comments/Remarks:

West/South Distribution Network & Reservoir Project 3
Form: 2207/F111, Rev. 0. Dated: 28/08/2023
PIR No.:
PAINTING INSPECTION REPORT (PIR)
PIR Date:
IN PROCESS INSPECTION SHEET: SURFACE PREPARATION
Components Part/s:
METSCCO AL YAMAMA AI NWC
Date: Time:
I Surface Preparation
A. Chemical Cleaning
1. Required? YES NO
1.1 If Required, Check The Type
Solvent Clean :
Detergent Wash :
Steam Clean :
1.2 If Required, Acceptable? YES NO
B. Grinding
1. Required? YES NO
1.1 If Required, Acceptable? YES NO
Remarks:
C. Abrasive Blasting
1. Dew Point- Start : Mid Point:
2. Substrate Temp.- Start : Mid Point:
3. Nozzle Press.- Start : Mid Point:
4. Anchor Pattern- Start : Mid Point:
5. Degree Of Cleanliness:
Start (Sa):
Mid Point (Sa):
6. Abrasive Type & Batch No.:
Remarks:
D. Pre-Priming Cleanliness
1. Dust & Abrasive Removed By Brushing? YES NO
2. Substrate Vacuumed YES NO
3. Acceptable For Priming YES NO
Form: 2207/F111, Rev. 0. Dated: 28/08/2023
PIR No.:
PIR Date:
IN PROCESS INSPECTION SHEET: PAINT APPLICATION
II Painting METSCCO AL YAMAMA AI NWC
A. Prime Coat Date: Time:
1. Ensure All Non-Explosion Proof Lighting Has Been
Disconnected Prior to the Start and During Painting.
2. Ventilation Acceptable? YES NO
3. Mixing Acceptable? YES NO
4. Ratio of Thinning - (If Req):
5. Dew Point: Start : Mid Point:
6. Substrate Temp: Start : Mid Point:
7. Average Wet Film Thickness: µ
8. Average Dry Film Thickness: µ
9. Prime Coat Acceptable YES NO
10. Product No.: Color:
Batch No.: Mfr. Date:
B. Intermediate Coat Date: Time:
Disconnected Prior To The Start And During Painting
2. Ventilation Acceptable? □ YES/ □ NO
3. Mixing Acceptable? □ YES/ □ NO
9. Intermediate Coat Acceptable: YES NO
C. Top Coat Date: Time:
Disconnected Prior To The Start And During Painting
2. Ventilation Acceptable? YES NO
3. Mixing Acceptable? YES NO
9.Final Curing Time: Required Time : At Steel Temp :
10. Top Coat Acceptable YES NO
Form: 2207/F111, Rev. 0. Dated: 28/08/2023
PIR No.:
PIR Date:
POST PAINTING INSPECTION SHEET: DFT

MEASUREMENT
Component Part/s 1st/Primer Coat DFT (µ) Intermediate Coat (µ) Topcoat (µ)
(No. Qty. Approx. Area etc.) Spot Readings Avg. Spot Readings Avg. Spot Readings Avg.
Coating Applied By:

(Brush, Roller, Airless, Conventional Spray)
Measurement Equipment, EC No.:

Name:
METSCCO
QCI Sign & Date
Authorized
Inspectors
AL
Sign & Date
YAMAMA
NWC Sign & Date
FIR No.:
FINAL (SHOP) INSPECTION REPORT (FIR)
FIR Date:

Item Description Verification of I&T Records (QR S. No) Any NCR Results
S. # Part/Assembly ID Qty. Ref. Dwg. No. MFIR WIR NDE Pr. Test PIR Open? Acc./Rej./Hold
*Indicate those Inspection & Test Activities that are not applicable as “n/a”.
Attachments to the FIR: Inspector’s Comments/Remarks:

APPENDIX B
Risk Assessment for manufacturing of

materials
Title Reference Rev. Pages
Risk Assessment for Manufacturing of Materials _ _ 1 of 11
1. Project’s HSSE Risk Assessment
‫ تقييم املخاطر باملشروع‬1.
Risk Assessment for manufacturing of the tank sections
‫ مصفوفة املخاطر‬Matrix Scoring /Risk

Sever ‫بالغ الشدة‬ 4 4 8 12 16
‫شدة التأثير‬ Significant ‫جسيم‬ 3 3 6 9 12

Impact Moderate ‫متوسط‬ 2 2 4 6 8
Minimal ‫بسيط‬ 1 1 2 3 4
1 2 3 4
Rare ‫نادر‬ Probable ‫محتمل‬ Likely ‫محتمل للغاية‬ Certain ‫مؤكد‬
/likelihood ‫االحتمالية‬
Legend
Risk Index Low Medium High Very High
‫تصنيف الخطورة‬ ‫منخفض‬ ‫متوسط‬ ‫عالي‬ ‫عالي جدا‬
Risk Score
1 to 3 4 to 6 7 to 9 10 to 16
‫الخطورة درجة‬
1 of 11
Date of risk assessment ‫أعضاء فريق التقييم‬ ‫قائد فريق التقييم‬
‫تاريخ التقييم‬ Risk assessment team members: Risk assessment leader:
Pieter Wardeck HSE Manager
21/09/2023 Planning Manager Pieter Wardeck
QC Manager
2 of 11
Consequence
Probability
Description of Hazard Control Measures Resp. Person
‫الخطر‬
Risk
No.
‫التأثير‬
‫وصف املخاطرة‬ ‫تدابير السيطرة والتحكم بالخطر‬ ‫الشخص املسئول‬
 Only the employed security officer will be allowed

 Delivery of materials, tools and to open and or close the access gates to the
METSCCO premises.
equipment by 3rd party suppliers
 Uncontrolled access to 3rd party  All visitors will need to sign in using the visitors ● Security department
signing log, that will indicate the rules of the ● QHSE department
vehicles on the METSCCO premises METSCCO workshop. ● Production manager
1 3 3 9
 Parking in non-designated parking and or  The employed security officer will indicate
which direction to follow to the allocated
offloading areas offloading, loading and parking bays.
 Manually loading and offloading of

 No person can manually lift more that 25kg or a 3rd
materials, tools and equipment of his/her body weight, lifting devices and or
mobile machinery to be utilized were required
Inspections of materials before the  Any substandard materials will not be offloaded and
offloading process may commence noted on the delivery note and sent back to the
from the QHSE department manufacturer.
 Embarking and disembarking on to the  Once the delivery vehicle has stopped the QHSE
2 2 2 4 department employees will climb on top of the ● QHSE department
delivery vehicle to inspect the materials ● Production manager
delivery vehicle to inspect the quality and quantity
of the materials that have been brought to the
 Substandard materials delivered
premises.
 Once the materials are approved for offloading it

will be the responsibility of the QHSE
3 of 11
department employee that the driver of the
delivery vehicle must stand outside his vehicle
during the inspection and offloading process.
 The QHSE department will ensure that the driver

is out of the delivery vehicles cab before the work
Use of overhead crane and lifting may commence.
equipment to move the materials to
the various location with in the  All lifting equipment and overhead crane must be
inspected by the competent and appointed
METSCCO workshop operator.
 Driver of the delivery vehicle staying in

 The operator’s certificate will be available upon
request
the cab of the delivery truck
 Substandard lifting equipment and  All employees that are working on the task must ● Overhead crane
be trained on the Safe Work Procedure for the
operator and
overhead crane used for the operation use of the overhead crane.
3 3 4 12 assistant
 All lifting equipment and overhead crane must be ● QHSE department
 Uncontrolled swinging loads
certified, and certifications can be presented upon ● Production manager
 Untrained operators operating the request.
overhead crane.  The assistant and the operators are the only one
who will be allowed to connect the crabbing
 Employees or visitors walking and or hooks to the materials that needs to be offloaded
standing under the suspended load  QHSE department to be present during the
offloading operation and ensure that all works are
completed according to the METSCCO Safe
Work Procedures.
4 of 11
 The path that will be used must checked by the
QHSE personnel and rigger assistant to ensure that
no employee or visitor walks under the suspended
load
 Where required entry points will be temporarily

closed to avoid unauthorized entry.
 Only the trained and appointed operator will be

allowed to operate the gas cutting machinery.
 The operator needs to verify the coordinate of the

valves and manhole according to the approved
drawings as per the client’s specifications
Moving material to into position at the  Before the cutting process may commence the
stationary gas cutting machinery to operator needs to ensure that there is enough gas in
gut the location of the manholes, the gas cylinders
inlet, outlet and draining valves
 If required, the operator will close the main
valves remove the bottle using a mobile gas
 Untrained operator ● Production manager
4 4 3 12 trolley and take it to the gas cylinders storage
area. ● QHSE department
 Failing to input the incorrect coordinates ● Gas gutter
 Gas cylinders replacement  Once all the cylinders are checked the main
supply valve can be reopened
 Hot melted shavings materials
 Before the gas cutting operation commences the
operator needs to ensure that there are no
employees and or visitors close to the gas cutting
equipment.
 Once the materials are cut according to the

client requirement the QHSE personnel and
production manager to conduct an over
inspection.
5 of 11
 Correct use of personal protective equipment will
be but not limited to hardhat, eye protection, ear
protection, overalls, gloves and safety shoes.
 No employee and or visitor will be allowed to

stand or walk underneath the suspended load.
 Only trained employees on the Safe Work

Moving the materials with the Procedure will be allowed to operate the roller
overhead crane to the roller machine machine.
to be rolled according to the client’s
specific profile  Before the materials will be fed into the roller
the operator needs to ensure that all employees
and or visitors are not near the machinery.
 Overhead movement of materials an ● Roller operator
employee and or visitors walking under a ● QHSE department
 Correct use of personal protective equipment will
5 4 3 12 ● Production
suspended load. be but not limited to hardhat, eye protection, ear
manager
protection, overalls, gloves and safety shoes.
 Untrained operators
 Moving machinery and materials  No personnel will be allowed to wear any loose
clothing or jewelry when operating and or working
close to the roller.
 Once the correct profile as been achieved the

materials will be placed on a roller bed.
6 of 11
 All electrical equipment to be inspected and
declared safe for use by the responsible
operator
 Any defective equipment will be removed from

the workshop and tagged not safety for use at the
maintenance department.
Once the materials are rolled
according to the specific profile the  The work area must be cleaned and ensure that
there are no flammable materials
overhead crane will move the
materials to the fabrication area, this  The surface area will be cleaned by means of
is to install manholes and valves to grinding; all grinding sparks must be as far as
the materials. possible directed away from the pedestrian
walkways.
 Hot work conducted i.e. grinding and
 Valves and manholes to be tagged into position and
welding must be inspected by the production manager,
● Welding operator
foreman and QHSE personnel before the full
 Untrained operators 3 3 9 ● QHSE department
6 welding may commence.
 Substandard welding ● Production manager
 Failure to test welding once completed  Once the positioning is approved by all parties the
area to be cleared of any unauthorized personnel
 Electrocution
 Fire  Once the welding has been completed, the welds
will be tested for any defects i.e. cracks
 Fume inhalation
 Fully charged fire extinguishers will be [present at
all hot work areas
 Correct use of personal protective equipment will be

but not limited to hardhat, eye protection, ear
protection, overalls, full face shield, welding
helmet, gloves and safety shoes
7 of 11
After fabrication the materials will be  Only trained and certified employees can
moved by the overhead crane to the operate the furnace machinery
furnace area for heat stress, this is to
 All areas inside, outside and the control room to be
ensure the integrity of the welding on inspected by the operator before the machinery may
the manholes and valves be started.
 Overhead movement of materials an  If all is in working order the inside of the furnace
employee and or visitors walking under a to be inspected for any unauthorized personnel
inside the furnaces
suspended load. ● Production manager
7  Failure to conduct the heat stress on the 3 4 12  The doors to be closed and ensure that all ● QHSE department
equipment has been connected. ● Engineering
materials that has been welded.
department
 Materials not placed in the furnace for an  The furnace will be started and left for the  Furnace operator
prescribed time frame according to the client and
adequate time period.
engineering department specifications
 Untrained operators
 Signage to be posted to indicate that the
furnace is operational
 No employee and or visitor will be allowed to

The overhead crane will move the  No employee and or visitor will be allowed to
materials to the sandblasting area
where the materials will be coated as  Only trained and certified employees will be
per the client’s specifications allowed to complete the sanding blasting on the
materials ● Blasting operator
● QHSE department
8  Overhead movement of materials an 4 4 16 ● Production manager
 Sandblasting equipment to be inspected by the
employee and or visitors walking under a responsible personnel ● Foreman
suspended load.
 Any defective equipment must be reported to the
 Personnel contact with hazardous maintenance and QHSE department immediately
chemicals substances
8 of 11
 Over and under blasting of materials  The operator will use the approved and issued
suite with fresh air supply when entering the sand
 Untrained operators blasting area
 Respiratory illness
 Work area to be inspected to ensure that there are
 Fresh air supply failure
no unauthorized personnel in the blasting area
 Suffocation
 Doors to be closed to ensure that the blasted
materials do not get contaminated.
 Excess sandblasting materials to be cleaned up and

reused if and where possible
 All unusable hazardous materials will be disposed

of in the allocated and provided waste bins
 Collection of the bins will be done by approved 3rd

party companies and waste disposal certification
will be supplied to the QHSE department.
 After blasting the materials the QHSE and

production personal will inspect the work to
ensure it is according to the clients specification
The overhead crane will move the  No employee and or visitor will be allowed to
materials to the spray-painting area stand or walk underneath the suspended load.
where the materials will be coated as
 Only trained and certified employees will be ● spray painter
per the client’s specifications allowed to complete the spray painting on the
9 4 4 16 ● QHSE department
materials ● Production manager
 Overhead movement of materials an  Foreman
employee and or visitors walking under  Spray painting equipment to be inspected by the
responsible personnel
a suspended load.
9 of 11
 Personnel contact with hazardous  Any defective equipment must be reported to the
maintenance and QHSE department immediately
chemicals substances
 Over and under spray of materials  The operator will use the approved and issued
 Untrained operators suite with fresh air supply when entering the
painting area
 Respiratory illness
 Suffocation  Work area to be inspected to ensure that there are
no unauthorized personnel in the painting area
 Operators to be issued with the correct

respiratory equipment met conducting spray
painting
 All unusable hazardous materials will be disposed

of in the allocated and provided waste bins
 Collection of the bins will be done by approved 3rd

party companies and waste disposal certification
will be supplied to the QHSE department.
 After spraying the materials, the QHSE and

production personal will inspect the work to
ensure it is according to the client’s
specification
 The QHSE and production department will notify

Final inspections conducted on the the client in a timely manner to conduct an
materials before it is loaded and inspection on the progress and the final inspection ● Production manager
before the materials are loaded and taken to the ● QHSE department
10 transported to the client 3 3 9
site for installation (if required) ● Client
● Driver
 Failure to inspect the materials  No material will leave the METSCCO premises if
the material has not been inspected and
10 of 11
 Sending substandard material to the stamped for approval by the relevant
departments
client
 Uncontrolled access to 3rd party  Delivery vehicle will be directed to the loading bay
by security when arriving at the METSCCO
vehicles on the METSCCO premises premises.
 Parking in non-designated parking and or  The delivery vehicle operator will stand outside the
cab during to the loading process.
loading areas
 The materials to be secured by means of straps and
 Overhead movement of materials an
confirmed by the driver of the delivery vehicle
employee and or visitors walking under a
suspended load.  No employee and or visitor will be allowed to
 Failure to secure the load once placed
on the delivery vehicle
11 of 11

Shop Fabrication Welding &amp; Painting Procedure 22-07 Rev-2

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Shop Fabrication Welding &amp; Painting Procedure 22-07 Rev-2

Uploaded by

Copyright:

Available Formats

Project Number 2200016412

Dammam Water Improvement Project South Strategic &

Al-Yamama Company for Trading & Contracting (AYC)

ILF Consulting Engineers

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501)

2200016406- 2 06/November/2023 M.A Baig

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 2 of 18

2. Scope & Purpose......................................................................................4.

6. Material Identification & Traceability.......................................................7.

8. Shop Fabrication Process..........................................................................7 to 14.

9. Type of Tank components....................................................................14 to 17.

10. Packing & Transportation........................................................................18.

12. Attachment ………………………………………………………….......18.

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 3 of 18

2. Scope and Purpose

SL.NO Mfr. Tag No. Description Type Location QTY Capacity

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 4 of 18

 Metscco are responsible for performing fabrication works.

 The assigned QC manager shall meet the requirements stipulated in PMF-012-QUA-121_02

 The Quality Manager shall assign QC Engineer/Inspector to prepare the Inspection

 The assigned QC manager shall meet the requirements stipulated in PMF-012-QUA-121_02

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 5 of 18

 Depending on the Fabrication Activities required for fabricating a specific item/component,

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 6 of 18

 Material shall confirm to NWC Spec PARTICULAR SPECIFICATION- DAMMAM-

7. Fabrication –Raw Materials

8. Shop Fabrication process

General - Components of tanks to be fabricated at shop.

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 7 of 18

 All tack welds shall be made by qualified welders.

 All tack welds shall be made using a qualified welder.

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 8 of 18

 All required Nondestructive Examination (NDE) shall be performed in accordance with

 Coating shall confirm to PARTICULAR SPECIFICATION- DAMMAM- PROJECT 3

 Protective coating shall be applied in accordance with surface

 After blasting, salt contamination test will be performed. REV:2

 Galvanizing/FBE coating shall be performed by approved sub-contractor (If required).

 Coating materials shall be stored in well-ventilated containers at storage temperatures as

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 9 of 18

Pre-Blasting Surface Examination.

Equipment Examination (Blotter Test)

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 10 of 18

Post Surface Preparation Examination.

Paint (Mixing) Preparation

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 12 of 18

REPAIR PROCEDURE FOR PAINTING DEFECTS.

Repair procedure as specified in Data sheet shall be followed to repair coating.

Repair Method for immersion coatings.

Repair Method for Atmospheric coatings.

BRUSH APPLICATION (if the internal surfaces are accessible)

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 13 of 18

 Inspection shall be offered as per approved ITP & requirement.

9. Types of Tank Components

 Upon inspection release annular plates shall be delivered to site.

Cleanout door assembly

 The beveled surface is grinded to give the smooth finish.

 The welded assembly shall be post weld heat treated at shop

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 14 of 18

Nozzles and Manholes

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 15 of 18

 The sump plates shall be cut as per the drawing requirements.

Shop Fabrication, Welding and Painting Procedure (2200016406-D3-AYC-010GEN-MEC-MS-04501) 16 of 18

 It is fabricated in segments so that it can be easily assembled at site.

Shop Fabrication Welding & Painting Procedure 22-07 Rev-2

Shop Fabrication Welding & Painting Procedure 22-07 Rev-2