DOC NO DATE PAGE NO 02 OF 07

PROJECT

TITLE
INSPECTION TEST PLAN FOR TANK FABRICATON

1.0

GENERAL The enclosed ITPs shall be followed for the works to be performed by the Contractor under this Tender. The provisions indicated for stagewise inspection by HPCL are a minim um and the contractor shall develop a detailed ITP and obtain approval for the same prior to commencement of work. Contractor to carry out 100% examination of all activities. LEGEND HP: Hold point; A point which require sin section / verification and acceptance by HPCL before any further processing is permitted. The Contractor shall not process the activity/ item beyond a Hold point without written approval by HPCL. Witness Point; An activity which requires witnessing by HPCL when the activity is performed. Review of Contractors documentation. Surveillance Inspection by HPCL; Monitoring or making observations to verify whether or not materials/ items or services conform to specified requirements. Surveillance activities may include audit, inspections, witness of testing, review of quality documentation & records, etc. 100% examination by Contractor.

2.0

W:

Rw: S:

WC:

Responsibility for execution of the inspection/ testing is with the Contractor.

Prepared by CONTRACTOR .

Name : Design: Hindustan Petroleum Crop. Ltd.

Concurred by

Name : Design: Hindustan Petroleum Crop. Ltd

Approved by

DOC NO DATE PAGE NO 03 OF 07

PROJECT

TITLE
INSPECTION TEST PLAN FOR TANK FABRICATON

S. No. STORAGE TANKS A. 1. 2.

ACTIVITY

VISHAL

HPCL

PRIOR OF FABRIATION Acceptance of the tanks foundation Incoming Material Owners Supply WC Rw Contractors supply, including check testing Welding Filler Material Approval /Qualification a) Manufacturing Test Certificate/Documents b) Testing, if any i) Carbon Steel WPS/PQR(Sample Copy attached from Previous HPCL Site Records) a) b) c) Procedure: i) WPS to be written for all the Weld Joints for for Bottom /Shell/Fl. Roof/A ppertunance etc Testing : i) Carbon Steel WC HP Approval of Final WPS / PQR WC HP

WC WC WC WC* WC

HP Rw HP Rw* W

3.

4.

5. 6. 7. 8. B 1. 2.

a) Welder performance Qualification Test b) Certification& Approval of welder Review of joint numbering in drawings mention Reference of 4.a.i. Suitability of plate bending machine Fabrication, erection, testing procedure for job FABRICATION / ERECTION OF BOTTOM Plate size, marking and cutting Blast cleaning & painting of underside of bottom plates

WC WC WC WC WC WC WC WC

W HP HP Rw HP HP W HP

Prepared by CONTRACTOR .

Concurred by Name : Design: Hindustan Petroleum Crop. Ltd.

Approved by Name : Design: Hindustan Petroleum Crop. Ltd

DOC NO DATE PAGE NO 04 OF 07

PROJECT

TITLE
INSPECTION TEST PLAN FOR TANK FABRICATON

S. No. 3. 4. 5. 6. 7. 8. 9. 10. 1. 2. 3. 4.

ACTIVITY Plate layout, overlap and fit up Sequence of welding Size and positioning of backing plate for annular plates Banking of electrodes Inter-pass cleaning Visual check of welding DPT/RADIOGRAPHY of annular plate butt welds and bottom plate butt welds (As applicable) Vacuum box test for bottom plate welding SHELL Plate size, marking and cutting Plate binding, curvature check, stacking Shell course alignments and fit-up of vertical and circumferential joints before welding a)Check Shell diameter @0,45,90,135,180,225,270,315,360 & circumference for circularity with strapping tap, perpendicularity, straight edge before welding and documenting (Each Shell wise & w.r.t. precede & ascend) Visual check of welding and back chipping a) inner side welding visual check b) Check shell diameter @0,45,90,135,180,225,270,315,360 & circumference for circularity with strapping tap, perpendicularity, straight edge before welding and documenting (Each Shell wise & w.r.t. precede & ascend) Location size and alignment of nozzles and other openings

VISHAL WC WC WC WC WC WC WC WC WC WC WC WC

HPCL S S W S S W HP HP Rw W W HP

5. 6.

WC WC WC

W W HP

7.

WC

HP

Prepared by CONTRACTOR .

Name : Design: Hindustan Petroleum Crop. Ltd.

Concurred by

Name : Design: Hindustan Petroleum Crop. Ltd

Approved by

DOC NO DATE PAGE NO 05 OF 07

PROJECT

TITLE
INSPECTION TEST PLAN FOR TANK FABRICATON

S. No. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. R.F. pads fit-up / welding

ACTIVITY

VISHAL WC WC WC WC WC WC WC WC WC WC WC WC

HPCL W W HP W W HP HP HP W S HP HP

PWHT of shell, RF pads, nozzles, manhole etc (If Applicable) Radiography marking (for random radiography only) Curb angle and Wind girder fit-up / welding DPT of Nozzles, etc. (as applicable) RF pads pneumatic test Shell to bottom fit-up Shell to bottom I/S welding root run visual/ oil chalk test Shell to bottom O/S welding visual and PT Fabrication and erection of stair ways Radiography a) Radiography interpretation b) Check shot for Radiography FLOATING ROOF

1. 2. 3. 4. 5. 6.

Temporary staging, spacing and levels Plate size, straightening and cutting Plate layout, overlap, fit-up welding Availability of approved calculations for design of buoys Buoys / pantoon fabrications Vacuum testing of roof plates welds

WC WC WC WC WC WC

Rw Rw Rw HP S HP

Prepared by CONTRACTOR .

Concurred by Name : Design: Hindustan Petroleum Crop. Ltd.

Approved by Name : Design: Hindustan Petroleum Crop. Ltd

DOC NO DATE PAGE NO 06 OF 07

PROJECT

TITLE
INSPECTION TEST PLAN FOR TANK FABRICATON

S. No. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. C. 1. 2. 3. 4.

ACTIVITY Location of sleeve support Pad plate welding with roof and sleeve support Fixing and welding of Buoys Initial Lift Support Fixing through sleeve Seal welding of support sleeve from beneath after dewatering Air test of Buoys / Pantoons Pantoon welding Location, fixing and welding of man-holes, drains etc. Shell to pontoon clearance Air Test of Pontoons for Leakproofness Seal fixing Floating Roof testing, as required e.g. flooding etc. Primary roof drains installation & testing TESTING Correctness testing arrangements especially size of Blind Flanges / vents/ drains/ temporary piping Mechanical/ Inspection clearance Earthing of ladder & shell Settlement reading through Dumpy Level during water filling

VISHAL WC WC WC WC WC WC WC WC WC WC WC WC WC WC

HPCL S S W W S S HP S W HP HP HP HP HP

WC WC WC WC

HP HP W HP

Prepared by CONTRACTOR .

Name : Design: Hindustan Petroleum Crop. Ltd.

Concurred by

Name : Design: Hindustan Petroleum Crop. Ltd

Approved by

DOC NO DATE PAGE NO 07 OF 07

PROJECT

TITLE
INSPECTION TEST PLAN FOR TANK FABRICATON

S. No. 5. 6. 7. 8. 9. Hammer test Air pressure test Vacuum test

ACTIVITY

VISHAL WC WC WC WC WC

HPCL HP HP HP HP Rw

Roof collapsibility test in case of floating roof ranks Vis-a-vis to FR Dessign approved Calibration of tanks from statutory authorities INSPECTION & TEST DOCUMENTS Review Test and Inspection documents

WC

Rw

Prepared by CONTRACTOR .

Name : Design: Hindustan Petroleum Crop. Ltd.

Concurred by

Name : Design: Hindustan Petroleum Crop. Ltd

Approved by