Project :500 TPD Sulphuric Acid Plant with 5.

0 MW Power Generation, Egypt

Name of Client : SPREA FOR CHEMICALS

EPC CONTRACTOR : NUBERG Engineering Limited

INSPECTION & TEST PLAN FOR STORAGE TANKS WORK

ITP NO. :- 9560/SITE/QAC/022/ITP-13
Inspection by Inspection by NBEL
Sl no. Activity Formats No. Remarks
Subcontractor CAT A CAT B
A PRIOR TO FABRICATION
Review Acceptance Report of the tanks
1 WC HP Rw Foundation Release note
foundation
2 Incoming Material Rw Rw 9560/NBEL/FORM/MECH/50,REV.0/ 9560/NBEL/FORM/MECH/51

Welding Filler Material

3 WC
Approval/Qualification
a) Review of Manufacturer’s Test
WC Rw Rw Manufactures test certificates
Certificate/Documents
b) Laboratory testing, if any WC Rw Rw Lab report

Carbon Steel WC W --

ii) Alloy Steel/Stainless Steel WC W -- Manufactures test certificates

iii) Low Temperature Services WC W -- Manufactures test certificates

4 WPS/PQR WC

a) Review of proposed procedure WC Rw Rw Proposed WPS

b) Testing WC

i) Carbon Steel WC Rw Rw 9560/NBEL/FORM/MECH/01,REV.0

ii) Alloy Steel/Stainless Steel WC W W 9560/NBEL/FORM/MECH/01,REV.0

c) Approval of Final WPS/PQR WC W W 9560/NBEL/FORM/MECH/01,REV.0

5 a) Welder performance Qualification Test WC W W 9560/NBEL/FORM/MECH/05,REV.0

Sheet 1 of 6
 INSPECTION & TEST PLAN FOR STORAGE TANKS WORK
ITP NO. :- 9560/SITE/QAC/022/ITP-13
Inspection by Inspection by NBEL
Sl no. Activity Formats No. Remarks
Subcontractor CAT A CAT B
b) Certification & approval of welders WC HP HP 9560/NBEL/FORM/MECH/04,REV.0/ 9560/NBEL/FORM/MECH/05

6 NDT Procedure Qualification WC

i) Review of proposed procedure WC Rw Rw 9560/NBEL/FORM/MECH/31,REV.0

ii) Witnessing of the proposed procedure

WC W W 9560/NBEL/FORM/MECH/31,REV.0
testing

iii) Approval of Qualified Procedure WC HP HP 9560/NBEL/FORM/MECH/31,REV.0

7 Review of Joint numbering in drawings WC Rw Rw As per Approved drawing

Review fabrication, erection, testing Procedures for

8 WC Rw Rw
job
B FABRICATION/ERECTION BOTTOM
Blast cleaning & painting of underside of bottom
1 WC HP S 9560/NBEL/FORM/MECH/07,REV.0
plates.
2 Plate lay out, overlap and fit up WC S -- 9560/NBEL/FORM/MECH/52,REV.0

3 Sequence of welding WC S -- 9560/NBEL/FORM/MECH/52,REV.0

Size and positioning of backing plate for annular
4 WC S -- 9560/NBEL/FORM/MECH/52,REV.0
plates
5 Baking of electrodes WC S -- 9560/NBEL/FORM/MECH/06,REV.0

6 Inter-pass cleaning WC W -- By Grinding/Wire Brush

7 Visual check of welding WC W S 9560/NBEL/FORM/MECH/52,REV.0

PT/MT/NDT of annular plate butt welds and bottom

8 WC W S 9560/NBEL/FORM/MECH/10,REV.0/ 9560/NBEL/FORM/MECH/12
plate butt welds (As applicable)

9 Vacuum box test for bottom plate welding WC W S 9560/NBEL/FORM/MECH/62,REV.0

SHELL

Sheet 2 of 6
 INSPECTION & TEST PLAN FOR STORAGE TANKS WORK
ITP NO. :- 9560/SITE/QAC/022/ITP-13
Inspection by Inspection by NBEL
Sl no. Activity Formats No. Remarks
Subcontractor CAT A CAT B
Shell course alignments and fit-up of vertical and
1 WC W S 9560/NBEL/FORM/MECH/54,REV.0
circumferential joints before welding
a) Check Shell diameter, circularity,perpendicularity,
2 WC W S 9560/NBEL/FORM/MECH/67,REV.0
straight edge before welding.

b) Check Shell diameter, circularity,perpendicularity

WC W S 9560/NBEL/FORM/MECH/67,REV.0
straight edge after welding

3 Visual check of welding and Back chipping WC S - 9560/NBEL/FORM/MECH/54,REV.0

4 Inner side welding visual check WC S - 9560/NBEL/FORM/MECH/54,REV.0/ 9560/NBEL/FORM/MECH/55

Location, size, alignment and fit-up of nozzles &

5 WC W W 9560/NBEL/FORM/MECH/56,REV.0
other openings
6 R.F. Pads fit-up/welding WC S - 9560/NBEL/FORM/MECH/56,REV.0
PWHT of shell, RF pads, Nozzles, manholes, etc.
7 WC S S 9560/NBEL/FORM/MECH/33,REV.0
(As applicable)
Radiography marking (for Random radiography
8 WC W W 9560/NBEL/SITE/QAC/026, REV.0/
only)
9 Curb angle and Wind girders fit-up/welding WC S Rw 9560/NBEL/FORM/MECH/57,REV.0

PT/MT of nozzles, wind girders and other attachments

10 WC W S 9560/NBEL/FORM/MECH/10,REV.0/ 9560/NBEL/FORM/MECH/53
(as applicable)

11 RF pads pneumatic test WC W W 9560/NBEL/FORM/MECH/42,REV.0

12 Shell to bottom fit up WC W S 9560/NBEL/FORM/MECH/58,REV.0

Shell to bottom I/S welding root run visual/Oil chalk
13 WC W S 9560/NBEL/FORM/MECH/58,REV.0
test
14 Shell to bottom O/S welding visual and PT WC W S 9560/NBEL/FORM/MECH/58,REV.0

15 Fabrication and erection of stair ways WC S -- 9560/NBEL/FORM/MECH/59,REV.0

16 Cleats welding for insulation WC S -- 9560/NBEL/FORM/MECH/59,REV.0

17 Review of radiographs interpretation WC HP Rw 9560/NBEL/FORM/MECH/12,REV.0

Sheet 3 of 6
 INSPECTION & TEST PLAN FOR STORAGE TANKS WORK
ITP NO. :- 9560/SITE/QAC/022/ITP-13
Inspection by Inspection by NBEL
Sl no. Activity Formats No. Remarks
Subcontractor CAT A CAT B
FIXED ROOF
Blast cleaning and painting Roof Structure,underside
WC W S 9560/NBEL/FORM/MECH/07,REV.0
1 of Roof plates
2 Location and Welding of Roof supports WC S -- 9560/NBEL/FORM/MECH/59,REV.0

3 Alignment and welding of Roof structures WC W -- 9560/NBEL/FORM/MECH/60,REV.0

4 Plate layout, overlap and fit-up WC W -- 9560/NBEL/FORM/MECH/60,REV.0

5 . Visual check of roof welds WC S -- 9560/NBEL/FORM/MECH/60,REV.0

Location, size and alignment of roof nozzles,man-
6 WC W S 9560/NBEL/FORM/MECH/60,REV.0
holes vents, etc.
7 PWHT (as applicable) WC

i) Procedure Review WC Rw Rw 9560/NBEL/SITE/QAC/027, REV.0

ii) PWHT cycle monitoring WC W -- As Per PWHT Recorder

iii) Time-Temp Chart Review WC W Rw As Per Signed PWHT Chart

8 RF pads fit-up & Welding WC S -- 9560/NBEL/FORM/MECH/60,REV.0

9 RF pad pneumatic testing WC W S 9560/NBEL/FORM/MECH/60,REV.0

PT/MT of Nozzles, vents & other attachments WC W S 9560/NBEL/FORM/MECH/10,REV.0/ 9560/NBEL/FORM/MECH

10

11 Welding of Roof plate with shell/ curb angle WC S -- 9560/NBEL/FORM/MECH/60,REV.0

FLOATING ROOF

1 Temporary staging spacing and levels WC S -- As per Approved drawing

2 Plate layout, overlap, fit-up/welding WC S -- 9560/NBEL/FORM/MECH/61,REV.0

Availability of approved calculations for design of
3 WC Rw --
buoys
4 Buoys fabrications WC S --

5 Vacuum testing of roof-plate welds WC W -- 9560/NBEL/FORM/MECH/62,REV.0

Sheet 4 of 6
 INSPECTION & TEST PLAN FOR STORAGE TANKS WORK
ITP NO. :- 9560/SITE/QAC/022/ITP-13
Inspection by Inspection by NBEL
Sl no. Activity Formats No. Remarks
Subcontractor CAT A CAT B
6 Location of sleeve supports WC S -- As per Approved drawing

7 Pad plate welding with roof and sleeve support WC S -- 9560/NBEL/FORM/MECH/61,REV.0

8 Fixing and welding of Buoys WC S --

9 Initial – lift WC S --

10 Supports fixing through sleeves WC S -- 9560/NBEL/FORM/MECH/59,REV.0

Seal welding of support sleeves from beneath after
WC S -- 9560/NBEL/FORM/MECH/59,REV.0
11 dewatering
12 Air test of Buoys Pontoon welding WC S --

13 Location, fixing and welding of man holes,drains etc WC W -- 9560/NBEL/FORM/MECH/61,REV.0

14 Shell to pontoon clearance WC HP --

15 Seal fixing WC HP --

16 Floating Roof Testing, as required e.g. flooding etc WC HP --

C TESTING
Correctness of testing arrangements especially size of
WC S -- 9560/NBEL/SITE/QAC/025, REV.0
1 blind flanges/vents/drains/ temporary piping

2 Mechanical / Inspection clearances WC HP HP 9560/NBEL/FORM/MECH/63,REV.0

3 Earthing of ladder & shell WC W W

4 Settlement readings during water filling WC W Rw 9560/NBEL/FORM/MECH/64,REV.0

5 Hammer test WC W W

6 Air pressure test WC W W 9560/NBEL/FORM/MECH/65,REV.0

7 Vacuum test WC W W 9560/NBEL/FORM/MECH/62,REV.0

8 Roof collapsibility test in case of floating roof tanks WC W W

9 Calibration of tanks from Statutory authorities WC Rw Rw Calibration Report

Sheet 5 of 6
 INSPECTION & TEST PLAN FOR STORAGE TANKS WORK
ITP NO. :- 9560/SITE/QAC/022/ITP-13
Inspection by Inspection by NBEL
Sl no. Activity Formats No. Remarks
Subcontractor CAT A CAT B
D NSPECTION & TEST DOCUMENTS

Review Test and Inspection Documents WC Rw Rw AS PER ITP

Legends: WC-100% Examination by Subcontractor, RW-Review of Subcontractor's Documents, W-Witness - Activity shall be Wtnessed 100% and accepted by NBEL,HP-
Hold Point, S-Surveillance Inspection by NBEL,
CAT A- All Site fabricated steel storage tanks for process fluid /Hydrocarbon, floating roof, tanks having capacity 600 cum or 10 m dia and 8 m height.

CAT B- Site fabricated steel storage tanks for Raw water, Fire water, waste water, DM water, etc. and all tanks not covered under “CAT A”
SIGNATURE

NAME

DATE ANAND SHARMA ASHWANI TYAGI RAJEEV SHARMA

Prepared By NBEL Checked By NBEL Approved By NBEL

Sheet 6 of 6