METSCCO Heavy Steel Industries Co. Ltd.

Field Welded API Std. 650 Tanks

Shop Pre-Fabrication Quality Control Procedure.
For

Upgrade Fire Water Protection System at SA GOSPs;

13 No. Fire Water Tanks Project.
BI No.: 00091

Document No.: QCP-0714-11

REVISION HISTORY
Rev.

Date

Description

Prepared by:
QA/QC Dept. Head

Reviewed by:
Project Mgr

Engg. Mgr.

Approved by:
Dy. General Mgr.

METCCO Heavy Steel Industries Co. Ltd.

Project: Upgrade Fire Water Protection System at SA GOSPs 13 No. Fire Water Tanks.
Document Title: Field Welded API Std. 650 Tanks Shop Pre-Fabrication Quality Control Procedure.
A

15th Oct.07

Initial Issue.

R. DSouza

B. Phillip

Cris M. S. Jr.

A. Choghari

Table of Contents
No.
1.0
2.0
3.0
4.0
5.0
5.1
5.2
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.4
5.5
5.6
5.7
6.0
7.0

Section Title
Scope
Purpose
References
Responsibility
Method Statements (Title only)
Material Control
Pre-Fabrication Control
Fabrication & Dimensional Control (Title only)
Bottom Annular Plates
Bottom Rectangular & Sketch Plates
Shell Plates
Curb Angle
Nozzles/Manholes
Permanent Attachments including Structures
Roof Plates
Welding Control
Painting Control
Final Inspection/Shop Release
Shipping/Delivery
Safety Precautions
Exhibits/Attachments

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1.0 Scope.
The scope of this procedure is to provide guidelines for the effective quality control of the shop pre-fabrication of Field
welded storage tanks, as per the requirements of API Std. 650 and 32-SAMMS-005, to be constructed for Upgrade Fire Water
Protection System at SA00 GOSPs Project and shall be applicable for all 13 No. Fire Water Tanks, bearing tag # U52-D-0201
at Ain Dar GOSP-2, U54-D-0101 at Ain Dar GOSP-4, U53-D-0101 at Ain Dar GOSP-3, 268-D-0412 at Ain Dar GOSP-6, U51D-0101 at Ain Dar GOSP-1, U57-D-0541 at Shedgum GOSP-2, U59-D-0201 at Shedgum GOSP-4, D28-D-0425 at Shedgum
GOSP-5, U27-D-0101 at Uthamaniyah GOSP-7, U28-D-0101 at Uthamaniyah GOSP-8, U30-D-0101 at Uthamaniyah
GOSP-10, U31-D-0802 at Uthamaniyah GOSP-11 and U32-D-0802 at Uthamaniyah GOSP-12.

2.0 Purpose.
The purpose of this procedure is to ensure that the above mentioned tanks material is pre-fabricated and examined in a
controlled manner.

3.0 References.
API Std. 650, 10th Edition, Add. 3
32-SAMMS-005
SAES-W-017
Form 175-324900
Document No.: QCP-0714-11, Rev. 0, Dated: 15th Oct. 2007

Welded Steel Tanks for Oil Storage.

Manufacture of Atmospheric Tanks.
Welding requirements for Tanks.
Tanks: Atmospheric, Steel Within the scope of 32-SAMMS-005.

METCCO Heavy Steel Industries Co. Ltd.

Project: Upgrade Fire Water Protection System at SA GOSPs 13 No. Fire Water Tanks.
Document Title: Field Welded API Std. 650 Tanks Shop Pre-Fabrication Quality Control Procedure.
Note: The references mentioned here-in shall provide the required acceptance criteria or references to it. Where specific
item/s are not specified or covered, industrys best practice shall be followed.

4.0 Responsibility.
The primary responsibility for the implementation of this procedure shall be with the QC Inspector assigned at the shop.
He shall ensure that the monitoring, verification and reporting required as per the applicable Std., specifications and ITP are
performed in a consistent manner in line with the guidelines provided by this procedure.
The QC Manager shall monitor & supervise the works performed by the Shop QC Inspector/s is consistent and meeting the
requirements of the applicable Std., specifications and ITP.
The Shop Production Engineer shall ensure that the request for inspection I provided to the QC Inspector appropriately so
as to facilitate smooth flow of the work. And also provide all necessary assistance that is within their scope of responsibility.

5.0 Method Statements:

5.1 Material Control.
The plates (bottom, shell & roof) & other constituent parts material of the tank shall be received at METSCCOs Riyadh
Workshop from the suppliers or used from the existing stock.
The Site Storekeeper shall receive the material at the workshop and inform the QC Inspector by providing him with the
verbal intimation, the Delivery Advice/Packing List and all documents received along with the delivery.
The QC Inspector shall check the material received for the following as a minimum, before forwarding the RFI to the
client:
The material is being ordered from the supplier, from whom it is received.
The material as mentioned in the suppliers Delivery Advice/Packing list is received and that it has not been
damaged during transportation.
All the material is conforming to the dimensional requirements and the corresponding documents required are
received. All material shall be clearly identified and provided with mill test certificates unless otherwise specified.
Review the documents received to be conforming to the applicable specification requirements.
Mark the inspection status, on the item with the help of the permanent paint marker or a suitable means that will
retain the marking, i.e. Accepted or Rejected or Hold. Also mark the material identification on the item, the
required identification, i.e. Job Order No., Specification, Heat No. (Information available on the material may be
encircled to highlight the identification).
Prepare and sign-off the Material Inspection Report (Doc. No.: SF.01). Notify the client for his review and
acceptance.
Any discrepancies in the supply noticed, shall be notified to the Purchasing Dept. to take necessary action.
If any material is received & accepted on conditional basis, the QC Inspector imposing the condition/s shall be
responsible to ensure that the conditions on which basis it is received / accepted is/are cleared prior to any welding
works are started/delivery of the item to the site
While at the workshop, the shop production crew shall assist the Storekeeper in proper & safe handling, storage and
preservation of the material. Material shall be stored in a manner that it shall not be in direct contact with the soil and as much
as possible covered to avoid damage and/or weather effects.
To use the stock material, the Storekeeper shall notify and identify to the QC Inspector the material intended to be used.
The QC shall check the material from the stock as if it is being received from the supplier (as stated above) and similarly follow
all other requirements.
Upon acceptance from the client the QC Inspector shall release the material for production use, by distributing the signed
MIR to all concerned, i.e. Original -to QA/QC Dept. Job Order file, Copies-to Operations, Stores & Purchasing. To the client if
specifically specified in the contract.
Storekeeper shall issue the material to the production crew.
The same procedure shall be followed for the welding consumables and painting consumables.
Note: The QC Inspector may issue all or any non-pressure containing parts material prior to the review and acceptance of the
Saudi Aramco Inspector, provided the material is acceptable and meeting all the specifications requirements.
Document No.: QCP-0714-11, Rev. 0, Dated: 15th Oct. 2007

METCCO Heavy Steel Industries Co. Ltd.

Project: Upgrade Fire Water Protection System at SA GOSPs 13 No. Fire Water Tanks.
Document Title: Field Welded API Std. 650 Tanks Shop Pre-Fabrication Quality Control Procedure.

5.2 Pre-Fabrication Control.

The Shop Production-in-charge shall, on a weekly basis, every Saturday, provide details of the planned production
activities, using Doc. No.: QF-0714-07, for the next two weeks. The QC in-charge shall prepare the Two weeks look-ahead
schedule and forward it to the Project Manager for his review and submittal to the client, every Sunday.
The inspection schedules involving client witness and/or hold points shall be notified and confirmed by the Shop
Production-in-charge, at least five (5) Saudi Aramco working days in advance to the QC in-charge. The QC in-charge on his
part shall notify the client (Doc. No.: QF-0714-06) and arrange the necessary quality documents
On a day-to day basis, once any fabrication, welding or painting activity is completed and is ready for inspection, the Shop
Production-in-charge or his deputy shall request the QC Inspector to perform the inspection. The QC Inspector shall inspect the
completed activity and prepare the Fabrication (visual & dimensional) Inspection Report (Doc. No.: QF-0714-02), Welding
Inspection Report (Doc. No.: QF-0714-03) or Painting Inspection Report (Doc. No.: QF-0714-04). Also when the item is ready
for delivery, prior to the release of the item for shipment to site, the Shop Production-in-charge shall notify the QC Inspector to
inspect, prepare the Final Inspection Report (Doc. No.: QF-0714-05) and to arrange for client review/verification and release
of the item for delivery/shipment.
A copy of the accepted report shall be provided to the Shop Production-in-charge, for each inspection completed, for his
further action.

5.3 Fabrication & Dimensional Control.

5.3.1. Bottom Annular Plates.
The Bottom Annular plates shall be cut on the CNC profile cutting machine, and then the heat number marking shall
be transferred (required only where it is not part of the plate/item), and the identification marks (J.O. #, Tank #, part/item
number) as required shall be hard punched.
The Shop Production-in-charge or his deputy shall notify Shop QC Inspector, when the plate/s are completed and
ready for inspection. The Shop QC Inspector shall inspect the plate/s, against a template and prepare a Fabrication (visual &
dimensional) Inspection Report (Doc. No.: QF-0714-02) and notify the client, and provide him with the report for his
review/verification.
A copy of the accepted report shall be provided to the Shop Production-in-charge for his further action.

5.3.2. Bottom Rectangular & Sketch Plates.

The rectangular plates shall be kept as mill cut while the sketch plates shall be cut either on the CNC profile cutting
machine or by a pug cutting machine guided with a rail specially fabricated to suit the radius of the bottom plate (the guide
rail shall be examined prior to use).
The Shop Production-in-charge or his deputy shall notify Shop QC Inspector, when the plate/s are completed and
ready for inspection. The Shop QC Inspector shall inspect the plate/s, against a template and prepare a Fabrication (visual &
dimensional) Inspection Report (Doc. No.: QF-0714-02) and notify the client, and provide him with the report for his
review/verification.
A copy of the accepted report shall be provided to the Shop Production-in-charge for his further action.

5.3.3. Shell Plates.

The shell plates shall be cut to square, edge prepared and bent/shaped (rolled) to the curvature of the tank radius.
The Shop Production-in-charge or his deputy shall notify Shop QC Inspector, when the plate/s are completed and
ready for inspection. The Shop QC Inspector shall inspect the plate/s, against a template and prepare a Fabrication (visual &
dimensional) Inspection Report (Doc. No.: QF-0714-02) and notify the client, and provide him with the report for his
review/verification.
A copy of the accepted report shall be provided to the Shop Production-in-charge for his further action.

Document No.: QCP-0714-11, Rev. 0, Dated: 15th Oct. 2007

METCCO Heavy Steel Industries Co. Ltd.

Project: Upgrade Fire Water Protection System at SA GOSPs 13 No. Fire Water Tanks.
Document Title: Field Welded API Std. 650 Tanks Shop Pre-Fabrication Quality Control Procedure.
5.3.4. Curb Angle.
The curb angle shall be in pieces and shall be provided in the overall length basis (may be slightly longer for
adjustment and to be cut on site). Each angle shall be edge prepared and bent/shaped (rolled) to the curvature of the tank
radius.
The Shop Production-in-charge or his deputy shall notify Shop QC Inspector, when the plate/s are completed and
ready for inspection. The Shop QC Inspector shall inspect the plate/s, against a template and prepare a Fabrication (visual &
dimensional) Inspection Report (Doc. No.: QF-0714-02) and notify the client, and provide him with the report for his
review/verification.
A copy of the accepted report shall be provided to the Shop Production-in-charge for his further action.

5.3.5. Nozzles & Manholes.

The manhole neck shall be cut to size, edge prepared and rolled to the curvature of the manhole radius, the joint
between both the ends of the fitted together for welding. Also the manhole flange shall be fabricated from the plate and fitted
to the neck, once the neck longitudinal seam is welded. The nozzles shall be fabricated from standard pipe and fittings, and
the fabrication shall involve cutting to size, edge preparation and the joint fit-up. The reinforcing pad plates shall be cut to
shape and size, rolled to the curvature of the tank outside radius.
The Shop Production-in-charge or his deputy shall notify Shop QC Inspector, when the activity is completed and ready
for inspection. The Shop QC Inspector shall inspect the item/s, and prepare a Fabrication (visual & dimensional) Inspection
Report (Doc. No.: QF-0714-02) and notify the client, and provide him with the report for his review/verification.
A copy of the accepted report shall be provided to the Shop Production-in-charge for his further action.

5.3.6. Permanent Attachments including Structures.

The permanent attachments and structures shall include but not be limited to spiral stairway and its component parts,
internal ladders, brackets, support cleats, center drum/column, rafters, etc.
The Shop Production-in-charge or his deputy shall notify Shop QC Inspector, when the activity is completed and ready
for inspection. The Shop QC Inspector shall inspect the item/s, and prepare a Fabrication (visual & dimensional) Inspection
Report (Doc. No.: QF-0714-02) and notify the client, and provide him with the report for his review/verification.
A copy of the accepted report shall be provided to the Shop Production-in-charge for his further action.

5.3.7. Roof Plates.

The rectangular plates shall be kept as mill cut while the sketch plates shall be cut either on the CNC profile cutting
machine or by a pug cutting machine guided with a rail specially fabricated to suit the radius of the bottom plate (the guide
rail shall be examined prior to use).
The Shop Production-in-charge or his deputy shall notify Shop QC Inspector, when the plate/s are completed and
ready for inspection. The Shop QC Inspector shall inspect the plate/s, against a template and prepare a Fabrication (visual &
dimensional) Inspection Report (Doc. No.: QF-0714-02) and notify the client, and provide him with the report for his
review/verification.
A copy of the accepted report shall be provided to the Shop Production-in-charge for his further action.

5.4.

Welding Control.
All the welding production and inspection shall be performed, examined and controlled as per the requirements of
SAES-W-017, including the conditioning, storage and exposure of electrodes.
The welding production works involved at the shop shall include manholes assembly fabrication, nozzles flange to
neck assembly fabrication, spiral stairway- landing platforms, stair treads, brackets, supports assembly fabrication, internal
ladders assembly fabrication, roof support structure including rafters, cleats, supports fabrication.
The acceptance criteria for visual weld examination shall be as per the reference code/Std. specified in the section 3,
unless otherwise stated.
No NDE: PT/MT/RT shall be performed at the Shop.
After the welds are ready for welding and after completion of the welds and are ready for inspection, the Shop
Production-in-charge or his deputy shall notify Shop QC Inspector. The Shop QC Inspector shall inspect the welds and

Document No.: QCP-0714-11, Rev. 0, Dated: 15th Oct. 2007

METCCO Heavy Steel Industries Co. Ltd.

Project: Upgrade Fire Water Protection System at SA GOSPs 13 No. Fire Water Tanks.
Document Title: Field Welded API Std. 650 Tanks Shop Pre-Fabrication Quality Control Procedure.
welding against the requirements and prepare a Welding Inspection Report (Doc. No.: QF-0714-03) and notify the client,
and provide him with the report for his review/verification.
A copy of the accepted report shall be provided to the Shop Production-in-charge for his further action.

5.5.

Painting Control.
All the painting production and inspection shall be performed, examined and controlled as per the requirements with
the project requirements and the Saudi Aramco standards particularly SAES-H-100.
The painting works to be undertaken at the shop shall include the application of the complete paint system to the
bottom plate underside surface (APCS-3). All other painting shall be performed on-site, after the completion of the erection
of the tank.
The acceptance criteria for visual paint examination shall be as per the reference code/Std. specified in the section 3,
unless otherwise stated.
After each coat of paint is ready for application and after completion of each coat application and after drying, when it
is ready for inspection, the Shop Production-in-charge or his deputy shall notify Shop QC Inspector. The Shop QC Inspector
shall inspect the paint, weather conditions, equipment and the coating against the requirements and prepare a Painting
Inspection Report (Doc. No.: QF-0714-04) and notify the client (if client witness is required, client shall be appropriately
informed in advance), and provide him with the report for his review/verification.
A copy of the accepted report shall be provided to the Shop Production-in-charge for his further action.

5.6.

Final (Shop Release) Inspection.

After all activities including inspection and testing, as required by the shop ITP and applicable Std./specifications is
completed and the item/s is ready for final (shop release) inspection, the Shop Production-in-charge or his deputy shall notify
Shop QC Inspector. The Shop QC Inspector shall inspect the item/s against the requirements and prepare a Final Inspection
Report (Doc. No.: QF-0714-05) and notify the client (if client witness is required, client shall be appropriately informed in
advance), and provide him with the report for his review/verification.
A copy of the accepted report shall be provided to the Shop Production-in-charge for his further action.

5.7.

Shipping & Delivery.

Upon completion of shop inspection & testing and release of the item/s for delivery by the Shop QC Inspector, the
Shop Production-in-charge or his deputy shall make arrangements for the transportation of the item/s to erection site. The
Production crew shall pack and load the item/s in such a manner that it shall not be damaged or lost during transportation. In
general, the plates (bottom, shell and roof) shall be transported in saddles specially fabricated for the purpose or adequately
supported to avoid deformation of the formed edges & shape. The smaller parts shall be transported in boxes to avoid any
loss during transportation, while bigger and bulky structural parts shall be transported by directly placing them and fastening
with belt/chain sling, on the trailer/truck bed.

6.0.

Safety Precautions.
The inspectors- Client or In-House, shall be provided with safe and free access to perform the desired inspection and
testing, in compliance with the Saudi Aramco Construction Safety Manual.

7.0.

Exhibits/Attachments.
Applicable forms are attached along with the Inspection & Test Plans.

Document No.: QCP-0714-11, Rev. 0, Dated: 15th Oct. 2007