Reliance

Procedure For Quality control

of
Site Erected Atmospheric Pressure
Storage Tanks

EPCMD-2-QM00-JEP-ME-026

00

09.04.2012

Issued for Implementation

PPP

KMP / EMK / KSS

SNS

Rev

Date

Revision

Prepared
By

Checked By

Approved
By

Reliance
Contents
1.

Purpose ....3

2.

Scope ..3

3.

References ....3

4.

Abbreviations and Terms .... 3

5.

Responsibilities ...4

6.

Methodology ..4
1. Annexure I ...11
2. Annexure II

..16

EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 2 of 16

Reliance
1.

Purpose
The purpose of this procedure is to provide uniform approach and step by step
guidelines during fabrication, Erection inspection and final Testing of Storage
Tanks designed as per API 650.

2.

Scope
The scope of this procedure covers identification of material to be used for the
construction of storage tanks, inspection and testing procedures to be followed
during fabrication, erection and Testing of Floating Roof, Cone roof storage
tanks. This document is applicable to all personnel of Reliance involved in the
construction inspection of storage tanks designed as per API 650.

3.

4.

Reference
ASME Sec. VIII Div. I

Boiler and Pressure Vessel Code

ASME Sec. V

Non Destructive Testing

API 650

Welded Steel tanks for Oil storage.

API 620

Welded large low-pressure storage tanks.

SMPV

Static and Mobile Pressure Vessel (Unfired)

Rules.

EPCMD-2-QM00-JEP-ME-010-

Procedure for Pressure testing of API Tanks.

EPCMD-2-QM00-ITP-ME-050-

Inspection and Test plan for Storage tanks.

Abbreviations and Terms

API

American Petroleum Institution.

FOR

Field Observation Report

MT

Magnetic Particle Testing

PMI

Positive Material Identification

PSI

Pounds per square Inch

PT

Dye Penetrant Testing

PWHT

Post weld Heat Treatment

QMD

Quality Management Department

RT

Radiographic testing.

EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 3 of 16

Reliance

5.

6.

UT

Ultrasonic Testing.

VBT

Vacuum Box Test

WPS

Welding Procedure Specification

Responsibilities

Respective Area construction Manager is responsible to implement this

procedure at his area of working.

HOD of QMD is responsible for maintaining this procedure.

DCC is the custodian of this document.

Methodology
The following inspection procedure shall be adopted during fabrication and
erection of storage tanks designed as per API 650, in addition to stage
inspection activities specified in relevant Inspection and Test plan.

6.1

Tank Foundation
Before laying of the plates on the tank foundation, Reliance engineer shall
review and ensure the availability of the following documents.

Tank foundation handing over record with survey report.

Cathodic protection installation report for tank bottom plate wherever

applicable.

And Mechanical contractor along with Reliance engineer shall carry out
surveillance of tank pad / foundation for variation of foundation level. Incase if
any variation is observed clearance for of tank bottom plate erection shall not
be given till the rectification work is completed.

6.2

Material Identification
Wherever the material used in tank fabrication is in the scope of the contractor,
the same shall be identified by review of mill TCs followed by mill identification
marks on the plates (as applicable) by Reliance engineer. In case of client
supplied material, the contractor shall identify the material by mill marks and
maintain the records.

6.3

Sand / Grit Blasting and Painting

6.3.1

Plate materials used for shell and tank bottom shall be either grit or sand
blasted to achieve required surface cleaning. Priming of the surface cleaned
material shall be carried out with in 4 hrs (provided Relative humidity (RH) shall
be with in 85% or as recommended by the manufacturer). Inspection shall be

EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 4 of 16

Reliance
carried out as per relevant inspection and test plan number EPCMD-2-QM00ITP-ME-024. In addition to this the following tests are to be conducted as per
the requirement.

6.3.2

Salt contamination test for every batch of sand / grit used.

Adhesion test / Peal off test at random and record it.

Dry film thickness (DFT) of each coating.

Wherever salt deposition is observed on (Zinc based) prime coated plates /

fittings due to improper storing condition, the following recommendations are
given by the paint manufacturer prior to proceeding with subsequent coats.
(This surface phenomenon is initially due to formation of Zinc oxide, because of
the prolonged contact of water, and latter converts to Zinc carbonate)

High-pressure water washing / Low-pressure water wash with brushing

the surface. Ensure that only potable water is used for washing.

Remove localized deposition of washed substance from the paint surface.

Allow the surface to dry and then proceed next coats of paint as per
specification

6.4

Erection of Tank

6.4.1

Bottom, Annular / Sketch Plates

Underside of the plates used for tank bottom, annular and sketch shall be
painted (wherever applicable) with coal tar epoxy or any other paint
recommended. Annular / sketch plates of a tank shall be laid as per approved
tank bottom lay out drawing.
The following points shall be inspected during and after erection of tank bottom,
annular and sketch plates.

Stitch welding of backing strip with under side of annular plate (as shown
in the drawing).

Root gap and fit up of annular plates with backing strip.

Wherever applicable 50% (preferable alternate joints) of annular plate

butt joints shall be spot radiographed as per clause 8.1.2.9 of API 650.

Visual Inspection of all bottom / annular plate welds shall be carried out
as per clause 8.5 of API 650.

Vacuum testing or any other testing as specified in clause 7.3.3 of API 650
of completed annular joints shall be carried out. (In addition of vacuum
DPT can be carried out in shell resting portion of annular joint).

EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 5 of 16

Reliance

6.4.2

Lap welded joints of all bottom, sketch and sketch to annular joints shall
be lapped at least five times the nominal thickness of the thinner plate
joined (as per clause 5.1.3.5 of API 650) or as specified in the drawing.

In order to avoid buckling / distortion, approved weld sequence shall be

followed during welding.

All connected fillet welds shall be done with minimum two runs.

All bottom plate fillet weld joints shall be vacuum tested at specified
pressure (vacuum).

Vacuum Test shall be carried out as per procedure EPCMD-2-QM00-JEPME-010

Weld map shall be prepared for tank bottom and leaks if any observed
during vacuum test shall be repaired by approved repair procedure and re
tested to ensure its soundness.

Shell
All plates used for shell shall be squared and beveled before erecting at site.
Fabrication contractor shall nominate a person responsible for all fabrication
inspection, verification of correctness of the job and recording. RELIANCE
engineer responsible for fabrication inspection shall conduct surveillance audit
to ensure quality of the fabricated job. During each course of shell erection,
the respective discipline engineer shall verify the following activities.

In addition to shell joint fit ups, individual joint plumb, roundness of shell,
shell inner diameter shall be measured by the discipline engineer.

In order to ensure the verticality of shell at each stage of horizontal /

circumfarential joint fit up, individual and over all plumb shall be measured
by the discipline engineer. (Incase of shell erection is by jacking method at
least individual plumb ness shall be ensured).

Peaking, banding of all shell weld joints shall be measured. Wherever any
divination is observed, the same shall be repaired and re-inspected for its
acceptance by RELIANCE engineer.

Wherever buckling in the shell plate is observed, mark that area and check
the plate with radius (peaking), banding gauges. If the measured values are
out of the specified limits then that plate / buckled portion (as applicable)
shall be replaced with newly rolled plate.

Wherever required temporary structure shall be provided adjacent to the

buckled / marked area to avoid further propagation of induced stress in the
parent plate and the arrangement proposed shall be approved by RELIANCE
construction manager.

Clearance shall not be given for further erection of subsequent shell course

EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 6 of 16

Reliance
until unless the preceding course is inspected and cleared in all respects.

Contractor shall prepare a specific PWHT procedure including locations of

thermocouples and sketch showing structural support required for plate
supporting and submit for approval prior to commencement of PWHT.

Wherever PWHT is applicable, the distribution of thermocouples shall be

placed both sides of the plate to measure rate of heating and cooling. The
placement of thermocouples shall be in agreement with RELIANCE QMD
engineer.

Wherever nozzles are involved in PWHT, all connected welds shall be

inspected for cracks by any approved NDT method. RF pad pneumatic test
shall be carried out after PWHT, however contractor can conduct this test
prior to commencement of PWHT to ensure soundness of connected welds.

RELIANCE discipline engineer shall verify the orientation and elevation of all
shell nozzles and wind girders. Soundness of the nozzle welds shall be
ensured by any other approved NDT method and leak proof ness of nozzle
pads ensured by pneumatic test.

RELIANCE QMD engineer shall randomly mark Radiography spot on job /

weld map as per code requirement

A detailed weld map shall be prepared for tank and spot radiography of shell
joints are to be transferred on the weld map. Penalty shall be imposed on
repair of each spot radiography as per code requirement.

The soundness of the initial weld pass of shell to bottom, shell inside weld
shall be ensured with oil chalk penetration test or any other approved
method as specified in clause 7.2.4.1 of API 650 and other side final weld
with DPT.

All shell nozzles reinforcement (RF) pads shall be pneumatically tested at 15

PSI to ensure the soundness of the welds. In case of nozzles < 2 ( the
nozzle welds are to be tested by MT / PT method (as applicable).

In order to avoid cracks in butt weld joints of curb angle, first welded all
butt joints of curb angle from over head position (O/H) and then back-chip
to sound weld from down hand (D/H) position and carried out welding.

Gauge well / Still well pipes verticality shall be measured and ensure that
values are with in the acceptable limit. The pipe weld bead shall have
smooth profile and drilled holes are free of burs. Pipe external surface shall
be free of any cleats and tacks.

In order to avoid spark between deck sleeve and Gauge well / Still well pipe
assembly (in case of Floating roof tanks), spark arrest plates shall be
provided (as per the requirement of design / drawing), between the deck
sleeve and Gauge well assembly to avoid steel to steel direct contact and
act as spark proof.

EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 7 of 16

Reliance

6.4.3

The above points shall be taken care during fabrication and erection of tank
shell. Also points (before Hydro test) mentioned in check list enclosed as
annexure I shall be completed before releasing the tank for Hydro test.

Deck
Deck plates shall be laid on stage with required slope (as per drawing). During
deck erection QMD engineer shall ensure the following points.

All deck seams lap length shall meet the requirement of approved drawing.

All deck seams (only bottom deck seams incase of double deck) shall be
vacuum tested and rim joints, bulk head joints shall be penetration tested
to ensure the soundness of the welds.

Incase of double deck, clearance for erection of top deck plates shall be
given after ensuring that the bottom deck plates, structures and all
connected welds are free of any defects or damages.

A seal run between deck plate and sleeve / nozzle (down hand side of
bottom deck) shall be done for all deck (only bottom deck incase of double
deck) openings or welding shall be carried our as per weld detailed drawing.
Random inspection shall be carried out before Reinforcement (RF) Pad fit
up.

The soundness of root welding of all bottom deck openings shall be ensured
by conducting penetration test. Leaks if any found shall be repaired and retested.

Visual inspection of all deck seams including O/H (over head) welding of
sleeve / nozzles with deck plate shall be carried out as per clause 8.5 of API
650.

Arc strikes on deck (especially bottom deck) and sleeve / nozzle neck shall
be avoided. In case if any arc strikes are observed, it shall be grounded (do
fill up if required) and close visual inspection is to be carried out.

Wherever arc strikes are observed on deck, sleeve pipe / nozzle neck, the
same shall be removed by grinding and do fill up if required. The soundness
of the affected area shall be tested by penetration test or PT or vacuum test
as applicable.

All T joints of deck under side seams (only bottom deck incase of double
deck) and all deck seams of outer periphery shall be welded as per weld
detail drawing including the stitch welding of remaining length of deck under
side seams.

In order to avoid the arc strikes on deck (i.e. inside the pontoon boxes)
during welding, contractor shall ensure that only fully insulated cables and
capped / covered electrode holders are used. QMD will monitor it by regular
surveillance.

EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 8 of 16

Reliance

6.4.4

All swivel joints used for tank roof drain system shall be tested for leak
proof ness by internal pressure before installing into the system.

Roof drain system shall be tested before and after tank hydro test at
specified test pressure by contractor to ensure leak proof ness of the
system.

Cone Roof
RELIANCE engineer shall clear the self-supported cone roof structure before
erecting, if being assembled on the ground.

6.4.5

All structural members used shall be free of any type of visual defects.

Before erection of Roof structure visual inspection of welding connected to

anchor chair (Structure resting chair) shall be cleared.

Length of Lap of all connected members of the structure shall be checked

and ensured. In no case the lap length shall be less than the specified
length (as mentioned in the drawing).

Wherever the joints are provided in the primary / secondary members of

the structure, all such joints shall be spliced as recommended by
Engineering.

Fillet sizes of all structural welding shall be verified as per approved

drawing.

Welding / Bolting shall be provided for all main members connected

central drum and anchor chair.

All connected bolting holes shall be made elliptical as shown in the drawing.

Bolt holes shall be properly drilled and gas cutting is not permitted.

In order to avoid leakage of all nozzle connections with tank roof plate
during roof test, care shall be exercised during fit-up of nozzle, a seal weld
is to be done between nozzle neck to roof plate before fit-up of
reinforcement pad plate (wherever applicable).

Wherever applicable roof test of any cone roof tank shall be carried out
before application of roof paint, i.e. all weld joints shall be free from grease,
paint etc.

RELIANCE engineer shall verify the checklist enclosed as Annexure-I with

this procedure and ensure the completeness of the job before clearing the
tank for Hydro test.

with

During and After Tank Hydro Test

Before starting of hydro test contractor shall ensure that the final inspection of

EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 9 of 16

Reliance
client / client authorized representative is completed and signed on the
respective format.

6.4.6

Hydro test shall be carried as per approved hydro test procedure or EPCMD2-QM00-JEP-ME-010.

Water used for hydro test shall have salt content with in the acceptable
limit.

Tank foundation settlement reading during every stage of fill up shall be

recorded after due dwell time (as specified in the procedure). If any major
variation is observed, immediately water filling is to be stopped and
informed to the construction manager by Execution Engineer.

All weld joints of tank including bottom deck (deck in contact with water)
shall be witnessed for leakage.

Leaks if any observed during hydro test shall be repaired with approved
procedure or as per clause 8.1.7 of API 650. The repair of the tank shall be
carried out as per clause 7.4.4 of API 650.

After Tank hydro test, roof drain system shall be re-tested at the same
pressure as was tested to confirm the leak proof-ness.

In case of cone roof tanks, wherever applicable roof test (pneumatic test
at recommended test pressure) shall be carried out on all weld joints
connecting roof plates and roof to shell (as applicable). Weld joints covering
by this test method shall be free from paint, grease etc.

Full tank vacuum test shall be carried if the tank is designed for partial
vacuum. Contractor shall prepare separate procedure with necessary safety
precautions before proceeding for the test.

Quality Records
Quality Records for tank before and after hydro test shall be compiled as per
the requirement of relevant EPCMD-2-QM00-ITP-ME-050. Tank system dossier
(for civil and mechanical activities) shall be compiled as per Annexure-II of this
document.

EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 10 of 16

Reliance
Annexure-I
Check List For Tank Final Clearance
Tank Number:

Date:

Area:

Unit Number:

I.

Before Hydro Test

Activity Before Hydro Test

Verification and
Certification
Contractor Client

1. Tank bottom
a) Material identification reports of tank bottom plates
b) Under side blasting and painting reports for annular,
sketch and bottom plates, as applicable
c) Visual inspection of all tank bottom weld joints
d) NDE of tank bottom welding, incl. off annular plate
(PT, RT and VBT)
e) Water fill up test for bottom sump to be conducted
before installation.
f) Removal of deck staging angles.
g) Visual and NDE clearance of tank bottom plate as
applicable.
h) Fixing of anode cleats and its clearance wherever
applicable.
i) DP test for the tank bottom sump attachment weld.
j) Checking the gap between the sump and drain pipe
prior to and after hydro to ensure settlement within
limits.
k) Tank bottom and sump cleaning.
l) Visual inspection of all deck leg support bearing plate
welds.
m) Clearance to ensure that all legs are to bearing
plates free without any tacks
n) Weld map with welder Id, RT and VBT details
2. Tank shell
a) Material identification reports of tank shell plates
b) Weld visual of all circumferential and vertical seam
welds
c) Banding and peaking reports of all the courses
d) RT clearance for all circumferential and long seam
welds
EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 11 of 16

Reliance
Verification and
Certification

Activity Before Hydro Test

Contractor

Client

e) O/S and I/S shell surface and visual clearance

(fill and grind etc.)
f) Final plumbing reports
g) Weld map with welder id, RT details Welding
clearance of curb angle
3. Wind girders
a) Visual inspection of primary and secondary wind
girders welding
b) Drain holes provided in the wind girder (by drilling).
4. Shell to bottom welding
a) Oil chalk test report of root run (from inside) between
shell and annular plate
b) Visual inspection of Shell to bottom welding (I/s and
o/s)
5. Tank deck
a) Material identification reports of deck plates and str.
items
b) Visual inspection of deck bottom plate welding and
VBT reports
c) Deck bulk head and ring plates welding visual
inspection and oil chalk test reports. Oil chalk test of
roof drain sump inclusive of long seam.
d) Deck structure welding visual inspection, wherever
applicable
e) Visual inspection of welding for support leg sleeve, pad
and gusset plate (both top and Bottom incase of
double deck)
f) Visual inspection of gusset to bulk head plate welding.
g) Visual inspection of Overhead welding between sleeve
and deck bottom and its PT.
h) Visual inspection of Overhead welding of inside the
pontoons
i) Visual inspection of Deck top plate welding
j) Visual inspection of Blower opening welding and NDE /
oil chalk inspection, as applicable
k) Rim vent, roof drain sump inclusive of vertical seam.
oil chalk test
l) Visual inspection of seal angle welding
m)Visual inspection of foam dam welding
n) Emergency drain flange height from Top of deck plate
EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 12 of 16

Reliance
Verification and
Certification

Activity Before Hydro Test

Contractor

Client

o) Cleaning of pontoon boxes

p) Top Deck cleaning
q) Visual inspection of stitch welding of lower deck
overhead seams, wherever applicable
6. Shell nozzle assembly
a) All Shell nozzles are provided.
b) Visual inspection of all nozzle welds
c) NDE on nozzle reinforcing pad plates.
(PT / MT as applicable)
d) Review of PWHT report of all applicable nozzle
assembly.
e) Pneumatic testing of all nozzle R F pads
f) All nozzle flanges are correct and welded
g) Supports for < 2 nozzles and visual inspection of
welding (wherever applicable)
7. Erection and welding of gauge well / Anti
rotation device
a) Datum plate welding
b) Seal plate insertion
c) De-burring of Gauge well pipe drill holes.
d) Verticality of Gauge well pipe from Top Landing
Platform is measured.
e) Rollers and aluminum plate is fixed on the hatch.
f) Ensure free movement of the roller
g) Brazing of spark arrest strip with CS sleeve
8. Landing platform and stairway
a) Visual inspection of welding of landing platforms and
stair way
b) Splice plates welding clearance of stair case channel
joints if any.
c) Visual inspection of stair case gratings and handrail
welding.
d) TC verification for all G.I. parts to be done.
9. Roof drain Assembly
a) Visual Inspection of sump and roof drain piping
welding and availability of roof drain system hydro
test report.

EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 13 of 16

Reliance
Verification and
Certification

Activity Before Hydro Test

Contractor

Client

b) Visual inspection of all fixed and movable supports

welding
c) Roof drain assembly chain length is as per
requirement
d) Swivel joints site test report for internal pressure test
and ensure 3600 rotation.
10. Erection and welding of rolling ladder
a) Visual inspection of rolling ladder Welding
b) Clearance for the expansion of split pins
c) Clearance for the horizontally of steps
d) Welding clearance of supports on shell courses of
MVWS, foam detection systems and utility lines, as
applicable
e) Visual inspection of LSHH nozzle welding with shell
and its RF pad test wherever applicable.
f) Name plate Bracket and level chairs are provided.
g) Clearance of the hatch handle and lock pin for smooth
Operation (over gauge well / anti rotation device)
h) Deck man way lock pin and Deck man way ladder are
provided
i) Clearance for the deck Stopper assembly fixed and
split pin expand / weld as applicable.
j) Visual inspection of Gauge hatch welding at top of
gauge well pipe
k) Leg support pin and nut / split pin and its expansion
l) Fixing of earthing cleats / boss
m) Safety connection for CP (neck, flange, stock bar) is
provided

EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 14 of 16

Reliance
II.

During And After Tank Hydro Test.

Activity

1.

Verification and
Certification
Contractor Client

Settlement readings of Tank during filling with water

2. Monitoring of Deck to shell gap during Deck lifting.

3. Hammer Test and Visual Inspection of Shell as well as deck
plate after filled to specified level (bottom deck in case of
double deck)

Activity

Verification and
Certification
Contractor Client

4. Roof Pressure / partial vacuum (as applicable) Test in case

of Cone Roof tank.
5. Roof drain system re-hydro test after draining water and
inside cleaning of tank.
6.

Left out work if any from item no. I

EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 15 of 16

Reliance
Annexure-II
Records Compilation
Activity

contractor

Client

a) Test pack cover sheet

b) As built drawing of Tank foundation, Tank GA and cathodic
protection system drawings (as applicable)
c) Foundation clearance / acceptance report
b) Cathodic protection installation and acceptance report
c) verified check list with certification and Punch list
d) consolidated material identification report
e) consolidated NDT reports
f) Vacuum box test report for tank bottom plate
g) Vacuum box test report for bottom deck plate
h) shell verticality report
i) Peaking inspection report
j) Banding inspection report
k) piping pressure test reports
l) consolidated report on shell nozzle NDE, PWHT and PAD test
(as applicable).
m) consolidated report on shell nozzle orientation and elevation
n) weld map with welder Id. and NDE details
o) Radiography film hand over report
p) Mechanical clearance report for hydrostatic test
q) Hydro test Report
r) Tank settlement report
s) MVWS piping test pack
t) Detection system Test pack

EPCMD-2-QM00-JEP-ME-026, Rev: 00
Confidential Reliance. All rights reserved

Page 16 of 16