Menu

Required Documentation for Vessel Construction, Alteration and Repair

Required Documentation for Vessel Construction Alteration and Repair


All work should be performed per the requirements of the latest version of  ASME Section VIII Div. 1, API-510 and any/all applicable “your client” standards/specifications.

Note: all Section VIII Div. 2 Vessels should be considered on an individual basis.

Prior to start of fabrication and/or mobilization a complete set of detailed construction drawings should be provided to, reviewed by and accepted by at a minimum:

  • A client engineer or client designated engineer who specializes in pressure retaining equipment
AND
  • A person who is currently certified through the API organization as a 510 inspector in good standing.

A qualified inspector CWI and/or 510 is required to follow all the requirements below. If one is not provided by the contractor, a qualified third party inspector will be provided by the project owner.

Documents to be submitted to Client for approval prior to mobilization/fabrication:

  • Quality Control Manual
  • Copy of policies and procedures for ASME code work
  • Copy of all  applicable Code stamps, licensure, certification or qualifications
  • WPS’s, PQR’s, WPQ’s for all weld processes to be used
  • QA/QC personnel resumes and certification
  • Qualification records/visual acuity for NDE/QC personnel
  • Continuity logs for all welders to be utilized (if applicable)

Quality Control Package – Should be job specific and maintained onsite and updated daily by contractor QC. The package should be in a location accessible to Client inspection. The following documentation is required:

  • Scope of work
  • An Inspection Test Plan (ITP) prepared by the contractor and approved by the client prior to construction is required for each job. It must be maintained through out construction. This documentation to be submitted in package format for review and approval prior to any construction shop or field. The ITP should include all required visual and NDE inspection requirements and inspection hold points.
  • WPS’s, PQR’s, for all weld processes to be used
  • WPQ’s for all welders
  • MTRs with heat number for all plate, pipe, and welding consumables used
  • NDE test reports
  • Weld maps with heat number’s for material
  • Drawings and calculations for nozzle and manways installed or revised.
  • As built drawings for new bottoms, roofs, and shell replacements
  • Daily inspection reports for visual inspections and non destructive testing
  • Non conformance reports with documentation of corrections.
  • Facsimile of the repair name plate if applicable.
Repair Activities:
  • Any deviations from Client Standards or governing codes must be reviewed and approved.
  • Welding consumables.
  • Contractor QC should coordinate and review all required NDE. Reports will be maintained in the QC package.
  • Heat numbers must be transferred to each fabricated component.
After completion of the repairs and prior to acceptance, the QC package should be reviewed. Once approved, the QC package should be turned over to Client Inspection within 3 business days.

For New Construction

All design, fabrication, erection, and documentation should be per Client Standards and ASME Section VIII Div. 1.
Prior to Construction - Design review/approval of document packages to include:
  • Manufacturer’s design calculations.
  • General arrangement drawings with complete material specifications.
  • Detailed fabrication drawings.
  • Welding procedure specifications, procedure qualification records, and welder performance qualifications (current).
  • Heat treatment procedures if applicable.
  • Nondestructive examination procedures and testing procedures.(Inspection Test Plan).
  • Description of proposed test gaskets including material properties, dimensions, and design characteristics.
  • An Inspection Test Plan (ITP) prepared by the contractor and approved by the client prior to construction is required for each job. It must be maintained through out construction. This documentation to be submitted in package format for review and approval prior to any construction shop or field The ITP should include all required visual and NDE inspection requirements and inspection hold points.
During Construction - Interim documentation during construction
  • Rod control- Electrodes should be stored in accordance with industry standard or client’ specification (care of welding consumables).
  • Documentation- Receiving inspection and reports will be performed and maintained in “real time” up to date on site.
  • MTR’s for materials and electrodes maintained on sight with job package.
  • Heat number’s for materials should be indicated on the project weld mapping to correspond with the MTR’s maintained. Heat number’s must be transferred to each fabricated component.
  • Daily inspection reports for visual inspections and testing maintained daily.
  • Non conformance reports with documentation of corrections.
Post Construction
After completion of the repairs and prior to acceptance, the QC package should be reviewed, approved and turned over to Client Inspection within 3 working days.
Package to consist of the following as per API 650 appendix W:
  • Manufacturer’s Data Report (Code form)
  • Final General Arrangement and detail fabrication drawings, marked “as built” by the manufacturer, complete with dimensions and data, with complete material specification and parts list.
  • Design calculations
  • Copies of material test reports on all components requiring documentation
  • Nameplate rubbing/facsimile, including Code stamping
  • Completed copy Company Pressure Vessel Specification/Data Sheet
  • Completed copy of Company Tower Tray Specification/Data Sheet (if applicable)
  • Reports of results of all tests to include:
    • Welded vessel test plates (if applicable)
    • Hydro test pressure chart(s) 
    • RT performed w/film, maps, weld ID and film interpretations 
    • Heat treatment records which show complete cycle 
    • UT/MT and/or PT if applicable 
    • Hardness testing



Tags: Alteration Repair Vessel Construction