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PROCEDURE AUTHORIZATION AUTHORIZATION This procedure have been generated and implemented to identify the control that shall be applied by members of staff in the department when carrying out their duties
Department Authorization
Date:
Signed: This confirms that this procedure has been approved for official issue and that members of staff shall complete the tasks assigned in accordance with the mechanisms defined herein
Corporate Authorization (Company Director)
Date:
Signed: The procedure forms part of a formal system within the company which ensures that this document is handled in a controlled manner in accordance with documented procedures. This procedure will be subject to audit as part of the company policy towards quality
Quality Authorization Authorization
Date:
(Quality Management Rep' s)
Signed:
PROCEDURE REVISION Rev.
Date
0
11 Agustus 2011
Section
Outline of Changed
Authorization Authorizat ion
First Issue
1 2 3 4
STATEMENT OF CONFIDENTIALITY
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TABLE OF CONTENT Page 1.0
PURPOSE
4
2.0
SCOPE
4
3.0
DEFINITIONS
4
4.0
REFERENCES
5
5.0
RESPONSIBILITIES
5
6.0
PROCEDURES OF IN-SERVICE STORAGE TANK INSPECTION
5
6.1 DOCUMENTATION REVIEW
5
6.1.1 Previous Certificate
6
6.1.2 Tank Data
6
6.1.3 Manufacturing Data Record
6
6.1.4 Usage and Maintenance History
6
6.1.5 Reparation, Alteration and Reconstruction (if any)
7
6.2 PHYSICAL INSPECTION
7
6.2.1 In-Service Inspection
8
6.2.1.1 Roof Tank
8
6.2.1.2 Shell Tank
8
6.2.1.3 Tank Foundation
8
6.2.1.4 Fire Hazardous and Corrosion Protection
8
6.2.1.5 Tank Safety Equipment
8
6.2.1.6 Reporting
8
6.2.2 Out Service Inspection
9
6.2.2.1 Roof Tank and Structural member
9
6.2.2.2 Shell Tank
9
6.2.2.3 Tank Bottom
9
6.2.2.4 Tank Foundation
10
6.2.2.5 Fire Hazardous and Corrosion Protection
11
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6.2.2.6 Corrosion Control Equipment
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6.2.2.7 Tank Safety Equipment
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6.2.2.8 Recording
11
6.3 ACCEPTANCE CRITERIA
12
6.3.1 Document Review
12
6.3.2 Tank Component Inspection
12
6.3.3 Roof
12
6.3.4 Shell
12
6.3.5 Bottom
13
6.3.6 Foundation
14
6.3.6.1
Differential Settlement
14
6.3.6.2
Internal Bottom Distortion
15
6.3.6.3
Edge Settlement
15
6.3.7 Corrosion Protection System
15
6.3.8 Venting System
16
6.3.9 Fire Hazardous Protection System
16
6.3.10 Attachment
16
6.3.11 Appurtenance
16
6.3.12 Bund Wall
16
6.4 REPORTING, RECORDS AND DOCUMENTATION SYSTEM
7.0
16
6.4.1 INSPECTION LOG BOOK
17
6.4.2 INSPECTION REPORT
17
6.4.3 SURVEILLANCE REPORT
17
6.4.4 EXTERNAL DOCUMENT
17
ATTACHMENT
17
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PURPOSE a.
The purpose of this document is to ensure that the in-service storage tank is in safe condition.
b.
Provide guideline for surveyor to perform reviewing, inspection, verifying and testing of existing storage tank comply with requirements.
SCOPE a.
This procedure shall be applied for Storage tanks, that have been placed and have been inspected by an authorized inspection agency.
b.
The procedure covers the minimum requirement International Code and Standard, or Owner/User inspection procedure.
c.
This is Company approved procedure and shall be adhered to at all time except where Owner/User documents species other requirement.
DEFINITIONS a.
Surveyor or Engineer
-
The person that takes any inspection of storage tank under employed company who has the Storage tank Inspector Certificate
b.
Company
-
Andre
c.
Owner/user
-
The organization legally responsible for the operation, maintenance and safety, including the repair, modification or replacement of items in the plant of storage tank
d.
Inspection
-
The work necessary to check the tank for defect such as corrosion, cracking or other damage to certify the tank as safe for operation or in need of repair.
e.
In service inspection
-
On-line inspection, an external inspection being performed when the storage tank is used.
f.
Out-of-service inspection -
Off-line inspection, an internal inspection when the storage tank is not used
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REFERENCES The following minimum reference for Storage tank construction, but not limited to: API RP 575, Inspection of Atmosferic and Low – Pressure storage Tanks. API Std 653, Tank Inspection, Repair, Alteration and Recontruction. API Std 651, Cathodic Protection of aboveground Petroleum Storage Tanks. API Std 652, Lining of Aboveground Petroleum Storage Tank Bottom. API Std 650, Welded Steel Tank for Oil Storage. API Std 2000, Venting Atmospheric and Low-Pressure Storage Tanks. API Std 2015, Safe Entry and Cleaning of Petroleum Storage Tanks. EEMUA 159, User’s Guide to The Maintenance and Inspection of Above-ground Vertical Cylindrical Steel Storage Tank . EEMUA 183, Guide for The Prevention of Bottom Leakage from Vertical, Cylindrical, Steel Storage Tank . NFPA 30, Flammable and Combustible Liquids Code. NFPA 78, Lightning Protection Code.
5.0
6.0
Keputusan Direktorat 84.K/38/DJM/1998.
Jenderal
Minyak
dan
Gas
Bumi
Nomor
:
Keputusan Direktorat 39.K/38/DJM/2002.
Jenderal
Minyak
dan
Gas
Bumi
Nomor
:
RESPONSIBILITIES a.
The Company Management shall be responsible for ensuring that the necessary resources are made available for the requirements of this procedure to be carried out in the safe manner.
b.
Line Management shall be responsible for ensuring that the requirements of this procedure are fully implemented at all times.
c.
All employee involved in the implementation of this procedure shall be responsible for adherence to the requirements stated within.
PROCEDURES OF EXISTING STORAGE TANK INSPECTION 6.1. DOCUMENTATION REVIEW Before and during inspection performing the surveyor shall be review the following documentation : company work instruction no: F.SQ-WI.008.1 Rev. 0 Work Instruction for Storage tank In-Service Recertification, F.SQ-WI.008 Procedure For Inspection of Exist ing Storage Tank.doc
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company work instruction no: F.SQ-WI.008.2 Rev. 0 Work Instruction for Storage Tank Out of Service Recertification, company standard form no. F.SQ-F.008.1 Rev. 0 In-Service Storage tank Inspection and Verification Check List and company standard form no. F.SQ-F.008.2 Rev. 0 Out of Service Storage tank Inspection and Verification Check List, but not limited to : 6.1.1 Previous certificate Quality control system of the owner inspection / operator Quality control system review covers, but shall not limited to: Tank maintenance plan Working procedure Line of responsibility Reporting procedure Personnel competence Calibration scheme
6.1.2 Tank Data Standard require the maintaining of complete file recorded divided into three records by the owner / tank operator, which are: Manufacturing Data Record Maintenance history / inspection Reparation history / alteration
6.1.3 Manufacturing Data Record Manufacturing Data Record shall be reviewed, but not limited to: Quality control of manufacturing data record Used standard Name plate Material specification Drawings; Tank specification Design calculation Welding Procedure Specification; Procedure Qualification Records; Welder Qualification; Nondestructive Test; Hydrostatic test with survey settlement; Final Construction report All analysis result and material test
6.1.4 Usage and Maintenance History Usage and maintenance history consist of written note about tank usage (product changing and the change of usage recorded along with the condition such as temperature and product pressure) at all times along with the action taken on the maintenance of the tank.
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Usage and maintenance history shall equip with inspection history that inserted all action taken into measurement, condition of every part being inspected, and a record upon every inspection and test. Inspection history covers inspection reports. The primary obser vation for “safe operation” in the storage tank inspection is:
Corrosion rate level Remaining life
Corrosion rate and remaining life can be calculated using the following formula: Remaining life =
t actual – t minimum Corrosion rate
Remain life = the left over years of tank component, within year; t actual = measured thickness during inspection at the location or used component to determine the allowable minimum thickness, in or mm; t minimum = minimum thickness allowable at the location or certain component, in or mm
t previous – t actual Corrosion rate = Period between t previous and t actual Corrosion rate is stated in per year or mm per year. t previous = thickness at the same location with t actual measured at the previous inspection, with in or mm 6.1.5 REPARATION, ALTERATION AND RECONSTRUCTION (IF ANY) Reparation history / alteration shall insert every data gathered from a tank covers its construction, particularly those related with reparation, alteration. This record shall insert coating performances and used lining. This reparation history /alteration shall include location, scope, and used standard. This document shall be reviewed to obtain good engineering judgment.
6.2 PHYSICAL INSPECTION Visual and inspection result verification (measurement, calculation and recommendation) shall be performed by authorized inspection agency.
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Visual inspection shall be carried out with the F.SQ-F.008.1 Rev. 0 and F.SQF.008.2 Rev. 0 guidance. There are two forms of physical inspection, which are” 6.2.1 In-Service Inspection This inspection is done during the storage tank used. The inspection consists of: 6.2.1.1 Roof tank Visual inspection at the entire roof part. Verify result of wall thickness measurement. Verify result of Non Destructive Test (NDT). 6.2.1.2 Shell Tank Inspection performed including nozzle, drain, manhole, wind girder and other part at shell. Visual inspection the entire shell part. Verify result of wall thickness measurement. Verify result of Non Destructive Test (NDT). Verify result of minimum thickness calculation. 6.2.1.3 Tank Foundation Visual inspection the entire foundation part. Verify result of settlement measurement. Verify bund area (surround the foundation) Foundation condition shall be evaluated comply with requirements from standard API-653. 6.2.1.4 Fire Hazardous and Corrosion Protection Verify fire protection equipment. Verify result of corrosion control equipment measurement, such as coating and cathode protection. The voltage between tank and the ground, the maximal voltage is -0,85 Volt. The survey shall comply with API RP 651. 6.2.1.5 Tank Safety Equipment Pressure vacuum vents and breather valves shall be inspected visual. Ensure, whether there is a periodically functional test from the owner inspection record. 6.2.1.6 Reporting Minimum documents shall be arranged in the following: 1. Certificate of Inspection 2. Migas Appointment Letter 3. Previous certificate issued by MIGAS 4. Visual Inspection Report 5. Calculation Sheet 6. Construction Data Report 7. Copy of the Name Plate Rubbing 8. Inspection/Maintenance Records 9. As built drawing
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6.2.2 Out of Service Inspection This inspection is done whenever the tank not used so the inspection can cover the inside of tank. Prior to inspection, comply with API RP575 para. 7.1, condition listed below shall occur: Free from hazardous gas Free from liquid/residue that produce poisonous gas or flammable Isolated/attach with blinding (blind flange) Oxygen content (19, 5-23, 5%) The tank is cleaned enough to performed an inspection
The out of service inspection cover: 6.2.2.1 Roof tank and the structural member Perform visual inspection at entire the roof and its supports. If any corrosion found at the shell, the same inspection at the support column at the same level shall be conducted. Verify result of thickness measurement. Verify result of Non Destructive Test (NDT). Roof evaluation at the fixed roof type shall be conducted at support (rafter, girder, column and bases) particularly distortion (out of plumb) from the support column, there may be any possibility for internal corrosion at the column. For floating roof type, the area from the roof plate and pontoon, pitting, roof support system, perimeter seal, roof rolling ladder, anti rolling means, drain system (ref API 650 Appendix C and H)
6.2.2.2 Shell Tank Check for crack possibility at the shell bottom angle. Check for any corrosion possibility, especially at the vapor space area and liquid level line. Incase any corrosion found, thickness measurement and evaluation comply with API-653 paragraph 2.3.2.1 shall be done. Evaluation that might bring out effect against tank integrity shall be evaluated, such as corrosion, flaw detection, deterioration, service change and relocation. If shell thickness requirement shall not be fulfill, the corrosion or the damaged area shall be repaired, or allowable liquid level shall be decreasing or tank retired.
6.2.2.3 Tank Bottom For visual inspection on the entire bottom plate, and floor scanning using magnetic flux leakage. Ultrasonic corrosion
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scan or digital ultrasonic thickness shall be used for the detection area. Tank bottom shall be checked from any damage caused by the tank settlement. (Ref.API-653 App. B) Evaluate the bottom tank thickness by using magnetic flux leakage, corrosion scanning& ultrasonic test. The minimum thickness for tank bottom at the upcoming inspection shall be 0,05” – 0,10” (ref.Table 4-1 API 653) Tank Bottom measurement approximation shall use one of the following methods: Deterministic method: by calculating internal and external pitting (Ref.API-653 Par. 2.4.7.1) Probabilistic Method: using statistic approach from the thickness measurement. Tank bottom minimum thickness at the critical zone – or at the annular plate ring or area 12” from the shell inside the tank or area 12” from the shell inside the tank or at the annular plate ring is the smallest from half of the plate thickness (without any corrosion allowance) or 50% from the bottom minimum shell thickness but not least than 0,1”), The projection thickness of the shell weld – bottom plate is at the minimum of 3/8. Minimum thickness of annular plate is similar to the bottom plate critical zone.
6.2.2.4 Tank Foundation Perform visual inspection at the entire foundation part. Foundation can be made from underpinning, rocks, ring walls or bolster. This bolster shall be inspected against reform possibility and uncommon settlement. Settlement measurement result verification, and bud area (area around the foundation). Foundation condition shall be evaluated comply to standard requirement API-653.
If the foundation is specified as horizontal as the tolerance shall be: a. If concrete ring wall is given under the shell: The top of the ring wall shall be at the same level at maximum ⅛ for every 30 ft peripheral and ¼ from total peripheral measured by average height. b. If concrete ring wall is not given under the shell: ⅛ for every 10 ft from peripheral and ½”from total peripheral, measured by the average height.
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If the foundation deviation is specified, elevation difference around the peripheral shall be calculated from the highest point. Actual difference around the peripheral shall be determined by the specified height point. Actual height difference shall not exceed from the tolerance below: a. If concrete ring wall is given, ⅛” for every 30 ft from periphery height and ¼ from total periphery. b. If there is no concrete ring wall, 1/8” for every 10 ft of the periphery height and ½” for total height of periphery. 6.2.2.5 Fire Hazardous and Corrosion Protection Fire protection equipment such as flame arrester, earthen and concrete dikes shall be inspected visually while confrontation to the periodically inspection record of the owner. For fire safety equipment such as light fire extinguisher, other than visual inspection also watch the functional test record which supposed to be performed periodically. 6.2.2.6
Corrosion control equipment, such as coating and cathode protection shall be inspected. Ensure that the coating is intact other part that not painted shall be protected by system cathode protection. Do a different voltage measurement between the tank and the ground. The maximal protection difference is 0,850 Volt.
6.2.2.7
Tank Safety Equipment Pressure vacuum vents and breather valves shall be inspected visually. Ensure, whether the functional test exist periodically from the owner inspection record.
6.2.2.8
Recording Similar to new storage tank certification, the minimal of the documents is as follow: Certification of Inspection MIGAS Appointment Letter The authorization license of previous usage issued by Ditjen MIGAS Visual Inspection Report Calculation Sheet Construction Data Report Copy of Name Plate Rubbing Inspection/Maintenance Records As Built Drawing
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ACCEPTANCE CRITERIA Certification shall be handed out whenever there is no non-conformance report found or has been taken care in adequate manner. 6.3.1 Document review Acceptance criteria from the document review are completeness, validity, document rightness, along with adequate evidence. First of all, inspection report from the Authorized inspection agency shall comply with the date completeness criteria, and shall fulfill the technical criteria comply with code /standard as strand in the following sub chapters. 6.3.2 Tank component inspection Physical inspection shall appointed consistency related with the result of document review. 6.3.3 Roof API Std 653 4.2 – Any corrosion with average thickness less than 0.09 in occur within 100 in2 area shall be replaced. Structural part from the tank foundation (column, bottom, rafter, and block) shall free from any distortion, corrosion, and mechanical damage. A leak shall not be found at the float roof tank. The seal system, antirotation equipment, rain drainage system, and ventilation system shall work properly. 6.3.4 Shell Every shell course shall be measured by the method of actual thickness comply with API Std 653 4.3.1. Crack shall not permitted from the shell to the bottom Generally, the minimum thickness for every course is determined by calculating this formula (Only for tank with diameter less than 200 ft), add to the thickness to other pressure condition comply with API Std 653 4.3.3.5 t min = 2,6 ( H – I ) D.G
t min D H G S
S.E = minimum thickness, in; = nominal diameter, ft; = the height level of L for the worst corrosion area in every course up to the liquid maximum level, ft; = the mass of product; = Maximum allowable stress in psi, for the first course and the second course at minimal (0.80-Y or 0,429T) shall be
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used and min (0.88Y or 0.472T) shall be used for other course; = Specific minimum yield strength of plate, use 30000 psi if not known.
6.3.5 Bottom Leakage shall not be allowed at the tank bottom (either bottom plate or annular plate, if available). API Std 653 4.4.7.3 – minimum thickness of bottom plate shall not be less than the bottom plate thickness as listed in table 6-1 API Std 653, as rewritten below: Table 1 – Minimum thickness of bottom plate (API Standard 653 table 6-1) Minimum thickness at the bottom plate for the following inspection (in) 0.10
0.05
0.05
Tank Bottom / foundation design Bottom design / tank foundation without any detection and reservoir upon bottom leaking Bottom design / tank foundation meant to detect and gives reservoir upon bottom leaking The existence of reinforced lining (by using fiberglass or glass flake), thickness > 0.05 in comply with API RP 652.
Tank designed with annular plate, other than earthquake pressure, shall have the minimum thickness as given from Table 2 and Table 3 below (depend on the mass of the storage product) plus corrosion allowance. Note: Specified thickness in table 2 and table 3 is meant to give foundation with flat buffer as width as annular plate. The thickness shell plate is the bottom plate thickness at the construction. Table 2 – Annular Plate Thickness (in) for Product Mass < 1.0 [API std 653 Table 4-4] First course of shell The first shell course strength (psi) thickness (in) <24,300 <27,000 <29,700 <32.400 1 ≤ 0,75 0,17 0,20 0,23 0,30 0,75 1,50 0,27 0,40 0,53 0,68
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Table 3 – Annular Plate Thickness (in) for Product Mass ≥ 1.0 [API std 653 Table 3-1] First course of shell The first shell course hydrostatic test thickness (in) strength (psi) < 7.000 <30.000 <33.000 <36.000 t ≤ 0,75 ¼ ¼ 9/32 11/32 0,75 1,75 11/32 1/2 5/8 ¾ API Std 653 4.4.7.7 – the bottom plate thickness in the outer shell measured from the welded foot filled bottom-to-shell shall not less than 0,1 in. The projection length from welded foot filled bottom-toshell shall not less than 3/8 in. 6.3.6 Foundation API RP 570 7.2.3 – Shall not any erosion occur at the foundation, particularly at the ground foundation type. Nor any crack, threadbare caused by calcinations or alkali attack shall occurred. The part between bottom plate and foundation surface shall be covered with seal material to prevent water intrusion. API Std 653 Appendix B – Evaluation of tank foundation is primarily observed from the settlement tank bottom. All the measurement method in the acceptance criteria for every type of the following statement comply with API Std 653 Appendix B. 6.3.6.1 Differential Settlement With the adequate differential settlement measurement as described in the API Std 653 B.2.1, the maximum out-ofplane deflection allowed is described as follow: |S| ≤
(L 2 . Y . 1 1 ) 2[(E.H)]
S = deflection, in ft (out-of-plane distortion); L = the length of the arch between measurement points, in ft; Y = Yield strength, in psi; E = Young modulus, in psi; H = Tank height, in ft.
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6.3.6.2 Internal Bottom Distortion Internal bottom distortion can form shape into concave or protrusion at the tank bottom, and the depth/height shall not exceed BB. The following R measurement method in this formula complies with picture B-8 API Std 653. BB = 0,37. R BB = Protrusion height or the maximum depth of concave, in; R = circular radius as shown in the concave or protrusion, in ft; 6.3.6.3 Edge Settlement The edge settlement measurement method is described in the Picture B-5 API Std 653. Maximum edge settlement limitation is shown is API Std 653 picture B-10 and B-11., as inserted in the next page as picture 1 and picture 2. Permitted maximum settlement side for area with overlapping welding similar or parallel to shell (Figure B-10 API Std 653). Permitted maximum settlement side for area with overlapping welding similar or perpendicular to shell (Figure B-11 API STD 653) 6.3.7 Corrosion Protection System API RP 575 7.2.7 – In the corrosion protection system such as coating, particularly the one that lies at the submerged product (internal tank) shall not find any blemish reach to the other side of the metal such as blistering, holiday. API RP 651 – In the corrosion protection system such as cathode protection by using measurement method as API RP 651 8.3, at minimal shall fulfill these criteria: Negative potential shall value at least 850 mV with the attach cathode protection current. This potential shall be measured against reference saturated copper / copper sulfate (CSE) that connect with the electrolyte. Strength decreasing other than the one lay along the bottom edge of the tank-to-electrolyte shall be calculated for valid interpretation from this strength measurement. Negative strength shall be polarized at lest 850 mV against CSE. At least 100 mV measured cathode polarized between the bottom metallic surface of the tank and the stable reference electrode that connected with electrolyte. 6.3.8 Venting system
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The entire appurtenances on the roof, as if flame arrester, P/V valve, breather valve shall be calibrated, and packing at nozzle with proper condition, every dynamic part and shall not experience any significant corrosion. Strain part or grid from the flame arrester shall be cleaned and free from corrosion. Venting equipment capacity complies with tank specification as required in API Std 2000. 6.3.9 Fire Hazardous Protection System The fire hazardous protection system consists of the fire hazardous equipment and fire extinguisher equipment. API RP 570 7.2.6 - Every grounding system shall be well connected, and the total resistance from tank to the ground shall not exceed 25 ohm. Fire extinguisher equipment such as lightning rod, grounding, flame arrester and fire extinguisher equipment such as foam pipe, foam chamber, adherences, spray nozzle, are properly worked without any leaking or corrosion. 6.3.10 Attachments API RP 570 7.2 – At the ladder, platform, stiffeners, angle, stairs, anchor shall not be found any mechanical damage caused by corrosion or because other source that might endanger tank operation. If tank is equipped with insulation, tank shall not have any opening insulation that might potentially become water reservoir. 6.3.11 Appurtenances Components such as man way, nozzle, piping manifold, sample station, heater, mixer, access way, ladder, stairway, and platform shall not allow having mechanical damage caused by corrosion or other cause that might endanger tank operation. 6.3.12 Bund Wall Material used to form bund wall shall consist of water proof material. Bund wall shall capable to reservoir the biggest liquid volume that might eject from the biggest tank within one bund wall area. Interior height shall not exceed 1.8 m. If necessary, an additional judgment shall be conducted if a bigger bund wall is needed
6.4 REPORTING, RECORDS AND DOCUMENTATION SYSTEM During field inspection of Storage tank, the surveyor shall be make any record that described below, following company standard form no. F.SQF.008.1 Rev. 0 In-Service Storage Tank Inspection and Verification Check List and company standard form no. F.SQ-F.008.2 Rev. 0 Out of Service Storage Tank Inspection and Verification Check List, but not limited to : F.SQ-WI.008 Procedure For Inspection of Exist ing Storage Tank.doc
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6.4.1 Inspection Log Book During performing inspection, the surveyor or engineer shall be make log book of inspection that contain inspection activities including result of verifying, non-conformity record and the problem that arise during inspection. 6.4.2 Inspection Report After inspection activity has been completed or finish, the inspection personnel shall be make inspection report use company standard form no. F.SQ-F.007.1 Rev. 0 Form for Storage tank Report of Inspection and signed by Technical Operation Manager. 6.4.3 External Document Document controller shall be record the date of receiving transmittal prior to distribute to Technical Operation Department Authority, the document shall be reviewed and the status shall be recorded by surveyor or engineer use the company standard form no. F.SQF.008.3 Rev. 0 Form For Storage tank Recertification Document Check List.
7.0
ATTACHMENTS F.SQ-F.008.1
Rev. 0
F.SQ-F.008.2
Rev. 0
F.SQ-F.008.3
Rev. 0
F.SQ-F.007.1 Rev. 0 F.SQ-WI.008.1 Rev. 0 F.SQ-WI.008.2 Rev. 0
In-Service Storage Tank Inspection and Verification Check List Out of Service Storage Tank Inspection and Verification Check List Form for Storage Tank Recertification Document Check List Form for Storage tank Report of Inspection Work Instructions for Storage Tank In-Service Recertification Work Instructions for Storage Tank Out of Service Recertification
F.SQ-WI.008 Procedure For Inspection of Exist ing Storage Tank.doc