PROCEDURE FOR PREPARATION OF THE QUALITY CONTROL

MANUFACTURING DOSSIER
VICEPRESIDENCIA DE REFINACIN Y PETROQUMICA
Departamento de Ingeniera

VRP-GRP-P-501
Elaborado:
27/09/2011

Versin: 4

1/7

1. OBJECT

This procedure defines the prescriptions for preparation of quality control manufacturing dossiers for
ECOPETROL S.A. refineries.

This procedure describes the contents required by ECOPETROL S.A for the acceptance of a QCMD and
also specifies the characteristics for: delivery time, hard copies, electronic copies, required language,
units system, and all aspects related to the formal presentation of a QCMD for ECOPETROL S.A.

2. GLOSSARY

Contractor: Is the party that carries out all or part of the design, engineering, procurement,
construction, commissioning or management of a project or operation of a facility. The
principal may undertake all or part of the duties of the contractor.

Principal: (ECOPETROL) The party that initiates the project and ultimately pays for its design
and construction. The Principal specify technical requirements

HT: Hardness Test.

MT: Magnetic Particles Examination.

NDE: Non Destructive Examination.

PQR: Performance qualification record.

PT: Liquid Penetrant Examination.

PWHT: Post Weld Heat Treatment.

QCMD: Quality Control Manufacturing Dossier.

UT: Ultrasonic Test.

WPS: Welding procedure specification.

3. GENERAL CONDITIONS

3.1. IMPORTANT NOTE

If the documents that are requested to be included in the Quality Control Manufacturing Dossier have
been previously sent to ECOPETROL S.A. for approval and/or information, the copy shall be:

A. For documents issued for approval, the copy included in the QCMD shall be the latest edition
with ECOPETROLS approval stamp.

B. For documents issued for information, the copy shall be the same to the document previously
acknowledged by ECOPETROL S.A. with its corresponding stamp.

C. The latest approved edition of each document shall be included in the QMCD. Every document
shall have the stamps and signatures of all the involved parties.


PROCEDURE FOR PREPARATION OF THE QUALITY CONTROL
MANUFACTURING DOSSIER
VICEPRESIDENCIA DE REFINACIN Y PETROQUMICA
Departamento de Ingeniera

VRP-GRP-P-501
Elaborado:
27/09/2011

Versin: 4

2/7

D. All documents drawings purchase orders, invoices, inspections reports, PDT (detail projects
schedule) shall be duly signed and stamped by the responsible person.

E. The documents filled out and implemented during construction will be included in the
construction dossier. The document VRP-GRP-P-501 Procedure for Preparation of the Quality
Control Manufacturing Dossier (hereinafter QCMD), establishes guidelines for the delivery of
equipment manufacturing dossier. Therefore does not apply to construction in field activities.

F. Refer to the document VRP-DPY-P-006 Instructions for the delivery of technical documentation
to the CIT(Centro de Informacin Tcnica) ECOPETROL S.A., which states:

Language: The general index will be in Spanish, lists related documentation will be in the
language in which it has prepared the document, operating manuals, maintenance and
special procedures should be permormed in Spanish.

Number of Documents and Copies: The given information must have one (1) original
paper version and one (1) digital magnetic media (CD, DVD).

G. The equipment manufacturing dossier is a document that integrates all manufacturing
documentation for each unit or equipment package, which includes the detail of each piece of
equipment.

H. The equipment manufacturing dossier will be prepared by the package responsible vendor. it
must contain all the documentation per referenced unit, listed in paragraph 4.1 of the VRP-
GRP-P-501 Procedure for Preparation of the QCMD.

I. For the project Modernization of the Barrancabermeja Refinery (PMRB), the Project
Management Consulting (PMC) must perform a complete inspection of QCMD and Equipment
Inspection Plan (ITP) and in some cases ECOPETROL SA will carry out QCMD inspections if
necessary.

J. The pages should be numbering QCMD (list), progressively.

K. ECOPETROL SA requires to include all materials certificates and quality control tests
certificates, carried out to ensure the integrity of the equipments

L. The certificates can be specific or general, it is important to include all the quality controls
certificates defined in the ITP and technical specifications. These must correspond to an
international laboratory as an example: UL, CEFT, CSA.

M. For instrumentation refers to VRP-GRP-I-202 Criterios de Documentacin de Instrumentos.

4. DEVELOPMENT

The Quality Control Manufacturing Dossier is the complete collection of all certificates, test reports,
inspection documents and any other document relevant to testing activities performed during the
supply, as per the Purchase Order and relevant technical attachments.

Unless otherwise specified the Quality Control Manufacturing Dossier is part of the supply and shall be
issued by contractor for each itemized equipment and/or material ordered by ECOPETROL S.A. Any cost
derived from the preparation of the QCMD shall be included in the proposal and under any condition
shall:

PROCEDURE FOR PREPARATION OF THE QUALITY CONTROL
MANUFACTURING DOSSIER
VICEPRESIDENCIA DE REFINACIN Y PETROQUMICA
Departamento de Ingeniera

VRP-GRP-P-501
Elaborado:
27/09/2011

Versin: 4

3/7


The Quality Control Manufacturing Dossier shall be prepared according to the following conditions:

One Quality Control Manufacturing Dossier per piece of itemized equipment.

One Quality Control Manufacturing Dossier for each unit package and machine (composed by
several sections for different components).

One Quality Control Manufacturing Dossier for each batch of delivered bulk material (i.e.
piping, instruments, etc.) for each material requisition.

All parts of the Quality Control Manufacturing Dossier shall be filled-in during fabrication or production
by the contractor, in accordance with the instruction contained herein and as per any project
instructions. ECOPETROL S.A. inspector and/or third part inspector shall, check, sign and stamp the
documents as they are available after each inspection or testing activity.

ECOPETROL S.A. inspector shall check the Quality Control Manufacturing Dossier for completeness and
correctness; each Quality Control Manufacturing Dossier shall have an index and the sheets shall be
progressively numbered.

Vendor shall fill-in all the requested information and the inspector (as well as the inspection Authority if
any) shall sign and stamp the cover sheet.

The Contractor shall send to ECOPETROL S.A. the required number of copies of the Quality Control
Manufacturing Dossier within the date specified in the MR Part II document one additional copy shall be
delivered together with the goods and indicated in the relevant packing list.

Any delay in the supply of the Quality Control Manufacturing Dossier by the contractor shall be
considered a non-compliance with purchase order requirements.

The Quality Control Manufacturing Dossier contents shall comply with the instruction shown in chapter
4.1 that anyhow shall be considered as a guideline.

Final approval of the Quality Control Manufacturing Dossier contents shall be given by the inspector.



















PROCEDURE FOR PREPARATION OF THE QUALITY CONTROL
MANUFACTURING DOSSIER
VICEPRESIDENCIA DE REFINACIN Y PETROQUMICA
Departamento de Ingeniera

VRP-GRP-P-501
Elaborado:
27/09/2011

Versin: 4

4/7

4.1. CONTENTS OF THE QUALITY CONTROL MANUFACTURING DOSSIER

TABLE 1. CONTENTS OF THE QUALITY CONTROL MANUFACTURING DOSSIER

CONTENT OF QUALITY CONTROL
MANUFACTURING DOSSIER
EQUIPMENT AND/OR MATERIAL CATEGORIES
A
B
C D E
F
b1 b2 b3 b4 f1 f2 f3 f4 f5
1. Index X X X X X X X X X X X X X
2. Manufacturer data report For A-1 X X X
3. Material summary report X X X X X X X X X X
4. Materials certificates and/or test
reports including the positive
material identification
X X X X X X X X X X X
5. Mechanical test reports on prod.
Coupons
(4)

X X X
6. Welding book (including welding
key form, WPS, PQR, welding
consumables certificates, weld
repairs (if any), PWHT
X X X X X X X
7. Non destructive test reports
UT, PT, MT, HT, Wall thickness
measurements (shell)
Wall thickness measurements (other
components)
X X X X X X X X X
8. Heat treatment chart (if any) X X X X X X
9. Hydrostatic and/or pressure test
reports
X X X X X X X X X X
10. Painting certificate X X X X X X X X X X X
11. Visual & dimensional test reports
X X X X X X X X X X X X
12. Thickness Base line report
(corrosion base line (TML))
(5)

X

X



13. Name plate print or copy
(1)
X X X
14. Inspection release certificate
(2)
X X X X
15. Balancing test report X X X
16. Running test and/or performance
test report
X X X X X X
17. Operational test report and/or
certif.
X X X X X
18. Explosion proof and/or intrinsic
safe certificate
(3)

X X X X
19. SIL level certificate for
instruments
(3)

X X X

1
For electrical equipment limited for motors and transformers.
2
If required.
3
Issued independent organization (e.g. TUV).

PROCEDURE FOR PREPARATION OF THE QUALITY CONTROL
MANUFACTURING DOSSIER
VICEPRESIDENCIA DE REFINACIN Y PETROQUMICA
Departamento de Ingeniera

VRP-GRP-P-501
Elaborado:
27/09/2011

Versin: 4

5/7

CONTENT OF QUALITY CONTROL
MANUFACTURING DOSSIER
EQUIPMENT AND/OR MATERIAL CATEGORIES
A
B
C D E
F
b1 b2 b3 b4 f1 f2 f3 f4 f5
20. Type test certificates X X X
21. Noise test report
(2)
X X X X
22. Stamp transfer report for each
portion of material
X X X
23. Laboratory report of chloride
content for the water employed for
hydro-test or pneumatic test
X X X X X X X X X X
24. Internal vessel cleaning report
for installation of refractory lining
(4)

X X X
25. External corrosion protection
system report
(4)

X X X X X X X X X X X
26. Quality Plan
(4)
X X X X X X X X X X X X X
27. Refractory certificates
(4)
X X X
28. As-Built for assembly & parts
drawings
X X X
29. Calculation sheets X X
30. UDS User design specification for
U2 vessels
X
31. Fabricator Data sheet for the as
built equipment
X X X X X X X

EQUIPMENT AND/OR MATERIAL CATEGORIES:

A: Pressure Vessel, Heat Exchangers, Heaters, Boilers, Surface Condensor, Towers, Reactors, Tanks,
Stacks.

B: Pumps, Compressors, Turbines, Drivers, Fans.

b1: Main equipment.
b2: Aux., press equipment.
b3: Auxiliary machinery.
b4: Instrumentation.

C: Piping, Transfer Lines, Tubes, Fittings, Expansion Joints, Spring Hangers, Valves, Structures,
Ejectors, Exhausters, Eductors.

D: ELECTRICAL.

E: INSTRUMENTATION (Including safety & control valves).

F: PACKAGES.


4
If applicable.
5
Thickness Base scope Table 2

PROCEDURE FOR PREPARATION OF THE QUALITY CONTROL
MANUFACTURING DOSSIER
VICEPRESIDENCIA DE REFINACIN Y PETROQUMICA
Departamento de Ingeniera

VRP-GRP-P-501
Elaborado:
27/09/2011

Versin: 4

6/7

f1: Pressure Vessel, Heat Exchangers, towers, etc.
f2: Machinery.
f3: Connecting piping.
f4: Electrical & instruments.
f5: Assembled units.

TABLE 2. THICKNESS BASE LINE FOR PRESSURE VESSEL AND PIPING

TIPO EQUIPO COMPONENTES
TMLs
(spot)
DRUMS/REACTORS/TOWERS
CAPS 5/u
SHELL 5/u
NOZZLES 2/u
BOOTS 3/u
EXCHANGERS HEAT
CHANNELS 3/u
BONETS 3/u
SHELL 5/u
SHELL CAP 3/u
NOZZLES 2/u
HEATERS/BOILERS
TUBES 2/u
UES 2/u
ELBOWS 2/u
TANKS
ROOF 5/u
RINGS 5/u
FLOOR 5/u
NOZZLES 2/u
PROCESS PIPING
3"< OD < 6" 3/10 m
6"< OD < 12" 6/10 m
OD > 12" 9/10 m


5. CONTINGENCY

No Apply.