Quality Assurance for BASF Offgas Treatment Skid Package Manufacturing

Project: BASF Integrated Site, Guangdong, China

Period: Oct 2024 – Feb 2025

Role: Site Quality Manager / Client Representative

Overview

As part of the BASF Integrated Site development in Guangdong, China, YEZRO provided independent quality surveillance and manufacturing oversight services during the fabrication of multiple Offgas Treatment Skid Packages supplied by ZK Shanghai(7 sets).

The skid-mounted systems were designed to support environmental compliance and process safety by collecting and treating waste gases generated from chemical production units. Fabricated in accordance with BASF engineering specifications and ASME requirements, the packages incorporated stainless steel process piping, automated valves, instrumentation, and modular steel structures.

Our responsibility was to ensure that all manufacturing activities complied with project specifications, international codes, and client quality expectations from raw material receiving through final factory acceptance testing.

Material Traceability and Incoming Inspection

Quality assurance began with comprehensive verification of incoming materials.

Inspection activities included:

✔ Pipe and fitting identification

✔ Material Test Report (MTR) verification

✔ Valve and instrument conformity checks

✔ PMI verification where required

✔ Heat number traceability control

✔ Dimensional verification

Special attention was paid to maintaining full material traceability throughout fabrication to meet BASF quality requirements and future operational reliability.

Welding Surveillance and Fabrication Control

A significant portion of the manufacturing scope involved stainless steel process piping fabricated from 304L and 316L materials.

YEZRO monitored critical fabrication stages including:

Fit-up inspection prior to welding
Root pass visual examination
Welding parameter compliance verification
Weld appearance assessment
Distortion control and alignment verification
ISO drawing conformity checks

By maintaining continuous surveillance during fabrication, potential non-conformities were identified and corrected at an early stage, reducing rework and supporting schedule performance.

NDE Witnessing and Quality Verification

To validate weld integrity, Non-Destructive Examination (NDE) activities were witnessed and reviewed in accordance with project requirements.

Inspection scope included:

Radiographic Testing (RT)
Liquid Penetrant Testing (PT)
Visual Examination (VT)

All inspection reports, radiographic films, and acceptance records were reviewed against applicable ASME acceptance criteria before release.

This process ensured compliance while providing an additional layer of confidence for the end user.

Skid Assembly and Mechanical Completion

Following piping fabrication, inspections focused on modular skid assembly.

Verification activities included:

Structural steel inspection
Pipe support installation checks
Instrument mounting verification
Valve orientation confirmation
Accessibility and maintenance considerations
P&ID and Isometric Drawing compliance

Close coordination between fabrication, quality, and engineering teams contributed to smooth assembly and minimized punch-list items during final inspection.

Hydrostatic Testing and Surface Treatment

Prior to final acceptance, hydrostatic pressure testing was witnessed to verify system integrity under operating conditions.

Additional inspections covered:

Test package review
Pressure test witnessing
Pickling and passivation verification
Surface preparation inspection
Coating and painting quality assessment

Successful completion of these activities demonstrated readiness for final assembly and client acceptance.

Factory Acceptance Test (FAT)

The final stage involved witnessing Factory Acceptance Testing (FAT) against approved engineering documentation.

Key verification points included:

✔ P&ID compliance

✔ Instrument installation verification

✔ Valve functionality checks

✔ Mechanical completeness review

✔ Nameplate and tagging verification

✔ Preservation and shipping preparation

✔ Documentation package review

The FAT confirmed that the skid packages met project requirements and were ready for shipment to the BASF Integrated Site.

Delivering Quality for Global Industrial Projects

Projects of this scale demand more than routine inspection activities. They require systematic quality management, effective communication between stakeholders, and a deep understanding of international engineering standards.

Through independent surveillance and proactive quality control, YEZRO helped ensure that the Offgas Treatment Skid Packages were manufactured safely, efficiently, and in full compliance with BASF specifications and ASME code requirements.

As industries continue to pursue higher standards of safety, environmental performance, and reliability, YEZRO remains committed to supporting global projects with professional inspection and quality assurance services.

Suggested Photo Captions

Photo 1

Welding Inspection of Stainless Steel Process Piping During Fabrication