Storage Tank (API 650) Shop Fabrication Inspection 1 Material Receiving Inspection Report Check visual (free of lamination & damage). Check certificate (keaslian, Heat No & Plate No). Check dimensional (Length, Thickness, Width & Diameter). 2 Marking Check dimensional marking. Check transfer heat no. 3 After Cutting Check dimensional. Check traceability (Heat No & Plate No). Check Stamp Marking. 4 Rolling Check visual (free of damage). Check edge preparation. Check Rolling radius. 5 Painting Check material painting (batch no, self life, brand). Check Ambient Condition (surface & whether). Check DFT. Field Erection Inspection 6 Dimensional Inspection 1 Peaking banding Peaking measured using a horizontal sweep board 36 inch (900 mm) long. Tolerance of peaking shall not exceed exceed ½ inch (12.7 mm). Banding measured using a straight edge vertical sweep board 36 inch (900 mm) long. Tolerance of peaking shall not exceed ½ inch (12.7 mm). 2 Roundness Check roundness at 0°, 45°, 90°, 135°, 180°, 225°, 270°, 325° Radius measured at 1 foot above the bottom corner weld s hall not exceed the following tolerance: Diameter olerance < 40 ±½” 40 – 40 – 150 150 ±¾” 150 – 150 – 250 250 ±1” ≥250 ±1¼” 3 Plumbness Check at 0°, 45°, 90°, 135°, 180, 225°, 270° The plumbness of the top of shell relative to the bottom of the shell not exceed 1/200 of the total tank height. The out of plumbness in one shell plate (single course) shall not exceed 1/250 of the course height. 7 Visual Visual examinations shall be carried out during all stages of fabrication to ensure that the completed fabrication meets COMPANY satisfaction and approval with particular attention being paid to the following: following: A weld shall be acceptable by this kind of inspection if the conditions are fulfilled : The weld has no crater cracks or other surface cracks.
The maximum acceptable undercutting is 1/64 inches of the base metal for vertical joints, and 1/32 inches maximum for horizontal joints. For the welds that attach nozzles, manholes, clean-out opening, and permanent attachments, no undercutting exceeds 1/64 inches. The frequency of surface porosity in the weld does not exceed one cluster (one or more pores) in any 4 inches of length, and the diameter of each cluster does not exceed 3/32 inches. Welds that fail to meet the criteria given in paragraph above, shall be reworked prior to hydrostatic testing as follows : Defects shall be removed by mechanical means or thermal gouging processes. If the resulting thickness is less than minimum required as per hydrostatic test design conditions, re-welding is required. The repair weld shall be visually examined for defects prior to reexamined by radiography. 8 NDT 1 Oil leak test media solar, method spray, temperature ambient, holding period 4 hours. 2 Vacuum box test Vacuum testing shall conduct as follows: Vacuum testing is conveniently performed by means of a metal testing box, 6 inches wide x 30 inches long, with a glass window in the top. The open bottom is sealed against the tank surface by a sponge-rubber gasket. Suitable connections, valves, and gauges should be provided. Approximately 30 inches of the seam under test is brushed with a soap solution or linseed oil. The vacuum box is placed over the coated section of the seam, and a vacuum is applied to the box. Bubbles or foam produced by air sucked through the welded seam will indicate the presence of porosity in the seam. A vacuum can be drawn on the box by any convenient method, such as connection to a gasoline or diesel-motor intake manifold or to an air ejector or special vacuum pump. Vacuum box tested using a test pressure at least 3 psi gauge or as specified on Company specification. 3 Radiography test Radiographic examination method shall be in accordance with the ASME section V, Article 2. Radiographic inspection is required for shell butt weld, annular-plate butt welds, and flush-type connection with butt welds. Inspection by radiographic method is not required for roof-plate or bottom-plate welds, for welds joining roof plates to top t op angle, the top angle to the s hell plates, shell plates to bottom plates, or appurtenances appurtenances to tanks. Number and location of radiographic shall minimum as specified on API Standard 650, Section 6. Vendor shall submit proposal of number and location of radiographic to CONTRACTOR/COMPANY for review and approval. The radiographers shall be certified by the manufacturer meeting the requirement as outlined by ASNT Recommended Practice SNT-TC-1A and its supplement. Vendor shall submit the radiography test result to CONTRACTOR/COMPANY for review and approval. The penetrameter image as result of radiography shall clearly enough for visual examination on a radiograph viewer. The acceptance criteria of radiographs result shall be judged as specified on ASME Section VIII Div. 1, par. UW-51 (b).
Repairing defective welds shall be done by chipping or melting out the defects from one or both side of joint, as required, and proceed with re-welding. All repaired welds are subject to be re-tested as specified above. 4 Penetrant test Liquid penetrant examination shall be performed in accordance to ASME Section V, Article 6. Magnetic particle examiner shall meet the requirements on API Standard 650 par. 6.4.3. The acceptance criteria and repair of defects shall be per ASME Section VIII, Division 1, Appendix 8, Par. 8-3, 8-4, and 8-5. 5 Ultrasonic test Ultrasonic examination method shall be in accordance with ASME Section V, article 5. Ultrasonic examiner shall be qualified in accordance with as specified on API Standard 650 par. 6.3.3. The acceptance criteria and repair of defects shall be per ASME Section VIII, Division 1, Appendix 12, Par. 12-3 and 12-4.
Joint Defect (Radiography Test) POROSITY : is the result of gas entrapment in the solidifying metal. Ciri: Tampak dalam radiography bayangan bulat hitam dengan pinggiran rata / jelas. Standard: 1. ANSI B31.1 Diameter max 1/3 T atau 1/8 in. (Setiap diameternya) porosity yang diizinkan adalah 3 x besar max. pada luas 1 in. dari las. 2. ASME IX & I Diameter max. 0.06 T untuk setiap panjang 6 in. atau 20% T atau 1/8 in. Porosity yang ada pada tebal material 1 in. besarnya tidak lebih dari 30% T atau ¼ in. atau 5/32 in. Untuk T > 2 in. besar porosity tidak lebih besar dari 3/8 in. 3. API 1104 Besar bulatan porosity max. 1/8 in. atau 25% T. Cluster (lokasi porosity atau porosity terkumpul) luas max. tidak lebih dari ½ in. dan besar tiap porosity tidak lebih dari 1.6 mm pada lasan sepanjang 12 in. Hollow Bead : Pada setiap hollow bead besarnya tidak lebih dari ½ in. pada la s sepanjang 12 in. 4. API 850 Sama dengan standard ASME Sect. IX SLAG INCLUSIONS : are nonmetallic solid material entrapped in weld metal or between weld and base metal Ciri: Tampak dalam radiography bayangan hitam dengan garis pinggir yang tidak beraturan Standard: ANSI B31.1 Besar/panjang max. Lebar max. (2.4mm) Panjang las 12 in. panjang tidak lebih 1 in. 2. ASME IX & I T mat. 19.05 mm .3 mm T mat. 19.05 – 57.15 mm 1/3 T
T mat. 57.15 mm mm 3. API 1104 Pada pengelasan sepanjang 12 in. panjangnya tidak lebih dari 2 in. dan lebar 1.6 mm. 4. API 850 Sama dengan API 1104. INCOMPLETE PENETRATION (IP) or lack of penetration (LOP) : occurs when the weld metal fails to penetrate the joint. Ciri: Tampak dalam radiography jalur hitam ditengah-tengah las secara kon tinyu atau terputus-putus dan pinggirannya lurus atau tajam Standard: 1. ANSI B31.1 : Tidak mengizinkan 2. ASME IX & I : Tidak mengizinkan 3. API 1104 : Tidak mengizinkan 4. API 850 : Tidak mengizinkan INCOMPLETE FUSION : is a condition where the weld filler metal does not properly fuse with the base metal Ciri: Tampak dalam radiography gambar bayangan hitam bulat dan tergantung dari arah datangnya sinar. Standard: 1. ANSI B31.1 : No Allowable 2. ASME IX & I : No Allowable 3. API 1104 : Las sepanjang 12” IF tidak lebih dari 1” (8 % dari 12 in.) 4. API 850 : No Allowable INTERNAL OR ROOT UNDERCUT : is an erosion of the base metal next to the root of the weld. Ciri: Tampak dalam radiography jalur hitam sepanjang las Standard: 1. ANSI B31.1 Kedalaman concavity tidak lebih dari 1.6 mm atau 0.2 T. Bila pada film negatif warna concavity sama dengan base metal diijinkan. 2. ASME I & IX Tidak diijinkan. 3. API 1104 Maksimum 6.35 mm dengan dia luar. lebih kecil sama 69.85 mm dan dia. luar lebih besar sama dengan 60.32 mm. 4. API 850 Tidak diijinkan. EXTERNAL OR CROWN UNDERCUT : is an erosion of the base metal next to the crown of the weld. Ciri: Tampak dalam radiography bayangan hitam dikedua pinggiran las Standard: 1. ANSI B31.1 : Pada pengelasan sepanjang 12 in. panjangnya tidak lebih dari 2 in. dan kedalamannya 0.8 mm atau 25% dari tebal metal. 2. ASME I & IX : Pada pengelasan sepanjang 12 in. panjangnya tidak lebih dari 2 in. dan kedalamannya 0.8 mm atau 10% dari tebal metal. 3. API 1104 :
Pada pengelasan sepanjang 12 in. panjangnya tidak lebih dari 2 in. atau 1/6T dan kedalamannya 0.8 mm atau 12.5% dari tebal metal. 4. ANSI B.31.1 : Pada pengelasan sepanjang 12 in. panjangnya tidak lebih dari 2 in. dan kedalamannya 0.8 mm atau 12.5% dari tebal metal. EXCESS WELD REINFORCEMENT : is an area of a weld that has weld metal added in excess of that specified by engineering drawings and codes Ciri: Tampak dalam radiography jalur putih yang kontinyu atau putus-putus dalam bayangan las. Standard: 1. ANSI B31.1 T mat. 6.35 mm 1.6 mm T mat. 6.35 mm – 12.7 mm 3.2 mm T mat. 12.7 mm – 25.4 mm 4.0 mm T mat. 25.4 mm 4.8 mm 2. ASME IX & I T mat. 1.6 mm – 2.4 mm .8 mm T mat. 2.4 mm – 4.8 mm .6 mm T mat. 4.8 mm – 25.4 mm .4 mm T mat. 25.4 mm – 50.8 mm 3.2 mm T mat. 50.8 mm – 76.2 mm 4.0 mm T mat. 76.2 mm – 101.6 mm .5 mm T mat. 101.6 mm – 127 mm .3 mm T mat. 127 mm 7.9 mm 3. API 1104 Sama dengan ASME Sect. IX 4. API 850 T mat. 12.7 mm Ep. Ver.2.4 mm Ep.Hor.3.2 mm T mat. 12.7 – 25.4 mm Ep. Ver.3.2 mm Ep.Hor.4.8 mm T mat. 25.4 mm Ep. Ver.4.8 mm Ep.Hor.6.3 mm CRACKS : can be detected in a radiograph only when they are propagating in a direction that produces a change in thickness that is parallel to the x-ray beam Ciri: Tampak dalam radiography seperti rambut memanjang lancip, berwarna hitam. Standard: 1. ANSI B31.1 : No Allowable 2. ASME IX & I: No Allowable 3. API 1104 : No Allowable 4. API 850 : No Allowable
Coating & Painting Inspection AMBIENT CONDITION
Before initiating surface preparation or coating operations, the temperatures (air and surface), dew point, relative humidity, and wind velocity must be checked to ensure that they conform to
specification requirements. SSPC-PA 1 provides information on proper conditions for shop and field painting. Since ambient and steel temperatures may change quickly, they should be measured periodically throughout the day. ASTM E 337 dictates that the ambient condition test or environmental test should be done: “before, during, and after” the application and they must be monitored at least every four hour interval, even more when the condition are unstable. TEMPERATURE
The application of a coating system shall occur only when the air & substrate temperature is within the range indicated by the manufacturer’s written instructions for both application and curing. A
rule of thumb, no work shall be done when air temperature below 50C and surface temperature less than 30C above dewpoint temperature. DEWPOINT
Dewpoint is defined as the temperature at which moisture will condense. Dew point is important in coating work because moisture condensation on the steel surface will cause freshly blast cleaned steel to rust, or a thin, often invisible film of moisture trapped between coats may cause premature coating failure. RELATIVE HUMIDITY
Due to curing of coatings may be adversely affected by humidity that are too low or too high, no coating shall be applied unless the supplier or manufacturer’s written technical requirements for
humidity are met. High humidity may cause moisture to condense on or react with uncured coating films to cause blushing or other adverse effects. However, for certain inorganic zinc and onepackage, moisture-curing polyurethane coating, require a minimum humidity for curing, but for most organic coatings, the rule of thumb, no work shall be carried when relative humidity above 85%. WIND VELOCITY
For field or open air application, wind velocity may blow airborne contaminants to work surfaces and coating materials. It also contributes to dry spray, dusty-spotted effects to the coated surface and accelerates solvent evaporation time which may cause immature drying. No work shall be done in the open air field when the wind velocity above 24 km/hour. AMBIENT TEST INSTRUMENTS
1. Surface Magnetic Thermometer is used to measure steel substrate temperature. Must be allowed to stabilize on surface to be measured for at least 5 minutes. Must be used at actual location, avoid direct sunlight, and must be calibrated often. 2. Sling Psychrometer is used to measure wet and dry temperatures. These information are then used to calculate dewpoint and relative humidity (some latest instrument has dewpoint and relative humidity scales). 3. Dewpoint calculator is used to calculate dewpoint temperature and relative humidity. Prior to use this instrument, data must be first obtained from the Sling Psychrometer. 4. Anemometer is used to measure wind velocity.
PRE-SURFACE PREP. INSPECTION
Before the start of surface preparation for coating, all necessary construction or modification of items requiring coating should have been completed. This includes grinding of welds and sharp edges and filling of pits. Likewise, the surface must be free from all contaminants. Also, the job site must then be inspected for complete readiness (i.e., all required operational and support equipment is present, and access for inspection of work is available). This incl udes safety aspects such as ladders and scaffolding, power, and traffic control, so that the inspector can safely perform his duties. ABRASIVE CHECK
All new mineral and slag abrasives must be inspected for physical and chemical properties as described in SSPC – AB 1. Recycled ferrous metal abrasives must be checked for cleanliness and f ines as described in SSPC – AB 2. The abrasives should be properly labeled for identification. Even if a sieve analysis (ASTM C 136) is provided by the supplier, it is prudent to run a check at the job site or retain a sample for later analysis should cleaning rates be lower or profile heights other than anticipated. A simple test can be conducted for contaminants or fines in the abrasive. A spoonful of abrasive is placed in a vial of distilled water and shaken vigorously. It is then checked for: • Oil or grease that forms a surface sheen • Fines suspended in or at the surface of the water • Color or turbidity from dirt • Soluble salts by conductivity or deposition upon evaporation • Acidity or alkalinity with pH paper BLASTING EQUIPMENT CHECK
All air compressors and blasting equipment should be checked for proper size, cleanliness, operation, and safety. Hand or power tools should also be checked for operation and safety, and should be used only as specified in their standard operating procedures. These checks should be made before the start of abrasive blasting and periodically thereafter, especially after a change of abrasive. Air and blast hoses should be checked for damage and constrictions and should be as short and of as large a diameter as practical to reduce frictional losses of air pressure. The blast hose should have a static grounding system. Couplings should be of the external fit type, secured well, and safety-wired. Blast nozzles should be of the venturi type, with a flared exit to allow more rapid and uniform cleaning. An orifice gauge should be used to check the nozzle size (inches) and air flow (cfm at 100 psi). This wedge-shaped instrument or bore-nozzle inserted into the rear of the nozzle has a measuring range of 1/4 to 5/8 inch and an air flow range of 81 to 548 cfm. Nozzles should be discarded after an increase of one size (e.g., 1/16 inch is the difference between a #6 and a #7 nozzle). All nozzles must have a deadman control that will automatically shut off the flow of air and abrasive when released.
The compressed air used in abrasive blasting must be checked to determine whether oil and water traps have completely removed contaminants. This is done by the blotter test described in ASTM D 4285. A clean, dry, white blotter or cloth i s held about 18 inches (450 mm) in front o f the blast nozzle with the air flowing for one to two minutes. Oil and water contaminants are detected visually on the blotter or cloth surface. Abrasive blasting is usually done at pressures between 90 and 100 psi for efficient blasting. Higher blasting pressures may produce even higher blasting rates. A pocket-sized air pressure gauge with a hypodermic needle can be used for determining cleaning pressure at the nozzle. The gauge is inserted in the blasting hose just before the nozzle in the direction of the flow. Instant readings can be made up to 160 psi. POST-SURFACE PREP. INSPECTION
Steel surface cleanliness requirements for abrasive blast cleaned steel (i.e., SSPC levels of surface preparation) can readily be determined using SSPC-VIS 1 photographic standards. SSPC surface preparation standards define cleanliness in terms of visible contaminants such as rust, mill scale, paint, and staining. Two commonly used methods for determining the profile (average peak-to-valley depth) of blasted steel surfaces are described in ASTM D 4417. The Testex Press-O-Film Replica Tape method is preferred, because it is easy to conduct, accurate, and produces a permanent record. The tape consists of a layer of deformable plastic foam bonded to a Mylar backing. The tape is rubbed onto the blast-cleaned surface with a plastic swizzle stick to produce a reverse replicate of the prof ile. The tape profile is then measured with a spring micrometer. The micrometer can be set to automatically subtract the two-mil (50 µm) thickness of the non-deformable Mylar backing. An alternate procedure, in which a surface profile comparator is used, is available for determining surface profile. Comparators include ISO, Clemtex, and Keane-Tator instruments. Basically, they use a five-power illuminated magnifier to permit visual comparison of the blast-cleaned surface to standard profile depths. Standards are available for sand, grit, and shot-blast cleaned steel. Another concern are the non-visible contaminants such as soluble salts, (e.g., c hlorides and sulfates). These salts are deposited from the environment, e.g., marine air, and industrial pollutants. They can cause problems such as flash rusting of steel or blistering of applied paint films. These contaminants are not removed by abrasive blast cleaning (or other mechanical methods). A good indication of salt contamination on blast-cleaned steel is the rapid rerusting of the steel in the absence of condensing moisture. ASTM D 4940 provides a water extraction test procedure for determining salt concentration. Extraction methods include swabbing, rigid limpet cell, and Bresle cell procedures. After extraction, the water is tested for conductivity and/or specific salt ions. Test kits for analysis of chloride, sulfate, and ferrous ions, as well as pH, are commercially available from suppliers of coating instruments. They contain strips, swabs, papers, and operating instructions for simple chemical testing. Abrasive blast cleaned steel surfaces should be checked to determine if all the residual abrasive has been removed by vacuuming, brushing, or blowing. Detection of residual abrasive can be done by
pressing a piece of transparent cellophane (Scotch) tape onto the cleaned steel and then pulling it off. If any abrasive is visually detected on the piece of tape, further removal of abrasive is required. All blasted steel surfaces should be primed as soon as possible after cleaning, and always on the same day except in dehumidified spaces. If not primed soon enough, particularly on humid days, flash rusting of the steel may occur. If any flash rusting is observed, the steel must be reblasted. PRE-COATING INSPECTION • Coating storage conditions • Mixing procedures • Thinning materials and amounts • Tinting, or color verification • Straining of coatings to remove large particles • Viscosity • Spray equipment check INSPECTION OF COATING APPLICATION
Inspection during and after coating application consists chiefly of checking for: • Induction time and pot life • Wet and dry film thicknesses • Holidays • Adhesion • Curing • Cosmetic and film defects INDUCTION TIME AND POT LIFE
For coatings that cure by chemical reaction (thermosetting), the inspector should check to see that the manufacturer’s induction time and pot life requirements are met. WET FILM THICKNESS
Wet film thickness (WFT) measurements should be made immediately after paint application to determine if the coating is sufficiently thick to obtain the desired dry film thickness (DFT). Measurement is less accurate on highly pigmented (e.g., zinc-rich) and quick-dry coatings. Since measurement of WFT destroys the film integrity, the coating must be repaired after the measurements have been completed. The most widely used type of WFT gauge, described in ASTM D 4414, consists of a thin rigid metal notched gauge, usually with four working faces. Each of the
notches in each face is cut progressively deeper in graduated steps. The face with the scale that encompasses the specified thickness is selected for use. To conduct the measurement, the face is pressed fi rmly and squarely into the wet paint immediately after its application. The face is then carefully removed and examined visually. The WFT is the highest scale reading of the notches with paint adhering to it. Measurements should be made in triplicate. Faces of gauges should be kept clean by removing the wet paint immediately after each measurement. DRY FILM THICKNESS
DFT measurements are made after complete curing of coatings to determine if specified thicknesses have been met. Calibration of gauges and measurement of DFT by magnetic gauge are described in detail in SSPC-PA2. Magnetic gauges are normally used for determining coating DFT on steel surfaces. They rely on the fact that the thicker the coating, the smaller the magnetic field above the coating. Typical measurement error may be 3 –10 percent. There are several factors that adversely affect DFT measurements with magnetic gauges. These include: • Roughness of steel surface (deeper blasted surfaces result in higher measurements) • Steel composition (high alloy steels may have erroneous measurements) • Thickness of steel (there is a minimum thickness for gauge accuracy) • Curvature of steel surface (measurements may be erroneous) • Surface condition (contaminated coating surfaces may cause high readings; “pull -off” magnets
may adhere to tacky surfaces; probes may indent soft paints) • Orientation of gauge (must be held perpendicular to surface) • Other magnetic fields (strong magnetic fields from direct current welding or railway systems
may interfere) All magnetic thickness gauges should be calibrated before use. It is also good practice to check the calibration during and after use. Gauge suppliers provide a set of standard-thickness, nonmagnetic (plastic or nonferrous metal) shims to cover their working ranges. The shim for instrument calibration should be selected to match the desired coating thickness. It is placed on a bare steel surface with the same profile that will be used for the coating application, and the gauge probe is placed on it for calibration. If the instrument does not agree with the shim measure, it should be properly adjusted. If adjustment is difficult, the reading for bare steel can be added or subtracted from field readings to determine actual thicknesses. The steel surface used for calibration should be a masked-off area of the steel being painted or an unpainted reference panel of similar steel, if possible. Another calibration system utilizes a set of small, chrome-plated steel panels of precise thickness, available from the National Institute of Standards and Technology (formerly the National Bureau of
Standards). These standards are expensive but very accurate. SSPC-PA 2 presents detailed information on the calibration and use of both pull-off and fixed probe gauges. HOLIDAY DETECTION
Newly coated structures on which the coating integrity is important (particularly linings or coatings in immersion conditions) should be tested with a holiday detector to ensure coating film continuity. A holiday (sometimes called discontinuity) is a pinhole or other break in the film that permits the passage of moisture to the substrate. This allows substrate deterioration to begin. Holidays are not easily detected visually, and must be located with electrical instruments called holiday detectors. Holiday detectors are available in two types, low and high voltage, as described in ASTM D 5162 . Low-voltage (30 to 70 volts) holiday detectors are used on coatings up to 20 mils (500 µm) in thickness. These portable devices have a power source (a battery), an exploring electrode (a dampened cellulose sponge), an alarm, and a lead wire with connections to join the instrument to bare metal on the coated structure. A wetting agent that evaporates on drying should be used to wet the sponge for coatings greater than 10 mils (250 µm) in thickness. The wetted sponge is slowly moved across the coated surface so that the response time is not exceeded. When a holiday is touched, an electric circuit is completed through the coated metal and connected wire back to the instrument to sound the alarm. Holidays should be marked after detection for repair and subsequent retesting. High-voltage (above 800 volts) holiday detectors are used on coatings greater than 20 mils (500 µm) in thickness. The exploring electrode may consist of a conductive brush or coil spring. The detector may be a pulse or direct current type. It should be moved at a rate not to exceed the pulse rate. If a holiday or thin spot in the coating is detected, a spark will jump from the electrode through the air space to the metal.
Electrode Calculation
Electrode Calculation
Final Documentation/Dossier Format Purpose The intent of this format is to define the requirement/procedure for the compilation and submission of final documentation/dossier for handover to Consultant at the end of contract. Reference Subcontract agreement no xxxx
Final Documentation/Dossier Subcontractor shall submit a final documentation/dossier including its index for Consultant review and approval. The index of the dossier shall contain the document, technical data or record of inspection and QAQC contribution during performance of the service. Detail document as noted in the subcontract document deliverable register (latest revision) shall be included in the final documentation/dossier. Final documentation/dossier is parts of subcontract agreement between Consultant and Sub Contractor as described in exhibit A subcontract no xxxx dated 17 September 2007 Format and Layout The format and layout of the dossier shall be in accordance with the following list; 1. Index and Table of Content 2. Subcontract Agreement no xxxxxxxx and its Amendment 3. Project Management Plan 4. Company Specification and Procedure 5. QA/QC Record 6. Vendor Final Documentation 7. Miscellaneous Record Each section shall have a tabbed divider with the section detail or number on the tab. A front sheet shall preface each section and describe detail of the content of the section, including an index if is not clearly detailed on the above check list, which shall be included in each binder. Detail document which are not clearly described on the above list will be advised and listed on the other file attached to this final documentation/dossier procedure. Front of Book Index and table of content shall be provided at the front of book and shall clearly indicate the project title, book title, book number and volume number in which specific data/record required can be found. Introduction A general introduction shall be provided by subcontractor in book 1 volume 1 giving detail about the project overview and sub project/contract where applicable. Project Summary A Project summary shall be prepared and presented after introduction section in book 1 volume 1. A project summary shall details a latest project status that it has been achieved by subcontractor at the end of contract. A subcontractor may giving the detail of how many work order closed, cancel, remaining work order, latest value, progress achievement, st atus of non conformance was taken of, detail corrective and preventive a ction that ever taken, quality engineer contribution to the project and others highlight during performance of the service.
Subcontract Agreement and its Amendment Subcontract agreement including its amendment shall be included in the final documentation/dossier. It then followed by latest subcontract document deliverable regist er. Project Management Plan Each subcontractor perform the work under Project Management shall prepare a project management plan before commencement the work. Subcontractor’s project management plans that are included in the final documentation/dossier shall have Consultant’s stamp indicate review and approval from Consultant have been obtained. Project management plan, as a minimum, shall consist of; project execution plan, quality management system plan (project quality plan), project control management plan and HES management system plan. Project management plan shall be the latest revision. Company Specification and Procedure Company specification is intended to define project specificati on and giving the outline to subcontractor about minimum requirement during performance of the service. All company specification and procedure pertaining to pressure vessel, pipeline and storage tank inspection service shall be presented in the dossier. Quality Record Quality record is systematically format/procedure developed by subcontractor to collect, index, file, store, maintain, and turnover to Consultant and or Company at the end of service. All quality activity such as; developing process control (procedure), inspection procedure, ITP, assigning quality personnel, inspection and testing, verification, audit, continual improvement, calibration and others related to quality shall be documented in section of quality record. Quality record is intended to showing QAQC contribution to the project. Quality record, as a minimum, shall consist of the following; - Quality organization including qualification of personnel - Quality process control, which shall consist of procedure, standard operating, guideline and work practice - Procedure to adequately control the inspection and testing. - Inspection Record - Record of concession request or RFI - Non conformance log and record and its report - Corrective and preventive action were taken of - Audit report by subcontractor QA/QC’s engineer - Record of data sheet and test certificate (acceptance) Procedure, standard operating, guideline and work practice shall be latest revision and shall have Consultant and Company approval. Vendor Final Documentation Where any equipment used during performance of the service that is supplied by sub vendor, a
clear and legible copies of manufacturing data record shall be provided and these will be verified by Consultant and or Company. Miscellaneous Record All document pertain the project that are not described and detailed in above section, shall be include in miscellaneous record. This section may include; minutes of meeting, weekly and monthly report produced during the project, latest work order register, closed work order and its certificate (if any), project correspondence and etc. Any technical agreement that has not been incorporated in procedure shall be presented in miscellaneous record. Audit Reports Any audit performed by Consultant and or Company during the performance of the inspection service shall be included in the final documentation / dossier and be presented at miscellaneous record. An audit carried out by subcontractor QA/QC engineer shall contain at qualit y record section. Binders Format Binders Type Binders shall be A4 with the color of white and shall have 3 holes. Each binder shall have a plastic cover on the f ront and spine for inserting the cover page and spine detail. Front Spine and Information Each book shall have a front page and spine inserted into the plastic covers in accordance with the attachment of this format/procedure (page 5 and 6). Front page and spine information in each book, as a minimum, shall include the following; 1. Project title 2. Book title 3. Book number 4. Volume number 5. Subcontractor name 6. Document number Binders Content Binders shall be set out in accordance with the above section of this procedure and each binder shall be no more than 90 % full content. This is intended to leaving space for any additional information which might be added in later at Consultant and or Company discretion. Consultant Review and Approval The final documentation or dossier shall be submitted to Consultant for review and approval after completion of the contract. Consultant will not approve for any uncompleted and unsatisfied data or record that should be
included in the final documentation/dossier. Subcontractor shall responsible to complete the unapproved dossier until approval from Consultant is obtained. The final documentation or dossier will be reviewed and approved on site. A cert ificate of handover final documentation /dossier shall be required by subcontractor. The final documentation/dossier shall be dispatched to Consultant and or Company at subcontractor expense. Attachment Attachment 1 Data book cover page Attachment 2 Data book spine information
Inspection & Test Plan (ITP) I TP is
the minimum requirement of the activities for quality control and inspection of the field construction work. This Inspection and Testing Plan outline the extent of witness inspection and its reporting. CONFL I CTING REQUI REM ENTS
Should conflicts exist between this specification and other documents, the following order of precedence shall govern:
1. 2. 3. 4. 5. 6. 7.
Scope of Work Data Sheets This Specification Other Company Specification Other Referenced Publications Approved for Construction Drawings Vendor’s Code
T I NSPECTI ON AND TEST PLAN REQUI REMEN
1. CONTRACTOR and/or its Vendor/Subcontractors shall prepare and execute all inspection and test. They shall conform to the above mentioned codes, standards, and project specifications. 2. CONTRACTOR and/or its Vendor/Subcontractors shall provide all inspection equipment for inspection activitie s. These activities are to assure themselves that adequate inspection personnel and back up equipment are in place in order to expedite their activities speedily so as not to impact on the construction schedule. 3. CONTRACTOR and/or its Vendor/Subcontractors shall prepare check sheets and inspection reports for carrying out the required quality control checks according to particular discipline work activities. All inspection and test reports forms shall be specific to the activity and items inspected. 4. CONTRACTOR shall also prepare a detailed inspection and test plan indicating inspection levels (spot witness, witness, hold point, etc), based on COMPANY definitions herein. The test inspection plan shall include witness/attendance requirements by COMPANY/MIGAS and/or THIRD PARTY. 5. Vendor or Subcontractor shall submit their inspection and test plan based on the CONTRACTOR’s inspection and test plan document for CONTRACTOR/COMPANY review and approval. 6. CONTRACTOR shall generate, maintain, documented, and collate the inspection records, which is done by them or by its Vendor/Subcontractors. The system employed shall insure full tractability of records including back up in accordance to COMPANY requirements.
CONTRACTOR shall submit the originals of all inspection data and other related documents to COMPANY, as required by the contract terms. 7. CONTRACTOR and its Third Party shall establish the inspection and test which are required for obtaining the SKPP (Sertifikat Kelayakan Penggunaan Peralatan) or Certificate of Worthiness to Utilize Equipment and SKPI (Sertifikat Kelayakan Penggunaan Instalasi) or Certificate of Worthiness to Utilize the Installation. I NSPECTI ON LEVEL DEF I NITI ON
Spot Witness (SW) Spot witness inspection is a point during construction activities where measurement, witnessing of work or inspection normally takes places. Formal written notification is not required, although oral or informal memo will normally be given. If the discipline inspector does not inspect the work at this point, the work may continue. However inspection data must be recorded, and the CONTRACTOR / Subcontractor is fully responsible to ensure that this is done before continuing the next work step. Witness Point (W) A witness point is a point in a construction activity where inspection must take place. ONTRACTOR/COMPANY QC Group shall be formally notified in writing of the inspection 24 hours in advance notice is for most accurate schedule) and will normally attend the inspection. Nevertheless, CONTRACTOR needs to include schedule of inspections in weekly meetings. On a case by case basis, the inspection witnessing may be waived. In this case, inspection may proceed without attendance. However, inspection data must be recorded and submitted for review and approval. All waivers will be given in writing prior to inspection execution (jointly approved by CONTRACTOR and COMPANY). Hold Point (H) A Hold Point is a point in a construction activity where formal written notification is given of an inspection (24 hours in advance notice is for most accurate schedule) and work shall not proceed until the inspection is performed. Nevertheless, CONTRACTOR needs to include schedule of inspections in weekly meetings. Mandatory attendance is required. Approval (A) A document or drawing, which is to be submitted for approval prior to proceed the activity. Review and Comment ( R ) A document or drawing, which is to be submitted for review/ comments. Verification (D) A document or drawing, which shall be submitted to COMPANY/CONTRACTOR for report/ comments. COORDI NATI ON
Quality Control and Inspection by CONTRACTOR For the items marked with “ SW “ and “ W “ under column “CONTRACTOR”, the quality control and inspection will be conducted by CONTRACTOR at their own responsibility. However, COMPANY shall have the right to inspect any works done by CONTRACTOR or Vendor at any time (except for “ W ”, a written notification from CONTRACTOR is required). Inspection Hold Point For item marked with “ H “ under column of COMPANY and CONTRACTOR, CONTRACTOR shall notify COMPANY in writing of the inspection scheduled date and time. Witnessing shall be jointly performed by CONTRACTOR and COMPANY. CONTRACTOR can not proceed the next work step activity until the inspection and measurement or test has been witnessed and approved by all attending parties. Notification of Inspection CONTRACTOR shall give a written notification to COMPANY for attending the inspection/testing. Document Approval
For item marked with “ A “ under column “COMPANY”, CONTRACTOR shall submit documents, drawing, etc. to COMPANY. For item marked with “ A “ under column “CONTRACTOR”, Vendor shall submit documents, drawing, etc. to CONTRACTOR for approval. Inspection shall not be conducted before COMPANY approves the required documents. Document Review For item marked with “ R “ under column “COMPANY”, CONTRACTOR will submit documents, drawing, etc. to COMPANY for review / comment. For item marked with “ R “ under column “CONTRACTOR”, Vendor shall submit documents, drawing, etc. to CONTRACTOR for review / comment. Document Verification For item marked with “ D “ under column “COMPANY”, CONTRACTOR shall submit documents, drawing, etc. to COMPANY for a report and/ or comments (if required). CONTRACTOR shall accommodate COMPANY’s comments (if any). For item marked with “ D “ under column “CONTRACTOR”, Vendor shall submit documents, drawing, etc. to CONTRACTOR for verification and review and or report.
