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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 inch (12.7 mm).
Banding measured using a straight edge vertical sweep board 36 inch (900 mm) long.
Tolerance of peaking shall not exceed 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 shall not exceed the
following tolerance:
Diameter Tolerance
< 40
40 150
150 250 1
250 1
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:
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 angle, the top angle to the shell plates, shell
plates to bottom plates, or 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 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 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 in. pada las 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:
1. ANSI B31.1
Besar/panjang max. 1/3 T
Lebar max. 1/3 T (2.4mm)
Panjang las 12 in. panjang tidak lebih 1 in.
2. ASME IX & I
T mat. s 19.05 mm 6.3 mm
T mat. 19.05 57.15 mm 1/3 T
T mat. > 57.15 mm 19 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. s 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 0.8 mm
T mat. 2.4 mm 4.8 mm 1.6 mm
T mat. 4.8 mm 25.4 mm 2.4 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 5.5 mm
T mat. 101.6 mm 127 mm 6.3 mm
T mat. > 127 mm 7.9 mm
3. API 1104
Sama dengan ASME Sect. IX
4. API 850
T mat. s 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 manufacturers 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 manufacturers 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 one-
package, 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 includes 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 fines
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 is held about 18 inches (450 mm) in front of 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 profile. The
tape profile is then measured with a spring micrometer. The micrometer can be set to automatically
subtract the two-mil (50 m) 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., chlorides 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 manufacturers 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 firmly 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 310 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 m) 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 m) 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 m)
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, status of non conformance
was taken of, detail corrective and preventive action 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 register.
Project Management Plan
Each subcontractor perform the work under Project Management shall prepare a project
management plan before commencement the work.
Subcontractors project management plans that are included in the final
documentation/dossier
shall have Consultants 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 specification 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/QCs 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 quality 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 front 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 certificate 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.
CONFLI CTI NG REQUI REMENTS
Should conflicts exist between this specification and other documents, the following order of
precedence shall govern:
1. Scope of Work
2. Data Sheets
3. This Specification
4. Other Company Specification
5. Other Referenced Publications
6. Approved for Construction Drawings
7. Vendors Code
I NSPECTI ON AND TEST PLAN REQUI REMENT
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
CONTRACTORs 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 DEFI NI TI 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 COMPANYs 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.