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QA/QC PLAN
PLN Document Number:
C 1 2 1 5 0 1 - 0 0 - G - 0 0 0 - 3 0 1 - 0 2 9 - 0
TABLE OF CONTENTS
1. GENERAL
7. PROCESS CONTROL
9. QUALITY AUDIT
1 GENERAL
This plan is provided for quality assurance and control to be applied and
implemented on the activities by the Contractor in compliance with the
Contract requirements of GRATI CCPP (PEAKER) EXTENSION
PROJECT 450MW at Grati Pasuruan Jawa Timur, the Republic of
Indonesia.
This QA plan shall cover all the activities of the Consortium members and
therefore will be reviewed and approved by all the members.
1) In line with Chapter 3.2 of the a.m contractual stipulation the following
1.1) Detailed Quality Control Procedures and special process
procedures four weeks before start of fabrication or installation
for Owners review
1.2) Instructions for storage and maintenance for the equipment prior
to installation
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1.3) Site Quality Control Program for Site Quality Control surveilance,
hold points and in-progress inspection points.
2) In line with Chapter 3.3 of the a.m contractual stipulation the following:
Overall Inspection Point Program/Customer Notification Point Program
which is to be submitted to owner for approval.
3) In line with Chapter 3.4 of the a.m contractual stipulation the following:
Vendor’s and Subcontractor’s Quality Control system and procedures
which are reviewed commented and approved by the Consortium,
Consortium shall be responsible for his subcontractors work.
4) In line with Chapter 3.7, 3.8 and 7 of the a.m contractual stipulation the
following: all radiographs with appropriate reports separately for
shops/manufacturing and for field shall be submitted to the owner for
review.
5) In line with Chapter 8 of the a.m contractual stipulation the following:
Shop Inspection Test Plan, schedule, procedures for shop inspection/
notifications etc. to be approved by owner.
Further the planning, operation and process control procedures and other
documentation as well as the related reports and records such as:
- Inspection and Test Plan (ITP)
- Inspection and Test Reports
- Field Design Control
- Field Document Control
- Field Material Control
- Field inspection and Testing Control
- Inspection, Measuring and Testing Equipment Control
- Process Control
- Welding/Welder Control
- Quality Audit
- Quality Record
- Non Conformance Control
- Corrective Action and Preventive Action
In line with Chapter 6 of the a.m. contractual stipulation for level 4 the
consortium shall provide the required program.
1.2 Definitions
The terms used throughout this plan shall have the following meaning
except where the context requires otherwise.
1.3 References
1.4 Abbreviations
- PM : Project Manager
- SM : Site Manager
- CM : Construction Manager (LEC Construction Discipline
Manager e.g: Civil Manager, Architecture Manager,
Mechanical/Piping Manager, E&I Manager)
- SI : Superintendent (Hutama Karya)
- SV : Supervisor
- SQM : Site Quality Manager (Manager QA/QC)
- FEM : Field/Site Engineering Manager
- FE : Field/Site (Design) Engineer
- FDC : Field/Site Document Controller
- FMC : Field/Site Material Controller
- QCI : Quality Control Inspector
1.5 Specified QA/QC levels for structures, material and component (and
associated services).
More in detail the Mechanical / Electrical equipment list will be provided by
Consortium Engineering.
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KKS
No. Description Function Remarks
Code
1. Turbine Generator and Auxiliaries Level 2 for
-Steam Turbines MAA/MAB/MAC miscellneous
-Gas Turbines MBA auxiliaries only.
-Generators MKA
-Generators Circuit Breaker BAC
2. Deaerator PBH/GBH/GCH/
GDH/GNH/GRH
3. Condenser MAG
11. Commissioning
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KKS
No. Description Function
Remarks
Code
1. All Pumps GAF/GDK/GNK
-Condensate Extraction Pump GRK/NDC/PAC
-Condenser Vacuum Pump PBK/PCC
-Waterbox Vacuum Pump
-Feed Water Pump
-CW Pump
-CCWW Pump
-Fire Pump
11. All piping & fitting and pipe EGD/EKG/END Piping pipe
support/hanger GAC/GBK/GCK support and
GDK/GNK/GRK hangers (as
NAA/NAB/NDA noted in the
NDB/NEA/NEB specification)
PAB/PBK/PCB
KKS
No. Description Function Remarks
Code
1. Chemical Feed System GBN/GDN/GCN
GNN/GRN/PBN
QC
2.1 Scope
2.2 Reference
2.3 Responsibility
(1) EM / FEM shall identify the field design and engineering requirements
to ensure that the design and engineering activities are developed
and reviewed in an orderly controlled manner at construction site and
shall be responsible for the issue of the design document created at
the site.
(2) FE shall establish a plan to perform the field design activities in proper
manner. He shall review the design document created at the site.
(3) Subcontractor shall support Contractor’s field engineering
organization in the site changes during the construction.
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2.4 Requirements
EM/FEM
- Overall control of the engineering work
- Responsible for engineering coordination with Owner, construction
disciplines and vendors
- To supervise and control all assigned field engineers
Field Engineer
- Responsible to identify the correct materials as per standards and
specifications
- Undertake design and technically support procurement/construction
- Report to the EM/FEM
- Engineering support for field changes/modification promptly and
efficiently
- Provide field engineering in support of construction and required
change notices to design requirements
- Preparation of As-Built drawings
3.1 Scope
3.2 Reference
3.3 Responsibility
3.4.1 General
(1) Upon receipt of the documents from FE or the home office project
team. FDC shall log it on Field Document Control Record and
review the following:
- Number of documents
- Sequence for revision numbering
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(2) FDC shall inform FE and the home office project team of any
discrepancies.
(1) FDC shall assure that superseded documents are withdrawn from
use.
(2) The responsible personnel shall replace the old documents with
the new revisions, and in case of the old documents to be retained,
they shall be marked ‘VOID’. On receipt of new revision, the
originals of the superseded documents shall be marked ‘VOID’
and placed in a reference file, as required.
CONTRACT
/ CODE &
STANDARD
PROJECT SPECIFICATION
DRAWINGS
QA/QC PLAN
QUALITY PROCEDURES
WORK PROCEDURE / WORK METHOD /
METHOD STATEMENT / WORK INSTRUCTION
ITP
CHECK LIST
INSPECTION / TEST REPORT
QUALITY RECORDS
4.1 Scope
4.2 Responsibility
FMC shall ensure that all materials received on site have been
received with all appropriate documentation, material certificate,
delivery notes / packing list and related inspection test report.
(2) SV is responsible for the control of materials and equipment released
from storage for the construction.
(3) Subcontractor is responsible for preparing and submitting to contractor
his procedure to be implemented for all materials and equipment to be
handled, stored, and maintained for construction.
4.3.1 FMC shall considering the site situation prior to execution of any field
purchasing, and submit to SM for approval, where deemed
necessary to Owner, too.
The receiving inspections are required to verify the conditions and quantity
of all materials and equipment for the construction.
The receiving inspection shall be conducted at the job site or delivery point.
The receiving inspection shall be conducted by FMC, and related inspector
shall witness the inspection.
The receiving inspection shall be conducted to check the material status
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4.5 Storage
(2) FMC shall provide requirements for optimum storage and maintenance
procedure for the materials and equipment in consideration of the
vendor's information and specification.
(1) For a safe handling of material and equipment and to protect them
from damages, special handling tools and equipment shall be provided
and maintained in good condition by SV and worker.
(2) All instructions for material handling requiring special care shall be
established and maintained by SV which shall be implemented by all
workers.
(3) Damaged materials and equipment shall be immediately reported by
SV to FMC and owner.
4.7.1 Procedure
(5) Marking materials and methods that provide a clear and legible
type and leaving no detrimental effect on the product.
4.7.2 Identification
5.1 Scope
This procedure is provided for control of the field work inspection and test
(hereinafter called 'Inspection') to verify that equipment, materials,
component, piping systems, parts or systems are being located, installed,
assembled, connected and adjusted in compliance with the latest
construction drawings, instructions, procedures and other applicable
documents.
5.2 Reference
5.3 Responsibility
(2) Consortium shall submit the inspection plan at the planning stage of
construction.
(3) When required any additional plan during construction stage, SQM and
owner shall review the submitted and notify the comments to
subcontractor.
(1) SQM shall hold a general pre-inspection meeting with the Owner and
Subcontractor prior to beginning any inspection and tests to confirm all
applicable documents and clarify the requirement, characteristics,
method, conditions, acceptance criteria and records, and shall ensure
that Subcontractor clearly understands these items.
(2) SQM shall hold a regular inspection meeting with the Owner and/or
Subcontractor to discuss the any problems found during inspection,
examination or test.
(3) SQM shall hold a special quality meeting with the Owner and/or
Subcontractor, when required, to discuss the Special requirements,
serious accident and/or damaged item during the construction process
and cause of the problem found during the inspection.
5.6 Inspection
(2) SV and Field inspector shall file and maintain the approved
inspection report to hand over to Owner.
6.1 Scope
This procedure is provided for control of the inspection, measuring and test
equipment which are used during construction to ensure that equipment are
calibrated and adjusted at specified periods to maintain accuracy within
allowable limits, and that the controlled equipment are used for activities
affecting quality.
6.2 Responsibility
6.3 Procedure
6.3.2 Identification
6.4 Documentation
7 CONTROL PROCEDURE
7.1 Scope
7.2 Responsibility
7.3.1 General
(1) CM/SI and SQM shall identify the applicable regulations, codes
and standards for fabrication and installation, inspection points
and acceptance criteria.
(2) For the major products or important fabrication / installation, SI /
SQM shall request Subcontractor to submit procedures in that
the process sequence, inspection items and methods are clearly
identified.
(3) Consortium shall prepare inspection report to monitor and
confirm the compliance of work and products with the
requirements.
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7.4.1 General
(1) Special procedure shall include welding, heat treatment and non-
destructive examination.
(2) Special procedure shall be performed, inspected and tested by
the qualified personnel in accordance with the approved
procedure.
(3) The equipment used for the special procedure shall be verified
by means of testing or calibration.
(4) The qualification records of the personnel related to special
procedure shall be established, filed, and kept current.
7.5.2 Documentation
8.1 Scope
8.2 Reference
8.3 Responsibility
(1) Consortium shall establish and operate the welder control system
which controls the qualification of the welders to be assigned to the
individual welded joints, and which consists of:
- Organization for technical supervision of all welders
- Responsibility of individual
- Name of a welding engineer, a welding inspector, and a welding
format
- Authorization of qualification of welders
- Evidence of assignment of the qualified welder to individual welded
joints
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(1) Consortium shall perform the welder qualification test for each welding
process to be used in construction in accordance with the applied
codes, standards and specifications.
(2) For the welders qualified through the welder qualification test, SQM
shall assign an identification mark such as number, letter or symbol to
them.
(3) SQM shall register on the welder's personal card, the name, class of
qualification and photograph of all the qualified welder, and shall
summarize all of those on the welder control sheet.
(4) SQM shall have the right to disqualify a welder at any time when he
suspects the welder's ability.
(5) During the welding, each qualified welder shall maintain a marking /
label that identify clearly the Welder's ID No.
(1) Consortium shall perform the Initial welding control by radiography the
first weld of each welder and then periodical evaluation of each
welder's performance to determine acceptance or rejection of each
welder for further production welding. For the results of the initial and
periodical evaluation of each welder's performance, the welder control
sheet and report shall be maintained for supporting evidence to SQM.
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8.9 Documentation
The status and result of welder control according to this procedure shall be
documented by use of the applicable forms.
9.1 Scope
This procedure is provided in order to control the field quality audit that
needs to be planned and conducted during construction stage, to verify that
quality activities of Consortium and Subcontractors are being or have been
performed in compliance with their quality control plan approved by
Contractor and Owner.
9.2 Reference
9.3 Responsibility
10 QUALITY RECORDS
10.1 Scope
10.2 Reference
10.3 Responsibility
(1) SM in conjunction with the owner shall define the records, required to
be turned over to the Owner and / or Project
(2) FEM / SQM shall collect and file the records designated by the project,
and turn over them as scheduled.
(3) Each CM / FDC shall establish the filing and indexing procedures on
the records which will be collected at the field and shall keep records
clean and current, and maintain in the storage up to turn over.
10.5 Storage
11.2 Preparation
All Contractor Staff have the authority to raise Non Conformance Reports
when they observe a Non Compliance.
If required, the Site Quality Manager will discuss the Non Compliance with
the Construction Supervisor prior to NCR approval.
Site QC Inspector shall retain the original approved copy of NCR and
record its number upon an NCR register.