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Owner

PT. PERUSAHAAN LISTRIK NEGARA (PERSERO)


AGENCY OF THE MINISTRY OF MINES AND ENERGY
GOVERNMENT OF THE REPUBLIC OF INDONESIA

Consultant

PT. PLN ENJINIRING

Contractor

Grati CCPP Extension PJT 450MW Consortium

Project

GRATI CCPP (PEAKER) EXTENSION PROJECT 450MW

Revision Status:

Issued for Information


0 9 Jan 2017 Satrya JS KC Hwang YS Yoon
Approved by Owner on 23 Dec. 2016
B 17 Dec 2016 Issued for Approval Satrya JS KC Hwang YS Yoon
A 12 Nov 2016 Issued for Approval Satrya JS KC Hwang YS Yoon
Rev. No. Date Purpose Prepared by Checked by Approved by
Title:

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

Contractor Document Number:


Rev. Page
GR-LEC-G30-0301 0 01 of 29
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TABLE OF CONTENTS

1. GENERAL

2. FIELD DESIGN CONTROL

3. FIELD DOCUMENT CONTROL

4. FIELD MATERIAL CONTROL

5. FIELD INSPECTION AND TEST CONTROL

6. INSPECTION, MEASURING AND TEST EQUIPMENT CONTROL

7. PROCESS CONTROL

8. WELDING / WELDER CONTROL

9. QUALITY AUDIT

10. QUALITY RECORD

11. FIELD NON CONFORMANCE CONTROL

Appendix 1. Typical Consortium Site Organization Chart


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1 GENERAL

1.1 Scope and Purpose

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 plan covers the quality requirements for the Engineering,


Procurement, Construction and Commisioning of the Grati CCPP (Peaker)
Extension Project 450MW and provides as minimum the herein described
activities that are performed by Consortium and/or Subcontractor.

This QA plan shall cover all the activities of the Consortium members and
therefore will be reviewed and approved by all the members.

Each member of Consortium is responsible within his scope to make sure


that the Vendors and Subcontractors have their own acceptable Quality
Control System and that they also will implement them in line with this
QA/QC plan and the related procedures, instructions etc. to the extent as
applicable regarding their scope of delivery (procured equipment packages
and/or construction/installation etc).
Special attention shall be paid on interfaces between the members as well
as vendors and sub-contractors.

Consortium shall manage suppliers and sub-suppliers in accordance with


the Contract quality requirements.

Consortium shall establish the following documentation for its quality


management system as per the Contract, Book II A of V Part 4 Technical
Requirements, Section 2 General Technical Requirements, Subsection 2.7
Quality Assurance/Quality Control. These shall be implemented for the
QA/QC levels 1 to 3.

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.

- Owner shall mean the Owner or his authorized representative.


- Contractor shall mean Consortium of Grati CCPP (Peaker) Extension
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PJT 450MW (hereinafter Consortium) or his authorized representative.


- Vendor/Supplier shall mean the company from whom Consortium has
procured equipment or material
- Subcontractor shall mean the company to whom Consortium has
subcontracted a portion of the work.

1.3 References

Contract Requirements Quality Assurance / Quality Control


ISO 9000:2008 Quality Management Systems-Fundamentals and
Vocabulary
ISO 9001:2008 Quality Management Systems-Requirements

1.4 Abbreviations

Consortium Organization Charts of the members and abbreviations


(Detail of Consortium Site Organization Chart see Appendix 1.)

- 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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Table of QA/QC Level 1

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

4. HP piping and Bypass system LAB/LBA

5. Heat Recovery Steam Generator and HA Level 2 for


Auxiliaries miscellanous
auxiliaries only.
6. Isolated Phase Bus Duct BAD

7. Cathodic protection 500 KV Substation AC


Equipment

8. Main, Station and Unit Transformer ATA/BDT/BFT Level 2 for


BHT miscellanous
auxiliaries only.
9. Unit Metering and Protection AQA/ARA

10. Instrument and Control System C Level 2 for


welding,
concreate work,
testing of material

11. Commissioning
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Table of QA/QC Level 2

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

2. Radiator / Heat exchangers GBJ/GDJ/GNJ


GRJ/PBJ
3. Hydrogen Plant MKG

4. Closed Cooling Water System PG

5. Circulating Water System G/PA/PB/PS Including screen,


duct & piping, etc
6. Chlorination Plant GC/GD/PUN

7. Water Treatment Plant GB/GC/GD/GN


GQ/GR/GU/PD
8. Waste Water Treatment Plant GN/GQ/GR

9. Desalination Plant GCG

10. Auxiliary (Package) Boiler QH/QL

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

12. All valves & Control valves AA (KKS Equipment


Unit Code)
13. All tanks EGB/ENB/SGG Depend on their
purpose
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14. Flues, duct and dampers HN/QHN

15. All expansion joint

16. Fire Protection System AYE/CYE/SG


UYP
17. Non Segregate Phase Bus Duct BBP

18. Medium Voltage Switchgear AK/BB/BC/BD

19. Uninteruptable AC Power Supply ASN

20. DC Distribution equipment and Panels AP/BU/BV

21. Station Batteries and chargers BTA/BTL

22. Cicil and Structural Works Erection, UA


Testing

23. Standby Diesel Genset XJ/XK

Table of QA/QC Level 3

KKS
No. Description Function Remarks
Code
1. Chemical Feed System GBN/GDN/GCN
GNN/GRN/PBN
QC

2. Chemical Cleaning System EL/SD

3. Lube Oil Conditioners EH Gas & Steam


Turbine
4. Overhead traveling cranes for GT and SM Included other
ST necessary
miscellaneous
Hoists and
trolleys
5. Ventilation and Air Conditioning SA
System
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6. PDC Transformer and switch gears UAA/UAB/UAG

7. Motor Control Centres BHD

8. Cable and wires, Cable trays, conduit G (KKS Equipment


and fitting Unit Code)
9. Grounding & lighting protection BAU/BAW

10. Lighting BAU/BAW

11. Communication System AY/CY

12. Lighting System BAU/BAW

2 FIELD DESIGN CONTROL

2.1 Scope

This procedure provides the requirements for controlling field engineering


including field design in construction phase.
Field Design Control will be performed only for detail design on site.
Regarding Basic Design / Detail Design,
Engineering Manager for e-mail contact channel is: kslee@lottenc.com

2.2 Reference

Engineering Document Numbering System Procedure (GR-LEC-G30-0002)


Engineering Document Coordination Procedure (GR-LEC-G30-0004)
Engineering Internal Coordination Procedure (GR-LEC-G30-0007)

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

2.4.1 Field Design

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

2.4.2 Field Design Changes

FE shall perform the changes or revisions on the drawing /


specifications under the following conditions;

- Having trouble and/or interface with other designed parts / section


- Revisions requested from the Owner

2.4.3 As-built Drawings

FE shall establish and maintain the control procedures of as-built


drawings which have finally been incorporated into the construction.

3 FIELD DOCUMENT CONTROL

3.1 Scope

This procedure is provided for control of related documents which are


required to be maintained for the construction site.
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3.2 Reference

Engineering Document Numbering System (GR-LEC-G30-0002)


Document Control Log (GR-LEC-G30-0001)

3.3 Responsibility

(1) Consortium SM is responsible for approval of the documents created at


the field for outgoing issue.
(2) Each CM is responsible for establishing, maintaining and implementing
field document control system, based on the document control
procedure in Quality Assurance/Control Procedure.
(3) Each FE is responsible for ascertaining that all work within his
assignment is done in accordance with the latest revision of the
drawings and specification.
(4) FDC shall carry out reproduction, distribution, filing and maintaining of
the field documents to fulfill the requirements of this procedure.
(5) Subcontractor shall submit his own procedure to contractor for an
approval. The approved procedure shall be maintained by the
Subcontractor to control his documents at his office.

3.4 Document Control

3.4.1 General

The pertinent issues of appropriate documents shall be available at all


locations where operations essential to the effective functioning of the
quality system are performed.

(1) Obsolete documents are promptly removed from all points of


issue or use.
(2) Revisions shall be made by the originating discipline, reviewed
and approved by the same way as the original.
(3) Revised documents shall be identified by revision number with
identification marking on the revised parts.

3.4.2 Transmittal and Receipt

(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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- Date of revision / transmittal

(2) FDC shall inform FE and the home office project team of any
discrepancies.

3.4.3 Distribution and Review

(1) Document Distribution Log shall be prepared and maintained by


FDC to control the document distribution
(2) Document Distribution Log shall be indicated the number of
copies of each document to be provided to responsible personnel
in each Subcontractor and Owner.

3.4.4 Voiding Old Documents

(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.

3.4.5 Field Sketches and As-Built Drawings

(1) Field sketch and As-Built drawings shall be originated by FE,


progressive with the works.
(2) All As-Built documents shall be marked ‘AS-BUILT’ in a
conspicuous manner and shall be stored separately from active
documents.

3.4.6 Documents Prepared/Submitted by Subcontractor

(1) The control system in this chapter shall be applied on.


(2) Manufacturing work specified in subcontractor’s documents shall
be processed only after contractor’s and owner’s approval.
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STRUCTURE OF DOCUMENTATION SYSTEM

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 FIELD MATERIAL CONTROL

4.1 Scope

This procedure is provided for controlling the materials and equipment to be


used and/or installed at the field, and the requirements for the receiving,
storing and releasing of all materials and equipment including the field
purchasing materials for the construction.
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4.2 Responsibility

(1) FMC is responsible for preparing, maintaining and implementing the


material control procedures, which specify the material receiving,
handling, storage and issuing and field purchasing in the construction
site.

FMC provides necessary information concerning the material delivery


schedule, place and notice the request for material inspection to
owner.

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 Field Purchasing

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.

4.3.2 Assessment of Supplier

Receiving inspection is an acceptable alternative to the vendor


surveillance for the following items:

(1) Relatively simple products which can be fully inspected on


receipt at site, and which can be quickly replaced if rejected.
(2) Spare parts which can be fully inspected on receipt at site.

4.4 Receiving Inspection

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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against shipping document and to inspect for transportation damages. Any


discrepancies, damages, overages and shortages found shall be notified to
home office procurement group, damages to be reported to owner.

4.5 Storage

(1) The classification of storage shall be as follows:


- Outdoor storage
- Indoor storage
- Temperature controlled 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.

4.6 Material Handling

(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 Product Identification and Traceability

4.7.1 Procedure

Consortium shall establish the procedure for product identification


and traceability on the supplied products.
Subcontractor shall establish and implement the procedure for
product identification and traceability during field fabrication and
installation.
The procedure shall ensure:

(1) SV is responsible for the control of materials and released


equipment from storage for the construction.
(2) Correctness and traceability
(3) Prevention of inadvertent use
(4) Proper identification using tags, stamps, stencils, labels and
nameplates or traceable record.
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(5) Marking materials and methods that provide a clear and legible
type and leaving no detrimental effect on the product.

4.7.2 Identification

FE / FEM shall specify the marking requirements in the specification


or instructions, where deemed necessary.
SV / inspector shall monitor Subcontractor's activities relating to this
procedure.

5 SITE INSPECTION AND TEST CONTROL

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

Inspection and Test Plan to be submitted

5.3 Responsibility

(1) Consortium shall be responsible for:

- Establishing and maintaining the inspection plan,


- Inspection in accordance with applied procedure,
- Submitting the inspection records and results, which are required to
verify conformance to specified requirements,
- Qualification of inspection personnel
- Control of the inspection, measuring and test equipment used for
inspection.
- SQM shall be responsible for reviewing and approving of inspection
plan established and submitted by Subcontractor, prior to obtaining
owner approval.

He shall be responsible for coordination relating to inspection among


the Owner, Subcontractor and Contractor for control of witness
inspection, and for evaluating its records and results to verify
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conformance to specified requirements.

(2) SV / Field Inspector shall be responsible for witnessing the inspection


performed by Subcontractor at specified points, and review of records
and results to verify conformance to the specified requirements.

5.4 Planning and Procedure

(1) Consortium shall establish the inspection plan which must be


conformed to requirements specified in the Quality Requirements and
shall specify the inspection items described in the list of Field
Inspection Items into the quality plan depending on required quality
level of each item.

(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.

5.5 Inspection Meeting

(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

5.6.1 Performance of the Inspections

(1) Consortium shall perform the inspection required to verify


conformance and shall prepare and maintain the records of
inspected items.
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(2) Consortium shall evaluate the inspection results against


acceptance criteria to verify conformance of an item to the
specific requirements, and sign and date on the records for an
acceptable item. For an unacceptable item, Consortium shall re-
inspect after solving the causes of unacceptance.

5.6.2 Witness Inspection

(1) When a witness point or a random or partial witness point is in


construction sequence, Subcontractor shall submit the Application
for Inspection of an item to the SI and/or SQM at least one
working days prior to the inspection.
(2) For a random or partial witness item, SI and/or SQM or owner
shall select a witness item depending on a required quality level,
past performance and site conditions and shall inform the witness
item to Subcontractor.
(3) SQM shall arrange Field inspector for witness of the inspection,
examination or test of an item at a specified point. He may
arrange additionally the SV for random item without the
application for inspection if considered to be required.
(4) The SV / Field inspector who witnesses inspection shall review
records and results to verify conformance of an item to specified
requirements and shall sign and date on the inspection records of
an item only for acceptable inspection.

5.7 Inspection Report

5.7.1 Document Review Items

(1) Only for inspection items requiring the document review,


Subcontractor shall submit the inspection records to Consortium
for his review within one working day after inspection.
(2) SQM or SI / SV shall evaluate the inspection records and
certificates against acceptance criteria to verify conformance of
an item to specified requirements.

5.7.2 Inspection Report

(1) Subcontractor shall prepare the inspection report of each


inspection and test item for Consortium based on Inspection and
Test Plan.
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(2) SV and Field inspector shall file and maintain the approved
inspection report to hand over to Owner.

6 INSPECTION, MEASURING AND TEST EQUIPMENT CONTROL

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

(1) Consortium shall be responsible for calibration, maintenance, handling


and storage of the inspection, measuring and test equipment.
(2) SQM shall be responsible for checking the calibration records of the
measuring and test equipment prior to the field inspection and test
work.

6.3 Procedure

6.3.1 Calibration and Registration of Equipment

(1) Before starting the first inspection or test, Subcontractor shall


submit the List of Inspection, Measuring and Test Equipment to
SQM.
(2) Consortium shall calibrate the inspection, measuring and test
equipment through the manufacturer recommended facility within
the period and shall submit the calibration records to SQM or the
equipment should have a valid certificate which should be
submitted to SQM as well.
(3) The calibration record shall specify the record number,
equipment name and number, serial number, calibration date,
expiration date, name of calibration agency, accuracy status,
signature of calibration personnel etc.
(4) SQM and Field Inspector shall check their calibration records to
verify that equipment have been calibrated at prescribed
intervals in accordance with the acceptable criteria provided by
the manufacturer or vendor.
(5) For accepted equipment, Consortium shall register them on the
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registration log and submit it to SQM. The registration log shall


specify the registration number, equipment name and number,
serial number, manufacturer name, expiration date, calibration
record number, calibration criteria, etc.
(6) For any requirements, which are exceeding their expiration date
or are suspected to be, Consortium shall immediately calibrate
them and renew the expiration date in the registration log.
(7) SV and Field Inspector shall check the expiration date and
condition of equipment to be used prior to each witness
inspection or test and shall also evaluate effectiveness of them
during the witness inspection or test.

6.3.2 Identification

For accepted equipment, Consortium shall identify their registration


number and the expiration date directly on them.

6.3.3 Control of Defective Equipment

When the equipment is found to be out of calibration or when the


accuracy of the equipment is suspected, SQM shall direct
Subcontractor to segregate or tag them to preclude inadvertent use
until it has been re-calibrated.

6.3.4 Handling and Storage

Consortium and subcontractors shall properly handle and store the


measuring and test equipment under the suitable environmental
condition to maintain its accuracy.

6.4 Documentation

The result of control according to this procedure shall be documented by


use of the following:
(1) Control List of Inspection, Measuring and Test Equipment
(2) Calibration records of Inspection, Measuring and Test Equipment
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7 CONTROL PROCEDURE

7.1 Scope

This procedure is provided for control of the procedures which shall be


prepared and implemented in compliance with the applicable requirements
of standard, codes and regulations by contractor or his subcontractor
during construction.

7.2 Responsibility

(1) Consortium shall be responsible for establishing, maintaining the


procedures of fabrication and installation process including special
process in accordance with applicable specifications, codes and
regulations.

(2) Each discipline CM/SI shall be responsible for establishing, maintaining


the procedures of fabrication and installation process including special
process in accordance with applicable specifications and standards.

7.3 Fabrication and Installation Control

7.3.1 General

(1) Consortium shall establish the control measures to keep working


area clean and under suitable controlled conditions to prevent
products from mixing-in with foreign materials and so as not to
cause detrimental effects on products.
(2) Consortium shall monitor the controlled status of working area
giving recommendation for correction, if any.

7.3.2 Control procedure

(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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(4) Where qualification is required for specific work, the qualification


procedures and the records shall be maintained.
(5) Contractor shall monitor Subcontractor's performance
continuously to ensure that specified requirements are met.

7.4 Special Procedures

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.

7.4.2 Approval of Procedures

(1) The description procedures of special procedure are to be


prepared in accordance with applicable codes and specifications
to ensure, that the description meets the design requirement.
(2) Subcontractor shall obtain as a minimum the approvals on the
following procedures from SQM and owner prior to
implementation.
-Heat Treatment
-Nondestructive Examination (NDE)

7.5 Qualification of Personnel

(1) Consortium shall qualify the personnel as following:


- NDE personnel per ASNT Practice No. SNT-TC-1A.
(2) Consortium shall designate the identification of individual and
register all the qualified personnel. Registration Log shall be
included as minimum the name of person, activities, grade of
qualification, qualification codes (or standards), signature or
qualified person, etc.
(3) Subcontractor shall submit the registration log together with their
qualification records and resume to SQM for perusal and owner
acceptance 30 days before starting the first inspection and test
activities.
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7.5.1 Evaluation of Performance

(1) Consortium shall maintain the capabilities of the qualified personnel at


a required quality level during construction.
(2) When directed by SQM, Subcontractor shall demonstrate the
performance of inspection personnel to prove their capabilities.

7.5.2 Documentation

The status and result of control according to this procedure shall be


documented by use of the following forms:

(1) Registration Log of Qualified Personnel


(2) Qualification Records

8 WELDING / WELDER CONTROL

8.1 Scope

This procedure is provided for control of the qualification of welding


procedure and welders and for the assignment of a welder to each welded
joint during construction to ensure that all welds are made by the qualified
welder in accordance with the qualified welding procedure.

8.2 Reference

Welder Procedure Specification


Welder Qualification Procedure to be submitted later.

8.3 Responsibility

(1) Consortium shall be responsible for:


- Establishing and operating the welder control system to ensure that
all welds are made by the qualified welder in accordance with the
qualified WPS (Welding Procedure Specification).
- Qualification of the WPS/PQR and welder used in construction, and
for maintaining their ability at a required level.
- The quality of the welding made by his welders.
- Assignment of welding engineer.
(2) Contractor SQM shall be responsible for:
- Technical review of the WPS/PQR submitted by subcontractor.
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- Review of the plan of welder control system submitted by the


Subcontractor.
- Acceptance of the welding engineer and welders after checking their
qualification records submitted by Subcontractor.
- Observes the performance of the WPS / PQR and welder
qualification test along with owner, which are to be borne by
Subcontractor.
(3) SV / Field Inspector shall be responsible for monitoring the welder
control systemoperated by Subcontractor for assuring himself that only
the qualified welders have been used in construction.

8.4 WPS / PQR (Procedure Qualification Record)

(1) Consortium shall prepare the WPS to be used in construction in


accordance with the applied codes, standards, and specifications, and
shall submit those with supporting documents to SQM for his technical
review and approval before WPS qualification test.
(2) SQM shall perform a technical review on the WPS/PQR prior to
obtaining owner comments and notify those review results to
Subcontractor.
(3) Consortium shall perform qualification tests on the approved WPS by
assigning the welders who have been qualified through paragraph 8.6
hereafter.
(4) Consortium shall repeat to perform the qualification tests for any
WPS's failure on the qualification tests until those tests are passed
after the previous WPS's in appropriate manners.
(5) No production welding shall be undertaken until the welding
procedures have been qualified and approved by contractor and
accepted by owner.

8.5 Welder Control System

(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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- Authorization of initial evaluation and periodical evaluation of


welders
- WPS's no. and descriptions
- Training program for rejected welders
- Records to be taken and maintained.
(2) Subcontractor shall submit the plan of welder control system to SQM
for his review and approval in advance.

8.6 Welder Qualification

(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.

8.7 Execution of Welding

(1) Consortiumshall specifically assign the qualified welder to individual


welded joint. All welds shall be made by the qualified welder in
accordance with the qualified i approved WPS.
(2) For identifying the welder, each welder shall stamp, make or stencil his
identification mark adjacent to the welding made by him immediately
after welding. This welder identification mark on each welder joint shall
be recorded on the daily welding report and the isometric piping
drawings for tracing back welder's performance.

8.8 Welder Performance Evaluation

(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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(2) For periodical evaluation of welder's performance, Subcontractor shall


evaluate in every week the production welds done by each welder who
has passed the initial evaluation and those results against the
acceptance criteria by the following methods:
The periodical evaluation method of welder's performance shall be
based on the reject ratio of radiographic examination by film basis. The
examined welds of each welder shall not be less than 10% of his total
welds for the week.
Reject ratio shall be defined as a ratio of the number rejected to the
total number or examination taken in every week. The welder shall be
accepted for further welding or rejected depending on following
conditions:

- When the individual reject ratio is 5% and below, the welder is


acceptable.
- When the individual reject ratio in every week is less than 10%,
but over 5%, the welder is acceptable. However, the welder shall
be given a warning to prevent further increase for individual reject
ratio.
- When the individual reject ratio is more than 10% over, the welder
shall be rejected.

8.9 Documentation

The status and result of welder control according to this procedure shall be
documented by use of the applicable forms.

9 FIELD QUALITY AUDIT

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

Project Quality Audit Procedure will be submitted later.


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9.3 Responsibility

(1) Consortium shall be responsible for exhibiting indispensable objective


documentary evidence to the Auditor to certify the conformance of
quality activities.

10 QUALITY RECORDS

10.1 Scope

This procedure is provided for control of preparation and maintenance of


evidence of quality related to the construction and manufacturing.

10.2 Reference

Document and Drawing Control Procedure

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.

10.4 Quality Record

Records created during manufacturing and site construction shall be


classified as below:

- General documents related to quality assurance / control plan


- Construction and installation records
- Manufacturing records
- Inspection and test records
- Field design (change) documents
- Material Certificates
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10.5 Storage

Records in storage shall be identifiable, easy to retrieve, and arranged to


prevent deterioration, damage or loss.

11 FIELD NONCONFORMANCE CONTROL

11.1 Identification and Segregation of Nonconforming Item


Site QC Inspector shall verbally inform to the related construction
supervisor and subcontractor after issuance the nonconformance report.

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.

11.3 Disposition of NCR


Field engineer or construction supervisor shall prepare the disposition of
NCR and corrective actions to be taken, Site Quality Manager approve the
disposition and proposed corrective action prior to remedial actions
commencing.
Where the NCR relates to Sub-contractors work, the Construction
Supervisor shall issue a Job Instruction to the Sub-Contractor detailing the
action to be taken.

11.4 Verification of Corrective Action.


The Site QC Inspector and the Site Quality Manager shall endorse the
NCR as being accepted and closed.
Site Quality Manager shall submit the NCR and related reference
documents to the Owner of information.
The Site QC Inspector shall follow up for NCR close out.
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Appendix 1. Typical Consortium Site organization Chart

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