1 PURPOSE
1.1. This
procedure defines the activities of the QC Inspection section by the various
disciplines of the works. The
Inspectors will ensure the Quality of the work output in line with the relevant
TFE, International Specifications and Standards as applicable to the various
disciplines involved.
2 SCOPE
2.1. The detailed inspections are to be included
within the respective discipline procedures that are referenced within the following sections of
this document.
2.2. Inspectors
will be multidisciplinary and fully qualified with respect to welding and
painting. They shall also have a previous background in piping and structural
fabrication or vessel fabrication as shown on their CV also referenced at
interview stage.
2.3. Inspections
will be carried out at vendor locations in Batam,
Singapore and other
Indonesian locations as dictated by the PO’s
for equipment or materials.
3 VENDOR INSPECTION
3.1. When
advised by the Procurement section that an order has been placed with a vendor
of equipment or materials then all drawings and specifications relative to the
item(s) involved shall be made available to the QA/QC section.
3.2. When
advised by the procurement expediting section that the work is now imminent to
commencement an Inspector shall be nominated by the QA/QC section to attend the
Vendor location works. Some cases it may be that only visits according to the
agreed ITP shall be made and in other cases the Inspector may have to be
present full time. If during occasional visits the quality becomes suspect then
the inspection ratio shall be increased and maybe upgraded to full time cover
to ensure all quality requirements.
3.3. The
Inspectors duties will be but not limited to, verifying that all materials
correspond to the contract documents and specifications, all welding procedures
are approved by company, verify that the work is being carried out to them, set
up for welding is correct to the WPS being used, review all radio graphs,
witness dimensional checks and any hydraulic testing that may have to be
carried out.
3.4. The
inspector shall make out reports daily if covering more than one vendor or
weekly if based with one vendor, one copy to the QA/QC coordinator and original
to the QA/QC Manager retaining a copy for his own file. Any visits by the
Company QC personnel the Inspector shall if requested show the reports to him
and offer any information he requires. Visits of this nature to be recorded on
the reports also.
3.5. No
equipment or materials shall be released for shipping to the site until a
complete document review has been carried out and accepted by the QC inspector and the Company QC representative.
4 MATERIAL
CONTROL
4.1. This
section is cross referenced to the Material control Procedure No PMD-01-2-705-P
and the Material Receiving Inspection Report.
4.2. The
QC Material Inspector (s) for the
Fabrication yard shall be responsible upon request from the Material Controller
to examine first the condition of the delivery, then compliance to the purchase
order requirements. He will also make sure that adequate identification is
visible and relates to the certification with respect to the raw materials.
4.3. Items
of tagged equipment shall be checked against the specification, for items like
valves for an example and major equipment items against the approved drawings
and shipping list.
4.4. Any
overage, shortage or damage shall be recorded on the OSD report and handed to
the Material Controller for notification to the Purchasing section for action.
4.5. With
respect to cables when the drums are off loaded each cable shall have a
continuity leak check done by the Electrical QC inspector to ensure no leakage
is recorded through the covering coats, size of cable, rating and length shall
be recorded on the inspection report
4.6. Items
without the correct documentation, damage or out of compliance with the project
specification shall be put into the designated quarantine area and clearly
identified DO
NOT ISSUE and QC contact name and telephone No’ if available. The
follow up inspection when remedial action has been taken shall take place when
QC inspector(s) have been requested to recheck.
4.7. Upon
receipt of the first items to be quarantined a register shall be set up by the
QC Inspection stating date signed in, a brief detail of problem and date of
release signed by the Inspector who gave the release.
5 FABRICATION
5.1. For
details in this section see reference to the Work Procedures listed below:
Piping Fabrication Procedure No’ GND – 50 – 2 – 802 - B
Pipe Fabrication Welding Procedure No’ GND – 50 – 2 – 801 – B
Welding Inspection Procedure No’ GND - .90 – 2 – 817 – B ( TBE)
Material Control Procedure No’ PMD-01-2-705-P
Structural Steel Welding Procedure No’ GND-90-2-808-B.
Dimensional Control Procedure No’ GND-90-2-807-B
Post Weld Heat Treatment Procedure No’ GND-50-2-807-B
5.2. A
QC Inspector shall be in attendance when all qualifications for WPQR’s and
Welders qualifications are taking place in accordance with the WPS Qualification
Procedure No’ GNT-01-9-935-B (TBA).
5.3. During
these tests he will be attended by the NDE sub-contractors representative and
both shall confirm all the requirements to the codes and Company requirements
are met. The Company QC Welding Engineer shall also be requested to be in
attendance during these qualifications along with their 3rd party Company
representative and MIGAS.
5.4. When
the raw material is transferred to the fabrication shop the a QC Piping or
Structural Inspector shall check the cast numbers are evident and release it
for cutting by signing the traveler sheet and stamping with his unique ID stamp
5.5. During
the cutting a QC Piping or Structural Inspector shall check at regular
intervals to ensure the traceability of material. He will also during this
check make sure details are being entered onto the appropriate drawings. He
will endorse the traveler card and stamp also to identify that the particular
function has been witnessed, see Piping Fabrication Procedure No’ GND-50-2-802-B
and Pipe Fabrication Welding Procedure GND-50-2-801-B, Structural Steel
Fabrication Procedure No’ GND-90-2-806-B and Structural Steel Welding Procedure
No’ GND-90-2-808-B
5.6. At
the tacking up stage the QA/QC Coordinator shall be notified by the Fabrication
Shop Supervisor on the request form what welds are ready to be checked prior to
release for welding out. Any welds found to be out of compliance with the WPS
shall be rejected and reset for further inspection.
5.7. If
at this stage any excessive misalignment is showing other fittings shall be
check and if possible a new fitting shall be used and the original issue placed
into quarantine until a decision made on remedial action. The QC Inspector
involved will raise the problem with the QA/QC Coordinator who in turn will make
out a report to the Material Controller
5.8. Before
the release for welding the QC Inspector shall carry out a dimensional check to
ensure compliance with the drawing/isometric.
5.9. The
QC Inspection shall check in the stores that electrode ovens are working and
within the temperature parameters laid down by the electrode manufacturers.
Spot checks will also be made to ensure this is carried out and also the
electrode issue log is in compliance. See also the Pipe Fabrication Welding
Procedure No’GND-50-2-801-B the Structural Steel Welding Procedure GND-90-2-808-B
and the Material Control Procedure No’ PMD-01-2-705-P
5.10. It
will be the QC Inspection remit to witness any preheat requirement before
welding takes place and record in his log book the weld details. He will ensure
that a copy of the appropriate WPS posted close to the welder and that the
welder is qualified to carryout the particular process.
5.11. During
the course of the weld the QC Inspector will check the Interpass temperatures
do not exceed the parameters laid down in the WPS and also check the welder’s
quivers to ensure that the electrodes are at the approved temperature.
5.12. On
completion of the weld the QC Inspector shall carry out a visual inspection and
make sure the weld is numbered and the welder No’ stamped on using low stress
stamps and also identified on the appropriate drawings. The welding inspection
report form PMD-04-9-901-U Rev A shall be filled in by the appropriate
inspector carrying out the work.
5.13. The
QC Inspector will refer to the QA/QC coordinator to arrange any PWHT
requirements with the PWHT Subcontractor, see PWHT Procedure No’ GNT-01-9-911-B
Rev A when all pipe welds are cleared visually.
5.14. The
QC Inspector will on completion of any PWHT refer to the QA/QC coordinator who
will arrange any NDE requirements as per the line specification with the NDE
Subcontractor. Refer to procedure GND – 50 – 2 – 807 - B. for the NDE activities.
Following the NDE the QC Inspector(s) shall review the Radiographs with the
reports along with any MPI, UT or LP reports that may be required and stamp on
acceptance before offering to or with the Company Representative.
5.15. Any
repairs that may be required the QC Coordinator shall take up with the Welding
Supervisor and ensure they are carried out in line with the procedures and all
the parameters as per section 5.8 to 5.13 above. The welders log sheet shall
have the information entered and witnessed at the same time.
5.16. On
structural steel the QC Inspector shall ensure all slag, weld spatter is
removed and weld tacks ground with MPI inspection as required carried out. He
will also ensure all rat holes are free from sharp edges and conform to the
radius required and all contours are smooth ready for painting.
5.17. On
acceptance all inspection reports by Isometric / Drawing shall be filed for
inclusion into the final handover package and TOTAL E & P INDONESIE review .
6 BLAST AND PAINTING
6.1. Once
the fabrication has been released by the QA/QC Coordinator from the Fabrication
area it shall be removed to the Blast and Paint area
6.2. Checks
shall be made at least twice a day (start of shift am and after lunch PM) on
the Dew point and relative Humidity and a record sheet filled in (format yet to
be advised) by the QC Painting Inspector and the paint supplier Inspector. When
out of compliance the Inspection has the right to close down all blasting and
painting operations until conditions are back in compliance
6.3. The
QC Painting Inspector shall check that the blast finish is to the requirements
in the procedure. See the Blasting and Painting Procedure No’GND- 90-2-816-B
(TBA) and also the TOTALFINAELF General Specification GS COR 350. All site weld
prep’s, untested butt welds and any flange faces shall be taped prior to any
primer coat being applied. All piping shall be blown out to remove grit or sand
from the internal of piping and from all areas of steelwork before moving into
the paint area.
6.4. hen
the QC Inspector has cleared the blast area the primer coat shall be applied as
quickly after the blasting as is and the inspector shall take the DFT reading
at various points on the pipe /structure. He shall record the readings on the
daily log sheets along with the suppliers Inspector and the Company Inspector
(format yet to be advised).
6.5. The
rest of the paint coats will be brought up in a similar manner till the final
coat applied. On completion the QC Painting Inspector shall sign off the Items
on the traveller and the suppliers Inspector with the Company Inspector shall
sign off the inspection sheets.
6.6. Any
items that will be tested in the Fabrication yard then installed on the deck
units shall be fully painted including the welds before installation.
7
YARD INSTALLATION
7.1. The
deck steel installation shall be inspected during the erection procedure and
monitored by a QC Structural Inspector. The inspection form shall be used to
denote what has been inspected and by whom.
7.2. When
the above has been accepted equipment can be set into place and the request for
a QC Mechanical Inspector shall be made to the QA/QC Coordinator to have one
available as required. (Inspection Format to be advised)
7.3. On
release any piping to be attached shall be installed and monitored by a QC
Piping Inspector and the inspection form
shall be used to denote what has been inspected and by whom
7.4. All
installed items on the deck assembly shall be inspected for compliance to the
contract specifications and drawings with respect to valves, bolting, gaskets
etc by a QC Piping Inspector and any points raised shall be entered onto the
Punch List
7.5. Section
testing and leak testing shall be carried when the relevant authorization
forms have been signed off as per
procedures Flushing and Hydrostatic test procedure GND-50-2-803-B or Pneumatic Flushing and Test procedure GND-50-2-804-B
and witnessed by a QC Inspector.
7.6. Any
test blinds or spades shall be recorded on the Test Blind Register acknowledged
by the QC Inspector and kept by the Test Supervisor.
7.7. The
QC Inspector assigned to look after tests shall witness any flushing required
and record
7.8. On
completion of the Pressure Test the forms with all the test details, Rev A
shall be endorsed by the attending QC Inspector and stamped.
7.9. The
flushing of the lines or system shall be completed and the form of flushing
shall be completed and endorsed by the attending Inspector
7.10. Following
the testing the painting shall be touched up and inspected prior to the release
for shipping notice given by the QA/QC coordinator and the Company QC
Inspector.
8 SITE INSTALLATION
8.1. At
site installed items of equipment shall be checked by the Mechanical Inspector
prior to release for any piping or electrical requirements to be made.
8.2. For
the setting up and completion of structural and piping welds the QC Inspector
will in line with section 5.0 above carry out the various stage inspections.
8.3. Any
Post Weld Heat Treatment required to site welds shall be arranged by the QC
Coordinator as per section 5.0 above then carried out and witnessed by the
Welding Inspector to the procedure GND – 50 – 2 – 807 - B
8.4. All
site welds shall be subject to NDE as required by the specification and
arranged by the QA/QC Coordinator as per the Yard works.
8.5. Following
the NDE the QC Inspector(s) shall review the Radiographs with the reports along
with any MPI, UT or LP reports that may be required and stamp on acceptance
before offering to or with the Company Representative.
8.6. Before
any further testing takes place all the piping systems shall be subject to
punch listing by the Piping QC Inspectors and any points raised shall be noted
for action on the form GNT-50-9-901-W Rev A to the QA/QC Coordinator to advise
the piping section Supervisor of any remedial work that is required.
8.7. When
advised by the piping section that remedial work has been completed it shall be
rechecked again if cleared the system shall be released for testing preparation
by the authorization forms as appropriate and endorsed by the QA/QC
Coordinator.
8.8. Any
piping that has not been tested in the Fabrication Yard shall be tested see
Flushing and Hydrostatic test procedure GND-50-2-803-B or Pneumatic Flushing and Test procedure GND-50-2-804-B
and witnessed by a nominated QC Inspector and Company QC Representative.
8.9. When
all testing, flushing completed, test sections shall be reinstated and accepted
by Company all touch up painting to equipment and piping shall be completed and
witnessed by the QC Painting Inspector with final acceptance by Company signed
of along with the QC Coordinator.
9 TIE-INS
9.1 When
any tie-in work is planned The QC Coordinator shall allocate a QC Inspector who
will be made available to cover all the inspection points that will be included
in the relevant Tie-in Procedures e.g. Fabrication, Radiography, UT,
Installation etc.
10.0 FINAL INSPECTION DOSSIER
10.1 The
QC Coordinator shall prepare the final QC dossier along with the QA manager for
review by the Company for inclusion into the overall project handover
documentation to the Company.
Attachments
:
1.1.1. Register
of Authorized Inspectors
1.1.2. QA/QC
Organization Chart
1.1.3. Structural
Dimensional Control Inspection Report Form
1.1.4. Welding
Inspection Report Form
1.1.5. Piping
Dimensional Control Inspection Report Form
1.1.6. Material
Receiving Inspection Report Form
1.1.7. QC
Inspectors Weekly Report
1.1.8. Request
for Inspection
1.1.9. Daily
/ Weekly Vendor Inspection Report – Page 1
1.1.10. Daily
/ Weekly Vendor Inspection Report – Page 2
1.1.11. Test
Blinds Installation Register
1.1.12. Piping
System Test Punch List
1.1.13. Hydrostatic
Test Certificate
1.1.14. Flushing Certificate
1.1.15. Pneumatic
Pressure & Leak Test Authorization
1.1.16. Pneumatic
Leak Test Authorization for Systems with Previous Hydrostatic Test.