|DOCUMENTUM|8/18/2011|Paper Copies are Uncontrolled|

|DOCUMENTUM|8/18/2011|Paper Copies are Uncontrolled|

|DOCUMENTUM|8/18/2011|Paper Copies are Uncontrolled|

PHE ONWJ Ltd.

Structural and Piping Fabrication Quality Control

Revision Log Register

Document Number

PHEONWJ GSPE01 01

Document Title

Structural and Piping Fabrication Quality Control

Revision

Page

Date

Revision

PHE ONWJ

Reviewer

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PHE ONWJ Ltd.

Structural and Piping Fabrication Quality Control

Table of Contents

Revision Log Register ....................................................................................................................2

Table of Contents...........................................................................................................................3

1.

Scope......................................................................................................................................4

2.

References

.............................................................................................................................4

2.1 . Company Specification ...........................................................................................................4

2.2. International Standards and Codes.........................................................................................4

3.

Definition

4.

Abbreviations..........................................................................................................................4

5.

Responsibility

6.

Drawing

7.

Definitions

8.

Control

9.

Inspection

of Terms.................................................................................................................4

.........................................................................................................................4

..................................................................................................................................5

..............................................................................................................................5

System.......................................................................................................................5

Hold Points (IHP)...................................................................................................5

1 0. Documentation Control Sheet Packages ...............................................................................7

11.

Documentation Requirement .................................................................................................8

1 2. Sample Document Control Sheet1 0

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Structural and Piping Fabrication Quality Control

1. Scope

This procedure outlines the actions to be taken by CONTRACTOR and COMPANY in the

inspection of structural, piping and mechanical work. The actual tolerance requirements such

as coating thickness are listed in the project specifications and standards. This procedure is

not meant to supersede the specifications but to provide a framework that will allow timely

and accurate measurements to be taken.

2. References

2.1 .

2.2.

Company

Specification

PHEONWJ -G-SPE-0254

Specification for Package Skid-Mounted Equipment

PHEONWJ-I-PRC-001 1

Quality Manual

PHEONWJ-S-PRC-0005

Guidance on Platform Fabrication

PHEONWJ -S-SPE-01 02

Specification for Structural Welding

PHEONWJ -X-SPE-0001

Piping Fabrication, Installation and Testing Specification

PHEONWJ -X-SPE-0004

General Piping Design Specification

PHEONWJ-X-SPE-0005

Piping Material Specification

International

Standards and Codes

AISC

American Institute for Steel Construction

AISI

American Iron & Steel Institute

API

American Petroleum Institute

ASME

American Society of Mechanical Engineers

ASTM

American Society for Testing Materials

AWS

American Welding Society

3. Definition of Terms

COMPANY

Pertamina Hulu Energi (PHE) Offshore North West J ava Ltd.

CONTRACTOR

The party that carries out all or part of the design, engineering,

procurement, construction, commissioning or management of a

project. The COMPANY may undertake all or part of the duties of

the CONTRACTOR.

SUPPLIER/VENDOR

The party that supplies equipment and services to perform the

duties specified by the CONTRACTOR.

4. Abbreviations

AFC

Approved For Construction

DCS

Document Control Sheet

IHP

Inspection Hold Point

NDT

Non Destructive Test

5. Responsibility

Both of CONTRACTOR and COMPANY has the same responsibility for quality control,

especially for the work delivered by inhouse/blanket CONTRACTOR. However, COMPANY

inspection at the various hold points does not relieve CONTRACTOR of his obligation under

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Structural and Piping Fabrication Quality Control

the contract to perform quality control procedures to assure proper performance of the

WORK. Any additional defects discovered after the hold point inspections must be repaired

at CONTRACTORs expense. COMPANY also reserves the right to require additional

inspections per the fabrication codes and the terms of the contract.

6. Drawing

The basic documents for carrying out this procedure will be CONTRACTORs shop drawings,

COMPANY specifications and COMPANY standard drawings. CONTRACTOR is responsible

for preparing shop drawings in strict compliance with the contract drawings and good

engineering practice.

Deviations from the contract drawings must be specifically authorized in writing by the

COMPANY Project Engineer.

Any unauthorized deviations must be corrected at

CONTRACTORs expense no matter what the stage of the fabrication.

7. Definitions

7.1 .

Item:

7.2.

7.3.

7.4.

A Component part of a higher stage assembly.

Stage 0 Assembly: This is an item that has been either fabricated from stock

materials by cutting or purchased for inclusion in the structure or piping system such

as an anode, valve or flange. It includes only one item.

Stage 1 Assembly: This is an item that has been fabricated by connecting together

more than one stage 0 assemblies normally by welding, for example a brace or a

pipe spool.

Stage 2 Assembly: This is an item that has been fabricated by connecting together

more than one assembly at least one of which is stage 1 or stage 2, for example

jacket bent fabrication, pipe spool erection.

8. Control System

8.1 .

Stage

1 Assemblies: A Document Control sheet (DCS) shall be initiated by

CONTRACTOR for each stage 1 assembly. Generally this will be one DCS for each

shop drawing. If more than one stage 1 assembly is fabricated from one shop

drawing, then a DCS must be prepared by CONTRACTOR for each stage 1

assembly. CONTRACTOR shall supply cutting plans/details or VENDOR drawings of all

stage 0 assemblies to be included as items in the stage one assembly. Inspectors

verification of surface preparation, prime coating, dimension strap tests, hydrotest,

etc, of the Parts Used section of the DCS. The remainder of the form is for

documentation of the fabrication of the assembly.

8.2.

Stage

2 assemblies: CONTRACTOR shall initiate a DCS for each stage 2

assembly. The DCS is essentially the same as for the stage 1 assemblies except

that each item that is a stage 1 or stage 2 assembly must be verified to have a

finally approved DCS.

9. Inspection Hold Points (IHP)

9.1 .

CONTRACTOR is required to submit each item for inspection at various points in

fabrication.

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Structural and Piping Fabrication Quality Control

CONTRACTORs Quality Control Supervisor will inform the COMPANYs QA/QC

Engineer before 04.00 pm each work day of the IHPs that will be reached on the

following work day. The COMPANYs QA/QC Engineer shall assign inspectors to be

available at the various work stations at the times indicated by CONTRACTOR.

Fabrication may not proceed to the next step until the COMPANY Inspector has given

approval at the hold point.

9.2.

Inspection

9.2.1 .

Hold Points

Stage 0 Assemblies

dimensions
of
each
item
per

9.2.1 .1
Inspector shall verify
CONTRACTORs cutting instructions, assembly drawings, or

VENDOR drawings. Inspector shall further verify that the mill

certificates or mechanical tests have been obtained. Also, he will

verify CONTRACTOR purchased items against the specifications,

drawings and approved VENDORs list.

9.2.1 .2
Inspector shall approve the surface preparation of all items that

must be coated prior to incorporation into the stage 1 or stage

2 assembly.

9.2.1 .3
Inspector shall approve the prime coat application of all items that

must be prime coated prior to incorporation into the stage 1 or

stage 2 assembly.

9.2.1 .4
Inspector shall approve the top coat application of all items that

must be top coated prior to incorporation into the stage 1 or

stage 2 assembly.

9.2.1 .5
Inspector shall witness and approve the hydrotest of all items

that must be so tested prior to incorporation into the stage 1 or

stage 2 assembly.

9.2.2.

9.2.3.

Stage 1 and Stage 2 Assemblies :

Inspector shall verify that there has been final approval of the DCS of each

stage 1 and stage 2 assembly that will be included as items on the next

stage 2 assembly.

Inspections

9.2.3 .1
Inspector shall approve any surface preparation of the final

assembly that is required after all items have been incorporated

into the assembly.

9.2.3 .2
Inspector shall approve any prime coat of the final assembly that

is required after all items have been incorporated into the

assembly.

9.2.3 .3
Inspector shall approve any top coat of the final assembly that is

required after all items have been incorporated into the assembly.

9.2.3 .4
Inspector shall approve the dimensions of the assembly after all

items have been incorporated.

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9.2.4.

Structural and Piping Fabrication Quality Control

Weld Details

9.2.4.1
Inspector shall approve the fit-up of all welds.

9.2.4.2
Inspector shall visually inspect all welds.

9.2.4.3
Inspector shall approve all NDT reports.

9.2.4.4
Inspector shall approve all welding repairs. No repairs will be

allowed without notifying inspectors. Each repair shall be

documented on a separate line in the Weld Details section of

the DCS.

9.2.5.

Bolt-up Details

9.2.5.1
Inspector shall approve the fit-up between piping components

prior to the insertion of any flange bolts or tack welding for field

welds.

9.2.5.2
Inspector shall verify that pipe section and weld connection can

withstand specified test during strength test, without leak and/or

deformation indication.

9.2.5.3
Inspector shall verify that each flanged and threaded connection

did not leak during leak testing. This includes instruments and

other connections that were not verified for the hydrotest plus

the connections from 6.2.5.2 above.

1 0. Documentation Control Sheet Packages

1 0.1 . Each complete DCS will be approved by COMPANYs Project Engineer.

package will be prepared by CONTRACTOR.

The DCS

1 0.2. The following documentation will be required to be included with the DCS for it to be

considered completed.

1 0.2.1
The DCS sheet will be typewritten in a format similar to that shown in

Section 1 2

1 0.2.2
CONTRACTORs shop drawing of the assembly covered by the DCS. All

included items in the assembly must be shown in this drawing. All weld

numbers must be indicated in this drawing.

1 0.2.3
Cutting plans or VENDOR drawings for all stage O assemblies.

Exceptions will be standard piping components such as : flanges, bolts, etc.

that may be covered by a description on the DCS.

Where

1 0.2.4
The Mill Certificates for all pipe, plate and structural shapes.
Inspector cannot verify that the particular item actually is covered by the mill

certificates, mechanical test reports will be required. This applies to piping

materials, also.

1 0.2.5
The complete and approved DCS package for all stage 1 and stage 2

assemblies included as items on the subject DCS.

1 0.2.6
The NDT reports for all welds and weld repairs.

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Structural and Piping Fabrication Quality Control

1 0.3. The COMPANY QA/QC Engineer must sign each DCS prior to its being considered

complete. He shall verify the following prior to giving his approval.

1 0.3 .1
Every item included in the assembly is listed in the DCS.

1 0.3 .2
No item had undocumented fabrication work such as cutting, welding,

coating or the inclusion of additional items.

1 0.3 .3
Every applicable hold point inspection has been approved.

1 0.3 .4
All stage 1 or stage 2 assemblies included on the DCS as items have

their own approved DCS packages.

1 0.3 .5
The welder identified on every weld is properly qualified.

1 0.3 .6
The welding procedure used is applicable to the type of weld.

1 0.3 .7
All outstanding welding repairs are complete and properly corrected.

1 0.3 .8
All the documents listed in 1 0.2 above are included in the package.

1 1 . Documentation Requirement

1 1 .1 . CONTRACTOR shall provide COMPANY with the following documents :

1 1 .1 .1

1 1 .1 .2

1 1 .1 .3

1 1 .1 .4

1 1 .1 .5

Fabrication Procedures

Assembly Procedure

Quality Control Procedure

Material Test Certificates

All Welding Procedures Specifications and Procedures Qualification Test

Records

1 1 .1 .6
Individual Welder Identification Symbol

1 1 .1 .7
All Welder Qualification Certificates inclusive of back-up data

1 1 .1 .8
Weld Identification and Marking Scheme

1 1 .1 .9
All Non Destructive Test Procedures

1 1 .1 .1 0
All Non Destructive Testing Operators Qualification Certificates

1 1 .1 .1 1
Production Weld Test Reports inclusive of NDT Reports

1 1 .1 .1 2
Dimensional Survey Report

1 1 .1 .1 3
Pressure Test/Leak Test Report

1 1 .1 .1 4
Complete set of Document Control Sheet and back-up documents

1 1 .1 .1 5
A complete set of dimensional as built drawings

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Structural and Piping Fabrication Quality Control

1 1 .1 .1 6
Load out procedures and sea fastening arrangement

1 1 .2.

Document

Approval

CONTRACTOR shall submit for approval by COMPANY the following documents:

Approval Timing

Material Control
Procedures

Prior to any Construction

Fabrication Drawings

Prior to any Construction

Fabrication Procedures

Prior to any Construction

Assembly Procedures

Prior to any Construction

Welding Procedures
Specifications together

with the area of their

application

Prior to any Construction

Welding Procedure
Qualification Test

Records

21 days before use

Welding Consumables
Control Procedures

Prior to any Construction

Individual Welder
Identification Symbol

NDT Personnel
Qualification
Certificates

24 hours before

commencing work

7 days before commencing

work

Welder Qualification
Certificates

24 hours before

commencing work

AFC and Bid Structural

Tonnage Comparisons

Prior to any Invoicing

Document Control
Sheets

Prior to any Construction

Test certificates
for material

24 hour & before release

for Construction

Weld identification
and Marking Scheme

Prior to any construction

Painting Procedures

Prior to any construction

Load out Procedures and

21 days before load out

Sea Fastening details

Three copies of each of the above listed documents, shall be submitted to COMPANY

Authorized Representative at site.

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Structural and Piping Fabrication Quality Control

1 2.
Sample Document Control Sheet

RTAMINA HULU ENERG I Ltd .

Proj ect:

PE
Dcs#:

Shop Dra wing : ..

Item or
Dra wing
Hea t NBR or
Dimension
Surfa ce Prep.
Ta
g
#
or
Qty
Or
Desc
Mech
Test
NBR
Inspection
Inspection

I
Stag e " 0" Assembles

II
Stag e " 1 " & " 2" Assembles

Dcs Nbr
Appl Da te
Surfa ce Prep

Inspection

Prime C oat

Top Coa t

Dimension

F it - up

Weld Nbr.
Weld ed Nbr.
Procedure Nbr.

Visua l Inspection
Inspection

Weld Deta ils

Fit - up

Bolt- Up Deta ils

Dcs or Tag #
Dcs or Ta g #

Hydrotest
Lea k- Test

Inspection

App rova l

Inspector :
Chief
Da te:
Proj ect Engineer:

Analytical Data Worksheet

Prime Coa t

Top Coa t

Hydrotest

Inspection

Inspection

Inspection

Repa ir Required

NDT Report Nbr.

Yes or No

Da te:

Copy Atta ched

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