QUALITY DOCUMENT

OF

PRODUCT OIL TANKER

17,500 LTDW

NUMBER

: QA/QC.

REVISION

:A

PAGE

Of

PRODUCT OIL TANKER 17,500 LTDW

COVER SHEET
Document No.

MOS/H7008/TM Q01

Document Name

QAT INSPECTION & TESTING PROCEDURE FOR PIPING

Client Name

PT. PERTAMINA

Project Name

PASAMAN

Project No.

MOS-H7008

MOS/PPC/QAQC

MOS/PPC/QAQC

Established By

Checked By

Date

Date

Classification Society

Owner

Reviewed By

Approved By

Date

Date

QUALITY DOCUMENT
OF

PRODUCT OIL TANKER

17,500 LTDW

NUMBER

: QA/QC.

REVISION

:A

PAGE

Of

CONTENTS
Page
I.

GENERAL .

II.

REFERENCE ...

III.

RESPONSIBILITIES ..

IV.

SYSTEM DESCRIPTION ...

V.

SUMMARY OF PIPING INSPECTION PROCEDURE ..

VI.

APPENDICES .

11

QUALITY DOCUMENT
OF

PRODUCT OIL TANKER

17,500 LTDW

NUMBER

: QA/QC.

REVISION

:A

PAGE

Of

I.

GENERAL
Purpose
This procedure establishes the manner in which various inspections to be
coordinated, executed and documented. In addition, and in order to aid the
inspectors in the performance of their work PRODUCT OIL TANKER 17.500 LTDW
Project, the procedure provides inspection instruction to be performed during the
various phases of the work.

II.

REFERENCE
Meet the requirements of the NK classification Society Rules (Part D, Chapter 13,
Point 17)
Contract Specifications of PRODUCT OIL TANKER 17.500 LTDW PERTAMINA
(Chapter III, Section 9~10)
The international Convention for the prevention of pollution from ships the
requirements of API and ASME.B31.1
II.A. DEFINITION
a. Monitoring Point
An identified point in the fabrication during which an activity, work or
function is observed by inspector. Formal notice is not required to be
given.
b. Witness Point
An identified inspection point in the fabrication, which will be witnessed
or verified by Inspector. If inspector is not available fabrication process
can proceed. Records to be submitted to Client / Class (As Per ITP).
c. Spot Witness Point.
An identified inspection point in the fabrication, which will be spot
witnessed or verified by Inspector. If inspector is not available fabrication
process can proceed. Formal notice is not required to be given.
d. Hold Point.
An identified inspection point in the fabrication, beyond which shall not
proceed without the specified activity, work of function being witnessed
or verified by Inspector.
e. Review Point.
The quality record applicable to the specified inspection and test activity
shall be physically examined by Inspector.
f. Inspection and Test Plan
Schedule of all inspections and tests carried out during fabrication.

QUALITY DOCUMENT
OF

PRODUCT OIL TANKER

17,500 LTDW

NUMBER

: QA/QC.

REVISION

:A

PAGE

Of

II.B. Visual Inspection & Dimensional

An inspection work after welding of fabrication items in accordance with the
acceptance criteria of contract specifications and applicable standards. And
also, dimensional check shall be carried out during spool fabrication whether
the fabricated piping is within the allowable tolerance of requirements.

III.

RESPONSIBILITIES.
III.1.

Quality Assurance And Quality Control Dept. Manager

Has full responsibility of assuring that the quality of all phases throughout
the project including engineering, procurement, installation activities, etc are
properly controlled and archived in accordance with the Codes, Standards
and Specification.

III.2.

QA / QC Inspectors.
Is responsible for the followings tasks :
Scheduling daily work load and job assignment of Inspectors.
Monitoring the quality control activities and document inspection.
Preparation and Control Non Conformance Report (NCR)
Liaison with Company Engineer.
Monitoring production workmanship tasks.
Performing inspection and test.
Documentation of the inspection / monitoring results.
Liaison with Company Inspectors.
Verify correct drawing revision.

III.3.

Production Supervisors.
Performing Inspection for Self Active Control
Liaison with QA/QC Inspector.
Fit-up, Visual and pressure Inspection

QUALITY DOCUMENT
OF

PRODUCT OIL TANKER

17,500 LTDW
IV.

NUMBER

: QA/QC.

REVISION

:A

PAGE

Of

SYSTEM DESCRIPTION
The Inspection activities throughout the project shall be carried out in an adequate
manner as part of the process. For this purpose, the inspection request to Company
for witness and Hold Points shall be submitted to company for its witness in
advance 24 hours before.
IV.1. Definition of Inspection Stages
The various inspections shall be carried out by QAQ/QC Inspector as
described in the following.
IV.1.1. In Process Inspection.
In Process Inspection is intended to ensure that all phases of
fabrication work are being conducted in accordance with the
requirements of other related approved procedures.
Basically, all inspection activities during in process shall be carried
out on going basis. One assigned sheet of spool drawing will travel
all stages of fabrication together its spool from marking to final just
like traveler cards. After inspection is finished at some stage, QA/QC
Inspectors shall sign his signature on inspection column of the spool
drawing. And then the spool may be released to subsequent stage.
If materials are cut into two or more pieces according to the cutting
plan which is prepared by the Design Engineering Dept., the original
marking including spool and piece no. shall be transferred to all
pieces prior to cutting. The transfer of the original marking shall be
inspected by the production Supervisor, QA/QC Inspector and
indicated on the spool drawing.
Spool visual / final inspection shall be carried out before the release
of the pipe spool from the piping shop to the Assembly areas.
Inspector shall inspect all quality factors at final inspections such as,
weld visual, surface condition and dimension.
IV.1.2. Monitoring Inspection.
Monitoring inspection items shall be carried out by all the inspection
parties and is to ensure that work in progress in being under taken in
a proper manner. In this respect the Inspector shall pay particular
attention to the following aspects.
Joint fit-up is properly prepared in accordance with approved
WPS.
All welders are certified for the type of work they do, and that they
are qualified with the welding procedure in question

QUALITY DOCUMENT
OF

PRODUCT OIL TANKER

17,500 LTDW

NUMBER

: QA/QC.

REVISION

:A

PAGE

Of

The welding is performed in accordance with the applicable

procedures i.e. grinding / cleaning between passes, weaving
technique and within the essential variables of the procedure.
The correct consumables are used.
All surfaces finished paints including weldable primers shall be
removed from the weld groove when welding pre-painted
materials.
The consumables are properly stored and handled, confirm the
storage of the material, shall be storage above ground on the flat
surface or platform type skids, material shall be kept free of dirt,
grease, paint spray or other foreign material and protected from
corrosion.
The areas in which welding is being carried out are adequately
sheltered from the elements.
IV.1.3. Final Inspection.
All activities shall be visually inspected by the QA/QC inspector
before being released for any subsequent post activities which would
preclude later visual inspection. This form of inspection is intended to
verify both the results of all previous inspections and the
completeness of the work. For this reason, final inspection of piping
should be delayed until the results of all NDT accepted (if required).
Hydro test shall be carried out under QA / QC and Owner / Certified
Authority (NK Class).
IV.2.

Document.
All the document including spool inspection report shall be compiled by
QA/QC Dept. on an ongoing basis to maintain the traceability of spools and
hydro-test package.

QUALITY DOCUMENT
OF

PRODUCT OIL TANKER

17,500 LTDW

: QA/QC.

REVISION

:A

PAGE

Of

SUMMARY OF PIPING INSPECTION PROCEDURE.

Refer to attached procedure for each item.
Kind of
Inspection

Inspection Activity
to be Verified

Packing list
Verification
Checking heat
no, Tag No.
Type, size,
material grade,
thickness,
diameter &
length.
Transferring of
Original
marking.

5.1.
Material Inspection and pipe ID

V.

NUMBER

Instruction

All materials shall be verified

against mill certificate in
identification material.
Tolerance
of
pipe
wall
thickness : 12.5%
Pipe out-of-roundness : 1%
O.D (max 3.8 mm ID)
Tolerances of fitting 0.D
3 and below : 1mm
4
: +2, -1mm
5~6
: +3, -1mm
8
: 2mm
10 ~ 18
: +4, -3mm
20 ~ 24
: +6, -5mm
26 ~ 48
: +7, -5mm
Tolerance of fitting inside
diameter
2 and Smaller : 0.8mm
3 ~ 8
: 1.6mm
10 ~ 18
: 3.2mm
20 ~ 48
: 4.8mm
Wall thickness : min. 87.5% of
nominal thick
Center to end of Fitting
10 and Smaller : 2mm
12 ~ 30
: 3mm
32 ~ 48
: 5mm
Flange facing finish.
~ Raised face :125m~500m
~ Ring joint : 63m
Identification of pipe material
shall be carried out before
cutting after marking and
tabulated on going basis
according to material ID
procedure
NKK will random check the
material and grade.

Record to be
Prepared

- Spool
Drawing
- Mill
certificate
- Material
Piping
inspection
report

Insp. Involvement
PD QC NKK O/S

W/R

QUALITY DOCUMENT
OF

PRODUCT OIL TANKER

17,500 LTDW

Kind of
Inspection Activity
Inspection
to be Verified

Cutting
Misalignment
Groove angle

5.2.
Fit-up Inspection Fitting ID

Root Face
Root Opening
Tapered Angle
Tack Weld
Joint No.
Fitting Ident.

Instruction
All fit-ups to be checked by QC
Inspector on negative report
bases.
Tolerances:
as per the
qualified WPS.
Tapered angle (t 1) : 10~1.
Girth
seams
minimum
distance : 1 nominal dia. or
150mm whichever is greater.
Misalignment (circumferential
welds) : 1.6mm
Linear tolerances : face to
face, face to end, end
measurements of pipe, center
to end or center to face of
nozzles, center to face of
bends : 3mm

NUMBER

: QA/QC.

REVISION

:A

PAGE

Record to be
Prepared

- Spool
drawing

Of

Insp. Involvement
PD QC NKK O/S

S/W

- Spool / Fitup
Inspection
report

Rotation of flange
~ Rotation : 1.5 mm
~ Flange center deviation:
max 3 mm
~ Out of misalignment of flange
(squareness) : 0.8mm Max.
Kind of
Inspection Activity
Inspection
to be Verified

Instruction

Record to be
Prepared

Insp. Involvement
PD QC NKK O/S

QUALITY DOCUMENT
OF

PRODUCT OIL TANKER

17,500 LTDW
Weld defect

5.3. Visual Inspection

Arc strike
Spool No.
Joint No.
Spool
Dimension
WPS
Welding
consumable
Welder No. &
certificate
Inert gas
shielding

Kind of
Inspection

Inspection Activity
to be Verified

Weld metal shall merge

smoothly into the component
surfaces. The limits of height of
reinforcement and internal
protrusion are, as follows.
TW Height (mm)
TW 3
2.5
3,0 < TW 12.7
12.7 < TW 25.4

NUMBER

: QA/QC.

REVISION

:A

PAGE

- Spool
drawing

Of

S/W

- Visual
inspection
report

3.0
5.0

25.4 < TW
6.0
Any crack, lack of fusion and
surface
porosity
is
not
permitted.
Depth of undercut shall not be
greater than 0.5 mm
Splatter, overlapping at startstop to be grind smooth.
NDT if required

Instruction

Record to be
Prepared

Insp. Involvement
PD QC NKK O/S

QUALITY DOCUMENT
OF

PRODUCT OIL TANKER

17,500 LTDW

Pressur
e test

5.5.

5.4. Schematic & Pipe Line Diagram Inspection on board

P & ID draw.
Line Size
Equip. Material
Branch
Reinforcing.
Valve
Installation
Gasket & Bolt /
Nut
Pipe Supports
Dimension
All Vents and
drains should
be checked for
hydro-test

Test Medium
Test
Temperature
Test Pressure
Location of
Blinds Spades
Limit of test
Calibration of
Pressure Gauge
and Records

NUMBER

: QA/QC.

REVISION

:A

PAGE

Of

Line size to be checked as

per approved P & ID draw.
All materials should be
checked each service or
pressure
and
the
corresponding materials that
are suitable.
All the air vent / drains are
suitable
for
load
line
requirement.
Valves to be checked as
following items.
~ Flow direction
~ Valve type
~ Bolt nut / by pass installed
~ Chain wheel if necessary
~ Tag NOS as per P & ID
Gasket & Bolt Nut
~ Type & material should be
checked in accordance with
Drawing / Spec.
~ Bolts should be extend
completely through their
nuts & washer
Pipe support / reinforcing
pads should be checked and
satisfied.

- Installation
Inspection
Report

Test Systems shall be

Matched with P & ID and
Test Package drawing.
Test pressure with the design
press. exceeding 0,35 MPa
are to be subjected to
hydrostatic test together with
the weld fitting at a pressure
1
times
the
design
pressure.
The air leak testing is
conducted after completion
of installation pipe on board

- Pressure
Test
Inspection
Report

The air leak testing shall

be done by working
pressure and release until
0.2 bar and leakages is
checked by using soapy
water solution.
Instruction

Insp. Involvement

QUALITY DOCUMENT
OF

PRODUCT OIL TANKER

17,500 LTDW

5.3.
Painting

Kind of
Inspection Activity
Inspection
to be Verified
Surface
Preparation
Dry film
thickness
Visual Surface.

NUMBER

: QA/QC.

REVISION

:A

PAGE

Record to be
Prepared
Painting
Inspection
shall
control / inspected according
to approved paint insp.
Procedure.

- Paint
Inspection
Report

Of

PD

QC

NKK O/S
M