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QA/QC Requirements on

Fabrication

Presentation Outlines :
1. Objectives
2. General Flowchart
3. Documents for Review
4. Fabrication Flowchart
5. Lesson Learnt/Observations
6. Recommendations
Objectives
 To refresh PTS3 on the QA/QC
requirements for any fabrication job
 To ensure fabrication jobs meet PCSB
requirement
 To share the lesson learnt on QA/QC non-
compliance
 To recommend ways to improve QA/QC
compliance
General Flowchart

Yes Submit fabrication Start fabrication


Raise IN/ Submit Fabrication Review
schedule with QC monitoring/
Mail Request Documents to PTS4 by PTS4
as per ITP surveillance

No

Amend as per
Comments
Document for Review
 Inspection Test Plan (ITP)
 Procedures (painting, NDT, hydrotest,
PWHT (if any))
 Welding Procedure Specification (WPS)
 Procedure Qualification Record (PQR)
 Welding Qualification Test (WQT)
 Mill Certificate
 Mechanical Test Record
 Approved for Construction (AFC) drawing
 Mill certificate of material ordered
Fabrication Flowchart
QC-P1 QC-P4 QC-P5 QC-P6

MATERIAL RECEIVING CUTTING & DIMENSIONAL & PR-HEAT/ VISUAL


FIT-UP FIT-UP INSP. 1
RECEIVING INSPECTION PREPARATION WELDING INSPECTION

Contractor : W Contractor : W Contractor : W Contractor : W


PCSB :R QC-P3 PCSB :R PCSB :R PCSB :R
QC-P2

WPQT WQT Consumable


Contractor : W Contractor : W Control Contractor : R
PCSB :w PCSB :w PCSB :R

QC-P7 QC-P8 QC-P9

CHECK PAINTING
1 PWHT ON NDE HYDROTEST BLASTING RECORD 2
INSPECTION KEEPING
PWHT
Contractor : W Contractor : W Contractor : W Contractor : W Contractor : W Contractor : W
PCSB :R PCSB :R PCSB :W PCSB :W PCSB :R PCSB :R

OFFSHORE QC-P12 QC-P13 QC-P14 QC-P15 QC-P16

ASSEMBLY OF DIMENSIONAL PRE-HEAT/ VISUAL CHECK


2 FIT-UP PWHT NDE 3
SUB UNIT & FIT-UP INSP WELDING INSPECTION ON
PWHT
Contractor : W Contractor : W Contractor : W Contractor : W Contractor : W
PCSB :R PCSB :R PCSB :R PCSB :R PCSB :R

QC-P11

LINE
INSTALLATION
CHECK

QC-P17 QC-P18
CHECK ON/ ACID CHECK ON TOUCH-UP
3 FLUSHING & PAINTING
FLUSHING & CLEANING ACID PAINTING RECORD KEEPING
HYDROTEST INSPECTION
HYDROTEST CLEANING
Contractor : W Contractor : W Contractor : W Contractor : W
PCSB :w PCSB :R PCSB :R PCSB :R

NOTE : R - REVIEW
W - WITNES
Lesson Learnt/Observations
 TIA pipe support (2 cases)
 Painting not as per CORAL specification
 Contractor used house paint
Lesson Learnt/Observations
 DDPA/DDPC spool fabrication
 IN raised but no document submitted despite
reminders
 The fabrication was completed without PTS4
approve / surveillance
Lesson Learnt/Observations
 Container without
Approved for Construction
(AFC) drawing
 Request verification after
fabrication completed
 No AFC drawing was
established
 The drawing was not approved
by PTS2
Recommendations
 To get PTS4 involvement on fabrication
even if the fabrication is minor
 To get PTS4 involvement in the kick-off
meeting with Contractor
 To formulate a milestone payment that
include submission of complete QC
documents by Contractor to PCSB (PTS3
& PTS4)
 The documents MUST be completed with QC
inspector’s signature
 PTS4 to check IN raised in the system
regularly
THANK YOU

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