QC/QA PLAN

NORTH SUMATERA TRANSPORTATION, STORAGE

AND LNG RE-GASIFICATION TENDER (PACKAGE I).
 NORTH SUMATERA TRANSPORTATION, STORAGE AND LNG RE-
GASIFICATION TENDER (PACKAGE I).

2016

APPROVAL

Status Name Title Signature

Prepared Sofyan QA/QC Manager

Checked& Approved Suriyanto President Director

VERSION HISTORY

Version Implemented Revision Approved Approval Reason

# By Date By Date

0 M.Sofyan.S - Suriyanto -
1.0 Purpose

This quality control plan has been prepared to establish the quality control and Test to
be conducted at the project work site and fabricator.

2.0 Project Description

Project shall mean Transportation, Transferring and Re-gasification LNG Facilities

Project located at Sumatera Bagian Utara.

3.0 Project Definition

PT. Pertagas Niaga is Project owner

PT.ETI is PT.Enviromate Technology International the Contractor
Ditjen Migas, is Direktorat Jenderal Migas, an Indonesia state board Re-gulator of Oil
And Gas Activity for permit and safety Inspection.
PJIT is Perusahaan Jasa Inspeksi Teknis, a Migas Recommended Inspection Agency
for Migas SKPP and SKPI Certification
TPI, is a third party agency or consultant hired by project owner to supervise project
SPECIFICATION collectively means all technical specifications, drawings, requisitions
and other technical documents referenced in contractual documents.
QUALITY CONTROL collectively means quality control of the construction works for
compliance with the project specification and all the engineering and construction
procedures, specifications, codes of practices and engineering standards pertaining to
the contract and would be done by construction contractors.
Inspection Survey, Test and/or Examination and would be done by a Third Party
Inspection Company.
FIELD INSPECTION RECORD means the individual record of a required test or
Inspection.
MILL TEST REPORT is document generated by the manufacturer of material, which
completely identifies the supplied material and the specification under which it was
produced and reports all required test values necessary to demonstrate compliance with
that specification.
VT is Visual Test (Inspection).
DT is Dimensional Test (Check).
M is Monitoring which is a Random Check by direct/indirect inspection to ensure the
conformance of the item or activity.
H is Hold, which is work should not be continued until Inspection has been finished
successfully.
W is Witness, which is when a construction contractor notifies the EPC contractor and
the third party inspection agency Re-garding the day and the corresponding activity for
the inspection. In the case that an EPC contractor and inspection agency is not present,
the construction contractor will continue the respective activity.
RD is Review of Documents & Certificates.
WPS is Welding Procedure Specification.
PQR is (Welding) Performance Qualification Record.
WPQ is Welders Performance Qualification Certificate.
NDT is Non-destructive Testing.
PWHT is Post Weld Heat Treatment.
DFT is Dry Film Thickness.
P&ID is Piping and Instrumentation Diagram.
N/A is Not Applicable.
A is Approval, which is Review and Verification of Docs with applicable Specification,
and is required prior to proceeding.

4.0 Codes and Standards

The codes and standards that the contractor will follow will be laid out. These includes
codes and standards for installation, construction, fabrication, inspection and/or testing
of materials, services, or equipment for LNG Re-gasification project is in accordance
with those specified in the contractual documents, purchase order, requisition
specification, data sheets and drawings.
The Construction contractor will refer queries Re-garding the referenced codes and
standards to the EPC CONTRACTOR and TPI for decision.
5.0 Organization

DIRECTOR

PROJECT MANAGER

DOCUMENT CONTROL

QC. COORDINATOR

PJIT

QC. INSPECTOR
4.1 Job Description

4.1.1 Quality Control Coordinator

Responsibility

 Lead and coordinate the implementation of quality control function and

work stuff (quality control) in relation to the monitoring report (Inspection
report) and progress Mechanical Completion (MC) to the Project Manager
 Coordinate field supervisors are being subordinated supervision order to
run properly and accurately so that the installation can be run in
accordance with the project plan Re-garding cost, quality and time.
 Coordinate Inspection Testing Plan with PJIT and TPI

Structure of Coordination

 Tops of QC is the QC Coordinator for the project manager and the

subordinate coordinator QC are all members of the Inspection team.
 QC Coordinator after coordinating with the Project manager has the
authority to terminate employment with good reason because the work
could endanger the overall smooth running of the project.
 QC Coordinator has the authority to report to the Project manager,
personnel/member organizations including Contractor site
project/subcontractor when doing things that can make a smooth project
delays/harm either individually or together.

Task

 Coordinate Internal QC schedule meetings or by request if it finds any

discrepancies among team members in the field.
  Communicate and coordinate with the Sub contractor/vendor through
either Re-gular meetings or technical meeting by request if the field find a
non conformance before reported to the site manager.
 Coordinate with Project/Site Manager for the meeting for mismatch repair
(Corrective Action Request/CAR) in accordance with SOP/Procedure
Corrective Action if any member of the team discover non conformity

4.1.2 Quality Control Team (Inspector)

Responsibility

 Carrying out quality control function and work stuff (quality control) in
conjunction with field monitoring reports (Inspection report) and progress
Mechanical Completion (MC) to the Quality Control Coordinator.
 Collaborate with TPI and PJIT to carry out testing in field and fabricator
 Coordinating with logistic section and contractors/vendors in order that
control can work well and accurately so that the installation can be run in
accordance with the project plan Re-garding cost, quality and time.

Structure of Coordination

 Tops of the team QC is QC Coordinator.

 QC team reporting any discrepancies to the QC coordinator, QC coordinator
will report and ask for Corrective Action Request (CAR) to the site manager.
 Task

 Work with logistics section ensures that goods will come (incoming
material) and will be used for the installation of the project in accordance
with the specifications requested and required, if no quality control have
the authority to reject and return the goods to the vendor/contractor.
 Ensure that the work carried out in accordance with the installation
contractor as required and in accordance with the standards as well as
images that have been approved by the project owner.
 Create reports any Non Conformance Report (NCR) if at the time of
inspection to find any discrepancies during execution of work by the
contractor.
 Reporting the NCR to QC coordinator and project coordinator will ask the
Site and the contractor to make the effort corrective action (Corrective
Action Request/CAR) for a job that does not fit and categorized
Major/serious.
 Provide advice and technical and non- technical input on project operational
processes.
 Controlling operational processes in order to run the project in accordance
with the rules and does not violate the guidelines that have been agreed
upon.
 Prepare the following documents: Report of Inspection, Goods Receiving
Report (Material Receiving Report, Checklist Installation, Corrective Action
Report (CAR), Non Conformance Report (NCR) and others related to
project operations during job runs.
 To monitor the progress of the project.
 Coordinate with the site manager to report progress of work/Mechanical
completion status
4.1.3 Document Control

Responsibility

Coordinate and perform administrative activities on the receipt, recording, storage and
distribution of reports on the supervision/inspection of the quality of work, quality
management system documents.

Organizational Structure

Document Control/secretariat reports directly to the Project Manager

Task

 Providing receipts activity, recording, storage, retrieval and distribution of

documents quality management system.

 Record, receiving, incoming documents either activity or project

implementation monitoring project progress.

 Conduct document storage.

 Provide necessary documents returned by the various parties to the

following provisions that exist.

 Maintain system/master list of archives which are in its responsibility.

 Perform distribution of documents to the parties that require

ensuring the smooth operation of document control at the project
level/area/plant.

 Identify the training needs of the controlling document. Fostering the ability
of the controlling document in various ways on a Re-gular basis.
Availability of preparation for the Management Review Meetings, minutes
and spread.
Collecting materials for the implementation of appropriate management
review schedule. Distribute technical meeting invitation
  Develop and distribute minutes of meeting as directed by Quality Controller.

5.0 QC Plan Scope

The quality control plan covers the general field of inspection and testing of piping,
equipment, pipeline and structural steel, electrical, instrumentation, insulation and
painting activities during construction, installation, pre-commissioning and,
commissioning at LNG Re-gasification Project.

6.0 Reference Documents

This is the list of related engineering documents issued by EPC contractors

6.1 Drawing and Plot plan

6.2 Design and Calculation
6.3 Data Sheet
6.4 Specification

7.0 Quality Control And Inspection Plan

The project quality objective begin with pre inspection until project completion, focused
in the subcontractor and vendor ability and competency.
Vendor and subcontractor selection is based on good track record in similar project.
The 3 phase of Inspection is as follows:
 FLOWCHART 3 FASE INSPECTION

PRE INSPECTION INITIAL INSPECTION IN PROGRESS INSPECTION CHECKLIST COMPLETION

CHECK CHECK CHECK

-CERTIFICATE -INCOMING MATERIAL INSTALATION
-WPS INSPECTION (CIVIL,MECHANICAL,
-MATERIAL -VENDOR INSPECTION ELECTRICAL,
(ITP FOR SKPP MIGAS) INSTRUMENT)
- QA REPORT

-PREINSPECTION -MATERIAL RECEIVING -INSTALLATION

REPORT. REPORT (MRR) INSPECTION REPORT
-NC REPORT -NC REPORT -NC REPORT
-MDR -CAR
- PUNCHLIST

-PREPARATORY MEETING BY REQUEST -TECHNICAL MEETING

MEETING -PROGRESS MEETING
-VENDOR MEETING
7.1 Pre-Inspection

Pre-inspection to the selected vendor involve site/workshop audit, capability and

competency, legal formalities, certificate of compliance, WPS,PQR etc.
Any discprepancies to the finding of audit and survey will be subject to vendor termination.

7.2 Initial Inspection

7.2.1 Material Receiving

As soon as the equipment and materials are delivered to the site, receiving quality control
is performed by the material controller. After receiving quality control, the material
controller prepares the Material Receiving Report.
If any loss, damage or quality faults are found, a Shortage/Damage or Non-conformity
Report is made and reported to the site manager using the "Shortage/Damage or
Nonconformity Report".

7.2.2 Fabrication Inspection Based on Migas SKPP and SKPI Certification

Based on Migas Re-gulation (SK Dirjen 84.K th 1999) for the project which is under control
of Migas, such as pressure vessel shall be certified. The process cerification is prior to
Inspection Testing Plan (ITP) approval by Migas.

7.2.2.1 Purpose of Certification

Certification and verification is a standard practice in the international oil & gas business. It
serves to assure an owner and other relevant parties that the plant intended to be put into
operation meets a set of technical requirements and can be operated during all phases of
the life cycle in a manner which is safe for the personnel on site and the public in the
closer vicinity of the installation.
7.2.2.2 Certificate of Individual Equipment Worthiness (SKPP):

The certification covers equipments and facility operates in LNG Re-gasification Project:

• Pressure Vessels (standard API, ASME, SNI, ISO)

• Heat Exchanger
• Electrical Equipment (standard API, IEC, ISO)
• Rotating Equipment (Generator)
• Piping system (standard ASME, API, DNV-OSS)

7.2.2.2.1 Inspection And Testing Plan (ITP) according to SKPP certification

7.2.2.2.2 Verification and Inspection During Equipment Fabrication

Inspections during equipment fabrication and plant construction are carried out by
Independent Technical Inspection Company (Perusahaan Jasa Inspeksi Teknis/PJIT) which
appointed by the contractor/owner and approved by Direktorat Jenderal Migas. These
inspections include the following:

 Quality System of the fabricator, material traceability

 Material certificates
 WPS/PQR
 NDT
 Welder qualification
 Inspection of incoming items from vendors with tracking of open punch list items
carried over from procurement inspections
 Assembly and outfitting with the safety related facilities
 Surveillance of fabrication according to approved design documents
 Witnessing of mechanical completion tests and pre-commissioning

All of the Inspection item for SKPP shall be stated in the Inspection Testing Plan (ITP)
and must be submitted to Ditjen Migas for verification and approval.
ITP for Pressure Vessel, rotating equipment, electrical equipment and piping system can be
seen on annex 1.

7.2.2.3 Facility Worthiness Certification (SKPI)

Certification is carried out upon the completion of plant with all process equipment.
Verification will be conducted while plant in commissioning stage.
This including:

 Pressure containments (piping and vessels)

 Fire and Gas detection and fire fighting systems
 Emergency support systems (generators, UPS, batteries)
 Emergency shutdown systems and communication systems

Inspection During plant commissioning for Facility Worthiness Certification (SKPI) will be
carried out by Independent Technical Inspection Company (PJIT) which appointed by the
contractor/owner and approved by Ditjen Migas.
All of the Inspection item for SKPI shall be stated in the Inspection Testing Plan (ITP) and
must be submitted to Migas for verification and approval. The ITP for SKPI can be seen in
annex 2.

7.3 In Progress Inspection

7.3.1 Field Quality Control and Test

The quality control and test of field construction are carried out based on the inspection
and test plan (ITP) issued by EPC Contractors and endorsement of the plant owner.
Inspection and test that are not covered by the ITP shall be defined in conformity with
issued drawings, specifications, codes and standards during the progress of the work
execution stage depending upon specific WORK requirements.
Alteration is made in the form of changes as per specific WORK requirements from time to
time.
The construction contractor informs in writing the EPC Contractor and ITP of the inspection
points (WITNESS & HOLD), which are required to be witnessed before execution of any
stage of the work.

7.3.1.1 Civil

Inspection Testing Plan /Quality Control plan in Document ETI-QCP-CV-01

7.3.1.2 Civil Structure

Inspection Testing Plan /Quality Control plan in Document ETI-QCP-SS-02

7.3.1.3 Fix Equipment Installation

Inspection Testing Plan /Quality Control plan in Document ETI-QCP-FE-03

7.3.1.4 ISO Tank Installation

Inspection Testing Plan /Quality Control plan in Document in ETI-QCP-ST-04

7.3.1.5 Rotating Equipment Installation

Inspection Testing Plan /Quality Control plan in Document ETI-QCP-RE-05

7.3.1.6 Electrical Equipment Installation

Inspection Testing Plan /Quality Control plan in Document ETI-QCP-EE-06

7.3.1.7 Instrument Equipment Installation

Inspection Testing Plan /Quality Control plan in Document ETI-QCP-IE-07

7.3.1.8 Piping Construction

Inspection Testing Plan /Quality Control plan in Document ETI-QCP-RE-08

7.3.1.9 Welding Work

Inspection Testing Plan /Quality Control plan in Document ETI-QCP-WD-09

7.3.1.10 Insulation Work

Inspection Testing Plan /Quality Control plan in Document ETI-QCP-IS-10

7.3.1.11 Painting Work

Inspection Testing Plan /Quality Control plan in Document ETI-QCP-PT-11

8.0 Non-Conformance Control

Non-conformances are classified as follows:

 Major non-conformance: affecting the safety and operation of equipment or plant
component.
 Minor non-conformance: not designated as major non-conformance.
When a non-conformance is found, the non-conforming system or materials are marked or
tagged. A non-conformance report showing the cause and recommended corrective action
is prepared by quality control personal. Clarification of minor non-conformance would be
the responsibility of the quality control manager.
For major non-conformities, all repair procedures prepared by the construction contractor
would be submitted to the EPC Contractor and would be reviewed by the EPC Contractor
for approval.
Required quality control in sufficient details is done during the execution of any and all
repairs.
The process flow chart of Corrective Action and Non Conformance Report is by follows:
FLOW CHART OF CORRECTIVE ACTION REPORT (CAR) AND NON CONFORMANCE REPORT (NCR)

NC FINDING BY QC.INSPECTOR

NON CONFORMANCE REPORT (NCR)

REPORT TO SITE MANAGER

MAJOR
TECHNICAL REPORT HO
WORK IN “HOLD”
MEETING
STATUS

HO DECISION
MINOR

CORRECTIVE ACTION, CORRECTIVE

ACTION REPORT (CAR) ISSUED

WORK TO PROCEED
9.0 Documentation

Documents are prepared, reviewed, approved and issued by authorized personnel.

Documents requiring multi-discipline review are identified together with the key personnel
holding the primary responsibility and the parties who shall carry out the review.
Changes and revisions to the project documents are checked and approved by the same
discipline/group that conducted the check and approval of the original documents. Reasons
for, outline of, and points of the changes and revisions are indicated in the documents or in
their attachments.
The type of documents to be controlled, the elements of control and the numbering system
to be used on the PROJECT are defined.
The Document Control system
 Identify the key documents, e.g., documents for progress measurement (such as
P&IDs and Plot Plans), documents to be reviewed by CLIENT or requiring approval
by third parties (e.g., Licensors) or Regulatory authorities
 Allow access to the project personnel and CLIENT
 Record the issue dates and status
 Generate reports on the document status and warning reports for overdue
documents
A document distribution matrix is prepared, which relates data and document types to
interested parties. The distribution to the CLIENT and third parties is reviewed and agreed
upon with such external parties. Distribution within an organization is specified by each
section manger and reviewed by the Project Manager. Internal distribution is on an “as
needed basis”, i.e., selective distribution and not indiscriminate distribution to a large
number of project personnel. Key personnel ensure that the related disciplines/sections
have been included in the distribution list.
A master copy of each document is kept in a Centre File. When updated documents are
issued, the previous revision is marked “Superseded”.
The procedure of ETI Document Control is ETI-DC-PRO-01
10.0 Quality Records

The quality records control (including Quality Control Records) is the responsibility of the
Project Manager. The quality records include:
 The person in charge for specific items
 The identification of Regulatory and CLIENT requirements for permanent records
 Retrieval, filing and indexing of the fabrication record books
 Submission format, quality of reproductions, number of copies and archive
requirements
 Final disposition at completion of the work
 Results of reviews, inspections, tests, audits and materials certificates
 Qualification of personnel, procedures and equipment
 Non-conforming and corrective action reports
 Other documentation, such as drawings, specifications
Test reports are prepared within 7 working days of test completion and are submitted on
an immediate basis.
All repair procedure, specific method statements and Test Equipment Calibration
Certificates, as required by the requisition, are reviewed approved prior to use.
In case of conflict, the orders of precedence are as follows:
 Contract
 AFC Drawings
 Project Specification
 Other relevant Project Specification
 Applicable Codes and Standards

11.0 Form and Checklist

The EPC Contractor inspection and test plan has been considered in this quality control
plan.
The construction contractor controls the individual inspection procedure for in-process or
final quality control/testing, and records it. The records are Procedures cheklists and test
records that give evidence that the work has passed quality control and/or testing with
defined acceptance criteria.
The construction contractor holds pre-inspection meeting(s) with the EPC Contractor to
resolve questions concerning compliance with the individual quality control procedure,
specific quality control requirements, and related specification. The construction contractor
arranges for meeting attendance by all necessary means to achieve resolution of technical
questions, schedules, and quality control requirements.