PETRONAS RAPID PROJECT, PACKAGE 3, ELME

QAQC WEEKLY REPORT

PVE/ELME QAQC WEEKLY REPORT

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

1. Main activities (8 July ~ 14 July .2017)

1.1 Manpower: 44 personnel
Rapid
No. Disciplines Qty.
1 Overall 5
2 Piping (Note: 5 CSWIP) 5
3 NDT 3
4 Painting + Insulation/Fire Proofing 2
5 Mechanical Equipment 2
6 Reformer 1
7 Structure 2
8 Electrical & Instrumentation 4
9 Test Package 3
10 Assistant 2
11 Document Control 3
Total: 32

Multitask + MMHE + Painting & Blasting Workshops

No. Disciplines Qty.
1 Overall 0
2 Welding Engineer 0
3 Piping (Note: 3 CSWIP + 1 AWS) 4
4 NDT/PWHT 3
5 Painting 1
6 Document Control 4
Total: 12

2.0 Inspections
2.1 Multitask Workshop Inspection
Inspection Dia. Inch Remarks
CS Alloy SS
Fit up
Visual 3789 762 N/A 28-July-17 04-Aug-17
Qty.
Support (Visual) 17 ton N/A N/A 28-July-17 04-Aug-17
Spool Nos.
Release Note N/A 9 0
2.2 Surveillance & Other Activities at Multitask Workshop
- General Tool Box Talk (with all workers)
- Welding Tool Box Talk (with welders) & Piping Tool Box Talk (with fitters and helpers)
- Monitor the welding consumable daily progress for Baking, Holding & Issuing
- Monitor the piping CS, LA & SS materials preservation
- Observation: Material Preservation and update Quality boards

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

2.3 Rapid Inspection

Inspection Dia. Inch

1120 1510 1511 1512 1513 1531 1532 1533

CS Alloy SS CS Alloy SS CS Alloy SS CS Alloy SS CS Alloy SS CS Alloy SS CS Alloy SS CS Alloy SS

820 156 94 85 255 196 84 557 77 24 137
Fit Up
993 100 94 85 266 192 108 30 30 76
Visual 616
Qty. No/(Joint)
Support
Fit Up 16
Visual 13 16 4 8

2.2 Surveillance & Other Activities at Multitask Workshop

- General Tool Box Talk
- Monitor the welding consumable daily progress for 1120 Baking, Holding & Issuing
- Monitor the piping CS, LA & SS materials preservation
- Reminded all welder comply PTS such as windbreaker covering during working, welding consumable balance must be returned
holding oven after end of work, always connect quiver to electric power
- Observation: Material Preservation and update Quality boards
- Fit-up, visual, requested NDT for COLD BOX 1510

2.4 Structure Inspection

2.4.1 Material Receiving (if any)

None

2.4.2 Levelling and Plumbness

o 1120-SPS-008, 1120-SPS-009, 1120-SPS-010, 1120-SPS-010, 1120-SPS-011, 1120-SPS-014, 1120-SPS-029, 1120-SPS-030,
1120-SPS-034, 1120-SHL-001 & 1510-STR-1100

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

2.4.3 Bolt Tensioning report

Column, Beam & Base Plate Inspection for first/Final REMARKS COMPLETION
Torque
1512-STR -1100 3 Elevation

2.4.4 Handover activity

(STRUCTURE TO CIVIL) UNIT LOCATION DETAIL COMPONENT Remarks

Structure to Civil 1510-SHL-1100 Release for grouting

2.4.5 Welding activity report

Column, Beam & Base Plate VISUAL (ACCEPT OR REJECT) REMARKS (UT/MPI)
N/A N/A N/A

2.4.6 Others
o Bolts tightening reports was rejected by PMC due to Reports was claimed not tally as per ELECO & MMHE. (SNUG TIGHT
required 1st and 2nd torque)
- 1512-RCK-1140
- 1511-STR-1500
- 1513-RCK-1100
- 1511-RCK-1140
- 1513-STR-1500

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

2.5 Mechanical Erection Inspection

Discipline Inspection Area

Static Equipment Inspection;

1. Material/ Equipment 1510;1512;

1510-A-601; 1511-A-711; 1512-A-711; 1513-A-711; 1511-CE-207 (1511-F-201); 1510-X-001 1513
2. Civil/ Steel structure acceptance
1511
1511-A-711

3. Padding/support:
1510-X-001; 1510-K-153; 1511-A-711; 1511-CE-207 (1511-F-201) 1510;1511

4. Equipment installation (Verticality):

1510-V-445; 1510-V-433; 1510-E-414; 1510-E-416; 1510-V-411; 1510-E-413; 1511-CE-261 (1511-F-201); 1510
Mechanical 1510-V-450 (1510-K-154); 1510-V-451 (1510-K-154); 1510-V-452 (1510-K-154); 1510-V-453 (1510-K-
Equipment 154); 1510-K-154-CW; 1510-P-431A

5. Grouting release:
1120-P-011 B; 1510-V-450; 1510-V-451; 1510-V-452; 1510-V-453; 1510-K-154-CW; 1510-P-431A; 1510- 1120;1510
V-433; 1510-V-445; 1510-V-231

6. Pre-Alignment:
1120-P-011 B; 1120

7. Final anchor bolt tightening:

1120-P-009A/B; 1120-P-012A/B; 1120-P-004A/B; 1120-P-010A/B; 1120-P-013A/B; 1120-P-002A/B; 1120- 1120
P-001A/B; 1120-P-017A/B;

8. Final alignment:
NA

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

2.5.1 Internal Equipment Inspection;

Tag No.: Inspection items Area Status

1120-C-001 Inspected Equipment internals material 1120 Ongoing

1120-C-002 Inspected From Tray #30 to Tray #34 1120 Ongoing

1120-C-003 Inspected From Tray #01 to Tray #20, Construction team is 1120 Ongoing
closing man-way

1120-C-004 Inspected Equipment internals material 1120 Ongoing

1120-C-005 Inspected Equipment internals material 1120 Ongoing

1120-C-006 Inspected Coalescer installation, Disperser plate Distributor 1120 Ongoing

#3

1120-C-007 Inspected Equipment internals material 1120 Ongoing

1120-V-006 Inspected material for Inlet device 1120 Ongoing

1510-C-401 Inspected Equipment internals material 1510 Ongoing

1510-C-411 Inspected Equipment internals material 1510 Ongoing

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

2.6 Painting, Insulation and Fire Proofing

FP = Fireproofing, INS = Insulation, PAINT = Painting

Date Discipline Activities

8/7/2017 COA 1513-STR-1200 (column): Power tool and 1st coat (under SI)

COA 1513-RCK-1100: Power tool and 1st coat burn-mark area leg beam, E&I support.

9/7/2017 Off Sunday

10/7/2017 INS 1510-R-401 : Cellular glass inspection before cladding

11/7/2017 COA 1120-STR-1400: Power tool and 1st coat burn-mark E&I support.

COA 1513-STR-1200 (column): DFT check to release fireproofing.

12/7/2017 INS 1513-E-306: Rock wool inspection before cladding. - not ready

INS 1513-E-315: Final inspection. - not ready

13/7/2017 FP 1120-STR-1400: Remove contamination, repair painting, install mesh and pin.

FP 1513-RCK-1100: Finishing work for fireproofing

14/7/2017 FP 1120-STR-1400: Remove contamination, repair painting, install mesh and pin.

1120-STR-1400: Apply 1st & 2nd layer framing.

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

3.0 Welding Status Report (Note: Last Update 7/7/2017)

a. WPS, WQT, Active Welder and Welding Performance

WPS No
WPS PIPING 32
WPS STRUCTURE 3

As of date : 29/06/17 to 7/07/2017

WQT Position/Process No
1. Pre-qualification 0 0
2. Joined WQT SMAW,GTAW, GTAW/SMAW 68
3. Visual 5F 36
6G (CS) 12
6G (SS) 20
5F 0
4. RT (Preliminarily passed, 6G
6G (CS)
(SS) 12
20
waiting for Client's approval)

Note: Some of the welder qualified double process. .

Active Welder
Description
Multitask Workshop Rapid
Position/Process
3G/4G 7 18
6G 39 28

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

Note: Last update 7/7/2017

4.0 WELD REPAIR RATE STATUS:

4.1 WELD REPAIR RATE SUMMARY: WORK SHOP (MMHE EAST-FOE)
Total inspected Total Defect Total Repair rate (%)
Discipline TR Target
Cummulative Previous This Week Cummulative Previous This Week Cummulative Previous This Week

RT BY LENGTH
(IN MM) 287,584 - - 3,174 - - 1.10% 0.00% 0.00% 1%
( 20 inch)
RT BY JOINT
2,701 - - 42 - - 1.55% 0.00% 0.00% 3%
(< 20 inch)

4.2 WELD REPAIR RATE SUMMARY: SHOP (PVE MULTITASK)

Total inspected Total Defect Total Repair rate (%)
Discipline TR Target
Cummulative Previous This Week Cummulative Previous This Week Cummulative Previous This Week

RT BY LENGTH
(IN MM) 150,472 - - 101 - - 0.07% 0.00% #DIV/0! 1%
( 20 inch)
RT BY JOINT
3,916 32 337 53 - 1 1.35% 0.00% 0.30% 3%
(< 20 inch)

4.3 WELD REPAIR RATE SUMMARY: COMBINED SHOP (MMHE-FOE+PVE MULTITASK) 2.1+2.2
Total inspected Total Defect Total Repair rate (%)
Discipline TR Target
Cummulative Previous This Week Cummulative Previous This Week Cummulative Previous This Week

RT BY LENGTH
(IN MM) 438,055 - - 3,275 - - 0.75% 0.00% 0.00% 1%
( 20 inch)
RT BY JOINT
6,617 32 337 95 - 1 1.44% 0.00% 0.30% 3%
(< 20 inch)

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

Note: Last Update 7/7/2017

4.4 WELD REPAIR RATE SUMMARY: FIELD (PVE)

Total inspected Total Defect Total Repair rate (%)
Discipline TR Target
Cummulative Previous This Week Cummulative Previous This Week Cummulative Previous This Week

RT BY LENGTH
(IN MM) 28,073 0 5,423 0 0 0 0.00% 0.00% 0.00% 1%
( 20 inch)
RT BY JOINT
681 6 38 22 0 0 3.23% 0.00% 0.00% 3%
(< 20 inch)

4.5 WELD REPAIR RATE SUMMARY: COMBINED (FIELD+SHOP) 2.3+2.4

Total inspected Total Defect Total Repair rate (%)
Discipline TR Target
Cummulative Previous This Week Cummulative Previous This Week Cummulative Previous This Week

RT BY LENGTH
(IN MM) 466,128 - 5,423 3,275 - - 0.70% 0.00% 0.00% 1%
( 20 inch)
RT BY JOINT
7,298 38 375 117 - 1 1.60% 0.00% 0.27% 3%
(< 20 inch)

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

Note: Last Update 7/7/2017

4.6 DEFFECT ANALYSIS status (MM):

POROSITY/
TOTAL LENGTH
PREV LOP LOF SLAG WORM HOLE CONCAVITY U/CUT OTHERS
SHOP 75 1,510 492 1,284 20 262 129 3,772
FIELD 9 152 - 73 - - - 234

POROSITY/
TOTAL LENGTH
CURRENT LOP LOF SLAG WORM HOLE CONCAVITY U/CUT OTHERS
SHOP - - - 4 - - - 4
FIELD - - - - - - - -

POROSITY/
TOTAL LENGTH
TOTAL LOP LOF SLAG WORM HOLE CONCAVITY U/CUT OTHERS
SHOP 75 1,510 492 1,288 20 262 129 3,776
FIELD 9 152 - 73 - - - 234

Note:- Need to be mention if have any resons

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

Note: Last update 7/7/2017

4.7 WELDING, PWHT, HT & NDT BACKLOCG STATUS:

ACCUMULATIVE WORKSHOP status: MMHE EAST FOE
Actual Total Hardness Hardness RT BACKLOG
REQUIRE Visual PWHT PWHT PWHT HT PMI PMI PMI RT RT
Welded Backlog Test Test RT Repair Fresh
MENT Completed Required Completed Backlog Backlog Required Completed Backlog Required Completed Reshoot ASR
(Joints) Visual Required Completed Backlog Backlog Joint
100% 1458 1458 0 30 30 0 116 116 0 0 0 0 1509 1509 0 0 0 0 0

20% 1124 1124 0 459 451 8 665 665 0 0 0 0 499 497 2 0 0 0 2

10% 2982 2982 0 293 280 13 2413 2413 0 0 0 0 999 990 9 0 0 0 9

5% 6314 6314 0 230 228 2 73 63 10 0 0 0 1063 1057 6 6 0 0 0

TOTAL 11878 11878 0 1012 989 23 3267 3257 10 0 0 0 4070 4053 17 6 0 0 11

ACCUMULATIVE WORKSHOP status: PVE MULTITASK

Actual Total Hardness Hardness RT BACKLOG
REQUIRE Visual PWHT PWHT PWHT HT PMI PMI PMI RT RT
Welded Backlog Test Test RT Repair Fresh
MENT Completed Required Completed Backlog Backlog Required Completed Backlog Required Completed Reshoot ASR
(Joints) Visual Required Completed Backlog Backlog Joint
100% 3126 3126 0 482 458 24 568 554 14 1262 815 447 3422 3022 400 11 0 289 100

20% 2151 2151 0 102 98 4 1691 1691 0 442 285 157 587 546 41 0 0 39 2

10% 3781 3781 0 112 112 0 2620 2620 0 722 561 161 610 566 44 0 0 44 0

5% 8933 8933 0 189 181 8 196 194 2 59 28 31 921 860 61 1 0 60 0

TOTAL 17991 17991 0 885 849 36 5075 5059 16 2485 1689 796 5540 4994 546 12 0 432 102
Note: Including RT films done by EW and A-Star from 23/6 to 01/07.
ACCUMULATIVE WORKSHOP status: COMBINED SHOP (MMHE-FOE+PVE)
Actual Total Hardness Hardness RT BACKLOG
REQUIRE Visual PWHT PWHT PWHT HT PMI PMI PMI RT RT
Welded Backlog Test Test RT Repair Fresh
MENT Completed Required Completed Backlog Backlog Required Completed Backlog Required Completed Reshoot ASR
(Joints) Visual Required Completed Backlog Backlog Joint
100% 4584 4584 0 512 488 24 684 670 14 1262 815 447 4931 4531 400 11 0 289 100

20% 3275 3275 0 561 549 12 2356 2356 0 442 285 157 1086 1043 43 0 0 39 4

10% 6763 6763 0 405 392 13 5033 5033 0 722 561 161 1609 1556 53 0 0 44 9

5% 15247 15247 0 419 409 10 269 257 12 59 28 31 1984 1917 67 7 0 60 0

TOTAL 29869 29869 0 1897 1838 59 8342 8316 26 2485 1689 796 9610 9047 563 18 0 432 113

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

ACCUMULATIVE FIELD status: PVE

Actual Total Hardness Hardness RT BACKLOG
REQUIRE Visual PWHT PWHT PWHT HT PMI PMI PMI RT RT
Welded Backlog Test Test RT Repair Fresh
MENT Completed Required Completed Backlog Backlog Required Completed Backlog Required Completed Reshoot ASR
(Joints) Visual Required Completed Backlog Backlog Joint
100% 588 588 0 45 32 13 78 42 36 173 0 173 583 395 188 0 18 151 19

20% 271 271 0 69 57 12 256 184 72 5 0 5 44 44 0 0 0 0 0

10% 725 725 0 75 65 10 554 452 102 5 0 5 113 109 4 0 2 2 0

5% 5860 5860 0 22 14 8 6 2 4 0 0 0 327 317 15 0 1 14 0

TOTAL 7444 7444 0 211 168 43 894 680 214 0 0 0 1067 865 207 0 21 167 19

ACCUMULATIVE status:COMBINED (SHOP+FIELD) 3.3+3.4

Actual Total Hardness Hardness RT BACKLOG
REQUIRE Visual PWHT PWHT PWHT HT PMI PMI PMI RT RT
Welded Backlog Test Test RT Repair Fresh
MENT Completed Required Completed Backlog Backlog Required Completed Backlog Required Completed Reshoot ASR
(Joints) Visual Required Completed Backlog Backlog Joint
100% 5172 5172 0 557 520 37 762 712 50 1435 815 0 5514 4926 588 11 18 440 119

20% 3546 3546 0 630 606 24 2612 2540 72 447 285 0 1130 1087 43 0 0 39 4

10% 7488 7488 0 480 457 23 5587 5485 102 727 561 0 1722 1665 57 0 2 46 9

5% 21107 21107 0 441 423 18 275 259 16 59 28 0 2311 2234 82 7 1 74 0

TOTAL 37313 37313 0 2108 2006 102 9236 8996 240 0 0 0 10677 9912 770 18 21 599 132
Note: need to be mentioned the reason if have high backlog

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

5.0 Test Package, Line Check & Hydrotest (Note: Last Update 7/7/2017)
ISSURED by TR Hydrotest Visual Test Submit to TR Daily Total Remain Holding Holding By Weld
Today prepared By P&ID map Drawing
No Unit Total of TR
Receive Receive Approved
Total Prepared Total Prepared Total
Bar P&ID by TR
code
1 1120 775 233 0 461 135 314 95 3 3 0 230 545 228 0
2 1510 319 0 94 208 0 111 0 1 0 0 0 319 0 0
3 1511 341 321 344 208 142 133 96 219 99 22 221 120 0 6
4 1512 341 0 0 208 0 133 0 0 0 0 0 341 0 0
5 1513 341 0 0 208 0 133 0 0 0 0 0 341 0 0
6 1531 47 0 4 39 2 8 0 2 2 0 2 45 0 0
7 1532 43 0 0 31 0 12 0 0 0 0 0 43 0 0
8 1533 119 0 0 93 0 26 0 0 0 0 0 119 0 0
Total 2326 453 1873 1456 279 870 191 225 104 22 453 1873 228 6
Total Prepare
470
Done

6.0 Walkdown/Walkabout (Last Update 7/7/2017)

Item TOTAL Piping Equipment Structure E&I PVE (s)

Open Closed Open Closed Open Closed Open Closed Open Closed
Walkdown 73 12 9 2 30 1 5 5 7 1 1
Walkabout 34 1 1 21 0 2 0 5 0 0 4
107 13 10 23 30 3 5 10 7 1 5
OPEN 50 Closed 57

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 PETRONAS RAPID PROJECT, PACKAGE 3, ELME
QAQC WEEKLY REPORT

7.0 Surveillance Report (Note: Last Update 7/7/2107)

TOTAL CLOSED OPEN

TR 47 47 0
PMC 8 7 1
55 54 1

8.0 Non-Conformance Report (Note: Last Update 7/7/2017)

TOTAL CLOESED OPEN

PVE 8 8 0
TR 22 22 0
PMC 4 4 0
34 34 0

9.0 Status for FU & VI Reports for Unit 1120 & 1510 as table below: (Note: Last update 7/7/2017)

Receipted by Carbon paper Cleared Backlogs

Date
Fit Up Visual Fit Up Visual Fit Up Visual
07.Jul.17 453 346 132 118 321 228

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