ENGINEERING, PROCUREMENT, CONSTRUCTION AND COMMISSIONING

(EPCC) OF BUKIT TUA DEVELOPMENT PROJECT

KETAPANG PSC, EAST JAVA, INDONESIA

QUALITY PLAN
FOR
PRESSURE VESSEL
INLET SEPARATOR (V-2010)

PREPARED FOR
PC KETAPANG II LTD.

CLIENT

EPCC CONSORTIUM

CONTRACTOR
pt. KRAKATAU ENGINEERING
pt. RAGA PERKASA EKAGUNA
ENGINEERS & CONSTRUCTORS

VENDOR

PT TRANSALINDO EKA PERSADA

Job No. : QPCA00 Contract No. : 5600025662 Doc. No.:

Rev. Date Description By Chk. App. 11-BTORF-M-PRO-05-0020

A 19-11-13 Issued for Review IM MN VD

Rev : 0
A1 12-05-2014 Re-Issued for Review IM SH EK

B 06-06-2014 Issued for Construction IM SH EK PC Ketapang II Ltd. APPROVAL

B1 06-06-2014 Issued for Construction IM SH EK Sign :

0 04-08-2014 Issued for Construction IM SH EK

Date :
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QUALITY PLAN FOR PRESSURE VESSEL INLET SEPARATOR (V-2010)

REVISION LOG REGISTER

Revisions had been performed on following pages:

No Page Date Revision

1 All 04-08-14 Issued for Construction

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TABLE OF CONTENT

Title
Table of Content
1. Introduction Section 1
1.0 Introduction Section 1
2. Project Details Section 2
2.1 Project Number Section 2
2.2 Client Section 2
2.3 PT Transalindo Eka Persada Section 2
2.4 Certifying Authority Section 2
3. Project Management Section 3
3.1 General Section 3
3.2 HSE Section 3
3.3 Marketing and Contractual Section 3
3.4 Legal Section 3
3.5 Financial and Budgetary Control Section 3
3.6 Communications and Reporting Section 3
3.7 Documentation Section 3
3.8 Project Schedule Section 3
4. Quality System Requirements Section 4
4.0 Introduction Section 4
4.1 Management Responsibility Section 4
4.1.1 Quality Policy Section 4
4.1.2 Organization Section 4
4.1.2.1 Responsibility and Authority Section 4
4.1.2.2 Resources Section 4
4.1.2.3 Management Representative Section 4
4.1.3 Management Review Section 4
4.2 Quality System Section 4
4.2.1 General Section 4
4.2.2 Quality System Procedure Section 4
4.2.3 Quality Planning Section 4
4.3 Contract Review Section 4
4.4 Design Control Section 4
4.4.1 General Section 4
4.4.2 Organization and Technical Interface Section 4
4.4.3 Design Input Section 4
4.4.4 Design Output Section 4
4.4.5 Design Review Section 4
4.4.6 Design Verification Section 4
4.4.7 Design Changes Section 4
4.4.8 Design Review, Verification and Approval Section 4
4.5 Document and Data Control Section 4
4.5.1 General Section 4
4.5.2 Document and Data Approval and Issue Section 4
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4.5.3 Document and Data Changes Section 4

4.6 Purchasing Section 4
4.6.1 General Section 4
4.6.2 Evaluation of Subcontractor Section 4
4.6.3 Purchasing Data Section 4
4.6.4 Verification of Purchase Product Section 4
4.6.4.1 Supplier Verification at Subcontractor’s Premises Section 4
4.6.4.2 Customer Verification of Subcontracted Product Section 4
4.7 Control of Customer Supplied Product Section 4
4.8 Product Identification and Traceability Section 4
4.8.1 In Process Fabrication Identification and Traceability Section 4
4.8.2 Final Product Identification Section 4
4.9 Process Control Section 4
4.9.1 Welding Control Section 4
4.9.2 Control of Welding Consumable Section 4
4.10 Inspection and Testing Section 4
4.10.1 General Section 4
4.10.2 Receiving Inspection and Testing Section 4
4.10.3 In-Process Inspection and Testing Section 4
4.10.4 Final Inspection and Testing Section 4
4.10.5 Inspection and Test Records Section 4
4.11 Control of Inspection, Measuring and Test Equipment Section 4
4.12 Inspection and Test Status Section 4
4.13 Control of Non-Conforming Product Section 4
4.14 Corrective and Preventive Action Section 4
4.14.1 General Section 4
4.14.2 Corrective Action Section 4
4.14.3 Preventive Action Section 4
4.15 Handling, Storage, Packaging and Delivery Section 4
4.16 Control of Quality Records Section 4
4.17 Internal Quality Audits Section 4
4.18 Training Section 4
4.19 Servicing Section 4
4.20 Statistical Techniques Section 4

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1. INTRODUCTION

1.0 Introduction

The established Project Quality Plan as substitution of PT Transalindo Eka Persada

Quality Manual is designed to fulfill the requirements of

- ISO 9001:2008 International Standard for Quality Management System and,

- Specification for Vendor Quality Requirements.

This Project Quality Plan describes the quality system implemented to fabrication,
examination/ testing of Bukit Tua ORF project for pressure Vessel Tag No. V-2010
(INLET SEPARATOR) by PT. Transalindo Eka Persada.

The prime objective of PT Transalindo Eka Persada management is to provide

products which conform to Client Specification and Code requirements as well as
meeting client's expectations and needs whilst remaining competitive.

To achieve this objective it is the policy of PT Transalindo Eka Persada to establish and
maintain an effective and efficient Quality Assurance Program, planned, developed and
implemented in conjunction with other management functions.

2.0 PROJECT DETAILS

2.1 Project Number

PT Transalindo Eka Persada assigns job number T-498 base on NCA (Notice Contract
Award) have been issued for fabrication of:

1. 1 unit Pressure vessels tag no. V-2010 (INLET SEPARATOR)

2.2 Client

PT RAGA PERKASA EKAGUNA-PT KRAKATAU ENGINEERING

CONSURTIUM for PC KETAPANG II

2.3 PT TRANSALINDO EKA PERSADA

PT Transalindo Eka Persada project management for this project is

2.3.1 Project Engineer

Project Engineer will be ensure that personnel assigned to the project have the
necessary experiences, training and qualification as per contract requirement to
perform their intended function.

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Job description and role, responsibility statement for job types will be developed and
shall be utilized to identify the requirements of each position.

2.4 Certifying Authority

MIGAS and U2 Stamp (ASME Section VIII Div. 2 2013 Edition).

3.0 PROJECT MANAGEMENT

3.1 General

Managing Director is responsible for marketing and tender evaluation. At the time of
contract awarded, he will pass the “tender documents” to the Project Engineer.

Project Engineer is responsible to review contracts for commercial and schedule wise.

Refer to Section 4 paragraph 4.1.2.1

3.2 HSE

The project HSE Plan is outlined in HSE Documents.

3.3 Marketing and Contractual

Marketing and Contractual issues shall be referred to PT Transalindo Eka Persada

Managing Director.

3.4 Legal

Legal issues shall be referred to PT Transalindo Managing Director.

3.5 Financial and Budgetary Control

Financial and Budgetary Control issues shall be referred to Project Engineer.

3.6 Communications and Reporting

All correspondence, faxes, e-mail or letter to be addressed in the English language.

All quality record documents shall be sent using transmittal. The recipient
acknowledge receipt shall be sent back by email or by facsimile.

A weekly progress report shall be sent by Project Engineer to Client’s using email.

3.7 Documentation

The incoming and outgoing contractual document except for letters and faxes are
registered and distributed through Document Controller.

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3.8 Project Schedule

Project schedule is prepared using Microsoft Project. A progress report shall be issued
periodically by Project Engineer to Client. Any possible slippage shall be reported to
anticipate delays and offer solutions to bring the project on schedule.

4.0 QUALITY SYSTEM REQUIREMENT

4.0 Introduction

It is the policy of PT. Transalindo Eka Persada to maintain a Quality System in

accordance with the requirement of ISO 9001 Quality System.

PT Transalindo Eka Persada Quality system is certified by ISO 9001: 2008 Company
certified by LR Register.

4.1 Management Responsibility

4.1.1 Quality Policy

The PT Transalindo Eka Persada quality policy is stated in PT Transalindo

Eka Persada Quality Manual QAM-01 and QC Manual TEP-QM.01.

4.1.2 Organization

The PT Transalindo Eka Persada Project Organization Chart shows the

interrelation of all the personnel who manage, perform and verify work-
affecting quality. A summary of the duty statement for key personnel is shown
below.

4.1.2.1 Responsibility and Authority

The responsibility and authority of PT Transalindo Eka Persada project

key personnel are describes below.

a. Managing Director

The Managing Director is responsible for direct control of day to

day operation of the Company. He shall also be responsible for, but
is not limited to:

 Clearly define and establish the Company quality policies and

strategies so as to meet the management objective.
 Enforcing the Company Quality System on the organization.
 Preparation of tenders, contract negotiations and review.
 In conjunction with the QA/QC Manager, he shall review the
specifications and note that the Code/ Standards that are required and
complied with.
 All staffs under his control.
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b. QA/QC Manager

The QA/QC Manager reports directly to the Managing Director on

all matters relating to quality. He shall be responsible for, but is not
limited to:

 Monitor the implementation, operation and maintain the Quality

System.
 Register and control distribution of Quality Manual.
 Prepare the Inspection and Test Plan (ITP) and to obtain
establishment of hold points inspection from the Authorized
Inspector.
 Visiting suppliers and subcontractors whenever deemed necessary.
 The achievement of quality to agreed standards in all products
supplied by PT Transalindo Eka Persada. In close coordination with
Design Engineer, he shall determine the degree of Radiography
Examination and additional examination or testing required by the
applicable Code and/ or client specification.
 Implement the approved ITP and ensure that all departments and
subcontractors are following its requirements.
 Identify product non-conformity, recommend solutions through
designated channels, verify the implementation of solutions and
control further processing of non-conforming product until the
deficiency has been corrected, and initiate corrective action to
prevent recurrence of product non-conformity.
 Certify Manufacturer’s Data Report.
 Maintain qualification record of welding procedures and welder’s
performance. Qualify new welding procedures and welders when
required.
 Review subcontractor’s NDE procedures, ensure that the procedures
are in accordance with the applicable Code and the NDE operators
are qualified.
 Prepare hydrostatic test and heat treatment specification and ensure
that they are conducted in accordance with Code requirements.

c. Project Engineer(s)

The Project Engineer is responsible for project execution and

reports directly to the Managing Director. He shall be responsible
for the following, but is not limited to:

 Coordination between other departments, discipline and clients.

 Liaison with the client.
 Administration of the contract and budget control.
 Planning and scheduling.
 Material procurement coordination and monitoring.
 Coordination and scheduling of the subcontracted work.
 Coordination and supervision of the personnel under his
responsibility.
 Obtaining approval of documents from client when required.
 Monitoring the overall progress of the project, reporting in case of
anticipated delays and offering solutions to bring the project on
schedule.
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 Studying cost status and reporting to the management deviation from

its budget.
 Taking part in decisions relating to the nonconformance treatment
and corrective actions in close cooperation with the QA/QC
Manager.

d. Production Manager.

The Workshop Supervisor is responsible for all staff under his

control and reports directly to the Managing Director on any
matters relating to manufacture and assembly. In conjunction with
the Project Engineer he is also responsible for the completion of
the project within the scheduled time.

He shall be responsible for the following, but is not limited to:

 Ensure that the Quality Control requirements are maintained and

shall take an active interest in quality matters.
 Assist with the implementation and the development of existing and
new procedures in conjunction with the QA/QC Manager.
 Ensure that there are suitably qualified personnel to meet contractual
and quality system requirements, and that all personnel under his
control are aware of the quality procedures in his area of supervision.
 He shall report non-conformances in his area to the QA/QC Manager
and assist with the implementation of the resulting disposition and
corrective action.
 If a non-conformance in quality is reported, he shall ensure that the
procedures or equipment under his control are rectified and staff
notified in order to correct the deficiency.
 Keep all staff under his control fully informed as to the customer's
latest requirements i.e., change in specification, delivery time etc.
 In conjunction with the QA/QC Manager, he shall ensure that all
personnel under his control is informed of, and in possession of all
necessary documentation and that they fully understand the standards
that they are required to work with.
 Control of the manufacturing of the product, i.e., both detailed
fabrication and completion within scheduled time.

e. Design Engineer

The Design Engineer is responsible to prepare design calculation

and construction drawing in accordance with Code requirements.
He reports directly to the Managing Director on any matters
relating to engineering.

He shall be responsible for the following, but is not limited to:

 Ensure that all design and drawing prepared comply with Code
requirements.
 Engineering coordination and supervision.
 Determine supplementary material testing when required by the
applicable Code or client specification.
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 Determine degree of Radiography Examination and other

examination method.
 When required, he shall prepare purchase specification for
subcontracted parts.
 In close coordination with Project Engineer, when required, he shall
obtain approval of document he prepared from client or other
certification approval body.

4.1.2.2 Resources

The project team personnel are selected from PT Transalindo Eka

Persada existing resources. Should any additional personnel be
required, they are selected based on particular technical skills and
previous experience. Welders shall be selected after they pass testing
as required by reference code(s).

4.1.2.3 Management Representative

The appointed Management Representative for this Project is the

QA/QC Manager.

4.1.3 Management Review

The Quality Plan and the HSE Plan for this project is reviewed by Managing
Director. At least one management review shall be conducted during this
project. The review should be chaired by Managing Director and attended by
the whole management team. The agenda of the review are as follow but not
limited to:

 review of quality system,

 review of non conformances and customer complaints,
 assessment of the results of internal audits.

4.2 Quality System

4.2.1 General

The reference Quality Manual for this project is PT Transalindo Eka Persada
Quality Manual TEP-QM.01. The project Quality Plan contains additional
requirements that shall be complied to.

4.2.2 Quality-System Procedure

The reference Quality System Procedure for this project is PT Transalindo Eka
Persada Quality Manual TEP-QM.01 with additional project procedures as
listed in VDRL.

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4.2.3 Quality Planning

The main quality planning for the project is this project quality plan and
specific item inspection and test plan as described in ITP T-498 (498-ITP-QC-
001).

4.3 Contract Review

The review is done in an informal way. Managing Director review contract during
tender stage and Project Engineer reviews contract prior, during and after completion
of project. Design Engineer reviews contract related to design requirements and QA/
QC Manager review contract related to QA/QC requirements.

4.4 Design Control

4.4.1 General

Design preparation and planning activity is outlined in TEP-QM.01 “Drawing,

Design and Specification Control”.

For this project PT Transalindo Eka Persada is responsible to prepare drawing

and design calculation for the item.

4.4.2 Organizational and Technical Interface

Design and drawing produced by PT Transalindo Eka Persada are submitted to

Client for approval. Any design and drawing comments from both parties will
be incorporated in PT Transalindo Eka Persada documents.

4.4.3 Design Input

Design inputs for the item are from Client’s specifications and Data sheets.
Any incomplete, ambiguous, or conflicting requirements will be resolved with
the Client.

4.4.4 Design Output

Design output is Pressure Vessel’s mechanical calculation and fabrication

drawing. PT Transalindo Eka Persada will be using appropriate software tool
for vessel design.

The Design Engineer is responsible to prepare design calculation and produce

fabrication drawing in compliance with Code requirements, client data sheet
and specification.

4.4.5 Design Review

QA/QC Manager or Project Engineer is responsible to review design

calculation and drawing prior to submission to Client.

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4.4.6 Design Verification

Design software prior to be used, shall be verified manually to ensure

compliance with the applicable Code. The current version of the software is
controlled from the printout of each page.

4.4.7 Design Changes

All design changes shall be reviewed and approved in the same manner as the
original design.

4.4.8 Design Review, Verification and Approval

This Pressure Vessel V-2010 is constructed under ASME VIII Div 2 (U2
Stamp), hence PT. Transalindo Eka Persada shall provide
MANUFACTURER’S DESIGN REPORT certified by REGISTERED
PROFESSIONAL ENGINEER. This kind of certification shall be obtained
prior commencement of fabrication.

It is the responsibility of the user or an agent acting on behalf of the user to

provide a certified USER’S DESIGN SPECIFICATION. This certification
shall be obtained prior commencement of fabrication and certified by different
REGISTERED PROFESSIONAL ENGINEER.

4.5 Document and Data Control

4.5.1 General

PT Transalindo Eka Persada document control procedure is outlined in

“Drawing, Design and Specification Control”.

The Document Controller is responsible for controlling contractual document

transmitted or received.

4.5.2 Document and data approval and issue

The Document Controller shall log all contract documents received from client
such as client specification or client drawing.

External submissions shall use Transmittal and logged in “Document Status

Control” by the Document Controller. The Document Controller is responsible
for maintaining the revision status of drawing, design calculation and other
contractual documents.

4.5.3 Document and data changes

Revisions to drawings and documents shall follow the same procedure as the
issue of new drawings or documents.

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All Revision to drawings or documents shall receive the same level of review
and approval as the originals.

4.6 Purchasing
4.6.1 General

PT Transalindo Eka Persada purchasing procedure is outlined in “Material

Control”

4.6.2 Evaluation of Subcontractor

At this moment, PT Transalindo Eka Persada does not have a formal

procedure for subcontractor evaluation. Project Engineer placed order to the
selected subcontractor base on their ability to meet PT Transalindo Eka
Persada purchase-specification, their previous performance and price
evaluation.

4.6.3 Purchasing Data

The Design Engineer in liaison with Project Engineer is responsible to review

the purchase specification and determined if there is an additional requirement
required by Code or client specification.

Purchasing specification shall detail essential information as necessary such

as:

 Drawings/ sketches
 Applicable Code requirements including Code Edition and Addenda.
 Tolerances
 Requirements for Non-Destructive Examination, heat treatment, impact testing or
hardness testing.
 Requirement of material test certificate.
 Packaging and dispatch instruction as required.
 Price
 Agreed delivery dates (Not ASAP etc.).
 Date of placement of order.

Purchase specification, when available, shall be attached to the Purchase

Order.

4.6.4 Verification of Purchased Product

4.6.4.1 Supplier verification at subcontractor’s premise

PT Transalindo Eka Persada may specify the need of verification at

subcontractor’s premise. When this is required, it shall be specified in
the Purchase Order.

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4.6.4.2 Customer verification of subcontracted product

Store man responsible to received subcontracted product against

Packing List and Purchase Order. He shall check the following prior to
QC Inspection;

Quantity and Size (Diameter, thickness, length etc.)

Material specification and its marking.

The QC Inspector is responsible for verifying and inspecting

subcontracted product against P/O and applicable reference
specification, as follows:

Material has clear identification as required by the Code (e.g., heat number,
material specification i.e. grade, type and class if applicable) and traceable to
material certificate when required.

For head and shell sections, the prescribed shape, thickness requirements
after forming and certification as required by the applicable Code.

Additional examination required by the P/O had been performed (such as

Non Destructive Examination, Heat Treatment, Impact Test and Hardness
Test) and test certificates are available and in compliance with the Code and
client’s specification.

4.7 Control of Customer Supplied Product

Upon receipt, purchaser supplied materials or items shall be subject to same level of
inspection as PT Transalindo Eka Persada purchased items using packing list and
material test certificates provided.

In case of the identification of non conformance, the Project Engineer shall notify the
client’s representative as soon as possible. In all cases, no disposition is taken before
consultation with the client.

4.8 Product Identification and Traceability

PT Transalindo Eka Persada supplied items are identifiable and traceable

continuously from the fabrication start until completion of the product.

The need of traceability of material is depend on customer and applicable code

requirements. For this project, all main material is traceable to its original
identification by transferring the heat number to the material and by using the
“Material Traceability Records” form.

4.8.1 In process fabrication identification and traceability

Every equipment during the process fabrication will be traceable to their

equipment number or description and job number. Job number, equipment
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number or description is shown on the inspection report. Every welding also

traceable to the welder who is welding the joint and its NDE report by using
the “Welding Traceability Records” form.

4.8.2 Final product identification

A name plate showing PT Transalindo Eka Persada job number and

equipment number will be installed on every item fabricated.

4.9 Process Control

PT Transalindo Eka Persada is a fabrication company which most of the fabrication

activity is welding. Welding control procedure is outlined in of TEP-QM.01 section 6
start from para 6.1 “Welding Control”. Other procedure will be prepared as necessary
when required by client specification.

4.9.1 Welding Control

The QA/QC Manager is responsible to prepare the Welding Procedure

Specification (WPS) and certify its Procedure Qualification Record (PQR) and
Welder/ Welding Operator Performance Qualification (WPQ).

The Workshop supervisor is responsible for assigning and supervising

qualified welders and welding operators for the production work.

The QA/QC Manager updates periodically list of qualified welders and

Welder Performance Continuity Log every six months. These records issued
to the Workshop Supervisor to ensure only qualified welders are assigned to
this job.

The Welding Procedure Map and the WPS(s) to be used for production shall
be transmitted to the Workshop supervisor and put on the notice board in
fabrication shop for easy access to the welder and welding operators.

4.9.2 Control of Welding Consumable

Electrodes and welding consumable receiving, storage and issuing shall be in

accordance with procedure “Welding Consumable Control Procedure”.

Welding consumables (electrodes, wire and flux) shall be stored at

temperature and humidity recommended by the electrode manufacturer.

The Storeman shall only issue welding consumable to the Welder/ Welding
Operator after signed Consumable Requisition.

Covered low hydrogen electrode shall be baked/ re-dried from its original
packing at temperature and period as per manufacturer recommendation. The
Storeman shall record the time in of baking and the time out use.

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4.10 Inspection and Testing

4.10.1 General

Procedures for inspection and testing is described in “Material Receiving

Inspection” and in “Examination and Inspection Program”.

4.10.2 Receiving inspection and testing

Before inspection by QC Inspector, Storeman shall check the received

material against Delivery Docket/ Packing List and Purchase Order. He shall
check the following prior to QC Inspection:

 Quantity and Size (Diameter, thickness, length etc.)

 Material specification and its marking.

The QC Inspector is responsible for verifying and inspecting all material to be used
for fabrication against Packing List, P/O and applicable material specification, as
follows:

Material has clear identification as required by the Code (e.g., heat number, material
specification i.e. grade, type and class if applicable) and traceable to material
certificate when required.

Contents of chemical analysis and mechanical test results on material test certificate
are in accordance with the respective material specification and P/O.

Material is free from defects and imperfections such as pitting, scaling, lamination,
etc. which would affect the safety of the vessel.

Head and shell sections for prescribed shape and thickness requirements after forming
and has the certification as required by the applicable Code.

Additional examination required by the P/O had been performed (such as Non
Destructive Examination, Heat Treatment, Impact Test and Hardness Test) and test
certificates are available and in compliance with the Code and client’s specification.

Item inspected matches with the “ Issued For Construction” drawing.

4.10.3 In-process inspection and testing

QA/QC Manager or his delegate shall examine items as per approved ITP. On
acceptance of each activity, the ITP is signed and dated by QA/QC Manager
or QC Inspectors. The item may then proceed to the next stage of fabrication.

Items requiring special processes or testing shall be controlled as per ITP and
relevant purchase specification by the QA/QC Manager or his delegate.

The material traceability shall be maintained by using “Material Traceability

Records”.
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The welding traceability shall be maintained by using “Welding Summary

Records”.

All non-conformities shall be handled in accordance with NCR procedure.

4.10.4 Final inspection and testing

On completion, the QC Inspector shall perform final dimensional check

“Dimensional Control Procedure”) and visual examination of welds and all
surfaces before hydrostatic test and before any required heat treatment or prior
to delivery.

The certifying agency and/ or client representative shall make his final visual
inspection before hydrostatic test. He shall sign and date ITP package, when
he is satisfied that the pressure vessel/ item meets the applicable Code
requirements. The QA/QC Manager shall ensure that all NCRs are properly
closed before pressure test.

4.10.5 Inspection and test records

The inspection and test records for this job will be prepared progressively
following the job progress. Manufacturing Data Report will be prepared by
QA/QC Manager, which consists of all inspection and test records. Items will
be released for delivery after “Inspection Release Notes” signed by PT
Transalindo Eka Persada QA/QC Manager and client representative.

Refer to document “Manufacturing Data Report Table of Content” for list of

Inspection and Test Records” TOC

4.11 Control of Inspection, Measuring and Test Equipment

PT Transalindo Eka Persada procedure is described in “Calibration of Measuring and

Testing Equipment”.

PT Transalindo Eka Persada assures that all inspection, measuring & test equipment
for final acceptance are calibrated, traceable and documentary proof of calibration
records are maintained.

Pressure gauges, pressure recorders, temperature gauges, thermocouples, volt-ampere

meters and all measuring instruments (when required) used for final Code acceptance
are calibrated.

The QA/QC Manager maintains a record for all calibrated items indicating equipment
name, brand/ manufacturer, calibration interval and serial number.

Should any of these equipment calibrations lapse, out of calibration and are not in use,
they shall be tagged with “do not use until calibrated”. QA/QC Manager shall arrange
for its calibration prior to use.

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4.12 Inspection and Test Status

PT Transalindo Eka Persada procedure for Inspection and Test.

The inspection and test status during fabrication is monitored through “Inspection and
Test Plan” and “Inspection and Test Status Color Coding of Sticker”.

COLOR DESCRIPTION
RED Reject Do not use
YELLOW Hold Do not use until cleared by QC
BLUE Accept Code material (Carbon steel)

4.13 Control of Non-Conforming product

All personnel shall be responsible for reporting to the QA/QC Manager for all
products or items suspected to be non-conforming.

The QA/QC Manager is responsible for preparing the Non-Conformance Report and
to determine the conditions that are adverse to quality. In close coordination with the
Project engineer, QA/QC Manager or Design Engineer shall be responsible for the
resolution of the non-conforming product.

The non-conforming item shall not be processed until the non-conformance has been
resolved.

The product shall be identified as per Inspection and Test Status Color Coding sticker
i.e., application of hold/ reject marker (or paint) by QA/QC Manager or his delegate
and place into a segregated area (whenever practicable).

4.14 Corrective and Preventive Action

4.14.1 General

Refer to “Non-Conformance and Correction Action Procedure.

The QA/QC Manager or Design Engineer, in close coordination with Project

Engineer, shall be responsible for providing disposition for resolution of the
non-conformances.

The disposition of non-conforming product may be,

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QUALITY PLAN FOR PRESSURE VESSEL INLET SEPARATOR (V-2010)

 Repair/ reworked to meet the Code or contractual requirements.

 use as is,

(Use as is and weld repair (if any) shall require technical justification by the
Design Engineer).

 Regarded for alternative applications or non Code use.

 Rejected or scrapped.

The QC Inspector will verify and sign the NCR after the item has been
repaired/ reworked to his satisfaction (i.e., according to approved resolution).
If required, the client’s representative may witness the repair.

4.14.2 Preventive Action

When repetitive non-conformance occurs, the QA/QC Manager will initiate a

corrective action request.

In conjunction with other department heads, he will investigate the cause of

non conforming products and the corrective action needed to prevent
recurrence.

The Corrective Action Request details a proposed long-term solution to

prevent recurrence. The QA/QC Manager shall nominate a period within
which the non-conformance is to be closed out.

The QA/QC Manager shall be responsible for the corrective-action follow-up

after the agreed period. If a repetitive non-conformance does not occur within
the agreed period, the corrective action report is to be closed out. Repeated
non-compliance to these agreed corrective actions should be reported to the
Managing Director.

4.15 Handling, Storage, Packaging and Delivery

PT Transalindo Eka Persada procedure for material storage is outlined in Procedure

for handling, packaging and delivery is outlined in project procedure “Packaging and
Preservation Procedure”.

Procedure for painting is outlined in project procedure “Surface Preparation and

Painting Procedure”.

4.16 Control of Quality Records

During the project execution all file related to project would be retained in project
engineering office, files related to engineering will be retained in engineering office
and files related to QA/QC will be retained in QA/QC office.

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All records shall be hard copies of computer prints out or hand printed, in ink and
legible. All records shall always be traceable and filed in proper manner.

After project completion all records are stored in document storage area and shall be
retained for max 3 years.

4.17 Internal Quality Audits

QA/QC Manager will conduct at least one internal audit during the period of this
project.

4.18 Training

PT Transalindo Eka Persada will only select the personnel base on their appropriate
education, previous experience and qualification. Only welders and welding operators
are subject to testing as required by the reference Codes.

4.19 Servicing

Servicing requirements is not applicable to this project.

4.20 Statistical Techniques

Statistical technique is not applicable to this project.

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