PHEONWJ-G-SPE-0101 0 - Structural and Piping Fabrication Quality Control

|DOCUMENTUM|8/18/2011|Paper Copies are Uncontrolled|
PHE ONWJ Ltd.
Structural and Piping Fabrication Quality Control
Revision Log Register
Document Number
PHEONWJ GSPE01 01
Document Title
Revision
Page
Date
Revision
PHE ONWJ
Reviewer
PHEONWJGSPE01 01 Rev.0
Page 2 of 1 0
PHE ONWJ Ltd.
Table of Contents
Revision Log Register ....................................................................................................................2
Table of Contents...........................................................................................................................3
1.
Scope......................................................................................................................................4
2.
References
.............................................................................................................................4
2.1 . Company Specification ...........................................................................................................4
2.2. International Standards and Codes.........................................................................................4
3.
Definition
4.
Abbreviations..........................................................................................................................4
5.
Responsibility
6.
Drawing
7.
Definitions
8.
Control
9.
Inspection
of Terms.................................................................................................................4
.........................................................................................................................4
..................................................................................................................................5
..............................................................................................................................5
System.......................................................................................................................5
Hold Points (IHP)...................................................................................................5
1 0. Documentation Control Sheet Packages ...............................................................................7
11.
Documentation Requirement .................................................................................................8
1 2. Sample Document Control Sheet1 0
Page 3 of 1 0
PHE ONWJ Ltd.
1. Scope
This procedure outlines the actions to be taken by CONTRACTOR and COMPANY in the
inspection of structural, piping and mechanical work. The actual tolerance requirements such
as coating thickness are listed in the project specifications and standards. This procedure is
not meant to supersede the specifications but to provide a framework that will allow timely
and accurate measurements to be taken.
2. References
2.1 .
2.2.
Company
Specification
PHEONWJ -G-SPE-0254
Specification for Package Skid-Mounted Equipment
PHEONWJ-I-PRC-001 1
Quality Manual
PHEONWJ-S-PRC-0005
Guidance on Platform Fabrication
PHEONWJ -S-SPE-01 02
Specification for Structural Welding
PHEONWJ -X-SPE-0001
Piping Fabrication, Installation and Testing Specification
PHEONWJ -X-SPE-0004
General Piping Design Specification
PHEONWJ-X-SPE-0005
Piping Material Specification
International
Standards and Codes
AISC
American Institute for Steel Construction
AISI
American Iron & Steel Institute
API
American Petroleum Institute
ASME
American Society of Mechanical Engineers
ASTM
American Society for Testing Materials
AWS
American Welding Society
3. Definition of Terms
COMPANY
Pertamina Hulu Energi (PHE) Offshore North West J ava Ltd.
CONTRACTOR
The party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a
project. The COMPANY may undertake all or part of the duties of
the CONTRACTOR.
SUPPLIER/VENDOR
The party that supplies equipment and services to perform the
duties specified by the CONTRACTOR.
4. Abbreviations
AFC
Approved For Construction
DCS
Document Control Sheet
IHP
Inspection Hold Point
NDT
Non Destructive Test
5. Responsibility
Both of CONTRACTOR and COMPANY has the same responsibility for quality control,
especially for the work delivered by inhouse/blanket CONTRACTOR. However, COMPANY
inspection at the various hold points does not relieve CONTRACTOR of his obligation under
PHEONWJ GSPE01 01 Rev.0
Page 4 of 1 0
PHE ONWJ Ltd.
the contract to perform quality control procedures to assure proper performance of the
WORK. Any additional defects discovered after the hold point inspections must be repaired
at CONTRACTORs expense. COMPANY also reserves the right to require additional
inspections per the fabrication codes and the terms of the contract.
6. Drawing
The basic documents for carrying out this procedure will be CONTRACTORs shop drawings,
COMPANY specifications and COMPANY standard drawings. CONTRACTOR is responsible
for preparing shop drawings in strict compliance with the contract drawings and good
engineering practice.
Deviations from the contract drawings must be specifically authorized in writing by the
COMPANY Project Engineer.

Any unauthorized deviations must be corrected at
CONTRACTORs expense no matter what the stage of the fabrication.
7. Definitions
7.1 .
Item:
7.2.
7.3.
7.4.
A Component part of a higher stage assembly.
Stage 0 Assembly: This is an item that has been either fabricated from stock
materials by cutting or purchased for inclusion in the structure or piping system such
as an anode, valve or flange. It includes only one item.
Stage 1 Assembly: This is an item that has been fabricated by connecting together
more than one stage 0 assemblies normally by welding, for example a brace or a
pipe spool.
Stage 2 Assembly: This is an item that has been fabricated by connecting together
more than one assembly at least one of which is stage 1 or stage 2, for example
jacket bent fabrication, pipe spool erection.
8. Control System
8.1 .
Stage
1 Assemblies: A Document Control sheet (DCS) shall be initiated by
CONTRACTOR for each stage 1 assembly. Generally this will be one DCS for each
shop drawing. If more than one stage 1 assembly is fabricated from one shop
drawing, then a DCS must be prepared by CONTRACTOR for each stage 1
assembly. CONTRACTOR shall supply cutting plans/details or VENDOR drawings of all
stage 0 assemblies to be included as items in the stage one assembly. Inspectors
verification of surface preparation, prime coating, dimension strap tests, hydrotest,
etc, of the Parts Used section of the DCS. The remainder of the form is for
documentation of the fabrication of the assembly.
8.2.
Stage
2 assemblies: CONTRACTOR shall initiate a DCS for each stage 2
assembly. The DCS is essentially the same as for the stage 1 assemblies except
that each item that is a stage 1 or stage 2 assembly must be verified to have a
finally approved DCS.
9. Inspection Hold Points (IHP)
9.1 .
CONTRACTOR is required to submit each item for inspection at various points in
fabrication.
Page 5 of 1 0
PHE ONWJ Ltd.
CONTRACTORs Quality Control Supervisor will inform the COMPANYs QA/QC
Engineer before 04.00 pm each work day of the IHPs that will be reached on the
following work day. The COMPANYs QA/QC Engineer shall assign inspectors to be
available at the various work stations at the times indicated by CONTRACTOR.
Fabrication may not proceed to the next step until the COMPANY Inspector has given
approval at the hold point.
9.2.
Inspection
9.2.1 .
Hold Points
Stage 0 Assemblies
dimensions
of
each
item
per
9.2.1 .1
Inspector shall verify
CONTRACTORs cutting instructions, assembly drawings, or
VENDOR drawings. Inspector shall further verify that the mill
certificates or mechanical tests have been obtained. Also, he will
verify CONTRACTOR purchased items against the specifications,
drawings and approved VENDORs list.
9.2.1 .2
Inspector shall approve the surface preparation of all items that
must be coated prior to incorporation into the stage 1 or stage
2 assembly.
9.2.1 .3
Inspector shall approve the prime coat application of all items that
must be prime coated prior to incorporation into the stage 1 or
stage 2 assembly.
9.2.1 .4
Inspector shall approve the top coat application of all items that
must be top coated prior to incorporation into the stage 1 or
stage 2 assembly.
9.2.1 .5
Inspector shall witness and approve the hydrotest of all items
that must be so tested prior to incorporation into the stage 1 or
stage 2 assembly.
9.2.2.
9.2.3.
Stage 1 and Stage 2 Assemblies :
Inspector shall verify that there has been final approval of the DCS of each
stage 1 and stage 2 assembly that will be included as items on the next
stage 2 assembly.
Inspections
9.2.3 .1
Inspector shall approve any surface preparation of the final
assembly that is required after all items have been incorporated
into the assembly.
9.2.3 .2
Inspector shall approve any prime coat of the final assembly that
is required after all items have been incorporated into the
assembly.
9.2.3 .3
Inspector shall approve any top coat of the final assembly that is
required after all items have been incorporated into the assembly.
9.2.3 .4
Inspector shall approve the dimensions of the assembly after all
items have been incorporated.
Page 6 of 1 0
PHE ONWJ Ltd.
9.2.4.
Weld Details
9.2.4.1
Inspector shall approve the fit-up of all welds.
9.2.4.2
Inspector shall visually inspect all welds.
9.2.4.3
Inspector shall approve all NDT reports.
9.2.4.4
Inspector shall approve all welding repairs. No repairs will be
allowed without notifying inspectors. Each repair shall be
documented on a separate line in the Weld Details section of
the DCS.
9.2.5.
Bolt-up Details
9.2.5.1
Inspector shall approve the fit-up between piping components
prior to the insertion of any flange bolts or tack welding for field
welds.
9.2.5.2
Inspector shall verify that pipe section and weld connection can
withstand specified test during strength test, without leak and/or
deformation indication.
9.2.5.3
Inspector shall verify that each flanged and threaded connection
did not leak during leak testing. This includes instruments and
other connections that were not verified for the hydrotest plus
the connections from 6.2.5.2 above.
1 0. Documentation Control Sheet Packages
1 0.1 . Each complete DCS will be approved by COMPANYs Project Engineer.

package will be prepared by CONTRACTOR.
The DCS
1 0.2. The following documentation will be required to be included with the DCS for it to be
considered completed.
1 0.2.1
The DCS sheet will be typewritten in a format similar to that shown in
Section 1 2
1 0.2.2
CONTRACTORs shop drawing of the assembly covered by the DCS. All
included items in the assembly must be shown in this drawing. All weld
numbers must be indicated in this drawing.
1 0.2.3
Cutting plans or VENDOR drawings for all stage O assemblies.
Exceptions will be standard piping components such as : flanges, bolts, etc.
that may be covered by a description on the DCS.
Where
1 0.2.4
The Mill Certificates for all pipe, plate and structural shapes.
Inspector cannot verify that the particular item actually is covered by the mill
certificates, mechanical test reports will be required. This applies to piping
materials, also.
1 0.2.5
The complete and approved DCS package for all stage 1 and stage 2
assemblies included as items on the subject DCS.
1 0.2.6
The NDT reports for all welds and weld repairs.
Page 7 of 1 0
PHE ONWJ Ltd.
1 0.3. The COMPANY QA/QC Engineer must sign each DCS prior to its being considered
complete. He shall verify the following prior to giving his approval.
1 0.3 .1
Every item included in the assembly is listed in the DCS.
1 0.3 .2
No item had undocumented fabrication work such as cutting, welding,
coating or the inclusion of additional items.
1 0.3 .3
Every applicable hold point inspection has been approved.
1 0.3 .4
All stage 1 or stage 2 assemblies included on the DCS as items have
their own approved DCS packages.
1 0.3 .5
The welder identified on every weld is properly qualified.
1 0.3 .6
The welding procedure used is applicable to the type of weld.
1 0.3 .7
All outstanding welding repairs are complete and properly corrected.
1 0.3 .8
All the documents listed in 1 0.2 above are included in the package.
1 1 . Documentation Requirement
1 1 .1 . CONTRACTOR shall provide COMPANY with the following documents :
1 1 .1 .1
1 1 .1 .2
1 1 .1 .3
1 1 .1 .4
1 1 .1 .5
Fabrication Procedures
Assembly Procedure
Quality Control Procedure
Material Test Certificates
All Welding Procedures Specifications and Procedures Qualification Test
Records
1 1 .1 .6
Individual Welder Identification Symbol
1 1 .1 .7
All Welder Qualification Certificates inclusive of back-up data
1 1 .1 .8
Weld Identification and Marking Scheme
1 1 .1 .9
All Non Destructive Test Procedures
1 1 .1 .1 0
All Non Destructive Testing Operators Qualification Certificates
1 1 .1 .1 1
Production Weld Test Reports inclusive of NDT Reports
1 1 .1 .1 2
Dimensional Survey Report
1 1 .1 .1 3
Pressure Test/Leak Test Report
1 1 .1 .1 4
Complete set of Document Control Sheet and back-up documents
1 1 .1 .1 5
A complete set of dimensional as built drawings
Page 8 of 1 0
PHE ONWJ Ltd.
1 1 .1 .1 6
Load out procedures and sea fastening arrangement
1 1 .2.
Document
Approval
CONTRACTOR shall submit for approval by COMPANY the following documents:
Approval Timing
Material Control
Procedures
Prior to any Construction
Fabrication Drawings
Fabrication Procedures
Assembly Procedures
Welding Procedures
Specifications together
with the area of their
application
Welding Procedure
Qualification Test
Records
21 days before use
Welding Consumables
Control Procedures
Individual Welder
Identification Symbol
NDT Personnel
Qualification
Certificates
24 hours before
commencing work
7 days before commencing
work
Welder Qualification
Certificates
24 hours before
commencing work
AFC and Bid Structural

Tonnage Comparisons
Prior to any Invoicing
Document Control
Sheets
Test certificates
for material
24 hour & before release
for Construction
Weld identification
and Marking Scheme
Prior to any construction
Painting Procedures
Prior to any construction
Load out Procedures and

21 days before load out
Sea Fastening details
Three copies of each of the above listed documents, shall be submitted to COMPANY
Authorized Representative at site.
Page 9 of 1 0
PHE ONWJ Ltd.
1 2.
Sample Document Control Sheet
RTAMINA HULU ENERG I Ltd .

Proj ect:
PE
Dcs#:
Shop Dra wing : ..
Item or
Dra wing
Hea t NBR or
Dimension
Surfa ce Prep.
Ta
g
#
or
Qty
Or
Desc
Mech
Test
NBR
Inspection
Inspection
I
Stag e " 0" Assembles
II
Stag e " 1 " & " 2" Assembles
Dcs Nbr
Appl Da te
Surfa ce Prep
Inspection
Prime C oat
Top Coa t
Dimension
F it - up
Weld Nbr.
Weld ed Nbr.
Procedure Nbr.
Visua l Inspection
Inspection
Weld Deta ils
Fit - up
Bolt- Up Deta ils

Dcs or Tag #
Dcs or Ta g #
Hydrotest
Lea k- Test
Inspection
App rova l
Inspector :
Chief
Da te:
Proj ect Engineer:
Analytical Data Worksheet
Prime Coa t
Top Coa t
Hydrotest
Inspection
Inspection
Inspection
Repa ir Required
NDT Report Nbr.
Yes or No
Da te:
Copy Atta ched
PHEONWJ GSPE01 01 Rev.0
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|DOCUMENTUM|8/18/2011|Paper Copies are Uncontrolled|

|DOCUMENTUM|8/18/2011|Paper Copies are Uncontrolled|

|DOCUMENTUM|8/18/2011|Paper Copies are Uncontrolled|

PHE ONWJ Ltd.

Structural and Piping Fabrication Quality Control

Revision Log Register

Structural and Piping Fabrication Quality Control

|DOCUMENTUM|8/18/2011|Paper Copies are Uncontrolled|

PHE ONWJ Ltd.

Structural and Piping Fabrication Quality Control

Revision Log Register ....................................................................................................................2

2.1 . Company Specification ...........................................................................................................4

2.2. International Standards and Codes.........................................................................................4

Hold Points (IHP)...................................................................................................5

1 0. Documentation Control Sheet Packages ...............................................................................7

Documentation Requirement .................................................................................................8

1 2. Sample Document Control Sheet1 0

|DOCUMENTUM|8/18/2011|Paper Copies are Uncontrolled|

PHE ONWJ Ltd.

Structural and Piping Fabrication Quality Control

and accurate measurements to be taken.

Specification for Package Skid-Mounted Equipment

Guidance on Platform Fabrication

Specification for Structural Welding

Piping Fabrication, Installation and Testing Specification

General Piping Design Specification

Piping Material Specification

Standards and Codes

American Institute for Steel Construction

American Iron & Steel Institute

American Petroleum Institute

American Society of Mechanical Engineers

American Society for Testing Materials

American Welding Society

Pertamina Hulu Energi (PHE) Offshore North West J ava Ltd.

procurement, construction, commissioning or management of a

project. The COMPANY may undertake all or part of the duties of

The party that supplies equipment and services to perform the

duties specified by the CONTRACTOR.

Approved For Construction

Document Control Sheet

Inspection Hold Point

Non Destructive Test

especially for the work delivered by inhouse/blanket CONTRACTOR. However, COMPANY

PHEONWJ GSPE01 01 Rev.0

|DOCUMENTUM|8/18/2011|Paper Copies are Uncontrolled|

PHE ONWJ Ltd.

Structural and Piping Fabrication Quality Control

at CONTRACTORs expense. COMPANY also reserves the right to require additional

COMPANY specifications and COMPANY standard drawings. CONTRACTOR is responsible

COMPANY Project Engineer.

CONTRACTORs expense no matter what the stage of the fabrication.

A Component part of a higher stage assembly.

as an anode, valve or flange. It includes only one item.

jacket bent fabrication, pipe spool erection.

1 Assemblies: A Document Control sheet (DCS) shall be initiated by

drawing, then a DCS must be prepared by CONTRACTOR for each stage 1

assembly. CONTRACTOR shall supply cutting plans/details or VENDOR drawings of all