QUALITY PLAN

PROJECT : NPK CHEMICAL PROJECT 500.000 MTPY

OWNER : PT PUPUK ISKANDAR MUDA
CONTRACTOR : PT PP (PERSERO) TBK
DOC. NO. : NPK-000-Q3-PE-1L02-V
ISSUED FOR : APPROVAL
JOB NO. : 801921-NPK-J
LOCATION : KRUENG GEUKUEH, NORTH ACEH, INDONESIA

0 21/03/20 QA/QC IFA MR LF AH

CHK APR
DATE ISSUE ISSUE
REV PREPARE CHECKED APPROVED OWNER
ISSUED STAGE PURPOSE
APPROVED
THIS VOLUME EMBODIES PROPRIETARY INFORMATION OF PT. PP
PERSERO THIS VOLUME OF THE MATERIAL DESCRIBED THEREON MAY
NOT BE COPIED OR DISCLOSED IN ANY FORM OR MEDIUM TO THIRD
PARTIES, OR USED FOR OTHER THAN THE PURPOSE FOR WHICH IT HAS
BEEN PROVIDED, IN WHOLE OR IN PART IN ANY MANNER EXCEPT AS
EXPRESSLY PERMITTED BY PT. PP PERSERO.

Revision Historical Sheet

 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

Rev Issue Propose Initial Date Submission

0 Approval MR 21/03/2020
 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

COMMENT AND RESPONSE SHEET

No Owner Comment Name Contractor Response Name

& Title & Title
Page
 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

TABLE OF CONTENTS

1 INTRODUCTION ....................................................................................................................1

2 SCOPE....................................................................................................................................1

3 OBJECTIVE ............................................................................................................................1

4 REFERENCES .......................................................................................................................1

5 ORGANIZATION AND MANAGEMENT RESPONSIBILITIES................................................2

5.1 Organization ........................................................................................................................2

5.2 Responsibilities ....................................................................................................................2

6 PROJECT QUALITY MANAGEMEBT SYSTEM ....................................................................6

6.1 Engineering .....................................................................................................................8

6.1.1 Engineering Works ...........................................................................................6

6.1.2 Drawing and Specificatiobs Control .................................................................7

6.2 Procurement ....................................................................................................................8

6.2.1 material Receiving and site Control ..................................................................8

6.2.1 Material Traceability ..........................................................................................7

6.3 Contruction and Isntalation ..............................................................................................6

6.3.1 Stucture and Structure Instalation Process Control ..........................................6

6.3.2 Welding Process ...............................................................................................7

6.3.2.1 Welding Control .................................................................................7

6.3.2.2 Welding Procedure ............................................................................8

6.3.2.3 Welding Electrode .............................................................................9

6.3.2.4 Welding Qualification .........................................................................9

6.3.3 Dimensional Check .........................................................................................10

6.3.4 Inspection and Testing ....................................................................................10

6.3.5 Calibration of Measurement and Test Equipment ...........................................11

6.3.6 Non-Conformance and corection ....................................................................11

6.3.7 Handling, Storage, Packing, Pressurization and Delivery ...............................11

 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

7 INSPECTION AND TEST PLAN .......................................................................................11

8 MDR ......................................................................................................................................12

Attachment ...............................................................................................................................
 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

1. INTRODUCTION

The Following sections provide statement of procedures, which are

incorporated in Quality Assuranc program estabilished by PT. INVIROMTE

TECNOLOGY INTERNASIONAL with in its framework of fabrication of the ETI

Quality Assurance manual with Regard to material procurement, mateial receipt &

site control, fabriction, contruction, delivery and documentation control

2. SCOPE

The works covered by the Project Quality Plan are limited solely to the scope

of work as defined by the client specifications: FAbrication, Instalation, Maintenance

service

3. OBJECTIVE

ETI with the objective of ensuring high quality of works and meet client satisfactions,

therefore ETI Project Quality Plan is designed to give a high degree of effective & efficient

control over all its activities concering fabrication, instalation mantenance service.

Eti Quality Assurance Departement has been empowered to undertake the duty and

responsibility of establishing, implementing and monitoring the diverse quality control funct

aions at its workshop and site. This will ensure that equipment, Mateial and Associated

Sructures will be fabricated and installed in accordance with the client requirement,

speciifications and drawings with specified codes/standards practice.

4.REFERENCES

AWS = AMERICAN WELDING SOCIETY

ASTM = AMERICAN SOCIETY TESTING OF MATERIAL

 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

DIN = DEUTCHES INSTITUT FUR NORMUNG

WPS = WELD PROCEDURE SPECIFICATION

PQR = PROCEDURE QUALIFICATION REPORT

WQTR = WELDER QUALIFICATION TEST RECORD

N/A = NOT APPLICABLE

NCR = NON-CONFORMANCE REPORT

RFI = REQUEST FOR INFORMATION

MDR = MANUFACTURER’S DATA REPORT

NDT = NON-DESTRUCTIVE TESTING

PWHT = POST WELD HEAT TREATMENT

Proc. = PROCEDURE

RT = RADIOGRAPHY TEST

UT = ULTRASONIC TEST

PT = PENETRANT TEST

MT = MAGNETIC PART TEST

5. ORGANIZATION AND RESPONSIBILITIES

5.1 Organization

The QA/QC Departement will be report directly to the workshop manager /project

manager

5.2 responsibilities

The responsibilities and functions of QA/QC Departement as follow;

1) QA/QC Coordinator

 Monitor implementation of field inspection procedure;

 Coordinates with goverment (DISNAKER) and their Inspection Agency to perform

 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

their duties;

 Verifies inspection/ testing result, documentation and issues to client;

 To maintain QA/QC Plan and control of the implementation of QA/QC Plan;

 To coordinate all QA/QC inspection and certification process of the job including

personel assigment, scheduling,documentation and reporting;

 To liaise with client QA/QC Coordinator aand involveed Third Party in order to

assure all QA/QC activities are monitored, controled and implemented as

required by Specifications, Standard/ code and client requirement.

2) QC Inspector

 To carry out all QA/QC activities on for ensuring that quality activities and related

comply with Specifications, Standar/Code and client requirement.

 Conduct fabication quality control activities in accordance applicable

Specifications, Standar/Code and client requirement.

 The activities are receiviing material, marking, cutting, fit up, welding, NDT,

painting and delivery.

 Provide and compile all on -site QA/Qc dossier documents, traceability record,

NDT report or other documentation as applicable.

 To exercise and analyze ao Non-conformities of the material, part and products.

6. PROJECT QUALITY MANAGEMENT SYSTEM

6.1 Engineering

6.1.1 Engineering Works

ETI will ensure that its engineers are familiar with the project specifications

and have common understanding of terminology and philosophy.

ETI shall perform fabrication engeneerig work requird for the safe and
 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

effective manner, in sufficient depth and detail so as to facilitate and timely

execution and completion of the work

6.1.2 drawing and Specifications Control

ETI project engineer shall be responsible for reviewing and ensuring that all

design drawings comply with design requirerment, client Specifications and

standard/code. ETI project engineer will be responsible for maintaining the drawings

/ report indeks up-to-date. Each drawing will be signed by responsible draffman and

counter signed by engineering supervisor and shall be reviewed and approval by

engineering manager, before being issued to client for approval. Any problem or

change with detail design are required revision in approval layout plant or

specification requirements will be brought to the attetion of the client and shall e

Approved before any change / revision can be affected. Project Engineer of ETI and

client respresentative shall approve any revision of drawing. Revised portiona of the

drawing ret o properly indicates by means of “clouding” with proper revision

identification. A brief description of revision number and date will be included in

blocks below each drawing and signed by draffman discipline / engineer. All void

drawing will be discarted or clearly marked as much. Quality Control shall follow up

to assure all Engineering Instruction have been completed.

6.2 Procurement

6.2.1 Material Receiving and Site Control

All main materials and equipment that subject to inspect when arriving on site

will be placed in a specially assigned “Hold Area” pending inspection and

 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

acceptance. Material and equipment will be visually examined for comliance with

the Purchase orders, invoice, material requisition and for any possible damage

during transportation. This will ensure that only intended materials and equipment

that meet with the quality requirement are released for use in fabrication and / or

sent to site. Any materilas and or equipment rejected will be clearly tagged and

retained for follow -up action with vendor.

A system of identifying all raw materials received will be established to

ensure the they are properly market, documnted and controlled for its intended use

during fabrication. This system will involve the use of codet o paint-mark material

that have been released for fabrication use. Material receiving will be documntaed

on the Material Receiving & Inspection Report.

6.2.2 Material Traceability

A material test report ( or certification) shall be requested for all raw

materials. One copy of The certificate is to accompany the material at delivery. The

material inspector shall verify whether the required marking (i, e heat number, type.

Work order etc) on the material is legible and correct before the material is accepted

in to stock. Materials without proper documents / certifications will be returned to the

vendor.

All structure material that withdrawn from store / warwhouse will be marked

with its heat number prior to fabrication. When materials are being cut, the cutting

machine operator shall be transfer the heat number on to every off cut profie. The

heat number is recorded on to special material Traceability Drawings by QC

inspector reflecting the actual location of the material.

 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

6.3 Construction and Installation

Separate sect of procedures are defined in ETI are defined TIMAS Quality

Assurance Program for each distinct facet of ETI contruction works. They are

designed to achieve an overall acceptable standard that satisfies cleint

requirements and specified codes of practice. Quality Control activities will be

implemented for welding process, dimensional check, examination,testing and

inspection. Procedures for control of these processes will be established to

coordinator and monitor all aspects construction activity.

Contractor’s item and sub-contractors work shall not be accepted for

corporation in installation unless accompanied by relevant certification dossier, as

applicable, suitably enclosed and accepted by contractor, company the certifying

authority, as appropriate control of company supplied product material. Item and

services delivered will be storage yard depending on size, weight, grade and type.

6.3.1 Process Control

Period to development of process control document of the structure

fabrication and instalation QA/QC departement shaal develop the preliminary

seqyencing of production process, inspection examination to ensure conformance

of the item tothe requirement of the applicable code and the contract specification.

Contruction Superintendent shall prepare installation manual, which specifies

production and inspection method, profesional execution, working sequence, suitable

production, installation and servicing equipment and possible special enviromental

 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

requrement and supposed to be prepared and approved by the customer if necessary at the

right time.

All necassary technical documention shall be available at that place and time activity

in question is to be carried out. In addition, detailed working instuction shall be prepared

period to starting the work in question. Client as per contract specification shall approve all

procedures that constitute part of installation procedure. All the special procedures shall be

prepared and incorporateed into the document deliverable list.

6.3.2 Welding Process

6.3.2.1 Welding Control

All welding process shall be performated by qualified and certified

welders with refer to approved and qualified WPS ( Welding procedures

Specification) and PQR ( Procedure Qualification Record). The qA/QC

Departement will be responsible for establishing the welding procdure

specification and execution of welding procedure qualification test and

prepare the welding procedure qualification record, welder qualification test,

and ensuring that only proper welding materials are utilizeed.

It will also be responsible for witnessing qualification welding,

monitoring production welding and performing examination and test of welds.

When there is doubt as to the ability of welders, pre-qualification will also be

carried out.

The QC/QA Depertement will maintain anu p to date list of all qualified

welders and operator giving welders name, identifiction number, welding

process qualified for and date qualified. The QA/QC Departement will ensure
 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

that the welding electrodes are properl stored and that suffucient care is

exercied by site personel to maintain intergrity of welding comsumable prior

to use.

6.3.2.2 Welding Procedure

Prior to commencing production welding, ETI shall establish detailed

welding procedure Specification (WPS) for welding the various parts of the

piping & structure as per connection detail of the drawing, material to be used

and welding process in accordance with Guidence on Industry Standard

Piping & Structure welding and approved.

Standard it may provide direction to welder to assure compliance with

code requirement. The construction Code used for refernce can be obtained

from the Client Specification and / or the fabrication drawings.

Essential variables are those in which a change, as describe in the

specified variables, is considered to affect mechannical properties of the

weldment, and shall require re qualification of the WPS. Supplementary

variables are thosein which when nocth toughness is required become

esential and shall require re qualification of the WPS.

Non essential variable are those in which a change, as describe in the

specified variable, may be made in the WPS without re-qualification. The

welding Procedure specification shall be reviewedby client and approved/

certified( if qualification i acceptable) by DISNAKER prior to start of

production welding for each particular joint to be used. For welding procedure

qualification, the following information shall be included;

 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

1. The scope of work performed under each procedure,

2. The base metal,applicable specification and relevant charateristic

(mechanical properties and chemical composition)

3. The welding process and equipment

4. Type, size and classification of welding electodes or filler metal

5. Type of current, current charateristics and current range

6. Applicable welding position

7. Weld type and size

8. Root preperation prior to welding from second side

9. Weldinig sequences performed to control shrinkage, exessive distortion

and residual stress

10. Repair welding precedure.

11. Welding progession.

6.3.2.3 Welding Electrode

All welding consumables, and their storage or drying conditions shall cnform

to its manufacturer procedures or applicable code/standard for the relevant welding

consumable

 Electrodes used shall conform to those specified in AWS standar dor

other applicable code/satndard.

 When the base metals of two different yield stress are welded

together, filler metal shall be selected based on the base which has

the higher yield stress.

6.3.2.4 Welder Qualification

 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

All welders and welding operators shall be qualified bytest as

prescribed in standard/codet o be used. No un-qualified personel shall

be accepted to perform the work. Record of the test result and

certificates of qualification of personel shall be made available to client

or client respresentative upon request to examine them.

6.3.3 Dimensional Check

The QC team will be responsible for ensuring that dimensional check

are carried out in a proper manner to ensure acceptable tolerances in

accordance with the specification, applicable codes and drawing. This will

involve checking for straightness and flatness of contruction materials prior to

use, proper lining-up of srtuctural component and aligment during and after

welding and final inspection for dimensions and lelveling after completion.

6.3.4 Inspection and Testing

Examination, inspection and testing will be performed as necessary

prior to assembly, during and after assembly to ensure that materials and

workmanship meet project requirement. They will be controled using process

control diagram and check list.

The Engineeering Departement will be responsible for preparation of

the inspction and procedures as per contract and applicable codes and the

QA/QC Departement will be responsible for the examination an test result.

Personel engaged in NDT will properly Qualified to ASNT level II will be well

versed with the project specifications equipment and NDT procedures.

 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

For NDT, a comprehensive set of procedures and schedule will be

established concerning Penetrant Test And ULtrasonic testing outline

methods,equipment and materials to be used. Similiar procedures will be

testing.

6.3.5 non-Conformance and Corective action

Measurement will be established to identify and non-conformities,

which are defects or deviation from project specifications and approved

procedures. All nonconformance materials, part, and products will be

identified, properly tagged as “reject” segregateed and disposed in according

to qualified procedures. The Qc team will maintain a record of all non-

conformances. The NCR Register to be develop to monitor find out ist

solution and monitor the status of replacement of repair.

6.3.6 handling, Storage, Packing & Delivery

The handling, storage and delivery of item identified on the activity

shall be controlled in accordance with material control procedures established

and implemented by ETI

7. INSPECTION AND TEST PLAN (ITP)

Most activities contributing to the performance to the performance of the

contract shall be subject to inspection and test to verify theur conformity to the

contract specification, and applicable Rules, Standard and Codes as well as

contractor procedures
 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

Inspection record shall be generated,maintained, document and collated by

ETI. The system employed shall insure full traceability of record including back up in

accordance to client specifications and requirements. ETI aas a contractor shall

submit the original of all inspection data’s and other related document to client, as

required in the contract terms.

Inspection And Test Plan (ITP) will be presented as matrix of the inspection

actifities to be carried out by contractor/vendors and monitored/verified by client/third

party to cover the contractual scope of work. Detailed inspection and test plan

indicating inspection level (spot withness, verify, review, withness, hold point,

monitor, etc) ETI shall also prepare check sheets and inspection report for carrying

out the required quality control check according to particular discipline work actifities

All inspection and test eports shall be specific to the actifity and items which are to

be inspected.

8. MDR (manufacturer Data Report)

The MDR of site shall be complied at site as the field construction is

progresing. The completed site MDR shall be submited to the client. As minimum,

the following inspection records shall be included in the MDR of site portion.

1. Completion / Acceptance Release Certificate

2. Manufacturing data

3. Inspection & test plan

4. Material list & material certificate

5. WPS/PQR & welder certificate

6. NDT plan

7. Summary welding record

 QUALITY PLAN

DOC.NO REV PAGES

NPK-000-Q3-PE-1L02-V 0 1 of 10

8. NDT report

9. NDT personel & equipment certificate/calibration

10. Sandbalsting and panting report

11. Paint material certificate & dry film thickness (DFT) certificate/Calibration

12. As built drawing