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Document Title : INSPECTION & QUALITY CONTROL

PROCEDURE

Reference No : QC-001-KC

00 12 Jun 14 Issue for use PRSN PRSN IJ

Rev Issue Date Description Prepared Checked Appvd
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Revision Sheet

Revision Date Description of Change

1 12 Jun 14 Issue for use

CONTENTS
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Section Title Page

1.0 INTRODUCTION 2

2.0 SCOPE 2

3.0 RESPONSIBILITIES 5

4.0 PROCEDURE 5
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1.0 INTRODUCTION

The purpose of this procedure is to provide an overview for individuals involved in quality
assurance and quality control inspection for protective coating services. Many times
inspection is considered the primary quality control activity when in fact inspection is only one
part of the quality assurance and quality control process.

This procedure describes the Inspection and Quality Control ( QC ) activities to be performed
by PT. KARINDA CORPORINDO in this project.

Quality Assurance is all the planned and systematic actions necessary to provide adequate
confidence that a structure, system, or component will perform satisfactorily in service.

Quality Control is the physical portion of quality assurance which ensures that materials,
methods, workmanship, and the final product meet the specified requirement.

2.0 SCOPE

This procedure applies to the inspection and quality control ( QC ) process. The activities that
performed from pre job activity to post job activity.
2.1 Pre-Job Review
2.1.1 Contract and Specification Review
 Prior to beginning any job the contract, specification and all supporting
document shall be reviewed by Painter Engineer and Site Coordinator and all
person in charged who responsible for overseeing the job.
 Written acknowledgement of the specification, revisions, supporting
documents, and correspondence shall be provided.
 Ambiguous specifications and uncertainties and differences of opinion should
be documented in writing and maintained in the job file.

2.1.1 Quality Control and Inspector Requirements.

All person designated as inspector may be required to have sufficient
documentation or records available for :
 Formalized training or certification of the inspector.
 Experience in the type of structure to be inspected.
 Inspection equipment required by the job specification available to the
inspector
 Record of calibration for all inspection equipment used by the inspector.
 Standard and procedures required to show conformance to job
specifications are available to the inspector.
 Approved copies of material supplier technical data sheets, application
instructions, and Material Safety Data Sheets ( MSDS )
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2.2 Inspection Test Plan ( ITP )

A written inspection plan to show conformance to the specification may be required.
The inspection plan should list inspection hold or work-stoppage point that conform
to individual specification requirements or industry standard and procedures.
The following listed inspection hold points are considered basic for most work.
Additional inspection hold points may be added if necessary :
 Prior to the start of work
 Immediately prior to the coating application
 Following the application of each coat
 Following the curing of the coating
 Final inspection and sign off, in accordance with job specifications.

2.3 Document Control

2.3.1 QC Inspector shall have sufficient inspection forms and record to show
verification to the specification.
2.3.2 The frequency of recording and reporting all documented information shall be
determined and understood by the inspector prior to beginning the inspection
assignment.
2.3.3 Form shall have their own unique numbering system along with a filing system
for efficient control.

2.3 Daily Inspection Activities

2.3.1 Revision Log
 The revision log shall document the receipt of all revisions and change to
the specifications and inspection procedures.
 Issuance of all revised specifications shall be documented along with
verification that all persons involved in the inspection process are properly
informed of any changes.
 The removal of obsolete specifications and procedures shall be verified.
2.3.2 Calibration Verification
 Calibration of inspection equipment is usually performed by a qualified
individual using industry accepted standards and issuing a certification that
the equipment is properly calibrated.
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 The inspector in field can only verify that the equipment used to perform
inspections is calibrated according to industry accepted standards and
procedures.
Normally the following information is required to show verification :
 Equipment type and serial number
 Required frequency and calibration method
 Record of calibration data
 Signature and date of person performing calibration verification.

2.3.3 Daily Inspection Report

The inspection daily report is probably the single most important document. QC
Inspector shall record observations and measurement on the painting job
conditions as required, and note any hold point.
This may included the following :
 Weather and site conditions
 Pre-surface condition and cleanliness
 Surface preparation monitoring
 Post-surface preparation and monitoring of cleanliness and profile.
 Pre-application surface cleanliness
 Coating material preparation and application
 Physical film properties or appearance properties
 Dry film thickness measurement according to specifications.
 Verification of corrective action prior to final approval.
 Drawing, sketches, or photographs indicating where work occurred and to
document the cumulative work progress.
 Record of instruments used to obtain measurements and calibration
verification.
 Record of application equipment and workforce.

2.3.4 Non conformance and Corrective Action

 Deviations or non conformance from specifications and stop-work orders
shall be documented and corrective actions issued.
 Corrective action taken to resolve deviation from specifications and
procedure shall be approved prior restarting work.
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 Follows up on the corrective actions shall be verified prior to final approval.

 Any specifications issues that were resolved should be further documented
to show non conformance to the specification.

2.3.5 Photographic Record

 Photograph of the inspection work taken by the inspector shall be
documented in such a manner that pictures can be properly identified.
 A record showing location, area, and conditions along with corresponding
number of the photograph shall be noted.
 Undeveloped film shall be properly stored and labeled until the film is
developed.

2.4 Post Job Activities

2.4.1 RecordKeeping
 After completion of the inspection activities, verify that all required entries and
supporting notes have been made and are legible.
 Signatures and dates required in documentation shall be verified
 Furnish any photographs ( with date taken and other identification on back of
photo ) and other supplemental documentation.
 Deliver or retain all documentation as required by contract or specification.

2.4.2 Traceability
 Many times inspection record and documentation are required to be properly
stored for a set period of time.
 Completed inspection records and documentation shall be filed and organized
in a manner that makes them easily accessible.

3.0 RESPONSIBILITIES

3.1 It is the responsible of the Painter Engineer to ensure that the requirement of this
procedure are complied with.
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4.0 PROCEDURE

The following are quality assurance and quality control activities that will be performed by
PT. AGHATON MANDIRI in this project.
Those activities to be performed to ensure that both of pre job activity and post job activity
accepted by Client.

4.1 Abrasive Conductivity and Salt Test Procedure

4.1.1 Reference
 ISO 8502-6

4.1.2. Apparatus ( Instrument and Accessories )

 Conductivity Meter Horiba B-173
 Glass Beaker
 Bestle Patch
 Reuseable Syringe
 Distilled Water

4.1.3. Operating Procedure

 Place the latex and spongy foam perimeter on the blasted surface
 Insert syringe into patch through latex and spongy perimeter and inject
1.5
ml
of distilled water into patch. Do not remove from syringe.
 With syringe still in patch, position needle and evacuated any air in patch.
 Once air has been removed, inject remaining 1.5ml of water.
 Remove syringe from patch.
 Rub surface of patch gently from 10 to 15 second to allows water to
dissolve
surface contaminant.
 Insert syringe into patch through spongy foam perimeter and extract
solution
foam patch.
 Measure conductivity of solution using conductivity meter model Horiba
B-
173 determine the conductivity in μS/cm.
 After the test completed :
a. Record the temperature of solution.
b. Remove bestle patch from the surface and clean surface. If required,
any adhesive residues from bestle patch left on the surface can be
removed by wiping the surface with a cloth moistened with suitable
solvent. Ensure that the solvent not damage the surface before use.
c. Rinse all component of the test kit in fresh water. The component can
then be used again.

4.2. Determination of Dust Content on Blast Surface Procedure

4.2.1 Reference
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 ISO 8502-3

4.2.2. Apparatus
 Clean Pressure Tape ( minimum width 1” )
 White paper backing
 Magnifying glass 10X

4.2.3 Operating Procedure

 Check and record identity material i.e part number and size.
 Removed approx 200mm of clear tape from the roll
 Hold the tape at the end. Ensuring a sample length of approx 150 mm.
 Place the tape adhesive side down onto the surface.
 Using thumb, rub the surface of the tape firmly, ensure there are no air void
and the tape in both direction such that each stroke takes about 5 to 8
seconds.
 Remove the tape and place it onto the clear sheet of white paper.
 Examine the dust particle under magnification and determine the dust
quantity using factorial standard figure 1.
 Examine the dust particle and determine the predominant dust particle using
the table 1.
 Record value or dust assessment obtained.
 Test should be conducted at three location to given overall presentation
on the surface.

Class Description of Dust Particle

0 Particle are not visible under X10 magnification
1 Particles are not visible with normal vision but under X10
magnification
2 Particle just visible with normal vision
3 Particles clearly visible with normal vision
4 Particles between 0.5mm and 2.5mm in diameter
5 Particles higher than 2.5mm in diameter

4.3 Measurement of Surface Profile by Replica Tape

4.3.1. Reference
 ASTM – D4417C

4.3.2. Apparatus
 Test Tape Coarse and X-Coarse
 Anvil Micrometer

4.3.3. Operating Procedure

 Select the correct tape range for profile to be measured :
Coarse 0-2 mils ( 0-50 micron ) and X-coarse 1.5-4.5mils
( 40-115 micron ).
 Remove the wax paper backing and place the tape on blasted surface with
the foam side down, that is put the dull side down.
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 Hold the tape firmly on the surface and rub the circular cut-out portion (
approx 3/8 inch ( 6.55 mm ) diameter ) with brushing tool until a uniform
grey colour appear.
 Remove the tape and place it between the anvils of a spring-loaded
micrometer. Measure the thickness of the tape ( compressed foam and
non-compressible plastic firm combine ). Substract the thickness of the
non-compressible film to obtain the surface profile.
 Measure the profile at a sufficient number of locations to characterize the
surface. As specified of agreed upon between the interested parties. At
each location make three to five reading and determine the mean. Than
determine the mean for all location and it as the profile of the surface.

4.4 Measurement of Environmental Condition

4.4.1. Reference
 ASTM – Standard E

4.4.2. Apparatus
 Sling Hygrometer, Whirling Hygrometer
 Dew Point Calculator
 Surface Temperature Gauge

4.4.3. Operating Procedure

 Wet bulb wick must be clean. Saturate wick with water, keeping dry bulb.
 Whirl or operate fan until both thermometer stabilize ( approx 15-20 sec
).
 Repeat above seps until two or more wet bulb reading equal to the lowers
reading are obtained.
 Observe wet and dry temperature and determine relative humidity and
dew point temperature psychometric table, graphs or dew point
calculator.

4.5. Measurement of Wet Film Thickness Procedure

4.5.1 Reference
 ASTM D 4414-A
 ISO 2808-7B

4.5.2. Apparatus
 Elcometer 112,115,154 Wet Film Comb Gauge

4.5.3. Operating Procedure

 Apply the coating material to a rigid surface substrate and test with gauge
immediately. The gauge shall be touched as soon as coating applied.
 Push the gauge perpendicularly into the wet film hence the two tabs rest
firmly on the substrate at the same time.
 Remove the gauge from the film and examine as being between the
clearance of the shorter tab not wetted by the film.
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 Clean the gauge immediately after each reading by wiping it on dry or

solvent dampened cloth hence subsequent reading no effected. Do not
clean with metal scrapper.
 Determine the mean and range of the reading.

4.6. Measurement of Dry Film Thickness

4.6.1. Reference
 ISO 2808
 SSPC PA2

4.6.2. Apparatus
 Elcometer DFT 345 series and 456 series
 Minitest 600B and series

4.6.3. Operating Procedure

 Use the instrument that have been calibrated.
 Take a sufficient number of reading to characterize the sample.
 For structure not exceeding 30 sqm in area, each 10 sqm area shall be
measured.
 For structure not exceeding 100 sqm in area, three 10 sqm areas shall
be randomly selected and measured.
 For structure exceeding 100 sqm in area, the first 100 sqm shall be
measured as stated in above section and for each additional 100 sqm of
area or increment thereof, one 10 sqm area shall be randomly selected
and measured.
 Report the instrument used, serial number, and mean of the thickness
reading obtained.

4.7. Adhesion Test Procedure.

4.7.1 Reference
 ASTM Standard D 4541
 ASTM D 3359, Method A
 ISO 4624

4.7.2. Apparatus
 Elcometer 108 Hydraulic Adhesion Tester ( Range Full scale 0-25 Mpa
) c/w Detaching assembly, Loading fixture ( Dolly ), Circular Cutter,
Adhesion glue : Araldite Standard Epoxy Glue ).
 Knife and pressure sensitive tape.

4.7.3. Operating Procedure

 Degrease area of coating to be tested using a suitable degreaser and
grind the area completely flat using 120 grinding paper. Dedust carefully
with a piece of clean cloth.
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 Grind dolly contact surface completely clean, even and with full coverage
of grinding marks in same direction using the 120 grinding paper. Dedust
with a piece of clean cloth.
 Glue on dolly using cyanoacrylate or epoxy glue and let dry following the
supplier instruction for use.
 Cut around the dolly down to substrate using a hollow auger of suitable
size.
 Attach Pull-Off Tester and pull off the dolly at constant speed of approx
0.5 Mpa/sec.