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Total Sheet 22

DOCUMENT NO. REV

BLA-E-PR-00-000-THE-505 B

Vendor's name PT. TELEHOUSE ENGINEERING


COMPANY’s name PT. Medco E&P Malaka
Purchaser JGC Indonesia-Encona Consortium (JEC)
Plant Location Alur Siwah - Aceh
Project name Block A Gas Development Project
Purchase Order No. 0-0709-0-P-2181-008-A
Equipment/Material name PORTACAMP
Item number ALL
Document title Inspection & Test Procedure (FAT Procedure)

BLOCK-A Project (JOB No. : 0-0709-00-0000)

ISSUE PURPOSE: FA ( by Vendor )

RESULT CODE : A, B, C, D, E (by Purchaser)

NEXT STATUS : FI, FA, AC, AB, CN, NA (by Purchaser)

RESUBMISSION DATE : (by Purchaser)

RESPONSIBLE DEPT./PERSON : (by Purchaser)


ISSUANCE TO COMPANY
Review Date: FOR APPROVAL
(by Purchaser)
A : Approved
B : Approved with Minor Comment
C : Review/Comment
D : Reject and to be Resubmitted
E : Retained for Info Only
Approval or review hereunder shall not be construed to relieve Vendor /
Subcontractor of his responsibilities and liability under the Contract.

BLOCK-A GAS DEVELOPMENT PROJECT

CLASS 1 X CLASS 2 CLASS 3

VENDOR PURCHASER COMPANY


REV DATE PURPOSE TO PURCHASER
PREP'D CHECK'D APP'D CHECK'D APP'D APP'D

B Issued for Information RDW KSA NOV

A 01 March 2017 Issued for Information RDW KSA NOV

PURCHASE ORDER
ORIG. SERIAL REV.
NO.
PURCHASER
DOC. NO.
V- 2181-008-A- 505 B
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RECORD OF REVISION

REV NO SECTION PAGE NO. DESCRIPTION OF CHANGES

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TABLE OF CONTENT

Cover
Record of Revision…………………………………….……………………………………………… 1
Table of Content…………………………………….…………………………………………………… 2
1. Scope…………………………………….…………………………………………………………………… 3
2. Refferences…………………………………….……………………………………………………… 3
3. Procedure…………………………………….…………………………………………………………… 3
3.1. General Inspection Plan (GIP) and Inspection Testing 3
3.2. Inspection Refference Documents…………………………………….……… 3
3.3. Material Inspection & Testing…………………………………….…………… 3
3.4. Fabrication Process Inspection & Testing………………………… 4
3.4.1. Process Cutting, Punch/Drilling, Bending, Roll and Others 4
3.4.2. Assembly/ Welding Inspection and Testing…………………………… 4
3.4.3. Non Destructive Testing (NDT)…………………………………….………………… 4
3.5. Painting Inspection…………………………………….………………………………… 4-5
3.6. Final and Packing Inspection…………………………………….……………… 5
4. Attachment…………………………………….………………………………………………………… 5
4.1. Attachment-1 : Standard Tolerance Material…………………… 6-14
4.2. Attachment-2 : Standard Tolerance Visual Welding…… 14
4.3. Attachment-3 : Standard Method Inspection & Toleranc 15-22

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1. Scope
This procedure applies to any measurement and monitoring starting from the arrival of the goods /
material, during the process production and final product production process results

2. Refferences
Customer Specification

BLA-M-TS-00-020 SPECIFICATION FOR SITE AND UTILITY DESIGN DATA


BLA-Q-PR-00-205 QUALITY CONTROL REQUIREMENTS TO VENDOR
BLA-Q-PR-00-203 MATERIAL CERTIFICATION AND TRACEABILITY FOR EQUIPMENT AND MATERIALS
BLA-G-TS-00-101 SURFACE PREPARATION, PAINTING AND GALVANIZING SPECIFICATION
BLA-T-PR-00-009 Field Preservation Procedure and Special Storage Requirement

3. Procedure
3.1. General Inspection Plan (GIP) and Inspection Testing Plan (ITP)
a) General Inspection Plan (GIP) established as a general guideline in product quality control at every stage
of the production process. This procedure specification explain detail activity requirement and acceptance
criteria for each inspection commence
b) Inspection Testing Plan (ITP) established as a specific guideline in product quality control at every stage
of production process for this Project. And established based on product quality requirement specified
in Purchase Order, Project Requisition and its applicable specification document.
c) GIP applied when there is no specific requirement to establish ITP as basis Inspection & Testing.

3.2. Inspection Refference Documents


a) The following documents are used as a reference implementation of the inspection and testing as
well as a guide to quality conformance criteria:
- Engineering Drawing, List and Specification
- Relevant Standard / Code (Materials & Production Process)
- Approved Procedures / Specifications (by Client)
- General Inspection Plan / Inspection & Testing Plan
- WPS / PQR
- Welding Map & NDT Plan
b) Each refferences document for inspection shall be ensure they are legal documents and latest
revisions. Any document that has expired (revised) must be removed from the work area, to avoid
user mistakes.

3.3. Material Inspection & Testing


a) Receiving Inspection shall performed on every purchase of materials / goods, before being stored in the
warehouse, or used for fabrication, or delivery to Site.
b) The following check item shall be verified at each receiving, according to Purchase Order specification :
- Material Specifications (Spec / size / grade)
- Identification of the material (Spec / size / grade)
- Visual material, no defects such as cracks, porous, laminate and severe rust (heavy corrosion).
- Dimensions Material (including sweep / chamber, etc.), in accordance with the applicable standard tolerances.
- Test Certificates / Mill Certificate, in accordance with the identification and Heat / Lot number listed material.
c) Specification Material must be verified through identification (Label / Marking) contained in the surface material,
and the test certificate / Mill certificate.
d) Any steel material which is not proper identification and mill certificate shall be rejected.
e) Material certificate shall has conformance with the following :
- Describe clearly the result of Inspection/Testing for Material properties.
- Stated clearly the conformance to the Standard and/or purchase order specification.
- Certificate date within 3(three) year before Purchase Order Date.
- Signed by Authorized Quality Personnel from Manufacturer
- Stamped with “True Copy” (if as copy Certificate)
f) Visual and Dimensional Material must meet the tolerances specified in the Standard Material (ASTM / JIS / etc),
as specified in purchase order. See attachment-1 for Standard Tolerance Material.
g) Visual and Dimensional Inspection result shall be recorded in Receiving Inspection Report. Accompanying with
Mill certificate and Laboratory Test Report (if any).

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3.4. Fabrication Process Inspection & Testing


3.4.1. Process Cutting, Punch/Drilling, Bending, Roll and Others Machinning Inspection & Testing
a) Fabrication process shall be verifiy according to Inspection & Testing Plan (ITP), approved Fabrication
Procedure, and specified requirement for fabrication process.
b) Identification Mark on each material/members shall be verify according to Drawing and List.
c) Process Cutting, Punch/Drilling, Bending, Roll and Others Machinning shall be inspected for Visual 100%
and dimensional randomly.
d) Dimensional check shall be verifiy according to latest revison Drawing and ensured within specified standard
tolerances. See attachement-2 (Standard Tolerances for Shop Fabrication).
e) Actual Dimension for non Assembly Members shall be recorded in Dimensional Inspection Report.
3.4.2.Assembly/Welding Inspection and Testing
a) Welding shall performed in accordance with specified Drawing, Welding Map and WPS/PQR.
b) Each Assembly members ( id mark) shall be verified according to Shop Drawing during fit-up Assembly
for the following :
i. Member QTY, position and overall dimensional assembly
ii. Hole diameter, arrangement and dimensional position
iii. Surface edge material preparation for welding
iv. Cleanlines weld contact area from any dirt, rust, paint, oil, etc.
v. Bevel size, gap, angle, etc of each joint
vi. The adequate of the size and position Tack Weld.
c) Type and specification of welding consumable used must be ensured in accordance with specified WPS / PQR,
and in good condition, as per Welding Consumable Handling Procedure.
d) Welder / Welding operator shall be verified about their qualification for welding joint position.
e) Welding process shall be verified as per specified WPS/PQR and the weld size as per specified Shop Drawing.
f) After welding, the following shall be verified :
i. Weld profile and size
ii. Material and/or welding defect that can be detected visually.
iii. Welding cleanliness from any welding slag and spatter
iv. Any distortion on material that affect to Dimensional Assembly
v. Welder Identification mark
g) Weld size and visual tolerance shall comply with specified tolerance on attachement 3 Standard Tolerance
Visual Welding.
h) Actual Dimensional Assembly (after welding) shall be recorded in “Dimensional Report” and shall be ensured
within Tolerance specified tolerancce on attachement 2 Standard for Shop Fabrication
j) The result inspection before and after welding shall be recorded in Welding Inspection Report.
3.4.3. Non Destructive Testing (NDT)
a) NDT shall be perform after Visual Inspection passed, with the extent to :
i. 30% MT/PT of welding joint
iii. 100% UT/RT for Splice Joint
b) NDT shall be performed by 3rd Party and shall comply with approved NDE Procedure for method, equipment,
consumable and personnel qualification.
c) The result of NDT shall be record in appropriate NDE Report.
3.5 Painting Inspection
a) Qualification Test shall be performed for each specified coating system, before mass painting
b) Painting shall be verified according to approved Blasting & Painting Procedure and specified Paint Manufacturer
Recomendation.
c) Painting Condition shall be verified for the following :
- Weather : No rain, fog, mist and rain
- Environment and Surface material : not below 50F (10C).
- Relative Humidty (RH) : Not greater than 85%
- Metal to dew point temperatur different : Not less than 5F (-15C).
- No Impurity on Material that could not be removed properly with abbrasive Blasting process.
d) Compressed air shall be verified about Dryness, Pressure and any Impurities.
e) Abbrassive Material shall be verified about type, condition, dryness and any impurities.
f) Surface preparation shall be verified about surface roughness as per specified (SA 2 ½).

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3.5 Painting Inspection

g) Paint Materials shall be verified for the following:


- Manufacturer brand, Type, Color Code as per approved paint type.
- Shelf life : not expired / within valdity date
- Paint material condition : No gelling, skinnig, high viscosity, sedimentation, etc to alarge degree.
h) Mixing method & ratio shall be verified as per approved Blasting & Painting Procedure and Paint
Manufacturer Recomendation.
i) Wet fillm thickness shall be verified randomly during paint application as per Paint Manufacturer recomendation.
j) Dry Film thickness shall be verified after drying/curing time with the extent as per SSPCPA-2 end ensure as
per Paint Manufacturer Recomendation.
k) Visual Paint shall be verified during painting and after drying (Primer, Intermediate & Top Coat), for the follwoing :
- Paint Surface Appearance : No Defect such as Mottling, Sagging, Blistering,Cracking, Flaking, Peeling,Deposits,
Impurities, etc.
- Color Appearance : No different with with Color sample or Color specimen.
l) Adhesion Test shall be performed minimum 3 (three) time : Initial, mid and last term of painting schedule.
As per method specified in ASTM D4541 or ASTM D3359
m) Any defect on painting shall be repaired as specified in Blasting & painting procedure.
n) Painted material/members shall not be packing before curing time achieved as per Paint manufacturer
recommendation.
o) Inspection & Test method and result shall be ensured within specified tolerance in attachement 4 Standard
Inspection Methode and Tolerance Blasting & Painting, and recorded in Painting Inspection Report.

3.6. FINAL and PACKING INSPECTION


a) Final and Packing Inspection shall be performed after finish surface treatment (Galvanizing/Painting) and
during packing. The following shall be verified during Final & Packing Inspection :
- Identification Mark : as per Shop Drawing
- Quantity : completeness as per Shop Drawing & List
- Material & Surface condition : No Defect.
- Packing method and specification : as per Approved Packing Procedure
- Packing Identification (Shipping Mark) : as per Approved Packing Procedure
b) Any Punch List from previous process shall be closed before Packing.
c) Result of Final Inspection shall be recorded in Final Inspection Report
d) Result of Packing Inspection shall be recorded in Packing Inspection Report.
e) Inspection Release Certificate (IRC) will be released by Customer (JEC) after Final & Packing Inspection and
Punch List verified as satisfied.
4. ATTACHEMENT
a) Attachment-1 : Standard Tolerance Material
b) Attachment-2 : Standard Tolerance Visual Welding
c) Attachment-3 : Standard Method Inspection & Tolerance Painting

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4.1. Attachment-1 : Standard Tolerance Material


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