QUALITY CONTROL

MANUAL
1.1 QUALITY POLICY STATEMENT

The management of COMPANY, hereby formally express its

intentions and direct that is committed to the following business
quality objectives.

- Provide quality work and services to specify, contractual and

regulatory requirements.

- Provide safe and secure working environment for employees.

- Maintain company corporate image, and reputation.

- Conduct business with honesty, integrity and efficiency.

- Achieve business success with continuing expansion.

- Minimize losses due to lack of quality on the basis of “get it right first
time”.

The management gives full support to all employees to carryout their

duties with defined authority and responsibility, thereby to achieve the
business quality objectives to the benefit of customers, employees and
company.
A) TOGETHER SUPPORTING OUR CONSTRUCTIONS WORKS

Our Common purpose is to serve our established clients in the

CONSTRUCTION Business. Our specific skills and experiences could
satisfy the need for the quality and safety.

B) SUPPPORTING CONSTRUCTION INDUSTRY

Our work team could deliver and satisfy every stage of a Project Work
from the design to final commissioning with competitive cost and to
control Unsafe Acts.

C) GROUP SPIRIT

Our teamwork contributes to our growth and develops diversification in

Business . It helps establishing the credibility of our Values.

D) INDEPENDENCE

We offer good services according to legitimacy of codes at Standard

Practices.
1.0 QC COORDINATOR PROCEDURE

1.1 Upon award of contrast, QA/QC manager would request the Project
Manager to arrange Inspection Coordination meeting with the client’s
QA/QC representative (s).

1.2 The purpose of the meeting is to establish a complete understanding of the

QC Inspection requirements and QA/QC procedures for the specific
project.

1.3 The meeting is to resolve questions involving compliance with client’s

order specifications.

1.4 The coordination procedure meeting with client’s QC personnel is to

familiarize client’s Basic Practices Procedures involving Design
Engineering, applicable codes and standards, Inspection Release Notices
and rejection Notices, waive inspections procedures and other related
fabrication procedures.

1.5 This Coordination Procedure is also to update information on revised

Engineering Dwgs and specifications in relation to QA/QC fields of work
requirement.

1.6 The Quality Control Coordination flow chart is shown in figure (i).
 Figure (i)

QC COORDINATION PROCEDURE

USE PROJECT
MANAGER

QA/QC
DEPARTMENT CLIENT’S PROJECT
TEAM + QA/QC DEPT

QC SCOPES OF WORK

- PRE-INPECTION MEETING
- CONTRACT DOCUMENTS
- ENGINEERING
- ERECTION & FABRICATION

DOCUMENTS

- QC LOGS, RECORD
- RELEASE AND REJECTION
NOTICED
- AUDITS
1.0 QC ROUTINE INSPECTION

1.1 The enclosed format of Routine Inspection shows how QC personnel will
carry out their functions, from where the Dept. gets the information. The
routine function does provide information about cooperation with other
department and the sequence in which the activities performed.

1.2 The QC will carry out inspection at stages of work site constructions /
erection and registered QC formats will be filled in and dates of inspection
performed

- Dimensional Inspection
- Visual Inspection (Ready for Welding )
- Verification of weld procedures
- Marking of welds
- Root-pass
- Back-gouging
- Drawing weld numbers
- Materials documents
- Pressure testing
- Clearing/ flushing
- NDT Reports
- Stress Relieving
- Final Acceptance / Signing

1.3 Certain activities are performed by the production supervisor / Foreman

during fabrications and subsequently entered the results in the QC register
sheets.
QUALITY ASSURANCE FUNCTION

QA MANAGER RESPONSIBILITIES

1) Review And Update QA/QC

Manuals
2) Engineering Standard System
3) Audit System on QC Check Lists
4) Quality of Certification System
5) Auditing Sub-Contractors/Vendors

QA/QC MANAGER RESPONSIBILITIES

1) Management And Control of

Welding System.
2) Management of Welders
Qualifications
3) Material Identifications System
4) Production Control System for
Erection Fabrication.

-
QC INSPECTION RESPONSIBILITIES

1) Inspection and Acceptance of

Incoming Materials
2) Documentation of Inspections Tests
3) Calibration of Measuring Oil Test
Equipments.
4) Material Flow For Fabrication and
Trace ability
5) NDT Examination, client and USE
QC.
6) QC Progress Plan.
ENGINEERING OFFICE

- Fabrication Work out

- Structure Welding Procedure
- Pipes And Program
- Weld No. Welders ID
- Weld Proc No.

PLANNER QC DEPT
- Detailed Plans Plan according to Client.
- Work Order Spec.

PRODUCTION DEPT. QC DEPT.

- Prod. Plans Plans the Inspection

- Drawings Programs
- Work Description
- Spec. / Codes

Correction to be provided QC provided Details Corrective

Action / Plans

Final Control

- Reporting
- Registration
- Signing

Fillings Documentation
 SCOPE

1.1 This standard covers the mandatory requirements for making metallic
materials normally used at Owner’s Plant to permit positive material
identification in the Store House, Shop and field.

1.2 The color-coding portion of this standard does not apply to:-

a) Miscellaneous machinery repair parts.

b) Materials not covered by the Color chart (Table 1); they must be
identified by the other two marking methods.
 MARKING REQUIREMENTS

2.1 The marking requirements described herein shall be applied by the

supplier (manufacturer or vendor) and are in addition to the usual marking
applied by the supplier (i.e. markings required by the ASTM, API, ANSI,
MSS and other which the materials are manufactured).

2.2 In general, each piece of material can have three types of markings :-

a) Mechanically applied characters indicating Material Type Symbol.

b) Painted characters indicating Material Type Symbol
c) Painted Color Code stripe(s).

2.3 The manufacture’s standard mechanical marking method will be

acceptable for that portion of this requirement if it result durable , legible
identification and contains at least the information required by this
standard. For example spelling out “Monel” instead of “MONL”, using
“ASTM TP 316” instead of only “316”, or including other data such as
heat treatment, weld method, or pressure rating is acceptable.

2.4 A single color system shall be used. Color Code stripe(s) shall comply
with Table 1.

2.5 Paint used for identification shall be durable and of distinctive identifying
colors. Color-coding of material shall be by use of a marker equal to Metal
Marker, as manufactured by the John P. Nissen, Jr., Company, Glenside,
Pennsyivania. Paints containing sulfur, led, or other metals are not
acceptable

2.6 Surfaces to be color-coded shall be cleaned and free of dirt, loose scale
and oil.

2.7 A magnet can be used to verify strongly magnetic or non-magnetic

materials.
CAUTION: Monel and stainless steel castings are slightly magnetic.
 APPLICATION OF MARKINGS

3.1 Pipe, Fittings. Shapes, Tube and Bar – Stripe entire length as shown in
Figure 1, Boxes or bundles of tubing or bar 1-inch or smaller may be color
coded by striping the box or binding straps.

3.2 Flanges – Stripe across edge up to hub as shown in Figure 2

3.3 Plate, Sheet and Strip – Stripe along any two edges or on surface near
edge for entire length as shown in Figure 3

3.4 Valves—Stripe across body from flange as shown in Figure 4

3.5 Bolting Materials – Stripe around midpoint or length (optional, if stamped

 POSITIVE MATERIALS
IDENTIFICTION

DEFINITIONS

4.1 The term inspector, as used in this standard, refers to the Owner’s
representative.

4.2 Positive Materials Identification is a procedure used to assure that

specified metallic alloy materials for use in the refineries, chemical plants,
and other facilities are properly identified as to their true elemental
composition and are marked according to specific industry standards N
Owner’s procedures.

4.3 An inspection lot is a group of components from the same heat number
from which a sample is drawn.

4.4 A representative sample consists of one or more units (pieces) selected at

random from the inspection lot, which will be examined to determine
acceptability of the inspection lot.
 GENERAL REQUIREMENTS
5.1 When PMI is specified by the Purchaser, the fabricator or vendor shall
provide a PMI program to comply with the requirements of this standard.

5.2 Records of PMI results shall be kept by the vendor or fabricator from a
period of one (1) vear for audit by the Owner. For fabricated equipment,
these records shall include and itemized listing of all components and
weldments on the form provided (Table 2) on its equivalent. Tabulation of
tested items must be keyed to as-built drawings and Mill Certification
Document Stamping through the use of reference numbers. One (1) copy
of test results shall be provided to Owner’s Engineer as part of the as-built
documents.

5.3 All materials purchased with PMI required shall be analyzed for chemical
composition using an acceptable method as defined in this standard. Test
result must conform to purchase documents, be properly identified to the
applicable specifications such as ASME, ASTM and color coded as
required by EXES 18-9-1-1B when specified.

5.4 A chemical analysis test shall be made on each component (100 percent )
PMI inspection, unless specifically exempted by the Owner’s Inspector
when Owner’s Inspector authorizes random inspection, failure of any
representative sample in an inspection lot rejects all components identified
as being part of that lot by heat number until 100 percent PMI has proven
each item’s chemical composition.

5.5 If inconsistencies occur between analyzer test results and Mill

Certification analysis, samples shall be tested by an Owner-approved
analytical laboratory.

5.6 After acceptance, all pieces shall be immediately marked. As described

below and segregated from materials, markings must be permanent and
readily visible. These markings are in addition to markings required by
other codes.

a) Each piece shall be marked with the “PMI” code letters using a
 Owner’s Inspector. The Owner’s Inspector shall approve the steel
stamp. In addition the PMI code letters shall be highlighted by a
small spot of green paint, and must remain readily visible during
fabrication and erection, until final protective coatings are applied.

b) Piping and heat exchange tubing shall be marked with the “PMI”
code letters near each end when length exceeds 10 feet. Less than
10 feet one marking is acceptable..

c) When specified, each piece shall be used (an “Alloy Identification

Stamp list” will be furnished by the Owner).

d) When a section or piece of material is used, additional markings

shall be applied as necessary to assure that both the piece used and
the piece remaining shall be marked as described above.

5.7 Controls shall be established to prevent the inadvertent use of untested

material or materials not passing PMI examinations

5.8 Any component of a fabricated assembly that has not been marked with
the ‘PMI” code shall be rejected by the owner’s Inspector if the
component’ chemical composition cannot be determined in its fabricated
location.
 SAMPLING PROCEDURES

6.1 Testing shall be done per the procedures outlined by the manufacturer of
the portable alloy analyzer or alloy sorter being used. The Owner’s
Inspector must approve modification of these procedures. Each analyzer
must be calibrated using known alloy standards.

6.2 One hundred percent PMI inspections per Paragraph 5.4 are required.
Random sampling shall only be acceptable when approved by the Owner’s
Inspector and 100 percent inspection of all remaining components is done
using approved (per Paragraph 7.4b) see back effect alloy sorting
equipment.

6.3 If random testing for alloy chemical composition is approved, the items
tested shall provide a representative sample of the inspection lot. The
representative sample shall be 100 percent for lots of five units or less. For
lots greater five units, the greatest of five units or 5 percent shall be
analyzed.
 ACCEPTABLE METHODS FOR PMI

7.1 Positive verifying the percent of ASTM will make Materials

Identification, ASME code specified elements present in the materials.
The Owner’s Inspector may approve analysis for major alloy elements
only. Specific elements to be analyzed for each material specification shall
be submitted to the Owner’s Inspector per Paragraph 5.1. Instruments used
shall have the sensitivity to detect the alloy elements in the specified
ranges.

7.2 Instruments or methods used for examination shall be of the type that will
provide quantitative, record able, elemental composition results for
positive identification of the alloy elements present.

7.3 The person(s) performing the PMI shall be knowledgeable about all
aspects of the operation. Qualifications of the tester, including training and
experience, shall be included in the PMI program required by paragraph
5.1.

7.4 Acceptable methods are listed below:-

a) Portable x-ray emission analyzers. Use of this type of equipment is

limited to the following instruments unless the Owner’s Inspector
gives prior approval.

“Texas nuclear Alloy Analyzer 9200 or 9255”

“Pitch ford Port spec.”

“Panametrics Panalyzer.”

“Columbia Scientific X-met 840

b) Owner-approved materials analytical laboratories using X-ray

emission spectrometry, optical spectroscopy, or wet chemical
analysis. These methods can be used for verification in cases
where results obtained with testing differ from Mill Certification
data.
7.5 A certificate offered by a vendor for chemical analysis previous done will
be accepted at the Owner’s Inspector discretion only when the Inspector or
witnessed the samples taken and the test was performed by a third party
Owner-approved materials analytical laboratory.

7.6 Chemical pot testing (qualitative, not quantitative) and other methods
using eddy current triboelectric testing, such as perimeter and
thermoelectric tests, are not acceptable unless specifically approved by the
Owner’s Inspector, and then only other quantitative methods are not
possible.
 TABLE 1
COLOR CODE FOR METAL
IDENTIFICATION

SINGLE STRIPE DOUBLE OR BROKEN STRIPE

MAGNETIC METALS COLOR NON-MAGNETIC METALS

Plain Carbon Steel None Aluminium - All Grades

Carbon Steel for Low Yellow Type 304 (18 Cr – 8 Ni)

Temperature Service (Below
–20F)

Carbon-Molly Steel White Type 316 (16 Cr – 10 Ni – 3 Mo)

AISI 4140 Steel Red Alloy 20 (20 Cr – 29 Ni)

1-¼ Cr – ½ Mo, Steel, Gray Red Brass (85 Cu – 15 Zn)

B-16 Studs

2- ¼ Cr – 1 Mo, Steel Orange In colony 800 ( 20 Cr – 32 Ni)

R.A 330
(19 Cr – 35 Ni – 1- ¼ Si)

5 Cr – ½ Mo Steel Green Type 316-L, Low Carbon

(18 Cr – 8 Ni)

9 Cr – 1 Mo Steel Purple Type 316-L, Low Carbon

(16 Cr – 10 Ni – 3 Mo)

12 Cr – 1 Mo, Steel, Black Hastelloy “B” (65 Ni – 30 Mo)

Type 4105, 405

17 Cr Steel ,Type 430 Pink Inconel 600 (72 Ni – 15 Cr )

3-12 Ni Steel Blue Monel ( 67 Ni – 30 Cu )

Ductile, Nodular Iron Brown Hastelloy “C”

(60 Ni – 15 Cr – 17 Mo)
 TABLE 2

POSITIVE MATERIALS IDENTIFICATION

DATA SHEET

Fabricator : Date of Inspection:

Job title : Inspection Agency :

Exxon Purchase Order: PMI Equipment :

Job Number : Operators :

Alloy Content, Percent

Specification Min.
Range Max.
Component
 TABLE II

COLOR CODE FOR RTJ

RING GASKETS IDENTIFICATION

RTJ, RING COLOR SPIRAL WOUND COLOR

Class Yellow Class Stripe

ANSI 600 ANSI 150 Yellow

Class Red Class Stripe

ANSI 900 ANSI 300 Red

Class Blue Class Stripe

ANSI 1500 ANSI 600 Blue

* For testing * Brown * For testing

Note : * Segregate
 WELDER QUALIFICATION TEST GUIDELINES

1.0 General

These Welder Qualification Test (WQT) Guidelines shall be followed in

all performance qualification tests of welders and welding operators. This
procedure is designed to determine the following :

- Welders / Welding Operators ability to deposit sound weld layers /

passes while following specific instructions contained within a
qualified WPS.

- Welders / Welding Operators ability to procedure sound weld in

specified position(s) using specified welding consumables.

Test booth with an approximate square area of 3.7m (12”) x 3.7m (12”) is
prepared to accommodate a maximum of three welders for testing in a
staggered system, i.e. first welder shall deposit he root pass and prepare it

2.0 USE shall designate an experienced knowledge competent and responsible

inspector who shall coordinate and supervise the test operations until
completion.

3.0 USE shall use radiography or ultrasonic (if it is impractical to use

radiography ) as the test method after test specimens have passed visual
inspection. However, the use of mechanical test shall be adopted if NDT is
not available.
4.0 Steps to be followed in conducting WQT :-

4.1 Ensure that Page one of approved WPS is carefully reviewed to

determine : -

- Code, which governs welders test

- Process (es) of welding to be used.

- Type of base metal if welder qualification test will be

subjected to mechanical testing.

- Specification and classification of welding consumables

required.

- Preheat required.

- Interpass temperature (Max) 220ºC

4.2 Review the appropriate procedure chart containing the details for
welding the thickness of the material. Ensure that the test specimen
is in accordance with the relevant procedure chart. Check the
heading of the procedure chart to be sure the appropriate chart is
used relation to the test position in which the welder(s) are to be
tested i.e. 1G, 2G, 3G, 4G, 5G, or 6G inclined.

Ensure the following:-

- Number of weld layers

- Filler metal classification and maker

- Filler metal diameter for a given weld layer

- Technique for depositing root pass and subsequent weld

passes, i.e. string, weave, split-layer or combination weave
and split layer.
 - Check welding equipment are calibrated and are with
correct electrical current, i.e. AC or DC (determine correct
polarity setting, i.e. straight polarity (-negative) or reverse
polarity (+ positive)

- Check amperage and voltage settings required

- Check the weld metal layer thickness intended for each

layer of weld.

- The procedure chart shows the minimum and maximum

number of weld passes which may be used to complete the
weld. By adding up the numbers in “weld passes per layer”
column you can see the total number of weld passes that
the welder should make the complete his test.

- Check travel speed specified for each electrode diameter.

4.3 Ensure that each welder to be tested is made aware of what he will be
tested with respect to specific details of the governing code and an
approved WPS.

4.4 Prior to giving clearance to prepare and/ or fit-up test materials the
following shall be determined :-

- Correct plate thickness or pipe diameter / wall thickness.

- Edge preparation of the material shall be as specified in the WQT

form
 If the above are satisfactory, check the following prior to final approval to
fit-up test pieces :-

- Ventilation i.e. provision made for exhausting welding fumes &

smoke.

- Safety of the test are and surrounding area from flammable /

smoke explosive materials.

- Adequate lighting for welds cleaning and visual inspection.

- Welders are to use appropriate range for welding, grinding or

chipping.

- Welding machine must have appropriate range for specified

current i.e. AC and DC and the polarity indicator set to the
requirement.

- Ground cable must be firmly attached to the work bench or stand.

4.5 After the requirement of step 4.4 has been followed and client
Representatives has given approval, the following must be done :-

- Ensure that test piece is at correct position

- Check that test piece is appropriately steel die stamped to indicate

the top of pipe and steel die stamped to indicate flat vertical,
horizontal or overhead when plate is used for testing.
4.6 The following shall be determined / verified during welding :-

- Correct welding current, i.e. amperage - voltage

- Travel speed

- Direction of travel for vertical welds progression.

- Ensure correct welding consumable diameter for each layer of

weld being used at specified flow rate, welding wire “stick out”,
cup size etc. if applicable.

- Use of specified technique in depositing weld i.e. string, weave,

split layer.

The following shall be determined upon completion of each layer of weld

deposited and shall continue until completion of the test.

- Average thickness of weld layer

- Approximate width of welds passes.

- Number of weld passes per layer.

- Cleaning of welds shall be done by power wire brush only.

After welding the acceptance of the following shall be determined :-

- Weld size

- Weld profile (height of reinforcement, width of weld, surface

irregularity)

- Convexity / concavity

- Sufficient throat for fillets.

 - Surface pinholes, craters, crater cracks.

- Root penetration.

- Start / Stop area defects

- Stray arcs outside the welding groove.

- Damage due to incorrect removal of temporary attachments.

- Distortion warpage.

4.7 Fill in the welder test WQT form after verification and recording of details
in step 5.

4.8 Compare records with the specified details of the WPS and those of the
client representative. If details of test weld reveal that qualification test
welding parameters do not comply with welding procedure specification
and applicable code or client requirements the welder shall be rejected.

If test weld parameters are within the ranges and tolerances of the
approved procedure and client representative has given visual acceptance
of the finished test piece the following shall be executed with the approval
of the Owner’s representative.

- Perform Nom-destructive testing or mechanical tests of the

specimen to determine weld soundness

- If radiography is used, ensure that test film is acceptable quality,

i.e. density, image sharpness, penetrameter, welders name or ID
number, film position zero (0) is top of test pipe and test position
too will be recorded on the film.

- Check each detail of radiographic or ultrasonic report to ensure

completeness and accuracy. The NDT report shall list the names
and ID number of each welders test examined whether he passes or
fails.
 - Acceptability or reject ability of NDT on the basis of strict
interpretation of governing code rules, all borderline interpretations
are considered failure.

- The client representative shall submit welder qualification test film

to client along with signed welders qualification certificate.

- If test specimens are subjected to mechanical testing, removal of

test specimens must be as specified by code designated area of test
the weld. The lay out shall be steel die stamped to indicate type of
test required, i.e. T for Tensile, R for Root bends F for bends and S
for side bends.

Only after steel die stamping may the specimens be cut from the test piece.
The identification stamped shall remain identifiable through-out specimen
preparation and testing.

4.9 Transfer all pertinent data on the WQT form using typewriter or by hand
using black ink and ensuring legibility. Have these sheets signed and dated
on the spaces provided for by all interested parties and a legible copy
given to client representative.

NOTE : USE representative must ensure that all data entered on the welding
qualification record are factual. Thus, it is imperative and requires that
your signature be legible above your printed name. Be sure that all
relevant form are completed and properly signed by owners representative.
 WELDING REPAIR PROCEDURE

GENERAL

- The following shall be considered as minimum requirements for the repair

of welds judged to be unacceptable under governing code, standard or
client Welding Specifications.

- A maximum of two (2) attempts may be made to effect an acceptable

repair of a weld defect in the same area when replacement of weld by
fusion welding.

- Any attempts beyond two repairs shall require client approval. A written
request shall provide all particulars necessary for client to evaluate
conditions to support AYE’S reasoning that additional attempts beyond
two are reasonable, practical and tempered with good engineering
judgment.

- Acceptance or rejection of repair welds shall be made on the basis of

testing as required by this specification on project materials and not on the
basis of test results obtained by AYE from qualification of a stimulated
weld repair procedures.
 CLASSIFICATION OF WELD DEFECTS

MAJOR DEFECTS: -

Weld defects which are revealed by Radiography or by Ultrasonic and are

determined to be sub-surface and not detectable by other non-destructive test
methods are requires welding to effect and acceptable repair.

MINOR DEFECTS : -

Weld defects which are revealed by Magnetic Partide, Dye Penetrant or visual
Examination and are judged to be surface imperfections, which can be rectified
without welding to affect an acceptable repair.
 WELDING REPAIR PROCEDURE

MAJOR DEFECTS : -

- The repair of major weld defects shall be accomplished in a planned,

coordinated manner and shall be executed in accordance with an client
approved weld repair procedure utilizing client approved WPS.

- The weld repair procedure as a minimum shall;

* Identity the type of defects as near as possible, i.e. slag inclusion,

lack of side wall fusion, porosity, cold lap, etc.

* Identity the location and record the depth of defect from the
surface of base metal from which NDT operations were performed.

* Identity the type, grade and thickness of base metal containing the
defect.

* Record the number of the client approved WPS utilized to

procedure the original weld.

* Identity the NDT method and procedure, which will be employed

to examine the completed excavation prior to depositing repair,
weld.

- Prior to commencing excavation by any metal melting process i.e. carbon

air arc gouging, the defect area and adjacent weld and base metal shall be
preheated to a minimum of 66ºC. the width of the preheated area shall be a
minimum of three times the base metal thickness or 50.8mm whichever is
greater. The length of the preheat area shall be a minimum of three times
the length of the defect or 152mm whichever is greater.

- Upon completion of the excavation and verified by NDT that the entire
defect removal has been accomplished, the excavation shall be contoured
to provide a groove geometry to deposition of required repaired weld
- The prepared excavation shall be measured , i.e. width of base of the

groove, width of the top of the groove, length of the deepest section of
groove and length of the groove at the surface which shall be recorded and
utilized in-development of the showing repair groove dimensions and base
metal thickness for attachment to weld repair report.

- The minimum width of repair weld shall be 12.7mm and the minimum
length of repair weld shall be 76.0mm for repair of major defects where
size of weldments permits.

- Prior to depositing the repair weld, the excavated area and surrounding
weld and base metal shall be preheat to a minimum temperature of 94ºC.

- The preheat area shall as a minimum , be not less than six (6) times the
base metal thickness or 76.0mm in width whichever is greater. The
minimum length of preheat area shall be three (3) times length of the
completed excavation.

- The repair weld shall be performed utilizing the same welding procedure
and technique as was employed to deposit the original weld.

- The completed repair weld, upon acceptance by visual inspection, shall be

non-destructively examined by the same NDT method utilized to detect
the original weld defect.

- In some cases where client approved any attempts beyond two repairs,
hardness test shall be conducted. Hardness Testing shall include the repair
weld metal and Heat Affected Zone. Test shall be conducted with a
portable hardness tester.

- To determine the acceptable hardness values, hardness test shall be

conducted on a portion of the production weld not affected by the repair
weld area. Values received by this rest plus 50 shall be the basis for
acceptable hardness in the repair area but not more than 225 BHN. Failure
to meet this criteria will require PWHT sufficient to reduce hardness to
acceptable level.
MINOR DEFECTS : -

- The repair of minor weld defects shall be accomplished in a planned,

coordinated manner.

- In those instances where it is evident that the rejectable area of the weld is
superficial, grinding method shall be utilized to remove or correct subject
defects. The defect removal area and adjacent areas shall be contoured
neatly by grinding to eliminate sharp transitions. The ground area
thickness shall be measured utilizing Ultrasonic or “D” meter.

- Area of thickness deficiency, if any shall be built-up by welding in which

case the entire weld repair shall be treated as major defects under section
3.1.
 TEMPORARY ATTACHMENTS

- All temporary tack welded supports, braces, dog leg plates, run-off plates
and strong backs used during fit-up operation shall be removed.

- Temporary weld attachments shall be made only on client approval with

the same care and procedure as for a permanent weld. Welding shall be
done using a qualified welder.

- Temporary weld attachments shall be removed by cutting with a flame

torch 6mm above the surface of the steel. This shall be done progressively
as the various items or portion of the structure are completed.

- The final finish and removal shall be by power grinding to the original
steel surface. After grinding, the surface shall be tested as per the
approved NDT Procedure.

- Gouging out the attachments by arc cutting will not be permitted.

P
 ARC BURN REPAIR PROCEDURE

MAJOR ARC BURN :-

- The repair of disposition of major arc burns shall be accomplished in a

planned, coordinated manner and shall be witnessed by client Site
Representative.

- Grind the arc burn area, preferably with a disc grinder, until evidence of
the burn is no longer evidence to the naked eye. Ground area shall be not
less than 50.8sq.mm.in area.

- The ground area shall be swabbed with a solution of 20% ammonium

persulphate. The visual presence of a darkened area (light to dark gray) at
the point of the arc strike is evidence of metallurgical notch has not been
removed and grinding and chemical swabbing shall be repeated until the
darkened area is no longer visible.

- After all grinding and checking with 20% ammonium persulphate is

completed and no evidence metallurgical notch visibly exists, the cross –
sectional thickness of the base metal in the ground area shall be measured
utilizing ultrasonic / “D” measuring equipment.

- If measured cross-sectional thickness of ground area is equal to or greater

than the minimum acceptable, the repair shall considered complete and no
further action is required.

MINOR ARC BURN : -

- The repair or disposition of minor arc burns shall be accomplished in a

planned coordinated manner and shall be witnessed by client Site
Representative.

- Grind the arc burn area, preferably with a disc grinder; until visual
evidence of the arc burn is no longer exist. Grinding shall be accomplished
in a workman like manner, which leaves no sharp grooves in parent metal
and does not objectionably distort the geometry of the adjacent weld.
- The cross-sectional thickness of ground area shall be measured utilizing
ultrasonic / “D” meter measuring equipment. The measured thickness shall
be recorded in the thickness measurement report for use in determination
of final disposition.

- If measured cross-sectional thickness is less than the minimum acceptable,

the entire ground area shall be filled with weld metal and blend ground to
conform to the original surface geometry of the base metal.

- Repair welding shall be carried-out in accordance with a Weld Repair

Procedure approved by client utilizing client approved WPS. Magnetic
Particle Testing shall examine the repaired area for sound weld.

- If measured cross-sectional thickness is equal to or greater than the

minimum acceptable, the repair shall be considered complete and no
further action is required.

SPECIAL INSTRUCTIONS :

1. Reference client Vol. I General Fabrication Specification.

 CLASSIFICATION OF ARC BURNS

MAJOR ARC BURNS:-

Arc Burns which are located outside a welding groove, wherein the measured
distance from the center point of the arc burn to the edge of a completed weld
exceeds 9.5mm.

MINOR ARC BURNS:-

Arc burns which are located immediately adjacent to a completed weld wherein
the measured distance from the center of a completed weld is 9.5 mm or less.
 WELD BUILT-UP (BUTTERING) PROCEDURE

- Root openings wider than those permitted in the drawings but not greater
than twice the thickness of the thinner part of ¾” (inch), whichever is less,
may be corrected by welding to acceptable dimensions prior to joining the
parts by welding.

- Repair of wide gaps by buttering shall be accomplished in a planned

coordinated manner shall be conducted in accordance to the approved
Welding Procedure Specification

- Prior to start buttering, areas to be buttered shall be subjected to magnetic

Particle Inspection for sound base metal.

- As much as possible, buttering shall be made in flat position (IG) utilizing

string bead technique

- Built-up weldments shall be subjected to PMI and hardness test for sound
welds. The hardness test value shall not exceed 225 BHN
1.0 SCOPE

1.1 This procedure pre-scribe the control of Low Hydrogen Electrodes

used at work site.

2.0 STORING

2.1 The low hydrogen electrodes received from supplier shall be

packed in hermetically sealed container of approved type and kept
in the dry storage area.

2.2 The newly open cans electrodes shall be stored in BAKING OVEN
and bake at 260ºC to 280ºC for minimum 2 hours.

2.3 Electrodes issue to welders shall be kept at their own Heater

Quivers with the lid covered at all times, at a temperature between
80ºC to 105ºC.

2.4 Electrodes returned by each welder after each shift shall be placed
in the Baking Oven. Left over electrodes shall be removed and put
to scrap.

2.5 MC shall record the issuance of electrodes to welder.

3.0 IDENTIFICATION OF USED ELECTRODES

The returned or excess electrodes are again re-oven with color marking
(Red) and placing t the bottom areas. Wet or damage electrodes are not
allowed to be stored in the oven.
 1.0 Fabrication Control for Tie – In of Spools

1.1 All tie0ins as specified in the approved ISO Drawings are to be

properly mark-out to the required dimension and checking the
wall-thickness prior to gas cutting or cold-cutting.

1.2 The prepared edges of the spools are brought in for correct
alignment and to avoid high and low configuration using set-
square sets or spirit – level gauges.

1.3 The bevel fit-up shall then meet the PQR welding docs as for root
gap and the closed bevel angle. The bevel shall be freed from
surface flaws and laminations.

2.0 Identification

2.1 All tie-in weldment shall be recorded with welder ID and pother
welding status requirement, i.e. process and RT exam inspection.

3.0 Visual Inspection

3.1 All tie-ins spools and associated tie-in including installation of

gaskets shall be closely monitored ensuring correct rating for each
line spec.

4.0 Pipe Support / Hanger

4.1 During the period of hydrotesting, the pipe is subjected to

continuous water load. The support and hanger shall be inspected
for axial deflection and movement. All deviation shall be recorded
and advice QA/QC USE’s representative.
1.0 GENERAL

1.1 The intent of this procedure is to ensure that all bolts, nuts of
gaskets installed at flange locations are correct and comply to
Spec. and Code.

2.0 HOLD POINTS OF INSPECTION

2.1 There are three categories of hold points of inspection.

1) Client Hold Point (H)

2) USE QC Witness Point (W)
3) USE QC Surveillance Audit (S)

2.2 The flanges installed must be documented and correct ratings to

the line.

3.0 PRE-INSPECTION

3.1 All pre-inspection to work activities such as pre-tightening, pre-

hydrotest, pre-leak test / reinstatement must be performed and
client’s representative must be informed.
4.0 DOCUMENTATION

4.1 All visual inspection must be recorded for final approval.

 BOLT / NUTS/ GASKET INSTALLATION

AND INSPECTION FLOW CHART

START (1) (2) (3)

ASSEMBLE (W) PRE-INSTALLED PRE-INSPECTION (H)

MATERIAL

° At Location ° Install bolts ° Check correct bolts

° Assemble all bolts/ and nuts hosely for Flange
nuts/ gaskets ° Drop gasket to rest on the ° RTJ Ring Inspection
° Check ISO Dwg./PID bottom bolts. Do not tighten bolts

(4) (5) (6)

(H) (H) (H)
TIGHTENING PRE-HYDROTEST HYDROTESTING
(S) & LINE CHECK
° Fasten all bolts/nuts ° PID / ISO check, ° Refer hydrotest
until hand tight ° Check all the Check list /formats
° Commence Torque integrated fittings

(7) (8) (9) END

FLUSHING REINSTATEMENT FINAL CHECK
& LEAK TEST
PID/ ISO (H)
° Refer flushing ° Refer Pre-instatement/ ° Complete check
procedure Leak Test Procedure PID/ISO and
° Inspect the fluid / Document all info.
Strainer ° Tape the flange / tag
° Sign Acceptance
 * INFORM PLATFORM
EMEGENCY IF SUPERVISOR / SAFETY
OFFICER / QC
ISOTOPES ARE LOST
* MEETING WITH CONTRACTOR
/ SEALED
CONTAINER * INFORM STATUTORY
GOVERNMENT
DAMAGED
* SURVEY THE AREA RADIATION
 * ADVISE QC ON WHERE – ABOUTS
THE SOURCE

* SUBMIT DECAY TABLE TO

PLATFORM
TRANSPORTATION
* SUBMIT PERSONNEL IDENTITY

* QC INSPECTOR TO REPORT
ISOTOPE STRENGTH AND TYPE OF
SEALED CONTAINER

* PERFORM DURING NIGHT

* HOT WORK PERMIT

WORKING
PROCEDURE ON * SAFETY WARNING SIGNS
PLATFORM /LAMP/ROPES

* SURVEY METER TO DETECT

EXPOSED

* TO ADHERE EPMI RULES AND

REGULATIONS
  DECAY CHART

 APPROVED SOURCE
CONTAINERS

 INFORM PUSPATI PER RECORD

ISOTOPE’S PURPOSE
SOURCE IRI 92
 RECORD OF INSPECTION, TEST
AND MODIFICATION ON
SOURCE CONTAINERS

 SAFETY SIGN ON CONTAINERS

 PROPER DOCUMENTATION

TRANSPORT OF 1) USERS NAME

ISOTOPES 2) VEHICLE
SOURCE FROM 3) SAFETY ASPECTS
USER CUSTODY
 PROCEDURE IF SERVE DAMAGE
TO CONTAINER

 NOTIFICATION TO SITE
SUPERVISOR/
SUPERINTENDANT

 LOCATION OFFSHORE
STORAGE OF PLATFORM AT SEA DECK WITH
ISOTOPES AT SITE PROPER MARKED

 CONSTANT CHECK THE

RADIOATION BY SURVEY
DETECTORS AND RECORD THE
RESULTS
 REQUIREMENT

 LICENSE FROM PUSPATI

 MEDICAL REQUIREMENT OF
MALAYSIA SINGAPORE

 RADIATION WORKERS OF
MALAYSIA/ RADIATION SAFETY
CONTRACTOR AUTHORITY
(ORGANIZATION)
 RADIOGRAPHIC PROCEDURES

 ORGANIZATION CHART

 RECORD KEEPING

!) PERSONNEL
2) MOVEMET OF ISOTOPES

 HAVE ATTENDED RADIATION

SAFETY

 TRAINING PROGRAMME FOR

RADIOGRAPHER/USERS
PERSONNEL
ENGAGED IN RT  MEDICAL EXAM/RECORDS

 WEARING FILM
BADGES/DOSIMETERS

 UNDERSTAND EPMI SAFETY

REQUIREMENT
6.0 RADIATION DOSE LIMITS AND MXIMUM ALLOWABLE
STRENGHT OF RADIOACTIVE ISOTOPES

6.1 All contractors/-classified workers engaged in handling radioactive

materials shall wear the dosage badge.

6.2 Current Malaysian Government regulatory requirements specified

the following dose limits:

Radiation Workers – Maximum 2 milirem per hour or maximum

100 milirem per week.

Non-Radiation Workers – Maximum 0.25 milirem per hour or

maximum 10 milirem per week.

6.3 For gamma radiographic purposes for offshore and onshore

activities, the maximum allowable radioactive strengths of the
Iridium 192 (IR-192) isotopes are as follows : -

i) Offshore - 20 Curies + 15
ii) Onshore - 40 Curies + 15
5.0 OTHER PRECAUTIONS

5.1 The client Supervisor-in-charge shall ensure that he is fully aware

of any planned radioactive work and the relevant emergency
procedure prior to issuing the required Hot Work Permit.

5.2 An announcement shall be made over the platform public address

system to advise all personnel of any radiographic activity being
carried out and the location of the activity at the start and
completion of the work. During that period all unauthorized
personnel shall stay away from the work area.

5.3 Only authorized personnel shall be permitted to handle radioactive

sources. The area where radiographic activity is being carried out
shall be roped off so that the maximum dose rate a6t any point of
the barrier is 0.25 mrem /hr.

International radiation warning signs and flashing lights shall be

used to control unauthorized entry of personnel to the area of
radiographic activity.

5.4 Client Construction Supervisor and/or inspector shall ensure that

the area outside the warning barrier around the working area is
surveyed during radiographic work by using an appropriate
radiation survey meter to ensure that radiation do not exceed the
dose limit for non- radiation worker as specified in section 6.2.

5.5 Emergency drills shall not be conducted when radioactive work is

in progress.

5.6 In emergency situations, Supervisor in charge shall ensure

radiographic equipment/ sources are in secure / safe positions.
4.0 TEMPORARY STORAGE OF RADIOACTIVE MATERIALS

4.1 All radioactive materials shall be stored in APPROVED shield and

transport containers which shall be locked when the radioactive
materials are not in use. The keys shall be in the custody of the
authorized personnel.

4.2 Radiographic materials shall be stored or kept in such a manner as:

i) To prevent any individual, not being authorized by the

license having access to them and,

ii) Not to create anywhere outside the defined storage area

accessible to any person other than a radiation worker, a
radiation level exceeding 0.25mrem/ hr and

iii) Not to suffer any person to other than a radiation worker to

receive a radiation dose in excess of 10 mrem in a period
of any seven consecutive days and,

iv) To ensure that the average level at one meter from the
center of each source does not exceed 2 mrem/ hr. and the
maximum radiation level does not exceed 10 mrem/ hr.

4.3 The radioactive material storage locker shall be placed and secured
in a manner that it would not be accident dislodged from a height
that would damage the locker or fall into the sea.

4.4 Adequate approved warning signs bearing the words “CAUTION

RADIOACTIVE MATERIAL” , “MERBAHAYA” and the basic
ionizing radiation symbol shall be displayed at the radioactive
materials storage area.

4.5 The temporary storage area at the location shall be designated by

3.0 RECEIPT AND DESPATCH OF RADIOACTIVE MATERIALS.

3.1 Approval from the client Supervisor-in-charge shall be received

prior to receipt or dispatch of any radioactive materials.

3.2 The time of receipt and dispatch of all radioactive materials shall
be recorded by client Supervisor-in-charge.

3.3 The strength of the radioactive source, as verified by the decay

chart of the isotope and a radiation survey meter, shall not exceed
the permitted radioactivity level as stated in the issued license and
the container design.

3.4 The client Supervisor-in-charge shall be advised of the quantity

and strength all radioactive materials received at this location and
shall be provided with a copy of the relevant decay chart.
2.0 TRANSPORTATION OF RADIOACTIVE MATERIALS

2.1 Radioactive materials shall be transported in APPROVED

Containers which shall be properly marked “CAUTION –
RADIOACTIVE MATERIAL – MERBAHAYA” and the basic
ionizing radiation symbol. The containers shall have tags bearing
the identification quantity and the strength of the radioactive
materials, and the date that the radioactive materials left the
Contractor’s premises.

2.2 The vehicle transporting radioactive materials over land shall be

placarded with adequate approved radiation warning signs bearing
the words “CAUTION – RADIOACTIVE MATERIALS –
MERBAHAYA” which shall be removed when the vehicle is not
carrying radioactive materials.

2.3 Supply boats shall be used for the transportation of radioactive

materials offshore. The containers shall be properly secured onto
the boat.

2.4 Transportation of the source over land is not allowed on any

vehicle transporting any client employee.