NCR Procedure

Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
Revision: 0.1 Status : IFC
Document Type : REP System/Subsystem : N/A Discipline: QUA Date : 12 – 08 - 2021
Originator Document No : N/A Page 1 of 14
PT PERTAMINA HULU MAHAKAM

BEKAPAI 3
SURFACE FACILITIES MODIFICATION AND
DOGLEG INSTALLATION (EPCIC)
NCR PROCEDURE
CLASS : 1
0.1 12-Aug-2021 IFC Issued for Comment WHY IP / AU SG
Rev Date Status Revision memo Issued Checked Approved COMPANY
This document is the property of PT Pertamina Hulu Mahakam and shall not be disclosed to third parties or reproduced without permission
of the COMPANY. Electronic Filename: ID-BKP-SOME-2009-504005_rev0.1.pdf
Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
TABULATION OF REVIEW PAGES
REVISION REVISION
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Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
COMMENT TABULATION
No PHM COMMENT CONTRACTOR RESPONSE
Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
TABLE OF CONTENTS
1. INTRODUCTION............................................................................................................................. 5
1.1 Plant Description ................................................................................................................... 5
1.2 Project General Description and Purpose .......................................................................... 5
2. DOCUMENT SCOPE ...................................................................................................................... 7
3. REFERENCE DOCUMENT ............................................................................................................ 7
3.1 Company Specification......................................................................................................... 7
3.2 International Code and Standard ......................................................................................... 7
3.3 COMPANY Supplied Document ........................................................................................... 7
3.4 Project Document.................................................................................................................. 7
4. DEFINITIONS ................................................................................................................................. 8
5. DUTY AND RESPONSIBILITY....................................................................................................... 8
5.1 QA/QC Manager .................................................................................................................... 8
5.2 QC Inspector ......................................................................................................................... 9
5.3 Work Site Fabrication Manager ........................................................................................... 9
5.4 OFFSHORE CONSTRUCTION MANAGER .......................................................................... 9
5.5 CONSTRUCTION Superintendent ....................................................................................... 9
5.6 CONSTRUCTION Supervisor ............................................................................................... 9
6. PROCEDURE OF NON CONFORMITY ....................................................................................... 10
6.1 Identification of the non conforming product.................................................................. 10
6.2 Preparation of the non conformance report (NCR) ......................................................... 10
6.3 Implementation of Corrective Action ............................................................................... 10
6.4 Verification of Corrective Action / CLOSE OUT NCR ...................................................... 11
7. ATTACHMENT ............................................................................................................................. 11
Attachment 1 : Non Conformance Flow Chart ......................................................................... 12
Attachment 1 : Non Conformance Report ................................................................................ 13
Attachment 2 : Non Conformance Summary Report ............................................................... 14
Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
1. INTRODUCTION
1.1 Plant Description
Bekapai is a COMPANY’s oil field located at offshore area in the Mahakam delta (East
Kalimantan) with water depths 30 – 40 meters and located about 40 kilometers south east of
the Senipah terminal.
COMPANY continues to develop of mature Bekapai offshore oil filed which was discovered in
1972 and start to production in 1974, with current facilities are:
 Nine (9) satellite wellhead platforms & inter-platform pipelines;
 Production (BP) & LQ platforms;
 12” export pipeline to Senipah Terminal (BP1-SNP);
 12” export pipeline to Peciko field SWP-K (BA-SWPK).
All effluents from satellite platforms are transported to BP1 and BA in order to have gas-oil-
water processing unit (separation, pumping, compression, and oily water treatment).
Production fluid from Bekapai field is routed to two (2) locations; multiphase production (mostly
gas and oil) is exported to Senipah Terminal (TPA) via 12” BP1-SNP pipeline and gas
production is exported to Peciko Field via 12” BA-SWPK Pipeline. The network of BEKAPAI
Platforms is shown in figure below.
1.2 Project General Description and Purpose

General Description
Bekapai development phase 3 covers modifcation of existing production facilities in order to
accommodate drilling program of several new wells with potential oil and gas reserve from
Bekapai filed. Modification and intervention of the existing offshore production facilities are for:
 BE and BH as the main platforms;
 BG and BA as host platforms;
 Reutilization of existing 6” inter-platform pipelines between BH to BG and BE to BA.
Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
With the current conditions:

 BH and BE as satellite wellhead platform, located at eastern of Bekapai field, with
minimum production and safety system without pressure relief system, where each
platform is hosting three (3) wells:
- One (1) BH well is still in production
- All BE wells are not in production
 BG is still in operating, latest development phase 2B was completed in 2015 with
additional production wells
 BA is a hub platform, gas export point to Peciko SWP-K without any wells in production
 6” pipeline from platform BE to BA are being preserved. The exsiting pipeline is not
equipped with dogleg
 6” pipeline from platform BH to BG is still in operating
In general, the new equipment under Bekapai 3 is illustrated below:
BE & BH Platform
Project Purpose
 Increase oil and gas reserves recovery by Reserve: 22.1 BcfGas & 2.8 MbblOil +
Condensate
 Drilling of 5 new wells from existing BE & BH platforms, with :
- Modification of the existing BE & BH
- Reuse of existing 6" pipeline from BE to BG (3.6 km) & 6" pipeline from BH to BG (1.9 km)
- Modification and integration work at the BA, BG & BP platforms
-
Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
2. DOCUMENT SCOPE
Purpose of this document is to describe the required Non conformance report to deliver the
Bekapai 3 Surface Facilities Modification and Dogleg Installation (EPCIC) project. This is
required in order to prove that the work is carried out properly accordingly to the applicable
Code / Specification.
3. REFERENCE DOCUMENT
3.1 Company Specification
No Document Number Document Title
1 MHK-COMP-SPE-EP-PVV-0171 Steel Piping Fabrication
Welding of Pressure Containing Piping and

2 MHK-COMP-SPE-EP-PVV-0611
Equipment
3 MHK-COMP-SPE-EP-STR-0201 Materials for Offshore Steel Structures
4 MHK-COMP-SPE-EP-STR-0301 Fabrication of Offshore Steel Structures
3.2 International Code and Standard

Standard For Welding And Brazing
1 ASME SEC. IX Edition 2017 Procedures, Welders, Brazers, And Welding
And Brazing Operators
2 ASME B 31.3 Edition 2015 Process Piping
3 AWS D 1. 1 Edition 2015 Structural Welding Code – Steel
3.3 COMPANY Supplied Document

1 Exhibit A, Annex No. 1 Scope of Work
3.4 Project Document
1 ID-BKP-SOME-2009-503001 Project Execution Plan
2 ID-BKP-SOME-2009-503005 Project Quality Plan
Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
4. DEFINITIONS
4.1 Non-conformance:
 Any defect, flaw, damage, inferior quality of material equipment or deviation of work performed
out of specifications, drawings or any other contractual documents or
 A deviation from a quality system element of the contractor or a departure from determined
criteria independent from contractual requirements, resolution of the nonconformity includes
application of existing procedures or
 A deviation from work procedures or instructions which have been accepted by the COMPANY,
or a departure from determined criteria inherent to the contractual requirements, this
nonconformity might requires informing or obtaining the COMPANY 's advising/review for the
proposed corrective action
4.2 Corrective Action or Disposition:
Solutions of any non-conformities such as rework, repair, scrap, use as is or rejected made by
Project Manager with advise from Construction Engineering based on Codes or Specification and
shall be approved by Company can give other solution
4.3 COMPANY shall mean PT PERTAMINA HULU MAHAKAM
CONTRACTOR shall mean PT. ASTA REKAYASA UNGGUL
5. DUTY AND RESPONSIBILITY

The details of NCR’s numbering and disposition is by CONTRACTOR QA/QC MANAGER.
5.1 QA/QC Manager

 Controls & ensures that the NCR has been correctly identified and that the relevant information
had been fulfilled within each NCR sections.
 Reviewing the non-conformance report with respect to the quality aspect and the impact so that
such a non-conformance will have final quality required
 Liaison with COMPANY with respect to the resolution (disposition) made
 Controls & ensures that Welding Procedure Specification have been in implemented during
welding activity.
 To take decision if during welding activity, meet some problem and make new calculation to
solve this problem.
 Reviewing the non-conformance report with respect to the quality aspect and the impact so that
such a non-conformance will have final quality required base on welding activity.
 Follow up the quality records during the progress of inspection and fabrication monitoring for
compilation.
Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
 Inform to Construction Supervisor and Foreman about deviations, defects or non conformance
performed during monitoring or related to welding fabrication activities and give advice or input
to Welder, Foreman to minimize any problem on the fabrication.
5.2 QC Inspector
 Initiates Non-Conformity Report (NCR) based on finding by CONTRACTOR or COMPANY's
Quality Notification that classified as requiring NCR follow up.
 Follows up and ensures that the corrective action task has been effectively implemented or
performed.
 Finally, close any non – conformities report.
5.3 Work Site Fabrication Manager

 Gathers personnel of the entity concerned by the NC Product / service in order to raise the
appropriate corrective action that will be implemented.
 Dispatches the NCR with ‘’corrective action’’ section filled up to the relevant entity for action.
5.4 OFFSHORE CONSTRUCTION MANAGER

 Responsible to Project Manager for all construction activities.
 Then, Work Site Construction Superintendent signs original and dispatches original to QA/QC
Manager and copies of the ‘non-conformance report’ to relevant entity but not restricted to head
of department of the person in charge of the corrective action for implementation of the
Correction and QC Inspector (to follow up the NCR Status)
5.5 CONSTRUCTION Superintendent

Construction superintendent shall be responsible for reviewing any non-conformance reports and
ensure that restoration work is implemented in accordance with plan and agreed schedule
5.6 CONSTRUCTION Supervisor

Each construction supervisor shall be responsible to prepare the restoration plan under direction of
superintendent. After restoration work has already finished, he shall notify QC Inspector for closing
the NCR.
Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
6. PROCEDURE OF NON CONFORMITY

6.1 Identification of the non conforming product
 The person who detected a non-conformity or the direct construction supervisor of the entity
concerned by, must mark the non conforming product or inform QC Inspector for the non
conformity
 Whenever possible, non-conforming materials shall be segregated and put in a dedicated
quarantine area which properly segregated and signed to prevent from inadvertent use. The
marking shall be performed using tags, marking ink, paint, tape or any other specific way of
identification The "QUARANTINE" marking shall be standardized and proposed to Company for
approval
6.2 Preparation of the non conformance report (NCR)

 The person who detects a non-conformance refers the matter to the QC Inspector or Quality
Department and also notified to all persons concerned
 The Quality Department initiates a nonconformity report according into the “NON –
CONFORMANCE REPORT‘’ form. QC Inspector shall completely filled as a minimum kind of
non conformance, non conforming conditions, corrective action shall be filled by related
person/department from CONTRACTOR and rectification/correction, verification of NCR by
COMPANY.
 When required, additional documents / drawings and / or photos shall be used to describe the
nonconformity and joined together with the ‘Non Conformance Report’ form
 The Quality Department must complete the ‘non-conformance report’ in such a way that the
deviation or the discrepancy is clearly described relative to the acceptance criteria
6.3 Implementation of Corrective Action

 Upon review and signature from QA/QC Manager, he then transmits an Internal Memo, together
attached with the Original of the ‘Non Conformance Report’, to Work Site Fabrication Manager.
 Work Site Construction superintendent, if required proposes a corrective action (by fulfilling
Corrective action in the form), shall be approved by COMPANY QSE engineer and CSR.
 The responsible of the entity in possession of the non conforming product shall gather the
necessary information from competent person in order to advise and plan the corrective action.
Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
. Proposed corrections may include:

 Rework : to meet specified requirements.
 Repair : to meet specified requirements.
 Use as is : Acceptance by waiver without repair.
 SCRAP or REJECTION : Shall not be used and related items shall be Segregated
 Other : Use any other method to do the corrective action
The date for application of the proposed correction shall be specified.
Proposed Corrective action shall be completed with appropriate explanations and reasons.
6.4 Verification of Corrective Action / CLOSE OUT NCR

 Quality Inspector checks and ensures that the implementation of the selected correction is done
effectively. Depending on the situation, Quality Inspector ensures that the product:
 Has been re-controlled after rework or repair.
 Has indeed been scrapped.
 Has been re-graded and is identified as such
 Documents explaining the verification of the correction can be added to the nonconformity
report.
 After verification of the correction has been accepted, the Quality Inspector to close NCR need
approval from COMPANY by QAQC Inspector/Engineer and CSR, the verification performed as
ACCEPTABLE or NOT ACCEPTABLE.
 If the NCR considered NOT ACCEPTABLE, CONTRACTOR shall be submitted new proposed
design drawing (completed with Calculation), request new material, CONTRACTOR shall be
make sure all of this activity and shall be approved by Company.
 Quality Department shall be files all the non conformity reports as a quality records and part of
Quality Dossier, NCR updates shall always be reported in the weekly meeting.
 Corrective action will submitted by Contractor to Company, how to the Contractor will closing
the NCR, evidence document can showing below, action for closing NCR:
 Has been re-controlled after rework or repair completed with Manufacture certificate, NDE
report, testing, photograph, all activity shall be witnessed by Company.
 Has been make new calculation, revision drawing and shall be approved from Company.
7. ATTACHMENT
Attachment 1 : Non Conformance Flow Chart
Attachment 1 : Non Conformance Report
Attachment 2 : Non Conformance Summary Report
Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
Attachment 1 : Non Conformance Flow Chart

Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
Attachment 1 : Non Conformance Report
BEKAPAI - 3
Revision Index
Surface Facilities Modification and Dogleg Installation
(EPCIC) Rev Status
Contract No. 4500010835
NCR PROCEDURE 0.1 IFC
NON CONFORMANCE REPORT ( NCR )

Laporan Ketidaksesuaian
Project : NCR No :
Contract : Report Date :
Client : Location :
Reference Document
Reported by :
Document yang relevan
Position :
Sign :
Non Conformance Description

:
Uraian Ketidaksesuaian
Root Cause
:
Masalah Utama
Corrective Action
:
Tindakan Perbaikan
Corrective Action By :
Date : Signature :
Position :
Target Closed Out Date :
Verification :
Verification By :
Date : Signature :
Position :
Preventive Action :
Tindakan Pencegahan
Final Disposition :
Use as is Re‐work Repair Reject
Other
Closed out by :
Status Closed Out Date :
Nama :
Position : ON TIME
OVERDUE
Sign : Date :
AR-QC-NCR-08/19
Contract : 4500010835
Document Number
ID-BKP-SOME-2009-504005
NCR PROCEDURE
Attachment 2 : Non Conformance Summary Report
Revision Index
BEKAPAI - 3 Surface Facilities Modification and Dogleg Installation (EPCIC)
Contract No. 4500010835 Rev Status
NCR PROCEDURE 0.1 IFC
Non Conformance Summary Report

Project : NCR No :
Contract : Report Date :
Client : Location :
CONTRACT NCR DATE NCR NCR CLOSED NCR CLOSED ON NCR OPEN

NO FINDING NON CONFORMANCE DESCRIPTION CORRECTIVE ACTION NCR CLOSE STATUS REMARKS
NUMBER NUMBER ISSUANCE DATE TIME OVERDUE
TOTAL 0 0 0
Prepared By, Reviewed By, Approved by

PT ASTA REKAYASA UNGGUL PT ASTA REKAYASA UNGGUL PT ASTA REKAYASA UNGGUL
QA/QC QC Manager Project Manager
AR-QC-Summary NCR-08/19

NCR Procedure

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Contract : 4500010835

PT PERTAMINA HULU MAHAKAM

0.1 12-Aug-2021 IFC Issued for Comment WHY IP / AU SG

Rev Date Status Revision memo Issued Checked Approved COMPANY

TABULATION OF REVIEW PAGES

No PHM COMMENT CONTRACTOR RESPONSE

1.2 Project General Description and Purpose

With the current conditions:

3.1 Company Specification

No Document Number Document Title

1 MHK-COMP-SPE-EP-PVV-0171 Steel Piping Fabrication

Welding of Pressure Containing Piping and

3 MHK-COMP-SPE-EP-STR-0201 Materials for Offshore Steel Structures

4 MHK-COMP-SPE-EP-STR-0301 Fabrication of Offshore Steel Structures

3.2 International Code and Standard

No Document Number Document Title

2 ASME B 31.3 Edition 2015 Process Piping

3 AWS D 1. 1 Edition 2015 Structural Welding Code – Steel

3.3 COMPANY Supplied Document

No Document Number Document Title

3.4 Project Document

No Document Number Document Title

1 ID-BKP-SOME-2009-503001 Project Execution Plan

2 ID-BKP-SOME-2009-503005 Project Quality Plan

4.2 Corrective Action or Disposition:

4.3 COMPANY shall mean PT PERTAMINA HULU MAHAKAM

CONTRACTOR shall mean PT. ASTA REKAYASA UNGGUL

5. DUTY AND RESPONSIBILITY

5.1 QA/QC Manager

5.3 Work Site Fabrication Manager

5.4 OFFSHORE CONSTRUCTION MANAGER

5.5 CONSTRUCTION Superintendent

5.6 CONSTRUCTION Supervisor

6. PROCEDURE OF NON CONFORMITY

6.2 Preparation of the non conformance report (NCR)

6.3 Implementation of Corrective Action

. Proposed corrections may include:

6.4 Verification of Corrective Action / CLOSE OUT NCR

Attachment 1 : Non Conformance Flow Chart

Attachment 1 : Non Conformance Report

NON CONFORMANCE REPORT ( NCR )

Contract : Report Date :

Non Conformance Description

Use as is Re‐work Repair Reject

Attachment 2 : Non Conformance Summary Report

NCR PROCEDURE 0.1 IFC

Non Conformance Summary Report

Contract : Report Date :

CONTRACT NCR DATE NCR NCR CLOSED NCR CLOSED ON NCR OPEN

Prepared By, Reviewed By, Approved by

QA/QC QC Manager Project Manager

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