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STANDARD OPERATING PROCEDURE
QUALITY CONTROL
SOP – SHE – 006
Revision ① ② ③ ④ ⑤ ⑥
Date
Prepared By
Reviewed By
Approved By
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LEMBARAN REVISI
Halaman ini memuat catatan semua revisi terhadap panduan SOP ini dan berikut ini adalah
revisi yang telah dilakukan pada panduan SOP ini :
REV. DATE BRIEF OF REVISION
0 April 12,2020 New Issued
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DAFTAR ISI
QUALITY CONTROL..............................................................................................................1
LEMBARAN REVISI...............................................................................................................2
DAFTAR ISI..............................................................................................................................3
1. SCOPE................................................................................................................................5
2. TERMINOLOGY...............................................................................................................5
2.1 COMPANY.................................................................................................................5
2.2 PT AKBARA MAULANA ABADI............................................................................5
2.3 SERVICES...................................................................................................................5
2.4 QUALITY...................................................................................................................5
2.5 QUALITY ASSURANCE...........................................................................................5
2.6 QA PLAN....................................................................................................................5
2.7 WA SYSTEM..............................................................................................................6
3. QUALITY ASSURANCE POLICY...................................................................................6
4. ORGANlSATlON...............................................................................................................6
4.1 Organisational Chart....................................................................................................6
4.2 Delegation of Authority...............................................................................................6
5. CONTRACT REVIEW......................................................................................................6
6. DESIGN CONTROL..........................................................................................................7
6.1 General........................................................................................................................7
6.2 Establishment of Design Interface...............................................................................7
6.3 Design Process Control...............................................................................................7
7. DOCUMENT......................................................................................................................9
7.1 General........................................................................................................................9
7.2 Control of Documents.................................................................................................9
7.3 Identification and Control of Documents....................................................................9
8. PROCUREMENT CONTROL...........................................................................................9
8.1 General........................................................................................................................9
8.2 Preparation of Requesition..........................................................................................9
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8.3 Review of Requisition...............................................................................................10
8.4 Selection of Vendor...................................................................................................10
8.5 Evaluation and Verification of Vendor's Performance...............................................10
9. MATERIAL INSPECTION..............................................................................................11
10. SHOP FABRICATION AND INSTALLATION CONTROL.......................................11
10.1 General Control of Fabrication and installation........................................................11
10.2 Environmental Control..............................................................................................11
10.3 Fabrication and InStaIlation Planning.......................................................................11
10.4 Special Proses Control...............................................................................................11
11. INSPECTION AND TESTING PLAN.........................................................................12
12. HANDLING, STORAGE AND SHIPPING.................................................................12
12.1 General......................................................................................................................12
12.2 Planning, Controling General....................................................................................12
12.3 Handling and Storage................................................................................................12
12.4 Packing and Delivery................................................................................................12
13. PRECOMMISIONING CONTROL.............................................................................13
13.1 General......................................................................................................................13
13.2 Planning.....................................................................................................................13
13.3 Implementation of Pre-commissioning.....................................................................13
13.4 Records......................................................................................................................13
13.5 Control of Measuring and Test Equipment................................................................14
14. QUALITY RECORDS..................................................................................................14
14.1 General......................................................................................................................14
14.2 Identification, Collecting and Fitting........................................................................14
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1. SCOPE
This procedure covers quality plan is to establish control procedures to be executed
properly and effectively in order the safe and reliable quality in Engineering,
Procurement, Inspection and Construction in compliance with the requirements
Stipulated in the Construction between Company and Contractor/Vendor. If there is
any conflict between this plan and the contract documents, the latest revision of the
contract documents shall take precedence.
2. TERMINOLOGY
COMPANY
Which is representative user and owner.
PT AKBAR MAULANA ABADI
which is responsible for the detail design, material and equipment procurement
and construction for the mechanical, electric and instrument equipment.
SERVICES
The performance of activities; such as design, fabrication, inspection, non
destructive, repair, or installation.
QUALITY
Fitness for use; meets intended purpose, performs satisfactory in service for
specified time.
QUALITY ASSURANCE
Planned, systematic procedures and actions to assure that the engineering design,
materials, equipment, structures and systems comprising a facility will, on
completion, conform to specified requirements and meet intended purposed.
2.6 QUALITY CONTROL
That part of quality assurance which, through checks, reviews, measurements,
test, inspections, determine that specifications are met.
g) QA PLAN
A detailed scheme developed and documented beforehand, for achieving the
desired level Of quality in a completed facility.
WA SYSTEM
The procedures, equipment, activities, organization and personnel used to
Implement quality assurance plan.
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3. QUALITY ASSURANCE POLICY
PT AMA quality assurance policy shall be formulated to achieve the product and service,
which are defined as on time schedule. competitive project cost, safely execution and
operation, are compliance with the COMPANY requirements. As part of quality assurance is
to satisfy the COMPANY at all stage of project, from design until commissioning. PT AMA
executing management shall be required to confirm their commitments to implement this plan
by signing the Quaijty Assurance Policy Statement.
Project Manager and each relevant manager are responsible for assuring that all phases of the
program for which he is responsible are operating strictly in accordance with the quality
assurance. The QA/QC Manager and his delegates have organizational freedom from
disciplines, being directly responsible for performing the work, and have the Authorities to
conduct audit, identify quality problems and to guide solutions.
4. ORGANlSATlON
This section covers the organization and its authority and responsibility in the
performance of activities affecting quality related to the Project, PT AMA shall
establish a Project Organization, which shall satisfy COMPANY's requirements. The
level of the responsibility and assigned authority of these personnel shall be clearly
indicated.
Organisational Chart
The overall project organization charts is available in contract document between
COMPANY and PT AMA
Delegation of Authority
Each Manager has the responsjbility for the functions assigned to him. Thé
Manager may delegate his taks to the designed personnel. However, this does not
relieve him of his responsibility.
5. CONTRACT REVIEW
At the award of the contract as applicable; PT AMA shall arrange and conduct a
preliminary review of the contract package to ensure that
Project requirements are adequately defined and documented
Any requirements are in compliance with any applicable codes and Standards.
When incomplete, ambiguous or conflicting inputs are found in the course of the contract
review, PT AMA's Project Manager will discuss With COMPANY to draw up the
requirements and result shall be recorded for confirmation.
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6. DESIGN CONTROL
General
This section covers the design and engineering control procedure to ensure that
PT AMA’s design is performed in strict compliance with COMPANY's
requirements, applicabie laws and regulations, codes and standards, and that the
quality requirements for equipment and material are properly attained.
Establishment of Design Interface
i) Design Interface between COMPANY and PT AMA
Engineering Manager shall control design interface by identifying
design and engineering responsibilities and establishing the
"Coordination Meeting" The design information transmitted across the
interface between COMPANY and PT AMA shall be incorporated in
such documents as construction drawing, P&lD, Data Sheet, etc for
proper control.
ii) Design Interface within PT AMA.
Engineering Manager shall Plot design activities, identify design input
and outputs, interface flow lines, etc. The internal screening. meeting
Shall be held to resolve interface problems by cross check and collation
between relevant design groups in timely manner Physical design
interfaces are identified by internal coordination meetings of design
groups within the design division.
Design Process Control
iii) Review of Design input from COMPANY
a) Engineering Manager shall conduct a preliminary review of the contract
package to ensure that requirements are adequately defined and
documented and that any requirements differing from those in the tender
documents are resolved.
b) Engineering Manager shall identify the design requirements such as
COMPANY's basic des·ign data, regulatory requirements, applicable
codes and standards, etc. to provide the consistent basis for succeeding
design work.
c) Design input shall be coordinated by Engineering Manager, considering
the past experiences of the similar plants, the feedback etc. who shall
confinn contents.
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d) When incomplete, ambiguous or conflicting inputs are found in the
course of the engineering review, Engineering Manager shall discuss
with COMPANY for drawing up the requirements. The results shall be
documented and immediately informed to Project Manager.
iv) Document Preparation.
a) On the basis of design inputs, Design Engineer shall prepare design and
engineering document, such data sheets, specifications, instructions,
drawings, procedures. etc.
b) The documents shall meet design-input requirements, contain or
reference productand/or acceptance criteria and conform to applicable
statutory requirements.
v) Review and Approval
Documents prepared by Design Engineer shall be reviewed and approved by
Engineering Manager.
vi) Design Verification
a) Design verification shall be conducted to verify, confirm and substantiate
the design, taking the importance to safety, complexity, degree of
standardization, state of art and the similarity to previously proven
design, the assumption, etc into account.
b) The design verification shall be conducted by means of the following
measures such as :
Undertaking demonstration or qualification test (s)
Carrying out alternative calculation.
vii) Control of Design Changes
a) Changes to design documents such as specification, procedures,
drawings, etc. shall be reviewed and approved, in principle by the same
manner as applied to the original.
b) In the event that inconsistening or in adequacy is found, the finder shall
request the originating design group to change the document, using
Engineering revision request and Engineering revision instruction sheet.
c) The proposed change shall be evaluated for the correctness and the
effectiveness including the impact on fabrication, schedule, cost etc.
d) The changed part shall be mar11.ed for easy identification and revis1on
date, revision number and the reason of the change shall be noted on the
document.
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e) The changed document shall be submitted to COMPANY for approval.
The original copy approved documents, including "As Built" drawings,
shall be submitted to COMPANY.
f) Obsolete documents shall be destroyed or withdrawn for disposition.
g) Files containing copies of the latest revision of documents shall be
maintained and easily accessible for use.
viii) Engineering Hold
Design engineering shall identify the Engineering hold. when the design is
uncertainties. The relevant work involved in such engineering hold shall not
proceed without the clear solution given by the responsible Design Engineer.
7. DOCUMENT
General
This section covers the procedure to control all documents affecting quality to
assure that documents are processed properly and that the latest applicable
documents are available to the personnel or organization concerned, on schedute.
Control of Documents
Project Administration shall control all receiving, recording, distributing and
filling by PT AMA Project Administration is responsible for the document control
He directs document control to collect, distribute and totally control documents.
Identification and Control of Documents
ix) Numbering document of Documents prepared by the relevant discipline
shall be System assigned a blished unique in for the accordance with the
Document Numbering system established unique in for the accordance
Project.
x) Listing of Documents
Project of Administration Documents shall list up the documents to be
submitted to COMPANY (DL -Manager Document shall List) and
document approved by the Department Manager shall be sent with a
Document Transmittal sheet.
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2) PROCUREMENT CONTROL
8.1 General
The section covers the procedure to ensure that purchased product and services
conform to specified requirements.
8.2 Preparation of Requesition
Project Engineer shall prepare the requisition on the basis of the COMPANY's Basic
Engineering Data, including the following as deemed necessary.
8.2.1 Scope of Supply.
8.2.2 Deliver Date, Location.
8.2.3 Applicable project codes, Standards, COMPANY'S specification Engineering
Design and QA/QC documents.
8.2.4 Requirements for personnel qualification, inspection and test, and shipping
preparation and reporting.
8.2.5 QA/QC requirement, such as establishment of QA Program, Non
Conformance Control, Inspection requirements, the extension of
8.2.6 8.26 Documents -to be supplied to Vendor-
8.2.7 Vendor's documents required such as : Fabrication procedure, WPS/PQR,
Qualified Personnel List, Inspection and Test Procedure, QA]QC Plan,
inspection and Test Records, Special Process Record Technical Documents,
etc.
8.2.8 Right to access and guarantee description.
8.3 Review of Requisition
A review of requisition and change there to shall be made to assure the adequacy of
specify requirement Review and approval Shali be conducted in the same way as
described in Para. 6.3.5 (c). Procurement Manager shall check the requisition and
attach the necessary documents for the inquiry or for the Purchase Order Project
Manager shall give the final approval
8.4 Selection of Vendor
8.4.1 PT AMA shall selected potenüal Vendor's in principle among "Approval
Vendor List
8.4.2 Procurement Manager shall issue Request for Quotation to potensial
Vendor's
8.4.3 upon request Of Project Manager. Engineering Manager and QA/QC
Manager shall perform QA,/QC surveillance to Vendors in accordance with
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the QA levels of products and service to be made. The results Shall be
reported to Project Manager.
8.4.4 The selection Of Vendor and extend of control shall be dependent upon the
type of product and services. Vendor's demonstrated capacity and past
performance of the similar work. the evaluation of Vendor's quotation, QA
evaluation and the capability on schedule and cost
8.5 Evaluation and Verification of Vendor's Performance
After the Purchase Order, PT AMA exerts the following control.
8.5.1 Review and Approval of Vendor's Documents
Vendor's documents shall be reviewed by Engineering Manager or QA/QC
Manager and approved by Project Manager for their compliance to the
requisition,
8.5.2 Control and Verification of Vendor/SubcontraCtor Performance
a) A kick-off meeting and pre-inspection meeting will be held between PT
AMA and Vendor for coordination and mutual understanding At the
monthly coordination meeting, the status of progress, schedule of inspection
and major problems are reported, discussed
b) PT AMA or his representative shall be afforded the right to acces Vendor's
facilities for communication and inspection,
c) Procurement Manager shall keep abreast of the current status and expedite
Vendor's Manufacturing and delivery schedule of product and Shali report
to Project Manager.
d) Inspection shall be performed to verify and confirm the compliance of
product to specification.
e) Audit shall be performed on QA activities of Vendor as necessary, taking
the performance to the specification,
9 MATERIAL INSPECTION
This section covers the identification procedure of product the correctness of product to
specified requirements for Material Inspection.
10 SHOP FABRICATION AND INSTALLATION CONTROL
10.1 General Control of Fabrication and installation
1.1.1 Environmental Control
a) Vendor/Subcontractor Shali establish the control measures to keep working area
clean and under suitably controlled condition to prevent product from mixing-in
of foreign materials and not to cause detrimental effects on product.
b) PT AMA shall check the controlled status Of working area at witness inspection
or by patrolling, as appropriate and give recommendation for correction, if any.
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1.1.2 Fabrication and InstaIlation Planning
a) Project Engineer and OC inspector shall identify applicable regulation, codes and
standard for fabrication and intallation, -inspection and monitoring point,
acceptance criteria, etc.
b) QC Inspector shall prepared Inspection and/or monitoring points, acceptance
criteria and process are made clear.
c) PPC Engineer shall prepared travelers. check lists records etc, to monitor and
confirm the compliance of work and product with the requirements.
d) Where qualification is required for specific work, the qualification procedures
and the records shall be maintained.
10.1.3 Special Proses Control
a) Welding Proses Control
Welding Shall be controlled in accordance with the regulation, codes,
standard and Welding Procedure Specification on Procedure.
Other special process such as Non Destructive Examination, cleaning,
special leak test shall be performed by the procedures, equipment and
personnel in accordance with applicable codes.
b) Training
the event that qualification are required are for special process and/or
personnel performing specific work. PT AMA shall establish and
perform necessary training to Obtain the qualification and to maintain the
required skill.
Identification methods for the qualified procedures and/or personnel shall
be established and the appropriate record shall be established and
maintained
PT AMA shall confirm the qualification and monitor the performance and
when any degradation is found, require to do re-training.
11. INSPECTION AND TESTING PLAN
This section covers Procedures for controlling inspection and testing to verify the
conformance of product and setvices to the specified requirements of the contract,
applicable codes, standard and Examination & inspection Procedure
12. HANDLING, STORAGE AND SHIPPING
12.1 General
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This section covers the controlling procedures to be established and carried out for
handling, Storage, shipping and preservation of material and equipmen
11.2 Planning, Controling General
11.2.1 PT AMA will identify the requirements on handling, storage and shipping on the
basis of legal restrictions
11.2.2 Where required, PT AMA Shall submit the procedures for review and approval. PT
AMA shall implement the work in accordance With the approved procedures and
shall generate the work records.
11.3 Handling and Storage
11.3.1 PT AMA shall provide methods and means of handling that prevent damages or
deterioration
11.3.2 Product in stock Shali be clearly identified by marking, tags, label, location etc.
11.3.3 Handling of heavy components shall be performed under controlled conditions.
Operator of special handling and lifting equipment shall be qualified or experience
in the use Of equipgnent.
11.4Packing and Delivery
11.4.1 Prior to packing PT AMA shall confirm the Cleanliness, coating, required records
of the product, materials to be used for packing and the completion of disposition
of Nonconformance, etc.
11.4.2 PT AMA Shall control packing, preservation and marking process to satisfy.
11.4.3 All Shipments shall be prepared and transported in conformance to specified
requirements and applicable carrier regulations,
11.4.4 PT AMA shall deliver the cargo to the specified port of loading within the term
delivery
11.4.5 PT AMA Shall supervise or conduct inspection for shipping as necessary.
12 PRECOMMISIONING CONTROL
12.1 General
This section covers the procedures to control pre-commissioning activities,
10.2 Planning
PT AMA shall prepare and arrange the following plans, procedures etc. with the
cooperation of pre-commissioning staffs and relevant Subcontractors.
10.2.1 Pre-commissioning Plan, identifying activity sequences, boundaries Of equipment
to be tested and released, pre-requisition, verification methods and inspection and
test point.
10.2.2 Identification Of acceptance and rejection criteria
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10.2.3 Adequate and appropriate equipment.
10.2.4 Suitable and controlled environmental conditions,
10.2.5 Subcontractor's Cooperation for significant product testing as required
10.2.6 Preparation of record form and checklist.
11 MPLEMENTATION OF PRE-COMMISSIONING
13.1 Pre-commissioning Verification
Pre-installation verification.
Identification check, physical condition cheek.
Installation verification
Equipment verification for commissioning readiness and confirmation of
satisfactory disposition Of pending problem, system check cleaning, pressure
leak-test, flow direction Check, in line instrumentation check, etc.
11.2 Measuring equipment shaft be calibrated and instruments shall be adjusted. Where
temporary items are mounted, they shall be identified and removed after the
completion of test.
11.3 Collection of data and evaluation
Data taken at each stage shan be analysed and evaluated of the. validi , inte ri and
com leteness. Whe.n an incompleteness is found, PT AMA shall fake corrective
actions.
11.4 Records
11.4.1 Records shall be co.Uected and compiled by the relevant engineers with prior
aggrement
11.4.2 Records shall include the result of analysis and evaluation corrective actions,
changes and modifications, calibration records etc.
11.4.3 Records shaU be controlled in accordance with section 15 of this document.
11.5 Control of Measuring and Test Equipment
11.5.1 Records are requested to plan and specify the characteristics to be tested,
measuring method to be employed and the acceptance limits.
11.5.2 PT AMA shall select appropriate measuring and test equipment in
their accuracy and capacity to the specified requirements.
11.5.3 Equipment, gases, jigs or such devices to verify the acceptability of PT AMA
shall select appropriate measuring and test equipment in their accuracy and
capacity to the specified requirements.
11.5.4 The measures shall .include the records and control logs, the identification of
validity to show the calibration status, the handling and storing to prevent
damage and deterioration.
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12 QUALITY RECORDS
14.1 General
This section covers the procedures for the preparation and maintenance of the
evidence of quality.
14.2 Identification, Collecting and Fitting.
14.2.1 Records required to be turned over to COMPANY shall be defined at an early
stage of the work by mutual agreement between COMPANY and PT AMA.
14.2.2 Records shan be classified into following categories
General Documents : QA Documents, Project Documents.
Engineering Documents Design Documents, including vendors
Documents.
Shop Quality RecordS Manufacturing Records, Inspection & Test
Records.
Construction Records Site Construction & Installation Records.
Commisioning Operation recorde
14.2.3 Project Administration shall establish the filling CO-de of documents and
prepare Quality records
14.2.4 Records shall be legible With Approved Signs.
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