Peningkatan Efektifitas Quality Control Project melalui Implementasi QA / QC PROGRAM

April 2015

ASSET INTEGRITY MANAGEMENT, means:DATA MANAGEMENT• EDMSDOCUMENT CONTROLLERQA/QC

• NCR SYSTEMRELIABILITY & INTEGRITY

• RISK BASED INSPECTION (RBI)• RISK BASED CERTIFICATION (RBC)• RELIABILITY CENTERED MAINTENANCE (RCM)• RELIABILITY, AVAILABILITY & MAINTAINABILITY (RAM)• ASSET PERFORMANCE ASSESSMENT (APA)• FITNESS FOR SERVICE (FFS)• PIPELINE INTEGRITY MANAGEMENT SYSTEM (PIMS)• MAINTENANCE ASSESSMENT PROTOCOL (MAP)• SHUTDOWN & TURN AROUND (SDTA)

COMPLIANCE ASSURANCE• CERTIFICATION• PERMIT

MEETING OBJECTIVES

1. To have feed back and improvement for QA / QC Program

2. To validate and to ensure the proposed QA / QC Program meeting with

PGE’s requirements and comply with applicable regulations

3. To know that QA / QC Program as Part of Asset Integrity Management

Process

4. Can be as references for QA / QC Team to develop each of Quality

Controller System

5. To know what is the meaning of QA (Quality Assurance) and QC

(Quality Controller)

6. To know where QA / QC Implementation

PROGRAM OBJECTIVES

1. To ensure compliance with project requirements (target HSE, quality &

performance, schedule, cost)

2. To minimize rework with main target is minimized potential hazard

3. Measurement Process (Key Performance Index)

4. As tools for main process:

• Data Management Function As Built Drawings, Equipment No, PSV

No, MOC, PSM, CDM, PROPER

• Reliability Function RBI, RCM, Safety Devices

• Document Controller Function Traceability System

• Compliance Assurance Function Certification, Color Coding, HSE

Program, Permit

Objectives of this program :

PROGRAM SCOPE

To develop QA / QC program for Karaha Project, geothermal power plant(GPP) including switchyard, the associated fluid collection and reinjectionsystem (FCRS) and 150 km Transmission System in Karaha, West Java,Indonesia.

1. Project Description

2. Scope of QA / QC Program

1. Piping2. Mechanical3. Civil4. Electrical5. Instrumentation & Controller

for following system (where applicable):

a) Fluid Collection and Reinjection Systemb) Geothermal Power Plantc) Civil and Insfracturesd) Additonal Supply and Servicese) Transmission 24.68 km

WHAT IS QA / QC ?

(ISO 9000, 3.2.10 – 11)

_____________________________________________

QUALITY ASSURANCE

• “A part of quality

management focused

on providing confidence

that quality

requirements will be

fulfilled”

QUALITY CONTROL

• “A part of quality

management focused

on fulfilling quality

requirements”

WHAT IS QA / QC ?

(ISO 9000, 3.2.10 – 11)

_____________________________________________

QUALITY ASSURANCE

A Strategy of Prevention

• It is focused on planning,

documenting and guidelines to

assure quality.

– specifications and

– industry or company standards.

• It is undertaken at the beginning of

a project,

• Activities are quality plans,

inspection and test plans, the

selection of defect tracking tools

QUALITY CONTROL

A Strategy of Detection

• All activities that are designed to

determine the level of quality.

• QC is a reactive means by which

quality is gauged and monitored.

These techniques and activities are agreed with customers and/or stakeholders

before project work is commenced.

QA / QC PIPING SYSTEM – an example

_____________________________________________

QUALITY ASSURANCE

No DescriptionCode

/Standard Ver.

1

Material

• Spec

• Receiving

• Storage and

Handling

ASME II,ASME

B36.10,ASME

B36.19M, etc.

• Mill

Certificate

and

• PMI (If

needed)

2 Design ASME B 31.1. • Stress

Analysis

3 Welding

• Procedure

• Personnel

ASME IX • WPS /

PQR

• WPQT

QUALITY CONTROL

No DescriptionCode

/Standard Ver.

1

Material

• Receiving

• Storage and

Handling

Approval

Procedure• Report

2 Integrity ASME B 31.1. Hydro test

3

Welding

• Consumable

Control

• Purity Gas

• Fit Up

• Welding

Inspection

• Preheating

• PWHT

• Hardness

ASME II Part C

ASME B 31.1

ASME V

• Certificate

Electrode

• Certificate

Gas

(Argon)

• Report (Fit

Up, Visual)

• NDE

(RT,PT,UT,

MT)

QA / QC PIPING SYSTEM – an example

_____________________________________________

QUALITY ASSURANCE

No DescriptionCode

/Standard Ver.

4• Cleaning

Before Paint

ISO 8501-1

SSPC

Approval

Procedure

5 • Painting &

Coating

NACE Approval

Procedure

6 • InsulationASTM C1696

Approval

Procedure

7 • Pickling Approval

Procedure

8 • Steam Blow Approval

Procedure

9 • ReinstateApproval

Procedure

QUALITY CONTROL

No DescriptionCode

/Standard Ver.

4• Sand

Blasting

ISO 8501-1

SSPC

• Report

Visual

Compare

ISO pic

5

• Painting &

Coating

Inspection

NACE • Ultra

Thickness

Measurem

ent

6 • Insulation ASTM C1696 • Report

7• Pickling Approval

Procedure

• Endoscopic

8

• Steam Blow Approval

Procedure

• Report

Target

Plate

9 • Reinstate

Approval

Procedure

• Line Check

• Torque

Report

QA / QC MECHANICAL STATIC SYSTEM – an example

_____________________________________________

QUALITY ASSURANCE

No DescriptionCode

/Standard Ver.

1

Material

• Spec

• Receiving

• Storage and

Handling

ASME VIII Div.

I & II

ASME II

• Mill Cert

• Certificate

Guarantee

2 • Design ASME VIII Div.

I & I

• Approved

Drawing

3 • Fabricator

Pressure

Vessel

ASME VIII Div.

I & II

ASME Stamp

U

4 Welding

• Procedure

• Personnel

ASME IX • WPS /

PQR

• WPQT

QUALITY CONTROL

No DescriptionCode

/Standard Ver.

1

Material

• Receiving

• Storage and

Handling

• Report

2Integrity ASME VIII Div.

I & I

• Hydro test

3

Fabricator ASME VIII Div.

I & II

• Expire

ASME

Stamp U

4

Welding

• Consumable

Control

• Purity Gas

• Fit Up

• Welding

Inspection

• Preheating

• PWHT

• Hardness

ASME II Part C

ASME B 31.1

ASME V

• Certificate

Electrode

• Certificate

Gas

(Argon)

• Report (Fit

Up, Visual)

• NDE

(RT,PT,UT,

MT)

QA / QC MECHANICAL STATIC SYSTEM – an example

_____________________________________________

QUALITY ASSURANCE

No DescriptionCode

/Standard Ver.

5 • Installation• Approved

Procedure

6 • Grouting Manufacture

Standard

• Approved

Procedure

• Certificate

Grouting

7 • Final Check

QUALITY CONTROL

No DescriptionCode

/Standard Ver.

5 • Installation

Approved

Procedure

• Report

Orientation,

Leveling,

Elevation,

Centerline

6

• Grouting Approved

Procedure

• Check

Material,

Surface

Preparation

, Mix of

Grout,

Curing,

Tightening

Anchor Bolt

7 • Final Check • Punch list

QA / QC MECHANICAL ROTATING SYSTEM – an

example

_____________________________________________

QUALITY ASSURANCE

No DescriptionCode

/Standard Ver.

1

Material

• Spec

• Receiving

• Storage and

Handling

ASME VIII Div.

I & II

ASME II

• Mill Cert

• Certificate

Guarantee

2 • Design ASME VIII Div.

I & I

• Approved

Drawing

3• Installation

• Approved

Procedure

QUALITY CONTROL

No DescriptionCode

/Standard Ver.

1

Material

• Receiving

• Storage and

Handling

• Report

• FAT

2Integrity ASME B 31.1. • Perform

test

3 • InstallationApproved

Procedure

• Report

Leveling,

Elevation,

Centerline

• Report Pre-

Alignment

• First

Alignment

(after

grouting)

• Final

Alignment

QA / QC MECHANICAL ROTATING SYSTEM – an

example

_____________________________________________

QUALITY ASSURANCE

No DescriptionCode

/Standard Ver.

4 • Grouting Manufacture

Standard

• Approved

Procedure

• Certificate

Grouting

5 • Final Check • Approval

Procedure

QUALITY CONTROL

No DescriptionCode

/Standard Ver.

6

• Grouting Approved

Procedure

• Check

Material,

Surface

Preparation

, Mix of

Grout,

Curing,

Tightening

Ancor Bolt

7• Final Check Approved

Procedure

• Punch list

QA / QC CIVIL SYSTEM – an example

_____________________________________________

QUALITY ASSURANCE

No DescriptionCode

/Standard Ver.

1 • Survey

2 • Soil

Investigation

3 • Excavation • Investigatio

n Existing

Facility

• Approval

Procedure

4 • Design ASCE 7

QUALITY CONTROL

No DescriptionCode

/Standard Ver.

1 • Survey • Report

Coordinate

s, Elevation

2 • Soil

Investigation

• Report

SPT,

DCPT,

Electric

Resistivity

3 • Excavation • Report

Depth and

with

excavation,

Slope

4

QA / QC CIVIL SYSTEM – an example

_____________________________________________

QUALITY ASSURANCE

No DescriptionCode

/Standard Ver.

5 Material

• Spec

• Receiving

• Storage and

Handling

SNI 03-1729-

2002• Mill Cert

6 • Foundation • Approved

Procedure

• Approved

Drawing

7 • Grouting Manufacture

Standard

• Approved

Procedure

• Certificate

Grouting

8 • Concrete

Work

ACI 207, ACI

301

QUALITY CONTROL

No DescriptionCode

/Standard Ver.

5 Material

• Receiving

• Storage and

Handling

SNI 03-1729-

2002• Report

6 • Foundation • Report

Elevation,

Padding

7 • Grouting Approved

Procedure

• Check

Material,

Surface

Preparation

, Mix of

Grout,

Curing,

Tightening

Anchor Bolt

8 • Concrete

Work

ACI 207, ACI

301

• Mechanical

Testing

QA / QC CIVIL SYSTEM – an example

_____________________________________________

QUALITY ASSURANCE

No DescriptionCode

/Standard Ver.

9 • Form Work ACI 347

ACI 318• Mill Cert

10 • Reinforcing

Bar Work

ACI 301, ACI

315, ACI 318

• Mill Cert

11 • Anchor Bolt • Mill Cert

12 Steel Structure

• Welding

• Painting

• Erection

• Final

• AWS D1.1

• SSPC

• WPS,PQR,

WPQT

QUALITY CONTROL

No DescriptionCode

/Standard Ver.

9 • Form Work ACI 347

ACI 318

• Material

Inspection

10 • Reinforcing

Bar Work

ACI 301, ACI

315, ACI 318

• Mechanical

Testing

11 • Anchor Bolt • Mechanical

Testing

12 Steel Structure

• Welding

• Painting

• Erection

• Final• AWS D1.1

• SSPC

• Report VT

NDE

• Report

Paint thick

• Report

Plumbness

, centerline,

elevation

• Punch List