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Env SPV DR B 001 QC Manual Rev.A

This document provides instructions for controlling the quality control manual for PT Envicon Ekatama. It states that the quality control manual describes the quality control system to ensure compliance with ASME Code requirements. It applies to all functions involved in design, purchasing, fabrication, inspection, and certification of components. The quality control manual structure reflects ASME Code requirements. The manual is prepared, controlled, and distributed by the QA/QC manager and reviewed by engineering, purchasing, and production managers.

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0% found this document useful (0 votes)

142 views92 pages

Env SPV DR B 001 QC Manual Rev.A

Uploaded by

yoey

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 92

QC MANUAL

EQUIPMENT : DEAERATOR WITH STORAGE TANK

DOCUMENT NO : ENV-SPV-DR-B-001

VENDOR SERIAL NO : J. 2267

CONTRACT / PO NO : TBA

COMPANY : PT. SOUTH PACIFIC VISCOSE

PROJECT : TBA

LOCATION : PURWAKARTA - JAWA BARAT

COMPANY APPROVAL

YOEY GARCIA 13-10-2020 PT. SOUTH PACIFIC VISCOSE

Issued for Oct

A
Review 01,2020
Rizki Perbawa Yan Rizal Aan Hendriyana
Prepared by Reviewed by Approved by
Rev Description Date
PT. ENVICON EKATAMA
DOCUMENT NUMBER Rev
QC MANUAL
ENV-SPV-DR-B-001 A

COMMENTS RESPONSE SHEET

Document /
No Company Comments Contractor Response Initial Remark
Page Ref
Document No ENV-ASME-QCM-01 Revision 10
Section ENV–QCM-A Date 10/12/2019
Subject Cover Page Page 1 of 1

PT. Envicon Ekatama

Jl. Inspeksi Kalimalang, Desa Karang Mulya, Teluk Jambe,
Karawang – 41361 , Jawa Barat – Indonesia
Telp : +62 267 400737, 400738 – Fax : +62 267 400739

FOR THE SHOP CONSTRUCTION AND FIELD ASSEMBLY

OF PRESSURE VESSELS, POWER BOILERS AND THEIR PARTS
INCLUDING BOILER EXTERNAL PIPING
IN ACCORDANCE WITH THE ASME CODE SECTION VIII DIV 1
ASME SECTION I, ASME B31.1 AND JURISDICTION REQUIREMENT

Controlled

√
Uncontrolled

HOLDER NO
ASSIGNED TO
PT.ENVICON EKATAMA
Karawang - Indonesia

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-01 Date 10/12/2019
Subject Definitions Page 1 of 3

1.0 PURPOSE :

This section defines specific terms and explains abbreviations referenced throughout this
Quality Control Manual.

2.0 TERMS AND DEFINITIONS :

2.1 ASME Code or Code – Refers to Section I , Section VIII Division 1, Jurisdiction
Requirement and any other sections of the ASME Boiler and Pressure Vessel Code made
applicable by any references code.

2.2 AIA – Authorized Inspection Agency – Inspection Agency accredited by ASME , with
whom PT EE has entered into a contract for providing services of AI/AIS for Inspection of
ASME Code related fabrication.

2.3 AIS - Authorized Inspector Supervisor

2.4 Authorized Inspector (AI) – An individual holding a valid National Bord new
construction commissions with the appropriate endorsment and designated as such by
an Authorized Inspection Agency.

2.5 Bill of Material (BOM) - A list of raw materials or components and quantity needed to
make and item, assembly, or end product.
Other forms of BOM are :

a. A BOM on the drawing to uniquely identify finished products and subassemblies

and parts of the finished product
b. Material List : A List of raw material and quantities needed to make an item

2.6 Construction - as used in this Manual, is an all-inclusive term comprising materials,

design, fabrication, examination, inspection, testing, certification, and stamping
certification mark.

2.7 Customer Requirements – Those requirements that are a part of customer specifications as
indicated on Contract information sheet , textural part , requisition , and / or drawings.

2.8 ECR/ECN – Engineering Change Request/ Engineering Change Note

2.9 ITP – Inspection and Test Plan

JL.Inspeksi kalimalang, Desa Karang Mulya, Teluk Jambe, Karawang 41361, Jawa Barat , Indonesia
Telp No : +62 269 400939, 400939, Fax No. : +62 269 400939 , Website : www.enviconekatama.com
PT.ENVICON EKATAMA
Karawang - Indonesia

Document No ENV-ASME-QCM-01 Revision 9

Section ENV–QCM-01 Date 03/12/2019
Subject Definitions Page 2 of 3

2.10 Inspection and Test Plan – Document that describe that sequence of fabrication , heat
treatment , inspection and examination operations required for a particular part of
assembly.
Shop traveler sheet may some times be referred to as processing, traveler, or Inspection
and Test Plan.
Inspection Point ( Hold, Witness, Review)

2.10.1 H- Hold Point

Hold point is an inspection, test, non destructive examination or fabrication
operation that must be witnessed by a specified party prior to subsequent
fabrication. Operation sequences at the required hold point shall not be
continued prior having been examined and released by a specified party.

2.10.1 W- Witness Point

Witness point is an inspection, test, non destructive examination or
fabrication operation that is designated to be witnessed by a specified party.
The specified party must be notified sufficiently in advance prior to
performing the designated operation. If the specified party fails to witness the
examination, the operation may be performed, with written consent of the
specified party.

2.10.2 R- Review Point

An inspection , which conducted by reviewing system or document related
to i.e, Reviewing of RT film, Inspection and Test reports / records or review
of a Quality system

2.11 Material Requisition – A document that specifies material ordering requirements.

2.12 Mark Number – Describes part characteristics to uniquely set it apart from all others
on the same drawing .

2.13 PMS – Purchase Material Specification

2.14 MSR – Material Substitution Request

2.15 MAWP –Maximum Allowable Working Pressure

2.16 MDMT – Minimum Design Metal Temperature

Document No ENV-ASME-QCM-01 Revision 9

Section ENV–QCM-01 Date 03/12/2019
Subject Definitions Page 3 of 3

2.17 MTR/MTC – Material Test Report/ Material Test Certificate

2.18 MTE – Measuring and Test Equipment

2.19 Nonconformance Report (NCR) – A condition which does not comply with applicable
rules of the Code this, QC Manual or other specified requirements. Non conformities
must be corrected before the completed component can be considered to comply with
the Code.

2.20 NDE – Non Destructive Examination

2.21 PT EE – PT Envicon Ekatama

2.22 PQR – Procedure Qualification Record

2.23 PWHT – Post Weld Heat Treatment

2.24 QA/QC Manager– Quality Assurance / Quality Control Manager

2.25 WPQ - will mean WPQ ( Welders Performance Qualification) and

WOPQ (Welding Operator Performance Qualifications)

2.26 WPS - Welding Procedure Specification

2.27 MDR/MPDR – Manufacturer’s Data Report / Manufacture’s Partial Data Report

2.28 PO – Purchase Order

2.29 MTO – Material Take Off

2.30 FC – For Construction

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-02 Date 10/12/2019
Subject Control of Quality Control Manual Page 1 of 2

1.0 PURPOSE :

The purpose of this Manual is to describe the Quality Control System, that assure
compliance with the applicable sections of the ASME Code.

2.0 SCOPE :

This Quality Control Manual applies to functions within PT EE involved in design,

purchase, fabrication, construction, inspection, and examination stamping & certification of
components and assemblies.

3.0 GENERAL :

3.1 The Quality Control Manual is structured to reflect the requirements of the Appendix A-300
of Section I and Appendix 10 of Section VIII Division 1, of the ASME Code .

3.2 The Quality Control Manual shall be prepared, controlled and distributed by QA/QC
Manager to all holders of controlled Manual within PT EE organization, after review and
approved by the QA/QC Manager and accepted by Authorized Inspector on the Table of
Content Section ENV-QCM-C.

3.3 The section within this Manual outline basic quality related systems and responsibilities in
Engineering, Production and Quality Assurance/Quality Control.
This Manual defines system requirements, while the quality control procedure detail the
methods used accomplish the control defined herein.

4.0 RESPONSIBILITY :

4.1 QA/QC Manager is responsible for preparing Manual changes and obtaining the AI’s
signature on the Table of Contents prior to release for distribution and implementation.

5.0 MANUAL REVISION :

QA/QC Manager shall review the Quality Control Manual bi-annually to determine the
need for revision to comply with Code Edition and internal company changes (Exhibit 1 :
Code Summary review ) .
Revisions to the Quality Control Manual shall be made and implemented within six months
of the Code Edition issue date. Any change is made to a section, the entire section shall be
revised and reissued. Each time a revised section is released to the holders of the Manual , a
revised Table of Contents showing section revision numbers shall be distributed with it.The
revision level of the cover page shall also be advance show the latest revision of the
Manual.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-02 Date 10/12/2019
Subject Control of Quality Control Manual Page 2 of 2

5.1 The revised text shall be indicated by use of bold and italic wording, For the latest changes
revision indicator shall appear and previous revision indicator if any shall be removed.
The revision on the form and format are identified by cloud mark and revision number in
triangle mark.
The revision indicator shall appear only the form in the QC Manual and not in the form
and format in use.

6.0 MANUAL ASSIGNMENT :

Two types of manuals are used, Controlled or Uncontrolled . The type of Manual is
specified on the title page.

6.1 Controlled Manuals are maintained current revisions, when issued, are forwarded to all
holders of controlled Manuals . It is the responsibility of the assigned recipient to remove the
superseded pages, insert the revised pages, and return the completed list of Distribution form
acknowledging receipt . An exhibit of this form is shows as
( Exhibit 2 : Document Control Record).
If acknowledgment is not received within Five working days from date of issue, QA/QC
Manager is responsible for initiating corrective action. Controlled Manuals are issued
only by QA/QC Manager and use within PT EE organization and a list of current
holders of controlled manuals shall be maintained.

6.2 Controlled copy of this Manual shall be issued to Site Manager & Site QC Engineer .

6.3 Uncontrolled Manuals are not maintained current. Uncontrolled copies are current when
issued to outside PT EE organization for information only.

6.4 A copy of controlled Manual shall be provided by QA/QC Manager to the Authorized
Inspector at shop and field site.

6.5 The QC Manual and Quality Control Procedure (QCP) published in English Language and
QA/QC Manager shall translation to Bahasa Indonesia (Local Language) for easy
understand and the AI not responsible for accepted.

7.0 QUALITY CONTROL PROCEDURE (QCP)

The Quality Control Procedure shall be prepare, controlled, and distribution by QA/QC
manager to all holders of controlled manual with PT. EE organization after review and
approved by QA/QC manager and accepted by the AI.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-03 Date 10/12/2019
Subject Authority, Responsibility, & Organization Page 1 of 2

1.0 GENERAL

1.1 The interrelation of all personnel who manage, perform and verify work affecting the
Quality are shown in this section. The organization chart of Company Legal Name
establishing the lines of Authority and Communications for the proper implementation of
this Manual are given in Chart No.1 of this section.

1.2 Delegation of Duties

1.2.1 Each person in a supervisory position may delegate the performance of their duties
to competent and when required qualified certified personnel under their
supervision however, they may not delegate their responsibility.

1.2.2 Each person in a supervisory position may carry out the duties of personnel
under their supervision, provided they are qualified and when required
certified to perform this work.

JL.Inspeksi kalimalang, Desa Karang Mulya, Teluk Jambe, Karawang 41361, Jawa Barat , Indonesia
Telp No : +62 267 400737, 400739, Fax No. : +62 267 400739 , Website : www.enviconekatama.com
PT.ENVICON EKATAMA
Karawang - Indonesia

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-03 Date 10/12/2019
Subject Authority, Responsibility, & Organization Page 2 of 2

Chart No.1 Organization

Supervisor

Site Store
Keeper
Site
Manager
Site
FIELD

Engineer
Site QC
SHOP

Sub Contract
Supervisor
Manager
QA/QC

QA/QC

NDE
QC
Purchasing

QC. Inspector
Manager

Supervisor
Manager
Store

Store
DIRECTOR

SPV/Foreman
Shop-
Production
Manager

Welding Operator
Welder /
Supervisor
Welding
Engineer
Welding
Engineering

Engineer
Manager

Design
Marketing
Manager

------------- Administrative Responsibility

Manager

Functional Responsibility
Finance

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-04 Date 10/12/2019
Drawing, Design Calculation and
Subject Page 1 of 5
Document Control

1.0 PURPOSE :

This Quality Control system shall provide procedures that will ensure that the latest
applicable drawing, design calculation, spesifications and instruction required by code as
well as Authorized change, are used for manufacture, examination, inspection and
testing.

2.0 SCOPE :

This Section describes the procedures and responsibilities for order entry, customer supplied
document control and design activities including distribution of the documents for
fabrication.

3.0 RESPONSIBILITY :

It is the responsibility of Engineering Manager to generate, review, approve and distribute

these (Refer to 1.0 above) document using document transmittal ( Exhibit 3 : Drawing &
Document Transmittal ) and make them available to the Authorized Inspector for his review.

4.0 ORDER ENTRY :

Upon awarding of a contract to PT EE, The Marketing Manager will prepare Work Order
and assign a Job number for the job after Minutes of Contract Review Meeting (Exhibit 4)
Marketing Department will distribute to QA/QC Manager , Engineering Manager, Welding
Engineer, Purchasing Manager, Production Manager and Store Manager.

The Job Order number shall be applied to all documents including but not limited to PO,
Drawing, Calculation etc. Code Edition on the client’s purchase order date shall be
followed for construction. For Boiler External Piping and parts, Code Edition in the contract
documents shall be followed for construction.

5.0 Design by the Company

5.1 Prior to receiving of an order for a Code item which, is to be designed by the PT EE,
the customer’s specification will be reviewed for adequacy by the Engineering Manager
for compliance with applicable Code requirements including loading, Para. UG 22 of
ASME Section VIII Div.1, Para PG 22 of ASME Section I as applicable. Any
deficiencies found shall be resolved with the customer before the start of Code design
work.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-04 Date 10/12/2019
Drawing, Design Calculation and
Subject Page 2 of 5
Document Control

5.2 Design Engineer prepares drawing, calculation, Material Take Off (MTO) (Exhibit 30)
and Purchase Material Specification which include the PWHT & NDE requirements.
Foregoing document shall be being hand carried by Design Engineer to Engineering
Manager for necessary Reviewing, Approval & Release.
Any Code non compliance shall be brought to the attention of the Design Engineer for
correction and re-submitted. Once the Engineering Manager is satisfied, he shall sign
and date the document for code compliance, followed by distribution to the department
concerned. The document shall be stamp “FOR CONSTRUCTION”.
In addition the Design Engineer shall verify the fibre elongation value for cold formed
section (shell, head, manhole, and other pressure boundary part) and state on drawing as
notes the requirements for heat treatment of cold formed parts.
Cold Forming requirement to be included in the Purchase Material Specification (PMS),
the requirement of Heat Treatment shall refer to ASME Sect. VIII Div.1, para. UG 99
and ASME Section I para. PG19 and PG20.

5.3 On review of document and drawing, if any design change is required to be

incorporated, same shall be informed to Design Engineer with Engineering Change
Request/ECR (Exhibit 5) and the Design Engineer shall issue Engineering Change
Note/ECN (Exhibit 6), Design change and modification are identified, documented,
reviewed and approved by Engineering Manager before issue for Construction.The
recipient of ECN shall record the ECN No , on the drawings, All ECN’s shall be in
corporated on the final drawinga and presented to the AI prior to final inspection.

5.4 Drawing will contain enough information to ensure proper fabrication. This information
will consist of but not be limited to design data material specification, grade and class,
dimensions and tolerance, Job Order, Code section and edition (and code case if
applicable and accepted to Jurisdiction ), WPS’s and drawing number. The design
calculations will contain as a minimum Code section, and the item serial number shall
be assigned on the drawing.

5.5 Onlly SA or SB material for which allowable stresses are listed in the ASME
Section II Part A, B, C And material permilled by the code edition and code case when
applicable and accepted by jurisdiction permitted by Code, shall be used for construction
of pressure parts. Other material permitted by the Code cases may also be used . The
Design Engineer shall prepare detailed design drawing. Such drawing shall include:

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-04 Date 10/12/2019
Drawing, Design Calculation and
Subject Page 3 of 5
Document Control

1) Bill of Material
2) The Applicable Code Edition and Code Case (if applicable)
3) Design Pressure / Temperature
4) MAWP / (Internal/External)
5) Corrosion Allowance
6) Minimum Design Metal Temperature (Vessel)
7) NDE Requirements
8) Heat Treatment Requirements
9) Hydrostatic/Pneumatic Test Pressure, test position and permissible test
10) Welding detail and production test plate and location of attachment (if any)
11) Fabrication Tolerances
12) Impact Test Requirements and / or exemptions.
13) Alloy verification requirement (if any)
14) Client’s and statutory additional requirement / specification (if any)
15) Special material testing requirement (if any)
16) Maximum design steaming capacity ( ASME Section I)
17) Heating surface (ASME Section I).
18) Pressure Relief (ASME Section I)
19) Special Services, Lethal or Non Lethal ( Vessel )
20) NB Registration
21) Stamping information for name plate detail

5.6 WPS are incorporated in drawing by Design Engineer with input from Welding
Engineer. For customer supplied drawing a welding map & NDE map shall be prepared.

5.7 Purchase Material Specification (Exhibit 9) shall contain information needed for
procurement of Code Materials and services. Purchase Material Specification for Code
Stamp Material including welding consumables are also prepared by Design Engineer
with information given by Welding Engineer.

6.0 CUSTOMER SUPPLIED DOCUMENTS :

The Engineering Manager is responsible for review and approval of customer supplied
document to assure Code compliance.
Customer supplied drawing may be used for fabrication provided they are reviewed and
approved by the Engineering Manager prior to their use. Customer supplied Drawing used in
the fabrication shop shall be stamped “CUSTOMER SUPPLY DOCUMENT “after review
and approval by the Engineering Manager. Any revised drawings or other customer
supplied document, which are revised, shall be reviewed, approved and distributed in the
same manner as the original.

Document No ENV-ASME-QCM-01 Revision 9

Section ENV–QCM-04 Date 10/12/2019
Drawing, Design Calculation and
Subject Page 4 of 5
Document Control
7.0 Units Measurement.
7.1 Either U.S. Customary, SI, or any local customary units may be used to demonstrate
compliance with all requirements of ASME Section I (related to materials, fabrication,
examination, inspection, testing, certification, and overpressure protection).

7.2 A single system of units shall be used for all aspects of design except where otherwise
permitted by ASME Section I. When components are manufactured at different
locations where local customary units are different than those used for the general
design, the local units may be used for the design and documentation of that
component.

7.3 Production, measurement and test equipment, drawings, welding procedure

specifications, welding procedure and performance qualifications, and other
fabrication documents may be in U.S. Customary, SI, or local customary units in
accordance with the fabricator’s practice. When values shown in calculations and
analysis, fabrication documents or measurement and test equipment are in different
units, any conversions necessary for verification of Code compliance, and to ensure
that dimensional consistency is maintained, shall be in accordance with the following:
 Conversion factors shall be accurate to at least four significant figures.
 The results of conversions of units shall be expressed to a minimum of three
significant figures.

7.4 All entries on a Manufacturer’s Data Report and data for Code‐required nameplate
marking shall be in units consistent with the fabrication drawings for the component
using U.S. Customary, SI, or local customary units. Units (either primary or
alternative) may be shown parenthetically. Users of this Code are cautioned that the
receiving jurisdiction should be contacted to ensure the units are acceptable.

8.0 The Engineering Manager is responsible to submit the design calculation & drawing to AI
for his review prior Fabrication. Any comments shall be incorporated in the revised
drawing for his review purposes.

9.0 Computer Aided Design.

9.1 When computer aided design calculations are used for Company designed Code
items, the Design Engineer is responsible for the input of correct design data and for
the verification that the correct output has been obtained, and the Engineering
Manager shall be responsible for the approval.
9.2 Computer aided design calculations shall show the program name and version
number on the output and the pages shall be numbered.
9.3 If commercially available or in-house developed computer aided design software is
used, the Engineering Manager shall verify the accuracy of computer programs for
each element used, prior to use by performing manual calculations or by an alternate
method and comparing the results against those of the program. These results shall be
maintained and made available to the Authorized Inspector. Any revisions to the
program will require re-verification.
JL.Inspeksi kalimalang, Desa Karang Mulya, Teluk Jambe, Karawang 41361, Jawa Barat , Indonesia
Telp No : +62 269 400939, 400939, Fax No. : +62 269 400939 , Website : www.enviconekatama.com
PT.ENVICON EKATAMA
Karawang - Indonesia

Document No ENV-ASME-QCM-01 Revision 9

Section ENV–QCM-04 Date 10/12/2019
Drawing, Design Calculation and
Subject Page 5of 5
Document Control
9.4 The Engineering Manager will review the Code Edition to determine if in house
computer programs are affected. Required revisions will be made within six months
of the Edition date.
9.5 The review of programs and all revisions are documented on a dated record signed
by the Engineering Manager, showing the program name and version number and
Code Edition when he is satisfied that the computer program has the capability to
produce acceptable calculations.
9.6 Computer aided calculations output are available for review and acceptance by the
Authorized Inspector. The Engineering Manager shall provide the Authorized
Inspector with any manual calculations requested to verify the computer output.

10.0 Distribution

Distribution of design document ( drawing etc ) shall be handled by the Design Engineer. He
shall keep document list and record the latest revision for each project and deliver new and
revised necessary documents to Production Manager and , QA/QC Manager . The recipient
of the document shall sign and date the drawing and document transmittal .

If the documents is a revision, the recipient of the document shall mark the superceded
document “ OBSOLETE “ place the document in the document file and withdraw the old
copy. Design Engineer may maintain one copy of the old revision for historical reason but
they Must Be Marked “ OBSOLETE”.

11.0 Document Control :

All documents shall be prepared, reviewed and approved in accordance with this Quality
Control Manual, Revision to documents requires review and approval in the same manner as
the original. All document relating to Code activities shall be made available to the
Authorized Inspector.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-05 Date 10/12/2019
Subject Material Control Page 1 of 3

1.0 PURPOSE :

This Section outlines the requirements for selection, procurement, inspection, marking and
identifying, storage, and issuance of material.

2.0 SCOPE :

The system controls and assures that material procured and received is properly identified
and that documentation, including material certification or test reports have been received
and approved. This system assures that only approved material is used for construction of
Code item.

3.0 Requisitions :
Based on the design, Design Engineer establishes technical requirements of material and
parts that includes:

 Ordering information as per material specification

 Any supplementary or additional tests required including impact test and heat
treatment, etc.
 Requirement of material test reports, certified material test reports or partial data
reports.

3.1 Material Take Off (MTO) (Exhibit 30) and Purchase Material Specification(PMS) (Exhibit 8)
for Code material including welding consumables are prepared by Design Engineer based on
FC drawings and qualified WPS, which list all Code requirements. These shall include the
technical requirement for material type or grade selected from the applicable Code Section II,
use for Code item and purchase purposes.

3.2 Completed Material Take Off along with PMS are reviewed for Code compliance by the
Engineering Manager, who would make any required corrections and approve by initial and
date the MTO and returns it to the Design Engineer.

3.3 Based on approved MTO, Store Manager is responsible for checking availability of stock
materials in inventory list. In case where material is not available, Purchase Request
(Exhibit 7) shall be raised by Design Engineer. The completed Purchase Request (PR) is
then submitted to Purchasing Manager for Purchasing Purposes.

3.4 Based on Puchase Request (PR) The Purchasing Manager, shall raised Purchase Order
(Exhibit 9) along with PMS and approved by Finance Manager and selected Vendor will
then be issued with P/O. Copy of Un-priced P/O with PMS will be sent to QC Inspector and
Store Supervisor for their receiving Inspection.

3.5 Additional Code material for field (if any), requested by the Site Manager, is requisitioned by
the Engineering Manager as described above.
It is the company policy that no purchasing of material for pressure parts will be carried out
from field sites.

JL.Inspeksi kalimalang, Desa Karang Mulya, Teluk Jambe, Karawang 41361, Jawa Barat , Indonesia
Telp No : +62 268 400838, 400838, Fax No. : +62 268 400839 , Website : www.enviconekatama.com
PT.ENVICON EKATAMA
Karawang - Indonesia

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-05 Date 10/12/2019
Subject Material Control Page 2 of 3

3.6 All Code material which have been received at the shop or field sites shall be placed in a
“Hold“ area waiting Quality Control inspection and release.

3.7 The QC Inspector, accompanied by Store Supervisor referring to the Purchase Order , PMS,
applicable drawing and ASME Section II and certificates, examines all Code materials for
spec, class, grade, dimensions, original identification marking, condition and quantity.
The QC Inspector shall verify dimension with calibrated MTE.
For Stock Material and Customer Supplied Material, Receiving Inspection shall be carried out
using PMS and BOM.

3.8 Information such as heat number, material specification, type or grade and all Code required
markings are recorded on the Receiving Material Report (Exhibit 10). If the QC Inspector
find the original identification marking and dimension is acceptable, he marks the material
with the applicable job number, signs and dates the Copy P/O and the Receiving Material
Report and Material Mill/Test Certificate and forwards them to the QC Manager.

3.9 Material Examination consists of the visual inspection for damage, dimensional inspection,
marking inspection to the applicable Code material specification requirements. During
receiving inspection the Shop QC Inspector must record all the original required marking on
the back side of Material Test Certificate.

3.9.1 Quality Control Inspector reviews and approves all material test report

3.9.2 Purchasing Manager is notified by the QA/QC Manager when the discrepant test
report receive , Purchasing Manager notifies the vendor concerning the discrepancy.
The discrepancy is resolved before the Quality Control Inspector approves
the test report.

3.9.3 It shall be the responsibility of the QA/QC Manager to inform Purchasing Manager
of any discrepancy on the Material Test Report so that corrective action can be
implemented.

3.9.4 Material received that do not comply with the ordering requirement ( such as
additional testing ) or fail to meet visual and dimensional criteria shall be handled in
accordance with the system outlined in the correction of non conformance Section of
this Manual (ENV-QCM-07).

3.10 Material purchased for contract are identified by Job Order and material specification
requirements. All stock shall be identified in accordance with the material specification
requirements.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-05 Date 10/12/2019
Subject Material Control Page 3 of 3

3.11 Material identity is maintained in accordance with Quality Control Procedure

(ENV-PR-10).

3.12 Receiving Inspection in the field is handled by Site QC Engineer using the PO and
applicable PMS, Manufacturer Partial Data Report.

3.13 The Shop Supervisor shall request the materials ( plate, pipe, flange, etc ) to store using
the Material Slip ( Exhibit 11 ) and Material Consumable to store using the Material
Consumable slip (Exhibit 12) .

3.14 Surplus material are identified and marked / tagged with heat number, material
specification and sizes, minor off cuts are disposed to scrap. Stock and surplus material
are recorder in Material Stock Record ( Stock Card ).

3.15 All pressure part material such as steel plates . tubes and pipes may not be stored in
open area. All storage material shall be correctly identified with sizes, grade and
specification.

3.16 Material Substitution Request - MSR ( Exhibit 13 ) for material substitution shall be
approved by Engineering Manager and QA/QC Manager and submited to AI for review
and when approved the drawing shall be revised to state the subtitation material.

3.17 If further material testing is required to be performed at receiving inspection or during

manufacturing operations considered as non conformity and shall be handle as per
Section ENV-QCM-07 of this Manual this activity are documented on the Inspection
Test and Plan.

3.18 Document generated in connection with material control are available to the Authorized
Inspector by QA/QC Manager.

4.0 RESPONSIBILITY :

4.1 QA/QC Manager is responsible for control related activities such as Reviewing Material
Test Report.

4.2 Repair of defects in base material may be repaired only with concurrence of the
Authorized Inspector on the method and the extent of repair and will be controlled in
accordance with Section ENV-QCM-08 dealing with correction of Non Conformities.

4.3 Identification of Material

Material identification shall be maintained throughout storage and installation.
Prior to subdividing Code material, identification shall be transferred by Shop Foreman
to the un marked portion of the material and verified by QC Inspector. The identification
of material shall be accomplished with marking devices and techniques that are not
detrimental to the function or quality of the material.

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Section ENV–QCM-06 Date 10/12/2019
Examination and Inspection
Subject Page 1 of 6
Program

1.0 PURPOSE :

This section outlines the system for controlling Inspections and Nondestructive
examinations.

2.0 SCOPE :

The system of Inspection and Test Plan, ( Inspection Control fabrication, construction,
Inspection ,examination operations, stamping and certification ) assures that the inspection
and nondestructive
examination requirements of the applicable Code, Quality Control Procedure and any
additional Contractual requirement are met. The system used for a particular component is
dependent on the component configuration, fabrication, processes used, and quantities
produced. This system permit the Authorized Inspector to designate specific inspection
points prior to the start of fabrication or construction and record all activities in Inspection
and Test Plan.

3.0 Inspection and Test Plan (ITP)

3.1 During the construction, Code items are controlled using an Inspection and Test
Plan (Exhibit 14), prepared by the QC Supervisor based on the FC drawings which
lists the sequence of fabrication, examination and inspection operations for each
item in the spaces provided.
3.2 QA/QC Manager shall include the quality control requirements for inspection,
examination and stamping & control test in the Inspection & Test Plan. He shall
review the Inspection & Test Plan and FC drawings with the AI to assign his
designated inspection points.
3.3 The QA/QC Manager and AI initials and date the Inspection & Test Plan in the
column provided to document their review prior to release the Inspection & Test
Plan to be used for the Code Construction.
3.4 The Inspection & Test Plan contains columns for the initials and date of Shop
Supervisor, QC Inspector and AI on the applicable line for those operations they
accept.
3.5 No work shall proceed unless the designated hold point as indicated in the
Inspection & Test Plan had been inspected, and signed off by the AI.
3.6 Revisions to Inspection & Test Plan shall be handled in the same manner as
original. The process pages of the ITP shall be attach to be revised ITP, minor
changes such as editorial changes to be made by the QC Supervisor and AI,
initialized and dated. Inspection & Test Plan shall be maintained by QC Supervisor
until job/project is completed and put on the job file upon certification of MDR.
When ever FC drawings are revised, the ITP shall be reviewed by the QC
Supervisor for changes. If no change is required, the review shall be documented
on the cover sheet of ITP.
JL.Inspeksi kalimalang, Desa Karang Mulya, Teluk Jambe, Karawang 41361, Jawa Barat , Indonesia
Telp No : +62 269 400939, 400939, Fax No. : +62 269 400939 , Website : www.enviconekatama.com
PT.ENVICON EKATAMA
Karawang - Indonesia

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-06 Date 10/12/2019
Examination and Inspection
Subject Page 2 of 6
Program

3.7 The QA/QC Manager or his designee has the responsibility for notifying the AI in
sufficient time in advance for his designated inspection / hold points.
3.8 The QA/QC Manager or his designee has the responsibility to stop or hold the work if
he found any non conformance during the Code’s construction.
4.0 Stage Examination & Inspection
Production Manager shall be responsible for fabrication as per the drawings. At the
appropriate stages identified on the ITP, he shall offer the stage to QA/QC Manager for
examination.
Shop Supervisor/Foreman made a Request of inspection as per of stages ITP to QC Shop
( Exhibit 15 : Request for Inspection).
Shell plates and edges of heads and other components are gas-cut/machined/ground to the
required edge preparation. Edges are examined visually or by PT or MT when required by
ITP. Adjoining edges of shell plates are shaped to a proper curvature by preliminary rolling
or forming in order to avoid objectionable flat spots and peaking at the weld joints. Rolled
shells are checked for out of roundness, shape and diameter to meet the tolerance
requirements. Re-rolling is permissible to achieve the required dimensions ( Exhibit 16 :
Shell Ovality Inspection Report ). If welded shell course is required to be re-rolled, the
weld shall be ground flush on both surfaces and the weld seam suitably crack detected.
Dimensions of shell and head shall meet the Code required tolerances. When external
pressure condition is applicable, the maximum plus or minus deviation from the true
circular form is verified using the template as per Code requirements
( Exhibit 17 : Dimensional Report).
Components shall be fitted, aligned and retained in position during welding using bars,
jacks, clamps or tack welds or other means. These temporary attachments are removed
when they have served their purpose in a manner so that it does not cause damage to the
materials.
Completed joints are examined to ensure that they do not exceed the tolerance requirement
of Code for alignment and weld reinforcements and that the weld surfaces are acceptable.
During stage examination, QA/QC Manager shall be responsible for :
1) Verifying identification and traceability of all materials used in fabrication
2) Examination of material before fabrication to ensure correct specifications
and correct thickness & dimensions.
3) Examination of weld edges and parts after fit-up to ensure they have been
properly fitted and that the joining surfaces re cleaned and within
alignment tolerances
4) Examination during and after welding and at other stages identified on ITP
He shall signify acceptance for all the stages on ITP and offer to AI in accordance with his
inspection point for his acceptance and signatures on ITP
Individual fit up and weld inspection is reported on Fit Up and Visual Examination
Report,Inspection stages are consolidated and then signed off on ITP.

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Examination and Inspection
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Program

5.0 Field Assembly

5.1 Field assembly of Code items controlled by the shop organization and implemented
by Field personnel.
5.2 The field Inspection & Test Plan with assembly drawings is reviewed and accepted
by the QA/QC Manager for Code and Quality control requirements, which he may
add if he found deemed necessary to do so.
5.3 The field Inspection & Test Plan and assembly drawings are then sent to the Field
QC Inspector, who will then review the Field Inspection & Test Plan with the AI at
field site to designate his inspection points, prior the start of Code Work.
5.4 The QC Inspector and AI initials and date the field Inspection & Test Plan to
document their involvement.
5.5 The field Inspection & Test Plan contains the columns for initials and dates to
confirm completion of each stage of operation by the QC Inspector, prior to the
inspection of the AI.

6.0 Final Inspection

6.1 When shop or field assembly of a Code item is completed, the QC Inspector perform
his final inspection. He initials and dates the Inspection & Test Plan when the item
meets all Code requirements and all nonconformity closed.

6.2 The AI will make his final inspection at the time hydrostatic or pneumatic test
required as specified in the Inspection & Test Plan. For parts for which would not
be tested until field assembly is completed, he makes his inspection after the
fabrication of the component completed.

6.3 When a pressure vessel is not provided with an opening or other means of access to
inspect internal surfaces, a hold point for the QC Inspector and AI will be shown on
the Inspection & Test Plan to permit internal inspection before starting the set up of
final closure weld.

6.4 Actual dimensions and the following material markings are recorded during final
inspection by the QC Inspector :

 The heat number for all material and plate number ( for plate )
 The material specification, type or grade for all material.
 Manufacturer/Sub contractor identification marking on sub assembllies
without welding.

This Receiving Material Report (Exhibit 10) is also provided, identifying each piece
with it’s corresponding drawing item, and traceable to the Mill Test Reports. This is
then sent to the Design Engineer for preparation of the As-Built Drawing and
MDR/MPDR

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Examination and Inspection
Subject Page 4 of 6
Program

7.0 Hydrostatic Test

7.1 Code required hydrostatic tests ( Exhibit 8 : Hydrotest Instruction and Report ) are
witnessed by the QC inspector and AI, following shop / field construction activities to
determine the structural integrity or repair of any leakage if required.
7.2 The QA/QC Manager will make sure that the AI has been notified sufficiently in
advance of each test so that he could witness the test.
7.3 The test pressure is applied, under close supervision of Shop Supervisor.
7.4 When the test meets Code Requirements and is accepted by the QC Inspector and AI,
they will initial and date the Inspection & Test Plan in the space provided.
7.5 Upon completion of the test, the Inspection & Test Plan and other supporting
documents are returned to the QA/QC Manager for review and filing as described in
ENV-QCM-12 of this Manual.
7.6 During the hydrostatic test of boiler, no part of the boiler shall be subjected to a
general membrane stress greater than 90% of its yield stress at test temperature.
7.7 All pressure and temperature gauge used in the test shall be in calibrated state and in
good condition. The serial number of the test gauge shall be recorded in the
hydrostatic test report form.
7.8 For ASME Section VIII Div. 1 vessels, it is recommended that the metal temperature
during the test to be maintained at least 30oF (19oC) above the minimum design metal
temperature, but need not exceed 120oF (49oC).
7.9 For ASME Section I boilers and boiler external piping, the test temperature shall not
be less than 20oC or more than 49oC.

8.0 Pneumatic Test.(Vessel only)

When hydrostatic tests cannot be performed, pneumatic test can be conducted as per code
requirements:
8.1 Pneumatic tests are conducted by the Shop or Field Supervisor. using a written
instruction prepared by the QC Supervisor which includes minimum test temperature,
test pressure, wall temperature, holding time, pressure increments, dial range of gauges
and other special requirements applicable to the type of test.
8.2 For ASME Section VIII Division 1 : pneumatic test pressure shall be at least equal to
1.1 times the maximum allowable working pressure to be stamped on the vessel
multiplied by the lowest ratio of the stress value S for the test temp of the vessel to the
stress value S for the design Temperature.
8.3 The QC Inspector and the AI sign and date this report , when they have satisfied
themselves that the test meets Code requirements in all respect.

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Examination and Inspection
Subject Page 5 of 6
Program

8.4 On welded pressure vessels to be pneumatically tested, the full length of the
following welds shall be examined for the purpose of detecting cracks :

(a) All welds around openings ;

(b) All attachment welds, including welds attaching non-pressure parts to
pressure parts, having a throat thickness greater than ¼ in. (6 mm).

9.0 Test Gauges

At least two gauges out of which one directly connected calibrated indicating pressure test
gauge located at the highest point of the Vessel/Boiler and one directly, visible to the
operator controlling the pressure
a) For ASME Sect. I : Dial pressure gauge used in testing shall preferably have dials
graduated over their entire range of about double the intended maximum test
pressure but in no case shall the range be less than 1 ½ time the pressure. (PG –
99.4.2)
b) For ASME Sect VIII Div. 1 : Dial indicating pressure gauge used in testing shall be
graduated over a range of about double the intended maximum test pressure, but in
no case shall the range be less than 1 ½ nor more than 4 times that pressure. (UG –
102).
10.0 ASME Certification Mark and Data reports

10.1 The QA/QC Manager has custody and control of the Certification Mark. He will issue the
required stamp for use at the shop or field site when shop construction or field assembly
is completed.
10.2 The Certification Mark is applied directly to the Code item, or on a nameplate to be
permanently attached to a Code items in the presence of the AI (Exhibit 19 : Stamping of
Vessels and Part) ( Exhibit 20 : Stamping Boilers and Part ). It is to be verified as correct
by the QC Inspector and AI before they initial and dates the Inspection & Test Plan.
10.3 When stamping the Certification Mark on the nameplate after attachment to the Code
item is not possible, it may be applied, with the prior concurrence of the AI, after
completion of all fabrication and examination, immediately before the hydrostatic or
pneumatic test. Any non-conformance found which cannot be corrected shall require
immediate removal of the nameplate and Certification Mark.
10.4 Upon completion of a shop and field constructed Code item, the QC Supervisor prepares
the Data Report from the final records, and submits for review by the QA/QC Manager,
who certifies it by sign and date when correct.
10.5 The completed Data Report, accompanied with the As Built Drawing, design calculation,
is then presented to the AI for his review. When he has satisfied himself that all Code
requirements have been met, he would then sign and date the Data Report.

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Examination and Inspection
Subject Page 6 of 6
Program

10.6 All records are returned to the QA/QC Manager for retention as described in ENV-QCM-
12 of this Manual.

11.0 Non Conformities :

Any non conformity found during fabrication or field assembly shall be controlled and
corrected as described in ENV-QCM-07 of this Manual, prior to QA/QC Manager shall
certify that the Code items construction comply with the Code, QC Manual and other
specification requirements.

12.0 RESPONSIBILITY :

12.1 Production Manager is responsible for implementation of Inspection and Test Plan.

12.2 The QA/QC Manager is responsible for the designation of required inspection and
examination, and for customer notification on witness points in accordance with
contractual documents.

12.3 The QA/QC Manager is responsible for assuring that required inspection points and
nondestructive examination points have been included on the Inspection and Test Plan.
The QA/QC Manager/ Field QC Inspector is also responsible for assuring that these
inspections and non destructive examinations have been completed, and that
interpretation sheets, radiographic films, and related documents are available to the
Authorized Inspector for review.

12.4 The QA/QC Manager is responsible for the custody of the ASME Certification Marks.
When required he will send the Certification Mark to the field site and Field QC Inspector
will have custody of it to the QA/QC Manager when Code stamping is completed.

12.5 The QA/QC Manager is responsible for the training and qualification of personnel
performing visual and dimensional examination.

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Section ENV-QCM-07 Date 10/12/2019
Subject Correction of Nonconformities Page 1 of 2

1.0 PURPOSE :

This Section outlines the system for the control of material, components, and
subassemblies that deviate from the applicable ASME Code requirements this Manual,
Quality Control Procedures, or contractual requirement.

2.0 SCOPE :

This Section describes the procedure to be followed in the correction of non conformities.
A nonconformity is any condition which does not comply with the applicable rules of the
Code this Quality Control Manual and any other specified requirement.

3.0 RESPONSINBILITY :

Disposition of nonconformities are responsibility of the QA/QC Manager. The

Engineering Manager shall be consulted for non conformities for the methods of repair.
The Production Manager will be responsible for implementation of disposition when
disposition of non conformity is approved.

4.0 IN-PROCESS INSPECTION :

4.1 Any person may identify a discrepancy. This condition will be brought to the attention of
the QA/QC Manager.

4.2 If a condition is deemed as nonconforming by the QA/QC Manager/ Site QC Engineer,

shall be tagged “ HOLD “ and NCR ( Exhibit 21 ) shall be filled out and after to the AI
for hold point inspection.

4.3 A condition which deviates from the original design, specification shall always be
considered as non conforming.

4.4 Repair to welds performed in process (example : indication discovered during RT, UT,
MT, PT ) will not be considered as nonconforming condition, if the condition is corrected
when discovered and qualified WPS and welder are used. However this shall not prevent
the writing of an NCR if deemed necessary by the shop QC inspector or site QC
Engineer.

5.0 RECEIVING INSPECTION :

5.1 Material found to be nonconforming during receiving Inspection shall be returned to the
vendor by Purchasing Manager if reject or used as non - Code material.

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Subject Correction of Nonconformities Page 2 of 2

6.0 DISPOSITION OF NCR

Disposition of NCR shall be reviewed and approved by the QA/QC manager and
Engineering Manager. Purchasing manager, and Production manager will be responsible
for implementation of disposition when disposition of non conformity is approved.

6.1 All NDE will be performed as the original method when the indications were found with
the use OF NDE.

6.2 The Production Manager may continue or start fabrication activities on nonconforming
items, provide that the QA/QC Manager/ site QC Engineer shall notify the AI and obtain
his consent.

6.3 Defects occurring in materials of pressure parts may be repaired by PT EE. (see 6.3
below)

6.4 All nonconformance reports disposition as use as is, repair, and reject shall be submitted
to the AI for his concurrence. Us as is disposition shall required technical justification by
the Engineering Manager.

7.0 COMPLETION OF NCR :

7.1 When the corrective action has been taken the shop QC Inspector and site QC Engineer
shall make an inspection as appropriate to assure the item meets the acceptance
requirements and sign-off the NCR. The completion of NCR shall be verified by the
QA/QC Manager and the AI.

7.2 The completed NCR will then the returned to the QA/QC Manager for filling in Project
File.

7.3 All repair to base materials shall be made using disposition proposed by
Engineering Manager and an approved procedure accepted by the AI .

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Section ENV–QCM-08 Date 10/12/2019
Subject Welding Page 1 of 5

1.0. PURPOSE
To establish the elements of welding control

2.0. SCOPE
This Section describes the control of WPS, PQR, Welder Qualification, Welding
Material distribution, and Welding Process. All welders and written welding procedures
will be qualified in accordance with ASME Code Section IX and the applicable
Construction Code. All welding will be done accordance with section IX with additional
requirements of the applicable Code of Contruction.

3.0. General :

3.1 Competency of Welding Engineers certification of PQR, WPQ and WOPQ

3.1.1. Welding Engineers shall as a minimum meet one of the following requirements :
3.1.2. Have a bachelor’s degree or higher in engineering or science, or is a certified AWS
CWI or Indonesia Welding Inspector.
3.1.3. Have minimum 3 years work experience in supervision of welding in a steel
fabrication company using ASME Section IX qualified WPS.
3.1.4. Have attended training conducted by a company or individual with sound
knowledge of ASME Section IX as determined by the QC Manager
3.1.5. The Welding Engineer shall have sound knowledge of the requirements of ASME
Section IX for qualification of welding procedures, welders / welding operators
and the company’s quality control system as described in this QC Manual. If WPS
and PQR involves other testing ( eg impact test), he shall also have sound
knowledge of the applicable construction Code ( eg ASME Section VIII Div.1).
3.1.6. Objective evidence of qualification, training or experience shall be maintained by
the QC Manager.

3.2 All welding on Code work is performed using Welding Procedure Specifications (WPS)
and competent welders and welding operators, qualified in accordance with applicable
clauses of ASME Code Section IX, related Code Section, QC Manual and other
specification.
3.3 Welding Procedure Specification:
3.3.1 WPS is prepared by the Welding Engineer to include all variables required for the
process by ASME Code Section IX and the intended range of production welding.
The required test welds are made under his supervision, and QC Inspector shall
record all variables during the test. Machining to size and testing of the required test
specimens is performed to meet with Section IX and ASME Section VIII Div 1
requirements by the independent testing laboratory, whose report of the test results is
reviewed by the Welding

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Section ENV–QCM-08 Date 10/12/2019
Subject Welding Page 2 of 5
Engineer for code compliance. If acceptable, he prepares and certifies the
Procedure Qualification Record (PQR).
3.3.2 Copies of the qualified WPS are provided to the Shop or Site Supervisor for the use
on production floors. The Welding Engineer maintains the copy WPS and PQR
packages in the project job file.
3.3.3 WPS and PQRs are submitted to the AI for his review, and are made available at
any time, upon request.

3.3.4 WPS are revised whenever there is a change in a any variable. A new WPS is
prepared and qualified whenever an essential or supplementary essential variable
(When impact test is a Code requirement) is to be changed or none of the existing
qualified PQR could support the required WPS
3.3.5 At the AI direction he may requests re-qualification of a WPS at any time, if he
has specific reason to question the WPS for a defined welding job. The AI shall be
given the opportunity to witness, the qualification of welding procedure (WPS).

3.4 Qualification of Welders and Welding Operators :

3.4.1 All welders and welding operators to be involved in Code welding shall be
qualified as per ASME Section IX, and the applicable Code Section used for
construction, under the supervision of the Welding Engineer. Machining to size
and testing of the required specimens or volumetric NDE, of the weld test coupon,
is prepared by a qualified testing laboratory. Their report of the test is reviewed by
the Welding Engineer. And if it meets the Code requirements the Welding
Engineer prepares and certifies the Welder / Welding Operator Performance
Qualification Record (WPQR), and put the Welders name in the Welder’s Log
(Exhibit 22) and Welding Operators Log (Exhibit 23).
3.4.2 A WPQR is also required for the welder who welds the test coupon used to qualify
a WPS or to re-qualify him, based on the performance essential variables used.
3.4.3 Copies of the WPQR and its welders Log are sent to the Shop or Field for their
involvement in Code welding. The Original WPQR is retained in the Welding
Engineer file.
3.4.4 A WPQR are available for review by the AI at shop or field site at any time he
requests. The AI shall be given opportunity to witness welder/welding operator
test.
3.4.5 All Qualified Welder / Welding Operator are recorded in the Welder’s Log and
Welding Operator Log.
3.5 Re-qualification of Welders and Welding Operators Log:
The Welding Engineer determines from the welder Log, when a welder qualification is
expired, when one of the following occurs:
a) A performance essential variable change.
b) When he has not welded with a process during a period of 6 months or more, his

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Section ENV–QCM-08 Date 10/12/2019
Subject Welding Page 3 of 5
qualifications for that process shall expire, unless, within the 6 month period prior to
his expiration of qualification ( Exhibit 24 Welder’s Continuity Log).
1.) A welder has welded with that process using manual or
semiautomatic welding, under the supervision and control of the
welding supervisor / site QC Engineer ; that will extend his
qualification for an additional 6 months.
2.) A welding operator has welded with that process using machine or
automatic welding, under the supervision and control of the welding
supervisor / field QC Engineer; that will extend his qualification for
an additional 6 months.
c) When there is a specific reason to question his ability to make welds that meet the
specification, the qualification that support the welding he is doing shall be revoked.
All other qualifications not questioned remain in effect.

3.6 Maintain of Qualified Welder and Welding Operator Qualification :

Each qualified welder shall be listed in the Welder Log maintained by the Welding
Engineer from monthly data provided by the Shop or field Supervisor using the welder
continuity log. The log indicates the last date each month on which each welder and
welding operator has welded in each process for which he is qualified.

3.7 Production Welding :

3.7.1 The Welding Engineer verifies that each welder is qualified to perform essential
variables to be used. The Welding Supervisor and field supervisor is responsible
for instructing the welder in the correct use of the WPS listed on the Weld Map
for each weld he may perform.
3.7.2 Each qualified welder would be given a unique symbol stamp No. with which to
identify each 1 m weld he makes. When stamping is precluded due to material
thickness and material spec or customer restriction, the weld shall be identified by
paint marker and transferred to a welding map which would indicate the welders
that performed each weld. The unique welder identification number issued to a
welder/ welding operator shall not be repeated and allocation record shall be
maitained in a register.
3.7.3 When radiographic test is a requirement to apply on the weld joint, the welder's
identification marking shall be visible on the radiograph accompanied with other
identification required by Code and client’s specification (if any).
3.8 Tack Welds:
3.8.1 Tacks welds, whether left in place or completely removed, are made by the
qualified welders using a qualified WPS designated on the drawing or Welding
Map and NDE Map
3.8.2 After preparation, each tack weld is visually examined by the QC Inspector, and if
crack is detected or otherwise defective, it shall be completely removed.

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Subject Welding Page 4 of 5
3.8.3 If left in place, the ends of each tack weld are proper preparation by grinding or
other suitable means to ensure complete fusion into the final weld.
3.9 Welding Material:
All welding consumables shall be handing in accordance with procedure QCP No.
ENV/PR/04 and welding materials are purchased and received as described in ENV-QCM-
05 of this Manual.

3.9.1 Welding material is stocked in a dry storage space and issued to welders by Store
Supervisor using issue Slip and authorized by Welding Supervisor.

3.9.2 It is advisable that Low hydrogen coated electrodes be ordered received in

hermetically sealed containers. When container cover is opened, the electrode are
to be placed in a drying oven maintained at the temperature recommended by the
electrode manufacturer, before issued to welders. The baking is recorded in the
Low Hydrogen Electrodes Baking Record .
3.9.3 Welding low hydrogen electrodes materials shall be stocked at dry storage space
and identified by its AWS specification and classification shelves as appropriate.
The store Supervisor will provide Daily Welding Consumable Report to record
the issuance, returning control of welding material and approved by QC Inspector.
3.9.4 Low Hydrogen covered electrodes should be issued only in a quantity sufficient to
complete the weld or for a period of four hours, the welder shall request the
required electrodes from the store by using Welding Material Issue Slip ( Exhibit
25) ( signed & dated by Welding Supervisor from the warehouse.
3.9.5 Unconsumed low hydrogen covered coated electrodes returned to storage are
examined for condition, cleanliness and identification before returned to a
segregated storage for recondition purposes. Damaged, unidentified or wet
electrodes are to be scrapped /discarded immediately
3.10 Production Test Plates:
3.10.1 Production test plates are prepared in accordance with a procedure prepared by
the Design Engineer and Welding Engineer and listed on the Inspection & Test
Plan.
3.10.2 The Welding Engineer supervises the welding of test coupons, which are
prepared and tested by a qualified testing house whose test report is reviewed by
the Welding Engineer for results or otherwise for retest. The AI shall be notified
in advance prior to the test who may witness the test if he desires to do so.
3.10.3 Test results are to be submitted for review by the AI.

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Subject Welding Page 5 of 5

3.11 Welding Records :

All the Welding processes mentioned in the History sheet for Welding (Exhibit 26) as
set forth in this section shall be available for review by the AI, History sheet of
Welding made by Welding Engineer, QC Supervisor reviewed by and approved by the
QA/QC Manager

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-09 Date 10/12/2019
Subject Nondestructive Examination Page 1 of 4

1.0 SCOPE

1.1 This section describes system for qualification and certification of NDE personnel
and method of carrying out Code required NDE including evaluation of their results.
1.2 Company does not have complete in-house NDE capability and all of the NDE
activities are subcontracted to an approved outside agency having proven experience.

2.0 NDE LEVEL III, WRITTEN PRACTICE & PERSONNEL QUALIFICATION

2.1 Company may uses services of an outside individual as NDE Level III.
2.2 The QA/QC Manager shall review the appointment of the Company Level III shall be
based on the following:

2.2.1 Qualification and Certification in accordance with his employer’s written practice
2.2.2 Valid endorsement on his ASNT level III or ACCP Professional Level III
certificate for RT, UT, MT and PT methods.
2.2.3 Experience in providing Level III services to other ASME Code certificate holders.
2.2.4 Experience in developing NDE procedures and monitoring NDE activities
including evaluation of results on pressure vessel and piping products to ASME Codes
based on result of review qualification and certificationon NDE Level III.

2.3 Based on result of review qualification and certification of NDE level III, the QA/QC
Manager made recommendation to Director for appointed company NDE Level III by
issuing a lettter of appointment.
2.4 The appointment shall be valid for a maximum of 3 years but the Director shall have
the authority to extend the validity or to cancel the letter at any time.

2.5 The NDE Level III shall be responsible for:

2.5.1 Training, examination, qualification and periodic technical evaluation of company

NDE personnel as per established written practice.

a) Establishing and Approving company’s RT, UT, PT and MT procedures

b) Demonstration, Qualification and certification of NDE procedures as per
applicable Code requirements
c) Resolve NDE related issues on behalf of company
d) Monitoring and control of NDE subcontractor as described in 3.0 below.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-09 Date 10/12/2019
Subject Nondestructive Examination Page 2 of 4

3.0 SUBCONTRACTING NDE

3.1 The Subcontractor shall provide the following documents for review and verification

3.1.1 Written Practice in accordance with ASME Section V, T-120 (e) (f) (g) (i) (j)
(k).
3.1.2 NDE procedures including their demonstration, qualification and certification
records.
3.1.3 Calibration records of the instruments to be used.

3.2 All above documents shall be verified and approved by NDE Level III on behalf of
the company & a copy of all the above documents shall be kept for records & for review
by AI.
3.3 On behalf of the company, NDE Level III shall verify that the subcontractor’s personnel
are qualified and certified in accordance with their employer’s written practice.
3.4 Subcontractor can use either the company procedures for carrying out NDE or
alternatively his own procedures provided the same are approved by company NDE
Level III. Evaluation of results shall be carried out by the subcontractor’s/ qualified &
certified Level II or Level III personnel as per the applicable Codes and procedures.
Subcontractor’s NDE report(including radiographic) shall be review by PT EE’s QC
Inspector and made available to the AI for review.

4.0 NDE PROCEDURES

4.1 Level III shall establish, maintain and approve RT, UT, MT and PT procedures.
4.2 NDE Procedures for UT, PT and MT shall be demonstrated and supervision of NDE
Level III and shall be witnessed by the AI. QA/QC Manager shall certify the NDE
procedures to be in accordance with T-150 of ASME Code Section V.
4.3 When required by Code, these procedures shall also be qualified by demonstration for the
range of essential variables intended to be used. Any change in the essential variable
shall require re-qualification by demonstration.
4.4 RT procedure does not require demonstration and achieving the required density
and penetrameter image on technique or production radiographs is considered as
satisfactory demonstration of technique.
4.5 Subcontractor’s procedure when used shall also be demonstrated and qualified as above.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-09 Date 10/12/2019
Subject Nondestructive Examination Page 3 of 4

5.0 NDE EXECUTION

5.1 Type and Extent of NDE requirements shall be specified on the drawings and ITP.

5.2 QA/QC Manager shall ensure that the required NDE is carried out at the appropriate stage.

5.3 When the NDE is subcontracted, QA/QC Manager shall make NDE Request and send it
to the subcontractor. This request shall clearly indicate the Job details and type, location
and extent of NDE and any other details required for identification or to perform required
NDE.

5.4 In case of spot radiography, the spots shall be clearly marked on the job with identification
of the spot. AI shall be given the opportunity to mark the spots for radiography.

5.5 In case of in-house NDE examination, no formal request is made. The examination is
however carried out as per ITP and drawing and reported as described below.

6.0 NDE EVALUATION AND REPORT

6.1 Evaluation and acceptance of NDE results shall be as per the Applicable Codes and
NDE procedures.

6.2 Evaluation shall be done by NDE Level II or Level III only. The names and qualification
of the persons who carried out and evaluated the results shall be clearly indicated on
reports.

6.3 Subcontractors may use their own format of reports (when approved By Level III) or
alternatively report the findings on the company formats.

6.4 Subcontractor’s reports shall be signed and accepted by QA/QC Manager on behalf of
the Company.

7.0 REVIEW BY AI

7.1 Written practice, NDE procedures and NDE Personnel Qualification Records including
the subcontractor’s records shall be submitted to AI for his review.

7.2 AI may ask for re-qualification of any NDE personnel or re-demonstration of NDE
Procedure for cause.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-09 Date 10/12/2019
Subject Nondestructive Examination Page 4 of 4

8.0 Qualification of Company Visual Examination Personnel boiler external piping

(ASME B31.1)

8.1 Visual Examination Procedures

Visual Examiner shall be qualified as per Visual Examination Procedure Document No.
ENV-PR-16.
All records of visual examiner qualification, training and certification shall be
documented and available to the AI upon request.
8.2 The following criteria may be used as alternative to the above requirements :
Qualification to AWS QC-1A.

9.0 CALIBRATION OF NDE EQUIPMENT

9.1 QA/QC Manager is responsible for calibration of Company owned NDE equipment.
9.2 Calibration shall be carried out as per ENV-QCM-11 of this manual.
9.3 QA/QC Manager is also responsible to verify calibration records of subcontractor’s
NDE equipments.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV-QCM-10 Date 10/12/2019
Subject Heat Treatment Page 1 of 2

1.0 PURPOSE :

This Section outlines the system used to control Heat Treatment.

2.0 SCOPE :

This Section describes heat treatment procedure and records when heat treatment is
performed.
All Treatment will be subcontracted to appropriate vendor.

3.0 RESPONSIBILITY :

The QA/QC Manager shall be responsible for monitoring or verifying heat treatment.
The QA/QC Manager shall review and approve heat treatment procedures as applicable for
Code compliance.

4.0 PROCEDURE :

4.1 The Design Engineer prepares the Heat Treatment procedure which shall include as
minimum the heating rate, Holding Temperature and time, cooling rate, number and
method of attachment of thermocouples location and their location.

4.2 The item to be heat treated shall be identified in such a manner that the identification will
be maintained after heat treatment.

4.3 The QC Inspector at shop/ site QC Engineer shall monitor the heat treatment of the Code
items. In all cases the Shop QC Inspector or Site QC Engineer shall review the heat
treatment records temperature and time chart as show on Post Weld Heat Treatment
Instruction (Exhibit 28) to assure heating rate, holding time at temperature and cooling
rate in compliance with the procedures. The QC Inspector at shop/ Field QC Engineer field
site shall monitor the thermocouple attachment.

4.4 When the item heat treated by the sub contractor and it is returned to the shop it shall be
inspected for damage due transportation, handling and heat treatment. If found damages or
if records are unacceptable, an NCR shall be written and handled as per section ENV-
QCM-07 this Manual.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV-QCM-10 Date 10/12/2019
Subject Heat Treatment Page 2 of 2

5.0 CONTROL OF RAW MATERIAL :

5.1 When heat treatment required by ASME Section II is not performed by the material
manufacturer, the treatment shall be performed by a subcontractor and the requirements of
paragraph 3.0 and 4.0 of this section shall apply.

5.2 The QC Inspector shall stamp the letter “ T “ Following the letter “ G “when applicable on
the mill plate after heat treatment has been performed. PT.EE subcontractor shall provide a
report which will be reviewed in accordance with this Section.
It will be attached to the original material test report as a part of the certification.

6.0 RECORD :

6.1 The subcontractor shall indicate on the heat treatment chart, the following information :

a. The items and parts to be heat treated by job number, drawing number and piece
identification markings.
b. The Number of the heat treatment procedure with revision status and date.
c. The date of heat treatment.
d. Method of heat treatment, furnace or local.
e. The Placement location of all thermocouples.
f. Chart Speed.
g. The charts shall be signed and dated by the operator or subcontractor authorized
representative.

6.2 The QC inspector shall sign and date the treatment chart when he is satisfied that the heat
treatment has been correctly carried out in accordance with the applicable procedure.

6.3 All PWHT record including calibration record of temperature recorder, thermo couple and
chart shall be submitted to the AI his review.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-11 Date 10/12/2019
Calibration, Maintenance, and
Subject Control Program for Measurement Page 1 of 2
and Test Equipment

1.0 Purpose :
This Section describes the methods to assure that all inspection, measuring and test
equipment used by PT.EE for fullfilment of applicable Code requrement are calibrated,
traceable and documentary proof of calibration records are maintained.

2.0 Scope :
The Section describes calibration procedure and records when such calibration is performed.

3.0 Responsibilities :
It is the responsibility of the QA/QC Manager to ensure that measuring and test equipment
used and calibrated to fulfill requirements of the applicable Code Sections, contractual, and
this Manual .

4.0 Procedures :

4.1 All measuring and test equipment are controlled by the Shop QC Inspector shall be identified
by permanent ID number.
4.2 The QC Inspector shall maintain a record for all calibrated items, They shall be listed in
Calibration Log (Exhibit 29), indicating equipment name, brand/manufacturer, calibration
interval, calibration date and next calibration date.
4.3 The Shop QC Inspector shall keep Calibration Log and Vendor calibration Records and make
available to the Authorized Inspector for his review.
4.4 All Measuring and test equipment shall have, at least, the date of last calibration and due date
show on the calibration sticker and ID number.
4.5 Discrepant Equipment :

4.5.1 When instruments are found out of calibration or damaged, the QC Supervisor
tags “REJECTED” , subsequently removes it from the work area and arranges for
calibration or replacement.
4.5.2 All Code items checked with such discrepant instruments are non-conforming
until the QC Supervisor has verified that they meet all Code requirements, or
they are re-tested with accurate instruments/standard gauges.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-11 Date 10/12/2019
Calibration, Maintenance, and
Subject Control Program for Measurement Page 2 of 2
and Test Equipment

4.5.3 Traceability is provided from recorded serial numbers of instruments used

from examination and test records.
4.5.4 After removal of a calibrated instrument or pressure gauges from a shop or
field site, it shall be immediately verified, so as to verify that the gauges was
in calibration status when last used at the shop or field site.

4.6 The frequency of calibration for hydrostatic test gauges shall be at 1(one) year intervals, and
vernier calipers shall be calibrated annually, or at any time when there is reason to believe
they are having error.
4.7 Impact testing machine shall conform to the applicable requirements of specification SA.390 or
ISO 149 part 1, 2, 3 and Specification ASTM E.23, requires Annual Calibration of impact
testing machine and six monthly calibration temperature measuring devices.
4.8 All calibrated equipment shall be stored in a suitable location so as to avoid accidental
damage.
4.9 All testing and calibration shall be conducted in an appointed testing laboratory. The testing
laboratory shall provide certification traceable to a know National Standard or equipment
manufacture standard when not specified by the Code or according to an approved procedure.

5.0 Subcontractor’s Equipments :

Prior to use, all subcontractors calibrations shall be verified by QA/QC Manager.
A copy of calibration certificate shall be retained in the job file.

6.0 Field Assembly Calibrated Equipments :

When required by Site QC Engineer, the calibrated equipment used in shop
fabrication may be sent for field assembly.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-12 Date 10/12/2019
Record Retention &
Subject Page 1 of 3
Manufacturer’s Data Report

1.0 PURPOSE :

This Section outlines the system for the maintenance of quality records, the assignment of
National Board serial numbers, and the preparation and distribution of Manufacturer’s Data
Reports.

2.0 SCOPE :

The system governs the retention of quality records, the assignment of National Board serial
numbers, and the preparation and distribution of Manufacturer’s Data Report as required by
the Code, the QC Manual and contractual requirements.

3.0 Distribution of Data Report (MDR/MPDR)

3.1 Copies of the Manufacturer’s Data Report shall be issued by the QA/QC Manager to the
following after the MDR has been accepted and signed by the Authorized Inspector.

For Section I, item a copy of the MDR shall be furnished to:

a. Client/Owner/User or their designated Agent;
b. Upon request to AI
c. Jurisdictional Authorities at the place of installation when required by law
d. Keep a copy of the MDR on file in a safe custody for at least 5 years

For Section VIII Div. 1 items a copy of the MDR shall be furnished to:
a. Client/Owner/User or their designated Agent;
b. Upon request to AI
c. Jurisdictional Authorities at the place of installation when required by law
d. Keep a copy of the MDR on file in a safe custody for at least 3 years

3.2 For Parts, Manufacturer Partial Data Reports (MPDR) shall be furnished in duplicate to the
Manufacturer of the completed Code Item . A copy shall be retained for 5 years for Boiler
part and 3 years for pressure vessel.

3.3 MPDR for replacement part or repaired part shall be forwarded to the user of an existing
Code items or his agent.

4.0 Registration to National Board

4.1 NB Registration Number Log (Exhibit 29) must be maintained by QA/QC Manager that
shows National Board registration numbers, the date issued, the manufacturer’s serial
number, and other data as may be required to identify the item.

Document No ENV-ASME-QCM-01 Revision 9

Section ENV–QCM-12 Date 03/12/2019
Record Retention & Manufacturer’s
Subject Page 2 of 3
Data Report

4.2 National Board registration numbers are to be assigned without skips or gaps of unused
numbers or duplication of numbers starting from “1”.

4.3 National Board numbers are to be issued following the pressure test. In the event an item is
not pressure-tested in the shop, the National Board number is to be issued at the time of
registration form certification.

4.4 The Data Report must bear the signature, commission number, and endorsement(s) of the
AI.

4.5 The QA/QC Manager responsible for submitting the Data Report to the National Board for
registration within 30 days after the AI signature.

4.6 The QA/QC Manager or his designee collects all records described in this Manual at the
completion of the job, and reviews them for completeness and Code compliance before he
prepares the ASME Manufacturer’s Data Report and the As Built Certification Dossier.

4.7 Upon Completion of the assembly of Code item , the QA/QC Manager or Site QC
Engineer shall certify the Manufacturer’s Data Report prior to submission to the field
Authorized Inspector for his review, signature and date. The Authorized Inspector shall
witness the application of the Certification Mark directly to Code item or to the nameplate
of the Code item.

4.8 Completed Code items shall be registered with the National Board when so requested by
the client or by jurisdiction at the location of installation when required.

5.0 Records Maintenance

For ASME Section I item and parts:

Radiographs and interpretation reports: Five (5) years

a. Ultrasonic Examination Reports : Five (5) years

b. Manufacturer’s Data Reports : Five (5) years.
c. Qualification Maintence Records For Welders And Welding Operator : Five (5) years

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-12 Date 10/12/2019
Record Retention & Manufacturer’s
Subject Page 3 of 3
Data Report

For ASME Section VIII Div. 1 items and parts:

1. Radiographs films are maintained until Data Report signed by

the Authorized Inspector.
2. Data reports is retained for three (3) years and/or may be
the National Board registered with additionally.
3. The following records shall be maintained for a period of at least 3 years:
 Manufacturer’s Data Report along with Manufacturer’s Partial Data Report
 Manufacturing drawings
 Design calculations, including any applicable Proof Test Reports
 Material Test Reports and/or material certifications
 Welding Procedure Specifications and Procedure Qualification Records
 Welders/Welding Operator Performance Qualification Records for each welder
who welded on the vessel
 Pressure part documentations and certifications
 All NDE Reports
 Process Control Sheet/Inspection Test Plan
 Heat Treatment records and test results
 Non-conformances and dispositions
 Pressure test records
 Repair Procedure and records

6.0 Retained Records as required by the QC system should be made available to the AIS or to
Review Team Designated by the ASME.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-13 Date 10/12/2019
Subject Field Site Assembly Page 1 of 4

1.0 PURPOSE :

This Section outlines the system for the Field Assembly.

2.0 SCOPE :

This Section describes the responsibilities and measures to control the construction work at
field assembly sites as per Code requirements. All field site activities shall be controlled from
the shop location as described below:

3.0 QC MANUAL CONTROL

3.1 QC Manual Control mention in Section ENV-QCM-02.

4.0 DRAWING, DESIGN CALCULATIONS AND SPECIFICATION

4.1 The necessary drawing and specification shall be prepared by Design Engineer and
approved by Engineering Manager.
4.2 The drawing shall be clearly identify the scope of field activity. Alternatively separate
drawings for field activities shall be prepared and approved by Design Engineer.
4.3 The drawing and specifications ( including their revisions) shall be distributed to Site
Manager and Field QC Engineer.
4.4 The Design Engineer shall get all drawings, calculations and specifications reviewed
by AI at site before start of the field activities.
4.5 Site Manager shall be responsible to ensure that only current controlled copies of the
drawings and documents are in use at site.

5.0 MATERIAL CONTROL

5.1 All requisition for material including welding material shall be prepared by the Design
Engineer as per Section ENV-QCM-05.
5.2 Material purchase may be performed at the shop or at field shall be as per Section ENV-
QCM-05.
5.3 All materials supplied by the customer and/or subcontractor shall be received by Site
Manager, inspected by the Field QC Engineer for Code Compliance. The Field QC
Engineer shall ensure that any partial fabricated parts supplied to the field shall have the
proper completed Partial Data Reports when supplied by subcontracted certificate
Holders and shall be responsible for the collection and attachment to the final
Manufacturer’s Data Report.
5.4 All materials required for field work may be received and inspected at site or inspected in
the shop and issued to the field as per Section ENV-QCM-05.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-13 Date 10/12/2019
Subject Field Site Assembly Page 2 of 4

6.0 Field Examination and Inspection Program

6.1 Installation of site fabricated items shall be controlled by the ITP. The ITP shall be
prepared by the Field QC Engineer and forwarded to the QA/QC Manager for his review
and approval.
The Field QC Engineer shall submit the approved ITP to the Authorized Inspector to
specify his inspection points.

6.2 Field examination and inspection of items shall be performed as per ENV-QCM-06 . The
Field QC Engineer shall inspect at the various stage of inspection determined. The
Authorized Inspector shall make his required inspections as indicated on the ITP.

7.0 Correction of Non-Conformities

7.1 All Non-Conformities shall be handled as per Section ENV-QCM-09 of this Manual.

7.2 The Field QC Engineer shall be responsible for maintaining any Non-Conformance
Reports (Exhibit 21) and informing the QA/QC Manager of on-going non-conformities
for his disposition.

8.0 Welding Control for Contracted Welders

8.1 All welding in field work shall be performed using Welding Procedures, Welders and
Welding Operators (By PT EE or sub contractor) qualified in accordance with Section
ENV-QCM-09 this Manual.

8.2 The Site Manager has the complete and exclusive administrative and technical
supervision of all Sub-Contracted Welders and Welding Operators and has the right to
assign and remove Subcontracted Welders and Welding Operators at his discretion
without involvement of any other organization.
Following conditions shall be met when PT EE uses subcontracted welders :

(1) All Code construction shall be the responsibility of the

PT EE.

(2) All welding shall be performed in accordance with the PT EE Welding

Procedure Specification which have been qualified by the Company in
accordance with the requirements of Section ENV-QCM-09.

(3) All welders shall be qualified by the PT EE in accordance with the

requirements of Section ENV-QCM-08.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-13 Date 10/12/2019
Subject Field Site Assembly Page 3 of 4

(4) Assignment of Welder Identification symbols shall be per section ENV-QCM-

08 paragraph 3.6.2.
(5) The QA/QC Manager shall obtain written evidence that this program has been
accepted by the Authorized Inspection Agency which provides the inspection
service.
(6) The Site Manager shall be responsible for verifying that all involved Site
Supervisor and welders are familiar with displayed WPS, and Weld Map and
details.
(9) PT EE shall be responsible for Code compliance of the code item, including
Certification Mark Stamping and providing Data Report Form properly
executed and counter signed by the AI.

8.3 The originals of the Welder Qualification Test Record are maintained by Welding
Engineer. The Field QC Engineer shall provide the Authorized Inspector copies of WPS,
PQR, Qualification Records of Welders or Welding Operators prior to assigning on Code
construction. Acceptance by the Authorized Inspector shall be documented by his
signature and date.

9.0 Nondestructive Examination – NDE

9.1 All field NDE shall be performed in accordance with Section ENV-QCM-09 of this
Manual.

9.2 All reports of NDE shall be reviewed and accepted by the NDE Level II before
submitting to the Authorized Inspector for his review.

9.3 All report of NDE shall be in accordance with Section ENV-QCM-09.

10.0 Heat Treatment

10.1 All Heat Treatment Work shall be performed in accordance with Section ENV-QCM-10
of this Manual.
Unless otherwise mentioned the Heat Treatment should be conducted by using
electric heat resistant elements (localized) Heat Treatment.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV–QCM-13 Date 10/12/2019
Subject Field Site Assembly Page 4 of 4

11.0 Calibration of Measurement and Test Equipment

11.1 All Calibration of Measurement and Test Equipment shall be performed in accordance
with Section ENV-QCM-11. The Site QC Engineer shall be responsible for ensuring that
all equipments are properly calibrated and in calibrated condition/status prior to use.

12.0 ASME Certification Mark and Data Report

12.1 Upon completion of the field installation, the Site QC Engineer shall certify the
Manufacturer’s Data Report and present it to the Authorized Inspector for his review,
signature and date. The Authorized Inspector shall witness the application of the ASME
Certification Mark directly to the Code items or to name plate.

12.2 QA/QC Manager shall have total control and custody of the Certification Mark. He shall
issue the required Stamp to the Site QC Engineer, who shall have custody and total
control at site and shall return it to the QA/QC Manager upon completion of field work.

12.3 All records shall be controlled by the Site QC Engineer and returned to the QA/QC
Manager for retention as per Section ENV-QCM-12.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV-QCM-14 Date 10/12/2019
Subject Certification Page 1 of 1

1.0 General

Only written signature and written date shall be used to indicated certificate’s
authorizations and approvals.

JL.Inspeksi kalimalang, Desa Karang Mulya, Teluk Jambe, Karawang 41361, Jawa Barat , Indonesia
Telp No : +62 267 400737, 400738, Fax No. : +62 267 400739 , Website : www.enviconekatama.com
PT.ENVICON EKATAMA
Karawang - Indonesia

Document No ENV-ASME-QCM-01 Revision 10

Section ENV-QCM-15 Date 10/12/2019
Subject Authorized Inspector Page 1 of 2

1.0 PURPOSE :

This Section defines the responsibilities of PT EE to the Authorized Inspector.

2.0 SCOPE :

PT ENV maintains a contract with an ASME Accredited Authorized Inspection Agency

for the services of an Authorized Inspector He has available all of the information and
documentation necessary to perform the Authorized Inspector’s duties under the Code.

3.0 GENERAL :

The AI is employed by an ASME Accredited Authorized Inspection Agency (AIA of

record) with whom the Company has a contract to perform the inspection services
required by the Code.

3.1 The QA/QC Manager arranges for the AI and AIS to have free access to the shop and
field sites include the sub-contractor work shop whenever Code work is being
executed, and to such parts of all plants that are concerned with the construction and
supply of materials for the Code item, when the AI or AIS request to do so.

3.2 If requested by the AI, his inspection points shall be inserted on the Inspection & Test
Plan for those operations he may wish to witness or inspect before the work proceeds.

3.3 The QA/QC Manager at the shop, or the Field QC Engineer at field site, is the
Company representative in assisting the AI.

3.4 The AI shall be provided with access to all drawings, calculations, specifications,
procedures, Inspection & Test Plan, repair written proposals, test and examination
results, inspection records and any other documents required as to allow him to
perform his duties as appropriate.

3.5 All Non conformance Reports for Code non-conformities and proposed disposition
and / or resolution are to be submitted to the AI for his review and acceptance.

3.6 The QA/QC Manager or QC Supervisor will notify the AI sufficiently in advance of
all tests and examinations so that he could present himself to witness the test.

3.7 The final records, together with the completed ASME Manufacturer’s Data Report
signed by the QA/QC Manager, are submitted to the AI for his review and
authorization to apply the Certification Mark and sign the MDR.

3.8 A controlled copy of the QC Manual shall be made available for use by the AI at the
shop as well as at the field site.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV-QCM-15 Date 10/12/2019
Subject Authorized Inspector Page 2 of 2

3.9 The AI will review and accept all changes to the QC Manual, before they are
issued to Manual Holders.

3.10 The QA/QC Manager will assist the AI Supervisor, and the AI during his required
audits the AI in order to monitoring the QC System.

3.11 All ASME Inspection at shop & field site are performed by the AIA of record,
company does not intend to use additional AIA.

3.12 The Site Quality Control Engineer is responsible for assuring that the Authorized
Inspector at field site has access to the documentation and activities necessary for
the performance of required Code duties.

3.13 ASME and NB is notified whenever the agreement is cancelled or changed to

another accredited Authorized Inspection Agency by QA/QC Manager.

Document No ENV-ASME-QCM-01 Revision 10

Section ENV-QCM-16 Date 10/12/2019
Subject List of Exhibit Page 1 of 1

Exhibit No Description Section

Exhibit 1 Code Summary Review ENV-QCM-02
Exhibit 2 Document Control Record ENV-QCM-02
Exhibit 3 Drawing & Document Transmittal ENV-QCM-04
Exhibit 4 Minutes of Contract Review Meeting ENV-QCM-04
Exhibit 5 Engineering Change Request ENV-QCM-04
Exhibit 6 Engineering Change Note ENV-QCM-04
Exhibit 7 Purchase Request ENV-QCM-05
Exhibit 8 Purchase Material Specification ENV-QCM-05
Exhibit 9 Purchase Order ENV-QCM-05
Exhibit 10 Receiving Material Report ENV-QCM-05
Exhibit 11 Material Slip ENV-QCM-05
Exhibit 12 Material Consumable Slip ENV-QCM-05
Exhibit 13 Material Substitution Request ENV-QCM-05
Exhibit 14 Inspection and Test Plan ENV-QCM-06
Exhibit 15 Request for Inspection ENV-QCM-06
Exhibit 16 Shell Ovality Inspection Report ENV-QCM-06
Exhibit 17 Dimension Report ENV-QCM-06
Exhibit 18 Hydrotest Instruction and Report ENV-QCM-06
Exhibit 19 Stamping of Vessels & Part ENV-QCM-06
Exhibit 20 Stamping Boilers & Part ENV-QCM-06
Exhibit 21 Nonconformance Report ENV-QCM-07
Exhibit 22 Welder’s Log ENV-QCM-08
Exhibit 23 Welding Operator’s Log ENV-QCM-08
Exhibit 24 Welder’s Continuity Log ENV-QCM-08
Exhibit 25 Welding Material Issue Slip ENV-QCM-08
Exhibit 26 History sheet for Welding ENV-QCM-08
Exhibit 27 Heat Treatment Intruction ENV-QCM-10
Exhibit 28 Calibration Log ENV-QCM-11
Exhibit 29 NB Registration Number Log ENV-QCM-12
Exhibit 30 Material Take Off ENV-QCM-05

PT.ENVICON EKATAMA QUALITY CONTROL MANUAL

Karawang - Indonesia CODE SUMMARY REVIEW
SECTION I , II ( A,B,C,D ) , V , VIII Division-1, IX
and ASME B31.1

Review Date Code Addenda Review By Effect to QCM Remark

* Deadline
ASME SECTION I Yes
No

QA/QC Manager
Yes
No

Engg. Manager
ASME SECTION II Yes
No

QA/QC Manager
Yes
No

Engg. Manager
ASME SECTION V Yes
No

QA/QC Manager
Yes
No

Engg. Manager
Yes
ASME SECTION VIII Division - 1
No

QA/QC Manager
Yes
No

Engg. Manager
ASME SECTION IX Yes
No

QA/QC Manager
Yes
No

Engg. Manager
ASME B31 .1 Yes
No

QA/QC Manager

Yes
No

Engg. Manager
* Edition of addenda becomes mandatory at the end of month noted.
Exhibit 2 : Document Control Record

PT.ENVICON EKATAMA
KARAWANG - INDONESIA

DOCUMENT CONTROL RECORD

Keterangan / Remarks
Diterima oleh / Receive by , ( Tanda tangan/Signature , Nama/Name & Tanggal / Date ) *
No. Jumlah Copy yang
No Nama Dokumen/ Doc't Name Dokumen/ Hal./Qty Rev dikirim / Completed Manual/
Doc. No. of sheet Dist. Copy AI ( H8) Procedure
* Revised page
only

Document Control by,

QA-QC Manager
Exhibit 3 : Drawing & Document Transmittal

Karawang - Indonesia

Owner / Client : Doc. No. :

Project Name : Rev.No. :
Job No : Date :
Equipment Service : Page :

DRAWING & DOCUMENT TRANSMITTAL

Document No./ Revision No.
No. Description Remarks
Drawing No. 0 1 2 3 4 5

DISTRIBUTION Engineering Department

DEPARTMENT QTY.COPY RECEIVE BY SIGN

PPC 1

PRODUCTION 3

QA 1
(………………………………………………………….)
QC 1
Exhibit 4 : Minutes of Contract Review Meeting

PT.ENVICON EKATAMA
Karawang - Indonesia

MINUTES OF CONTRACT REVIEW MEETING

Project Name
Customer
Date
Code Contruction

No. SUBJECT DESCRIPTION EXPLANATION PIC DATE REMARKS

1. Code Requirement ASME SEC VIII DIV 1 Are understand within the related
Manager & QA/QC dept will make
sure that the Quality requirements
QA/QC Manager
shall be met during the Contruction

2. Design Requirements ASME SEC VIII DIV 1 Design are sufficiently understand
and related design documents will Engineering
be prepared as required Manager

3. Welding Fabrication & ASME SEC .IX The Welding fabrication is will be Welding
Requirements ensure to meet with all the Engineer,
requirements Production
Manager &
QA/QC
Manager
4. Contruction ASME SEC VIII DIV 1
All welding fabrication, process,
handling , scheduling is available & Production
will be ensure to meet all the Manager
contruction Code
5. Resources Needs QM & QCP Resources for handling this project
is will be make prepared and
Production
ensure to meet with all the
Manager
competency requirements

6. Availability of Material ASME CODE REQUIREMENTS

Material required will be check in
Store Manager ,
the stock & purchase, all the
Purhase
working process shall be meet with
Manager
the requirement
7. Delivery Date QM & QCP Tray to catch up with the schedule
All related dept.
required by customer
Manager
8. Inspection Required by 3rd party ASME CODE REQUIREMENTS LR - INDONESIA
QA/QC Manager

Additional Note :

Review & Accepted .

QA/QC Manager Engineering Manager Welding Engineer

Purchase Manager Production Manager Store Manager

Exhibit 5 : Engineering Change Request

PT.ENVICON EKATAMA ECR No. :

Karawang - Indonesia
Date :

ENGINEERING CHANGE REQUEST (ECR)

Job No. :
Client/Project :
Drawing No. : Revision :
Part No./Item No. :

Description of Change Request

Prepared By Review & Approved By

Exhibit 6 : Engineering Change Note

PT.ENVICON EKATAMA ECN No. :

Karawang - Indonesia Date :
Ref. ECR No. :
Date :

ENGINEERING CHANGE NOTE (ECN)

Job No. :
Client/Project :
Drawing No. : Revision :
Part No./Item No. :

Engineering Change Request

Engineering Change Note

Prepared By Review & Approved By

Engineering HOD Engineering

Distribution Copy to : 1- Production 2- QA/QC
Exhibit 7 : Purchase Request

PR No. :
PURCHASE REQUEST
Job No. Customer Date

No. Material Name Spec. Mat'l Size Qty Unit Remark

Realization Date

Attachment : 1) As per Materail Purchase Spec. ( Yes / No ) 3) Required Certificate Material ( Yes / No )
2) Asper Sample ( Yes / No ) 4) etc ( Yes / No )

Prepared by Checked by Approved by

Store Director
Distribusi : 1- PURCHASE ( White ) 2- STORE ( Red ) 3- USER ( Blue )
Exhibit 8 : Purchase Material Specification
PURCHASE MATERIAL SPECIFICATION
PT.ENVICON EKATAMA
Karawang - Indonesia
CARBON STELL PLATES FOR
ASME CODE SEC VIII DIV 1 VESSEL

JOB NUMBER PMS NO.

VESSEL NUMBER/NAME PAGE

PROJECT DATE
DRAWING NO.

ENQUIRY PURCHASE ORDER √ NO: DATE:

SUPPLIER :
MATERIAL CARBON STEEL PRESSURE VESSEL PLATE
1 QUANTITY

2 SIZE / DIMENSION

3 MATERIAL SPECIFICATION Year ,

4 GENERAL SPECIFICATION Year ,

5 CODE / STANDARD

6 ACCEPTABLE ASTM DESIGNATION

Normalized As Rolled
7 SUPPLY CONDITION (HEAT TREATMENT)
Quinched & Tempered As per Specification

Required Not Required

8 IMPACT TEST
Specimen Orientation, Testing Temperature and Acceptance Criteria (If Required)

9 CUT LENGTHS FROM COIL Not Acceptable

Acceptable
10 MARKING / IDENTIFICATION As per Specification Other as Specification below

SUPPLEMENTARY REQUIREMENTS

S 1. VACUUM TREATMENT S 7. HIGH TEMPERATURE TENSION TEST

S 2. PRODUCT ANALYSIS S 8. UT in ACCORDANCE WITH SPECIFICATION A-435/ A 435M

S 3. SIMULATED PWHT OF MECHANICAL TEST COUPONS S 9. MAGNETIC PARTICLE EXAMINATION

11
S 4.1 ADDITIONAL TENSION TEST S 11. UT in ACCORDANCE WITH SPECIFICATION A 577/A 577M

S 5. CHARPY V-NOTCH IMPACT TEST S 12. UT in ACCORDANCE WITH SPECIFICATION A 578/A 578M

S 6. DROP WEIGHT TEST S 17. VACUUM CARBON DEOXIDIZED STEEL

Others (please specify)

ADDITIONAL REQUIREMENT
12
D
Maximum Columbium (Niobium) content can be up to 0.05% on heat analysis (Note of Table 1, SA-20)

OTHER MISCELLANEOUS REQUIREMENTS

1. Bend Test as per Table X 4.2 of SA-20 Required Not Required

13
2. Repair by welding is not permitted

3. Material test certificates as per EN10204-3.1 EN 10204-3.2

CHECKLIST FOR MATERIAL REQUIREMENT

3.2.1 Material conform to the specification & allowable stress as per Annex 3.1

3.2.1. 4 Fatique Analysis Required Yes No

3.2.6 Certification by material manufacturer Required Not Required

14
3.2.10 Tolerances Applicable Not Applicable

3.10.1 Heat Treatment of Sample Test Coupons Applicable Not Applicable

2.11 Impact Requirements Applicable Not Applicable

Any other special requirement of Part 3

Note : Please give mark for any option you chose

PREPARED BY REVIEWED BY APPROVED BY

Exhibit 9 : Purchase Order
Format No. : F/PRC/04 ,REV.0
PT.ENVICON EKATAMA
Jl. Inspelsi Kalimalang
Teluk Jambe - Karawang Barat 41361 Indonesia
Phone : + 62-267 - 400737 , 400738
Fax. : + 62-267 - 400739
No. NPWP : 01.364.626.0.431.000
PURCHASED ORDER NO. DATE :
SYARAT PEMBAYARAN
PENJUALAN SUPPLIER FAKTUR KEPADA/INVOICED TO: Terms of Paymant :

Jl. Inspelsi Kalimalang

Teluk Jambe - Karawang Barat 41361 Indonesia
Phone : + 62-267 - 400737 , 400738
Fax. : + 62-267 - 400739

Mohon dikirim barang-barang / Please send the undermentioned goods :

JML.SATUAN HARGA.SATUAN JML.SATUAN
No. BARANG/GOODS KETERANGAN/DESCRIPTION
QTY UNIT UNIT . PRICE TOTAL PRICE

TANGGAL PENYERAHAN/ KPP/PP No. : tgl. : PEMESAN SUPPLIES CONFIRMATION/

DELIVERY DATE : ORDERED BY : PERSETUJUAN PENJUAL :

Distribution : 1. Supplier ( White ) Mohon di Fax kembali ke PT.ENVICON EKATAMA

2. Accounting ( Red ) setelah di cap & ditandatangani
3. File ( Yellow )
4. Store ( Green )
5. QC ( Blue )
EXHIBIT - 10

RECEIVING MATERIAL REPORT

Customer / Supplier - Report No. -
Project - Date -
Contract No - Description -
Job No./ PO No. - Drg / Rev No -
TAG NO Sheet -

Compieteness of MTC
Identification of Mat'l
Correlation of MTC
No Description Spesification Size Qty Heat No / Plate No / Batch No Certificate No Result

Dimensional
Visual
Equipment used : 1. Ultrasonic Thickness Gauge Serial No. : 381042
Calibration date : July 09 , 2019 NOTE : - Visual of package is good ( no demage )
2. Measuring Tape 30 Meter . Serial No. : RM / 30 / EE - Identification and lot no of material are match with mill certificate
Calibration date : March 14, 2019
Prepared By Reviewed By Approved By Reviewed/Approved By Reviewed/Approved By Abbreviation :

 A - Release For Next Operational

R - Rejected

QC - Store SPV QA/QC HOD QA/QC

Exhibit 11 : Material Slip

PT. ENVICON EKATAMA FORMAT NO: F/STR/03REV.00

KARAWANG
BON PENGAMBILAN MATERIAL / Material Slip
NOMOR/ Number : . . . . . . / . . . . . . / . . . . . . / . . . . . .
JOB NO :
PROJECT : TANGGAL / Date :

KODE BARANG / NAMA BARANG / JENIS MATERIAL/ KETERANGAN /

UKURAN / Size JML / Qty
Mat'l Code Material Name Spec Mat'l Remarks

Request by Issued by, Received by, Approved by,

HOD - PROD. STORE PRODUKSI HOD - GUDANG

Note : Original / Store , Copy / Production

Exhibit 12 : Material Consumable Slip

PT. ENVICON EKATAMA

KARAWANG
BON PEMAKAIAN BARANG (CONSUMABLE) / Material / Consumable Slip
Nomor / Number : ………../…………./……….. ./ …………..

FORMAT NO: F/STR/04 REV.0 Tanggal / Date : ………………………………

KOE BARANG / NAMA BARANG / DIMINTA OLEH / Request by

JUMLAH / Qty UKURAN / Size
Mat'l Code Material Name Job No Foreman Receipt

Issued by Approved by,

( Store ) ( Production - SPV )

EXHIBIT 13 : Material Substitution Request

PT.ENVICON EKATAMA
Karawang - Indonesia
MATERIAL SUBSTITUTION REQUEST

No.
Job No.
Contract No.
Drawing No.
Change Requested by
Component :

Material to be Substituted Original Change Proposed

Drawing revision required

Approval

Engineering Manager Date :

QA/QC Manager Date :

Customer Approval Date :

( Via Tlp / Fax/Email )

Distribution to Authorized Inspector

Store Dept
Production Dept
QA/QC Dept
Exhibit 14 : Inspection and Test Plan
ITP NO
PT.ENVICON EKATAMA Revision
Karawang - Indonesia ASME Date
Page

INSPECTION AND TEST PLAN

CUSTOMER :
PROJECT NAME :
ITEM NUMBER & NAME :
JOB ORDER NO :

Reviewed & Approved Reviewed & Approved

No Prepared by Customer / AI
by Production by QA/QC MGR

Applicable Document List :

Applicable Revision Level of Document
Document No Document Name
0 1 2 3 4 5

Abbreviation :

FAB : Fabrication A : Assembly MT : Magnetic Test

MK : Marking SR : Stress Relief / PWHT UT : Ultrasonic Test
ID : Identification Marking FM : Forming RT : Radiography Test
CT : Cutting EP : Expanding PT : Pneumatic Test
BV : Beveling DI : Dimension Inspection LT : Leak Test
BD : Bending FD : Final Dimension HT : Hydrostatic Test
RL : Rolling FI : Final Inspection SB : Sand Blasting
FU : Fit-Up IR : Inspection Release PA : Painting
WD : Welding MDR : Manufacture's Data Report ST : Stamping
BC : Back Cipping VI : Visual Inspection S : Shipping
BG : Back Gauging NDE : Non Destructive test Test PK : Packing
TA : Trial Assembly DPT : Dye Penetrant Test M : Monitor

H - Hold point is an inspection, test, nondestructive examination or fabrication operation that must be witnessed by
a specified party prior to subsequent fabrication. Operation sequences at the required hold point shall not be
continued prior having been examined and released by a specified party.

W - Witness point is an inspection, test, nondestructive examination or fabrication operation that is designated
to be witnessed by a specified party. The specified party must be notified sufficiently in advance prior to
performing the designated operation. If the specified party fails to witness the examination, the operation may be
performed, with written consent of the specified party

R – Review point is an inspection , which conducted by reviewing system or document related to i.e, Reviewing
of RT film, Inspection and Test reports / records or review of a Quality system
ITP NO
PT.ENVICON EKATAMA Revision
Karawang - Indonesia ASME Date
Page
INSPECTION AND TEST PLAN
No Inspection Activities Acceptance Criteria Record
1 Material Inspection
a. Verified Manufacture Review Mill of Test - Receiving Material Report
Certificates,Symbol Stamp ( marking)
b. Heat No, Manufacture symbol stamp, - Drawing / ASME
stencile,size, material spec, plate no,etc) Sec.II Part-A
c. Stamp transferring of heat no, lot no, on shell - Receiving Material
before commencement of fabrication / cutting Procedure : EE/PR/10
d. Check visual and dimension of the Plates,
Pipes, Elbow, Fitting, Flanges, Dish Head etc.
2 Inspection During Fabrication
a. Marking
Check the marking on the plate for shell , - Request of Inspection
Flange Fabricate,Pad ,Support,Internal Part etc
b. Cutting
Grind smoth all the cutting surface before Fit- up - Request of Inspection
c. Fabricated Flange-Machining & Drilling
( if Applicable )
Check visual & Dimension - Dimensional Report
d. Rolling
Check the Radius and Ovality on the Plate after Rolling, - Drawing - Dimensional Report
ovality of the Shell shall not exceed 1% of nominal - Dimensional Inspection
Diameter at the Cross section ( if Any ) Procedure : EE/PR/05
e. Fit - Up
1. Check gap, alignment, dimension & orientation. - Request of Inspection
2. Fit-up Shell to Head, Shell to Shell
3. Fit-up Flange to Neck Nozzle
4. Fit-up Nozzle Neck to Shell, Nozzle neck to Head,
5. Fit-up Elbow to Nozzle neck or Pipe
6. Fit-up Pad to Shell and Neck Nozzle
7. Fit-up Coupling to Shell
8. Fit-up Skirt & Lifting Lug to Head
9. Fit- up Internal
f. Welding
1. All butt joint shell be full penetration and full fusion - History of Welding Report
as per WPS
2. All inside welds shell be ground smooth and out side weld
shall be wire brush - ASME Sec IX
3. Welds surface shall be free from spatter, porosity, - List of WPS
under cut and etc. - List of Welder
4. The welding electrode & filler wire shall be check by qc
before start to welding as per WPS
5. All welders shall be qualified
3 Non Destructive Test
a. Penetrant Test : 100%
b. Magnetic Test : No - ASME Sec VIII
c. Radiographic Test : Full Div I, UW-51 - NDE Report
d. Ultrasonic test : No - NDE Procedure
4 Final Dimension
a. Check overall dimension,orientation,elevation of nozzles - Drawing
b. Check complateness of all accessories - Dimensional Inspection
- Dimensional Report
c. Aceptance criteria for dimensional deviation shall be Procedure : EE/PR/05
as per drawing
5 Leak Test for All Pad ( Pressure 25 psi g ) - Leak Test Procedure - Leak Test Report
6 Hydrostatic Test - Drawing
- Hydrotest Report
Suction Drum Hydrotest Pressure : 36.4 Barg / 527.8 Psi g - Hydrotest Procedure
7 Blasting & Painting ( as per cuetomer spec ) - Customer Spec - Blasting & Painting Report
8 Name Plate
Name Plate Stamping " U " - Drawing - Copy / Rubbing Name Plate
9 Manufacturer's Data Report
Prepare Form U-1A and Form U-4 - ASME Sec VIII Div-I - Form U-1A & U-4
ITP NO
Revision
PT.ENVICON EKATAMA ASME Date
Page
INSPECTION AND TEST PLAN
Item No Step Name of Part & Process Prod Spv QA/QC Spv AI Remark
1 Design
1.1 Approval of Drawing and Design Calculation
1.2 Approval of Design Calculation
2 Welding Qualification and Documents
2.1 QC Manual
2.2 Qualification / Approval of Welding Procedure
2.3 Qualification / Approval of Welder and Welding Operator
3 Verification Material & Mill Cert Review
3.1 Plate
3.2 Pipe
3.3 Flange
3.4 Fitting & Accessories
4 Fabrication of Head ( Top & Bottom )
4.1 MK
4.2 DI
4.3 CT + BV
4.4 FM + DI/VI Subcont
4.5 SR Subcont( if any )
5 Fabrication of Shell
5.1 MK
5.2 DI
5.3 CT + BV
5.4 BD/RL
Fit Up
- Longseam Shell ( 102 )
5.5
- Bottom Head to Shell ( 100 )
- Top Head to Shell ( 101 )
Welding
- Longseam Shell ( 102 )
5.6
- Bottom Head to Shell ( 100 )
- Top Head to Shell ( 101 )
5.7 VI
5.8 RT
6 Nozzle NA
Fit Up
- Flange to Pipe
- Pipe to Elbow
6.1
- Pipe to Shell
- Pad to Shell
- Pipe to Pad
Welding
- Flange to Pipe ( 103 )
- Pipe to Elbow ( 104 )
6.2
- Pipe to Shell ( 105 )
- Pad to Shell ( 106 )
- Pipe to Pad ( 105 )
6.3 VI
6.4 PT
6.5 RT
7 Nozle NB
Fit Up
- Flange to Pipe
7.1 - Pipe to Shell
- Pad to Shell
- Pipe to Pad
Welding
- Flange to Pipe ( 107 )
7.2 - Pipe to Shell ( 108 )
- Pad to Shell ( 109 )
- Pipe to Pad ( 108 )
7.3 VI
7.4 PT
7.5 RT
ITP NO
PT.ENVICON EKATAMA Revision
Karawang - Indonesia ASME Date
Page
INSPECTION AND TEST PLAN
Prod Spv QA/QC Spv AI
Item No Step Name of Part & Process Remark
Sign & Date Sign & Date Sign &
8 Nozle NC Date
Fit Up
- Flange to Pipe
8.1
- Pipe to Bottom Head
- Stiffner Plate to Pipe and Bottom Head
Welding
- Flange to Pipe ( 112 )
8.2
- Pipe to Bottom Head ( 113 )
- Stiffner Plate to Pipe and Bottom Head ( 114 )
8.3 VI
8.4 PT
9 Nozle ND
Fit Up
- Flange to Pipe ( 112 )
9.1
- Pipe to Bottom Head ( 113 )
- Stiffner Plate to Pipe and Bottom Head ( 114 )
Welding
- Flange to Elbow ( 116 )
9.2
- Pipe to Elbow ( 116 )
- Pipe to Shell ( 115 )
9.3 VI
9.4 PT
10 Nozle NE
Fit Up
- Flange to Pipe
10.1 - Pipe to Bottom Head
- Pad to Bottom Head
- Pipe to Pad
Welding
- Flange to Pipe ( 115 )
10.2 - Pipe to Bottom Head ( 117 )
- Pad to Bottom Head ( 118 )
- Pipe to Pad( 117 )
10.3 VI
10.4 PT
11 Nozle NF
Fit Up
11.1
- Coupling to Shell
Welding
11.2
- Coupling to Shell ( 119 )
11.3 VI
11.4 PT
12 Nozle NG
Fit Up
12.1
- Coupling to Shell
Welding
12.2
- Coupling to Shell ( 120 )
12.3 VI
12.4 PT
13 Nozle NH
Fit Up
13.1
- Coupling to Shell
Welding
13.2
- Coupling to Shell ( 120 )
13.3 VI
13.4 PT
ITP NO
Revision
PT.ENVICON EKATAMA
Karawang - Indonesia ASME Date
Page
INSPECTION AND TEST PLAN
Prod Spv QA/QC Spv AI
Item No Step Name of Part & Process Remark
Sign & Date Sign & Date Sign &
14 Nozle NI Date
Fit Up
14.1
- Coupling to Shell
Welding
14.2
- Coupling to Shell ( 120 )
14.3 VI
14.4 PT
15 Nozle NK
Fit Up
15.1
- Coupling to Shell
Welding
15.2
- Coupling to Shell ( 127 )
15.3 VI
15.4 PT
16 Nozle NK
Fit Up
16.1
- Coupling to Shell
Welding
16.2
- Coupling to Shell ( 207 )
16.3 VI
16.4 PT
17 Nozle NL
Fit Up
- Flange to Pipe
17.1
- Pipe to Top Head
- Stiffner to Pipe and Top Head
Welding
- Flange to Pipe ( 122 )
17.2
- Pipe to Top Head ( 123 )
- Stiffner to Pipe and Top Head ( 124 )
17.3 VI
17.4 PT
18 Nozle MH
Fit Up
- Neck Manhole
- Flange to Pipe
18.1
- Pipe to Shell
- Pad to Shell
- Pipe to Pad
Welding
- Neck Manhole ( 125 )
- Flange to Pipe ( 127 )
18.2
- Pipe to Shell ( 126 )
- Pad to Shell ( 128 )
- Pipe to Pad ( 126 )
18.3 VI
18.4 PT
18.5 RT
19 Leg
19.1 FU
19.2 WD
19.3 VI
19.4 PT
20 Lifting Lug
20.1 FU
20.2 WD
20.3 VI
20.4 PT
ITP NO
PT.ENVICON EKATAMA Revision
Karawang - Indonesia ASME Date
Page
INSPECTION AND TEST PLAN
Prod Spv QA/QC Spv AI
Item No Step Name of Part & Process Remark
Sign & Date Sign & Date Sign &
21 Internal Parts Date
21.1 Fit Up
21.2 Welding
21.3 VI
21.4 PT
22 Non Destructive Test ( NDT )
23 Visual Inspection & Dimensional Check
24 Hydrostatic Test
25 Stamping Name Plate " U "
26 MDR
Exhibit 15 : Request for Inspection

Request for Inspection

PT. EVICON EKATAMA
Req't No :
Client : Job No : Drawing & Rev. No : Request by ,
( Forman / Spv)
Name :
Request of Inspection : Date :
Time :
Sign :

Inspector by ,
Name :
Date :
Result of Inspection : Sign :

Result of Inspection :

Accepted
Time :
Repair
Time :
Proposed Disposition (if any) : Rejected
Time :

Distribution : QC ( White ) Production ( Yellow)

Exhibit 16 : Shell Ovality Inspection Report

PT ENVICON EKATAMA
KARAWANG - INDONESIA

SHELL OVALITY INSPECTION REPORT

Project : Report No :
Job No : Date :
Drawing No : Material :
Revision No : Customer :
Description : Code :

L
0º
e

d1
d2

d3 IDE
270º 90º OU
TS

B
d4 A B IDE
INS

Bevel A / B
180º

Measuring Equipment: Roll Meter SR No. : ..............

Note : All dimension are in mm Wall Thickness SR No. : ......................

BEFORE WELDING AFTER WELDING

Design dim Actual dim ( mm ) Design dim Actual dim ( mm )
Description Description
d ( OD ) d1 ( OD ) d2 ( OD ) d3 ( OD ) d4 ( OD ) d ( OD ) d1 ( OD ) d2 ( OD ) d3 ( OD ) d4 ( OD )

Shell 1 Shell 1

Circum OD A Circum OD A
Circum OD B Circum OD B
Long ( L ) Long ( L )
Thickness ( T ) Thickness ( T )
Bevel / e 30º 30º Bevel / e 30º 30º
Tolerance d1-d3 d2-d4 Tolerance d1-d3 d2-d4
Result Result
Inspection Date Inspection Date
Inspector Inspector
Plate Heat No Plate Heat No
BEFORE WELDING AFTER WELDING
Design dim Actual dim ( mm ) Design dim Actual dim ( mm )
Description Description
d ( OD ) d1 ( OD ) d2 ( OD ) d3 ( OD ) d4 ( OD ) d ( OD ) d1 ( OD ) d2 ( OD ) d3 ( OD ) d4 ( OD )
A
Shell 2 Shell 2
B
Circum OD A Circum OD A
Circum OD B Circum OD B
Long ( L ) Long ( L )
Thickness ( T ) Thickness ( T )
Bevel / e 30º 30º Bevel / e 30º 30º
Tolerance d1-d3 d2-d4 Tolerance d1-d3 d2-d4
Result Result
Inspection Date Inspection Date
Inspector Inspector
Plate Heat No Plate Heat No
PREPARED BY REVIEWED BY APPROVED BY CUSTOMER/AI

Insp.Name : Spv. Name : HOD QA/QC : Name :

Date : Date : Date : Date :
Exhibit 17 : Dimensional Report
Page : 1 of 2

PT.ENVICON EKATAMA
KARAWANG - INDONESIA

DIMENSIONAL REPORT
CUSTOMER : REPORT NO :
PROJECT : DATE :
CONTRACT NO : DESCRIPTION :
JOB NO : DRG / REV NO :

SKETCH :

All Dimension are in mm

PREPARED BY REVIEWED BY APPROVED BY AI

Insp. Name : QC Spv. : QA/QC HOD : Name :

Date : Date : Date : Date :
Exhibit 17 : Dimensional Report
Page : 2 of 2

PT.ENVICON EKATAMA
KARAWANG-INDONESIA

DIMENSIONAL REPORT
CUSTOMER : REPORT NO :
PROJECT : DATE :
CONTRACT NO : DESCRIPTION :
JOB NO : DRG / REV NO :

DESIGN DIMENSION ACTUAL DIMENSION DIFF. TOL.

POINT RESULT REMARKS
( mm ) ( mm ) ( mm ) ( mm )

PREPARED BY REVIEWED BY APPROVED BY AI

Insp. Name : QC Spv. : QA/QC HOD : Name :

Date : Date : Date : Date :
Exhibit 18 : Hydrotest Instruction and Report (Page 1of 2)

Page : 1 of 2
HYDROTEST INSTRUCTION AND REPORT
TAG NO :
JOB NO :
CONTRACT NO :
DRAWING NO :
DESCRIPTION :
CUSTOMER :
LOCATION :
CODE OF CONTRUCTION : ASME SEC VIII DIV. I 2019 Edition
MANUFACTURE : PT . ENVICON EKATAMA
YEAR OF MANUFACTURE :

√ VESSEL EXCHANGER TANK, TYPE :

CAPACITY :
DESIGN PRESSURE :
MAWP :
OPERATING PRESSURE :
DESIGN TEMPERATURE :
OPERATING TEMPERATURE :

DESCRIPTION MATERIAL CORROSION ALLOWANCE

PRESSURE TEST DETAIL

TEST MEDIUM : FRESH WATER
ACTUAL TEST PRESSURE :
HOLDING TIME :
ACTUAL TEST TEMPERATURE :
PRESSURE GAUGE NO
TEMPERATURE GAUGE NO :
PRESSURE RECORDER NO :
TEMPERATURE RECORDER NO :
DATE OF TESTING :
RESULT : SATISFACTORY
Exhibit 19 - Stamping of Vessel & Part

Stamping of Vessel :

(NB Serial No)

Certified By
PT. ENVICON EKATAMA

MAWP……. Kpa - AT ….. º C (INTERNAL)

U MAWP……. Kpa - AT ….. º C (EXTERNAL)

MDMT …… º C – AT ……. Kpa

RT-1
MFG SERIAL NUMBER :………….

YEAR BUILD : ………

Stamping of Part :

CERTIFIED BY______________________
U
MANUFACTURER’S SERIAL NUMBER._____________
PART

Note :

1) The letter on these name plate shall be not less than 4 mm height and 8 mm
height for direct stamping

2) When Registered with National Board, NB Stamp and NB Serial Number

shall be stamped above the code required stamping.

3) The company may be abbreviated as PT.EE

Exhibit 20 - Stamping of Boiler and Parts

Stamping of Boiler :

(NB Serial No)

Certified By
PT. ENVICON EKATAMA

__________________
MAWP When Build
S
__________________________________
Heating Surface, Boiler and Waterwalls

__________________________________
Maximum Designed Steaming Capacity

MFG SERIAL NUMBER : ………

YEAR BUILD:

Stamping of Part :

CERTIFIED BY______________________
S
MANUFACTURER’S SERIAL NUMBER._____________
PART YEAR BUILD ___________

Note :

1) The letter on these name plate shall be not less than 4 mm height and 8 mm height for
direct stamping
2) When Registered with National Board, NB Stamp and NB Serial Number shall be stamped
above the code required stamping.

3) For boilers with no pressure-retaining part larger than 16 in. (400 mm) O.D., or for equipment
operating at temperatures above 800°F (425°C), a cast, etched, or stamped metallic nameplate
instead of stamping directly on the pressure-retaining material
Exhibit 21 : Nonconformance Report

PT.ENVICON EKATAMA
Karawang - Indonesia
NON CONFORMANCE REPORT
LAPORAN KETIDAK SESUAIAN
CUSTOMER REPORT NO
PROJECT DATE
CONTRACT NO DRAWING NO
JOB NO REVISION

NCR AS PER CODE YES NO

DESCRIPTION OF NON CONFORMANCE ( URAIAN KETIDAK SESUAIAN ) :

Inspector Name : Signature :

Problem Cause ( Penyebab Masalah)

Name : Signature :
Corrective Action ( Tindakan Perbaikan )

Proposed by : Signature :
Prepentive Action ( Tindakan Pencegahan )

Proposed by : Signature :
DISPOSITION APPROVAL ( DISPOSISI DISETUJUI )
QA / WELDING PRODUCTION ENGG PURCHASE CUSTOMER / AI
REMARKS OK/NOT OK OK/NOT OK OK/NOT OK OK/NOT OK OK/NOT OK
MGR ( NAME) NA
SIGNATURE
DATE

DECISION OF DISPOSITION / KEPUTUSAN DISOSISIS - MGR QA/QC USE AS IS REPAIR REJECT

REPAIR PROCEDURE REQUIRED / DIPERLUKAN PROCEDURE PERBAIKAN - MGR QA/QC YES NO

COMPLETION OF DECISION / DISPOSITION ( DISPOSISI TELAH SELESAI )

PERFORMED BY NAME SIGNATURE DATE INSPECTED BY NAME SIGNATURE DATE

PROD.MGR QC-INSPECTOR

RESULT : ACCEPTED REJECTED

Remarks :

SIGN : SIGN :
Customer / AI QA/QC MGR

COPY NCR : NOTE NA = NOT APPLICABLE OR NO PROPOSAL

PRODUCTION
STRIKE OF INCORRECT STATEMENT
ENGINEERING
PURCHASE/STORE IF BOX PROVIDE / AS APPLICABLE

CUSTOMER/AI
Exhibit 22 - Welder Log
Log No.
PT.ENVICON EKATAMA
WELDER’S LOG
Effective Priode

Welder Welder Name Process Position Groove Weld F.No. Backing Consumable Mode Up Gas P.No. Remarks
AC/DCS
ID No. Qualification Diameter Thk Insert (2) Down Backing
P DCRP
range Max
Inch Inch mm

Prepared by Reviewed by Approved by

Exhibit 23 : Welding Operator’s Log

Log No.
PT. ENVICON EKATAMA WELDING OPERATOR’ S L O G Effective Priode

Electron
Filler Friction
Welding : Filler
Welding Welding Spec. Base metal Laser Welding :
Welding Machine Welding Out –of Metal P&S
Operator Operator Metal(s) & ( EBW Type Inertia
Process Welding Process vacuum Eqpt Spec & No. Remarks
ID No. Name thk or ( YAG) Welding/
& Vice Class.
LBW) Vice Versa
Versa

Prepared by Reviewed by Approved by

Exhibit 24 : Welder’s Continuity Log

PT.ENVICON EKATAMA WELDER’S CONTINUITY LOG

Welder’s Name Welder’s Welding Priode :
Symbol Process Jan Feb Mar Apr May June July Aug Sept. Oct. Nov. Des
Qualified

Prepared by Reviewed by Approved by

Exhibit 25 : Welding Material Issue Slip

WELDING MATERIAL ISSUE SLIP

PT.ENVICON EKATAMA
KARAWANG
No. Date Time Issue *Time Return

Dia Request by Approval by Quantity

No Job No. AWS Joint No. Remarks
(  ) Name Sign Welder SPV/FRM Rec’d Return

Notes : Original ( Stock Keeper ) Copy ( Welding Engineer ) * Return Electrode if not used or after used within 4 hours
Exhibit 26 : History Sheet for Welding

PT ENVICON EKATAMA
KARAWANG - INDONESIA
Page of

HISTORY SHEET FOR WELDING

Customer : Report No. :
Project : Date :
Contract No : Description :
Job No : Drg No / Rev No :
NDE
No Description Material WPS No Weld Prosess Welder Stamp Visual Date Date / Result Inspector Remark
PT MT UT RT

PREPARED BY REVIEWED BY APPROVED BY CUSTOMER / AI

Inspector Name : QA / QC Supervisore : HOD QA/QC : Name :

Date : Date : Date : Date :
Company : Company : Company : Company :
Exhibit 27 : Heat Treatment Instruction

Page 1 of 5

PT.ENVICON EKATAMA POST WELD HEAT TREATMENT

Karawang - Indonesia INSTRUCTION
( FURNACE )
Job No : Date :
Description : Report No :
Part Name : Dwg No. :
Contruction Code : Cond.at : Shop/Sub.cont.shop
Heating rate (/hr) : Cooling Rate (/hr) :
Holding temp.range ( OC) : Holding time (/hr) :
Nom/max.thickness (mm) : Cooling methode :

Size Purnace Length :

Width :
Height :

Time

Comment : Prior to PWHT operation the PWHT checklist shall be completed

Prepared by, Reviewed & Approved Reviewed by

( Design Engineer) by, (Engineering Manager) (QC-Inspector)

Date : Date : Date :

Comment : Client Representative / Authorized Inspector

Sign : Date
Exhibit 27 : Heat Treatment Instruction

Page 2 of 5

PT.ENVICON EKATAMA POST WELD HEAT TREATMENT

Karawang - Indonesia INSTRUCTION
( FURNACE/LOCAL)
Job No : Date :
Description : Report No :
Part Name : Dwg No. :
Contruction Code : Cond.at : Shop/Sub.cont.shop
Heating rate (/hr) : Cooling Rate (/hr) :
Holding temp.range ( OC) : Holding time (/hr) :
Nom/max.thickness (mm) : Cooling methode :

Size Purnace Length :

Width :
Height :

Time

Comment : Prior to PWHT operation the PWHT checklist shall be completed

Prepared by, Reviewed & Approved Reviewed by

( Design Engineer) by, (Engineering Manager) (QC-Inspector)

Date : Date : Date :

Comment : Client Representative / Authorized Inspector

Sign : Date
Exhibit 27 : Heat Treatment Instruction

Page 3 of 5

PT.ENVICON EKATAMA POST WELD HEAT TREATMENT

Cooment : Prior to PWHT operation the PWHT checklist shall be completed

Prepared by, Reviewed & Approved Reviewed by

( Design Engineer) by, (Engineering Manager) (QC-Inspector)

Date :
Date : Date :

Comment : Client Representative / Authorized Inspector

Sign : Date
Exhibit 27 : Heat Treatment Instruction

Page 4 of 5

PT.ENVICON EKATAMA POST WELD HEAT TREATMENT

Karawang - Indonesia INSTRUCTION
( FURNACE/LOCAL)
Job No : Date :
Description : Report No :
Part Name : Dwg No. :
Contruction Code : Condition at : Shop/Sub.cont.shop

No Description of check Yes No N/A

1. Are all area of item to be PWHT free oil, grease, dirt etc

Is furnace loaded in a manner taht will prevent direct impingement

2.
between the item and the burner flame.

3. Are all flanges faces coated with de-oxidation coating

4. Are all blind flange, re-pad tell-tale hole plug removed

Is item adequately supported as to prevent distortion during the PWHT

5.
operation
6. Is the furnace Relative-Humadity controlled

Are item to be PWHT attached with thermocouple (s) ; number and

7.
placement is adequate and correct
Are thermocouples(s) and time-temperature recorder calibrated
8.
certificate copy to be submited/attached.

Are thermocouples adequately to item by suitables means without

9. determental to be material of item and adequately insulated with high
temperature resistant putty or other suitable means.

Are thermocouples adequltely supported by brick or other suitable

10. means to prevent shorting on metalic surface or direct contact with
burner flame

Prior to entering of the item furnace temperature is less than 800ᵒF

11.
( 427 ᵒC)
Checked by Approved by
( QC- Inspector) ( QA/QC Manager)

Date : Date : Date :

Exhibit 27 : Heat Treatment Instruction

Page 5 of 5

PT.ENVICON EKATAMA NOMINAL THICKNESS AS COVERING

Karawang - Indonesia THICKNESS FOR PWHT
Exhibit 28 : Calibration Log

PT.ENVICON EKATAMA
KARAWANG - INDONESIA

Rev :
CALIBRATION LOG Date :

ACCEPTANCE FREQUENCY OF CERTIFICATE NO / DATE OF DATE OF

CALIBRATION
NO DESCRIPTION MAKE QTY ID NO RANGE ACCURACY DEVIATION LOCATION CALIB'N AGENT NEXT
BODY
TOLERANCE CALIB`N REPORT NO CALIB`N CALIB`N

Remark : Prepared By Approved By

EXHIBIT 29 - NB Register Number Log

Month :
PT.ENVICON EKATAMA Code Item Rev. No :
Installa NB Register Data
NB Boiler / Pressure Vessel /
tion
Serial Date Issued. Job No MFG S/N External Piping Name and Designator
Locati MDR MDR Sent Remarks
No. Drawing No. Date Date
on
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Exhibit 30 , Material Take off

MATERIAL TAKE OFF

PT.ENVICON EKATAMA Customer
Karawang - Indonesia
Description
Job No.

Remark
No Desription Material Size Qty PMS No
Stock Purchase

Engineering. Store,

Engineering Manager Store Manager

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