Power Turbo-Systems/Power

Environment
Plants
SUPPLIER MONITORING INTERVENTION REPORT
IRN: T9A2-IR003



Alignment Meeting

Final Conformity Inspection







Q. Surveillance/Intermediate
Inspection

Pre-shipment Inspection





Project: CLAUS C Power Plant Project Unit: C-1, C-2 and C-3
Equipment :
External Piping
Equipment specification : QS-7707-0009 Rev. : 00

Inspection & Test Plan : ITP- T9A2PSP -1 Rev.02 For EN 19252
ITP-T9A2PSP-2 Rev.00 for EN 13480 and ITP-T9A2PSP-3 Rev. 01- For
ASME B31.1
Order No. : 104499 IO
Reference Contract No.: 66007707

EFU list : Rev. :

Supplier: PT AP ESI Surabaya, Indonesia Sub-supplier :

Place of intervention : PT AP ESI Surabaya, Indonesia Telephone No : +62 (31) 329 2080/2088
Fax No : +62 (31) 329 2168
Attendees : See on the page 2 on this report

Date of Intervention: 29-30 Sep. 2009

WORKSHOP DELIVERY DATES (Ex-works) MANUFACTURING PROGRESS PERCENTAGE
Contractual
Expected Realised
Supplier / Sub-supplier
C-1: CS 14 Dec 09
& Alloy 19 Jan 10
C-2: 18 Jan 09
C-3: 11 Feb. 09

TBA


- Procurement :
- Manufacturing :
- Final testing :
- Packing :
Discrepancies report attached : Yes / No Discrepancies (Number off) :
SUMMARY: Next Surveillance visit is on 7-8 Oct 2009 (To attend Grade 91 welding indoctrination).
Each related PMA for the following available MTRs was recorded progressively with the actual heat and
certificate number and was signed off by supplier and followed sign off by NoBo that found to be
satisfactory were meets specification no. QS-7707-0009 Rev. 00
MTR from Erne Fittings gmbh Austria (Elbow and Tee pipe) they were found some MTR date does not
cover by QMS Validity date expire on 24-07-2008. APESI requested this information and it was confirmed
with the QMS Certificate received from material supplier with valid until 19-06-2011 that found
acceptable.
Review the Alignment MOM issues to adjust PWHT Procedure , EN material Marking ID, Cleaning &
Painting Procedure, Storage & preservation procedure are under internal verification before submit as
required via SupplierNet. Training for personnel-VT Level II under EN 12952-6 and 13480-5 competency are
still on going for the QC-Personnel except for the four personnel were passed the Quiz after they have
got in house training.

Actions: To adjust the several quality procedure as required on Alignment MOM and followed submit as required via
SupplierNet
Attached Documents : None

Inspector/Date/Signature :
Condro Widiyarto/QA AP-W Rep. 01Oct. 2009
Distribution :

Quality Coordinator/Date/Signature :

Report Reference: T9A2- IR003




Power Turbo-
Systems/Power
Environment
QUALITY SURVEILLANCE / INTERMEDIATE INSPECTION


Reference
Document



Description / Action
esponsible
and due
date
1. SUMMARY/FINDINGS:
Proposed of this meeting: To review/verify available MTR-for ASME
B31.1 includes PMA for PED-Pressure Equipment Materials-.

Attendees:
1) Agustinus BASKOROMURTI-APESI PM
2) Wahyudin-APESI PQE
3) Lucky R. Prastiawan-APESI QCM
4) David - APESI QC-Inspector
5) Condro Widiyarto-EURTREU Inspector-QA APW Rep.

The following documents were used during this surveillance
inspection visit:
o ITP-T92APSP-3 Rev. 01: Inspection & Test Plan for ASME B31.1
o QS-7707-0009 Rev. 00: EN12952 & B31.1 Pressure Piping PED
Conformance
o ASME Section II Part A Code Standard 2007 Edition 2008 add.
o 07707-PMA-106B, 105, 234 WPB and 234 WPC Rev. B
o PS-HRSG-0004 Rev. D: Pressure Equipment Materials-PED

2. Review MTR/Inspection Certificate material:
Verify PMA material specification: All the following PMAs have
been accepted by Pressure Equipment Manufacturer AP-Inc
Windsor CT USA date 5 February 2009 and Notified Body no. 0871
(J-M Hequet) on 5 May 2009 from HSB International
o PMA no. 7707-PMA-106B Rev. B
o PMA no. 7707-PMA-105 Rev. B
o PMA no. 7707-PMA-234 WPB Rev. B
o PMA no. 7707-PMA-234 WPC Rev. B
Inspection Certificate of material EN 10204-3.1 for ASME B31.1 PED
conformance were reviewed as follows: Each related PMA for the
following available MTRs was recorded progressively with the
actual heat and certificate number and was signed off by
supplier and followed sign off by NoBo that found to be
satisfactory were meets specification no. QS-7707-0009 Rev. 00.
o Pipe material - ASME SA106 Grade B from Sumitomo Metals
Japan as mentioned on the spread sheet index no. 9A2-02:
NPS 10 x SCH 40/OD 273.1 x WT 9.27 mm (Heat no. J8K9281),
Quality Management System (QMS) for material manufacturer
acc. European Directive 97/23/EC by TUV CERT-Certification
Body for Pressure Equipment (Notified Body, ID no. 0035) with
certificate no. 01 202J/Q-02 0017 x valid until Oct. 2011, The
Inspection Certificate material was contained an EN 10204
3.1and MTR was validated by an Authorized representative-
independent of manufacturing department that found
acceptable were meets specification PMA no. 07707-PMA-106
B Rev. B, PS-HRSG-0004 Rev. D and ASME II Part A 2007 Edition
2008 Add.




o TEE material- ASME SA234-WPB from Erne Fittings gmbh Austria
as mentioned on the spread sheet index no. 9A2-13-14 with
the Inspection Certificate material was contained an EN
10204 3.1 and they were found some MTR date does not
cover by QMS Validity date expire on 24-07-2008. APESI
requested this information and it was confirmed with the QMS
Certificate received with expire until 19-06-2011 that found
acceptable.

o WELDOLET material- ASME SA105 from VIAR MECCANICA ITALY
as mentioned on the following spread sheet index no. 9A2-03A
up to 03H and 9A2-04A up to 04C with the Inspection
Certificate material included an EN 10204 3.1- MTR was
validated by an Authorized representative-independent of
manufacturing department.

Index
no.
QMS-ISO
9001:2000 by
Size Heat
number
MTR-
Certificate
date
9A2-
03A
12-6xx S XS 176668
9A2-
03B&C
5x4x1x S XS 168930 &
1T32491
9A2-
03D
10-6x1x S XS 1T34159
03E&F 3x1x S XS 07/75718 &
06/74167
03G&H 6x5x1 x S XS 07/76672 &
07/75718
20/07/2009
9A2-
04A
6x5x1 x S XS 1T33083
9A2-
04B
24x14x1 x S
XS
75473
9A2-
04C
APIQR
Registration
no. 0614 x
Expiration
date 10 Nov.
2011 and
registration
since 19 June
2006.
6x2x S XS 1T34165
20/07/2009
The above MTRs were reviewed that found acceptable were
meets specification PMA no. 07707-PMA-105 Rev. B, PS-HRSG-
0004 Rev. D and ASME II Part A 2007 Edition 2008 addenda.

o ELBOW material- ASME SA234-WPB from Erne Fittings gmbh
Austria as mentioned on the following spread sheet index no.
07 to 09, 10 & 12 with the Inspection Certificate material
contained an EN 10204 3.1 and they were found some MTR
date does not cover by QMS Validity date expire on 24-07-
2008. APESI requested this information and it was confirmed
with the QMS Certificate received with valid until 19-06-2011
that found acceptable.

Index
no.
QMS-ISO
9001:2000
by
Size Heat
number
MTR-
Certificate
date
9A2-07
9A2-08
9A2-09
9A2- 10
9A2-12
TUV Cert.
with reg. no.
12 100 3054
x Exp. date
19-06-2011
LR-45 NPS 3 x S 40
LR-45 NPS 6 x STD
LR-90 NPS6 x S 40
LR-90 NPS8 x S 40
LR-90 NPS10 x STD
486641
494435
494433
392553
387890
09/06/08
07/01/09
08/01/09
05/12/08
31/10/08






The above MTRs were reviewed that found acceptable were
meets specification PMA no. 07707-PMA-234 WPB Rev. B, PS-
HRSG-0004 Rev. D and ASME II Part A 2007 Edition 2008
addenda.


o TEE material- ASME SA234-WPB from Erne Fittings gmbh Austria
as mentioned on the spread sheet index no. 9A2-13-14 on the
following size and heat number with the Inspection Certificate
material contained an EN 10204 3.1 and they were found
some MTR date does not cover by QMS Validity date expire
on 24-07-2008. APESI requested this information and it was
confirmed with the QMS Certificate received with valid until
19-06-2011 that found acceptable.
Index
no.
QMS-ISO
9001:2000 by
Size Heat
number
MTR-
Certificate
date
9A2-13
9A2-14

TUV Cert.
with reg. no.
12 100 3054 x
Exp. date 19-
06-2011
4/4 x STD/STD
6/6 x STD/STD

480486
392554
10/10/2007
05/02/09
The above MTRs were reviewed that found acceptable were
meets specification PMA no. 07707-PMA-234 WPB Rev. B, PS-
HRSG-0004 Rev. D and ASME II Part A 2007 Edition 2008
addenda.


o ELBOW material- ASME SA234-WPB from Interfit Group
Vallourec, France as mentioned on the following spread sheet
index no. 15 up to 19 with the Inspection Certificate material
included an EN 10204-2004 3.1 and they were found to be
acceptable were meets specification PMA no. 07707-PMA-234
WPB Rev. B, PS-HRSG-0004 Rev. D and ASME II Part A 2007
Edition 2008 addenda.
Index
no.
QMS-ISO
9001:2000 by
Size Heat
number
MTR-
Certificate
date
9A2- 15
9A2-16
9A2-17
9A2-18
9A2-19

AF-AQCert.
with reg. no.
QUAL/2007/28
864 Exp. date
04-04-2010
LR-45 NPS 4 x STD
LR-45 NPS 8 x STD
LR-90 NPS 3 x STD
LR-90 NPS 4 x STD
LR-90 NPS 14 x S 40
351383
18487
978779
326916
54732F
23-04-2007
06-12 2007
07-10-2008
14-05-2008
09-02-2009



o FLANGE material- ASME SA105 from Flanschenwerk Bebitz
GmbH, Deutschland as mentioned on the spread sheet index
no. 9A2-27-28 with the Inspection Certificate material
contained an EN 10204 3.1 and they were found to be
acceptable were meets specification PMA no. 07707-PMA-105
Rev. B, PS-HRSG-0004 Rev. D and ASME II Part A 2007 Edition
2008 addenda.







Index
no.
QMS-ISO
9001:2000 by
Size Heat
number
MTR-
Certificate
date
9A2-27
9A2-28

TUV Cert.
with reg. no.
44 100
071888 Exp.
date 14 Nov.
2010
WN Flange 4 x # 300
WN Flange 6 x # 600

81303/2
344758/7
02.06.2008
02.06.2009



o ELBOW material- ASME SA234-WPB (Index no. 9A2-32-33) &
WPC (index no. 9A2-34) from TechnoForge Fitting & Flanges,
Italy with the Inspection Certificate material contained an EN
10204-2004 3.1 and they were found to be acceptable were
meets specification PMA no. 07707-PMA-234 WPB Rev. B (Index
no. 9A2-32-33) , 07707-PMA-234 WPC Rev. B (Index no. 9A2-34),
PS-HRSG-0004 Rev. D and ASME II Part A 2007 Edition 2008
addenda.
Index
no.
QMS-ISO
9001:2000 by
Size Heat
number
MTR-
Certificate
date
9A2- 32
9A2-33
9A2-34

TUV Cert.
with reg. no.
39 00 0300504
Exp. date 16
May 2011
LR-45 NPS 14 x S 40
LR-45 NPS 14 x S 40
LR-90 NPS 3 x S 160
934114
33027
978779

27/07/2009
27/07/2009
27/07/2009


o Flange material- ASME SA105 from ULMA, Spain as mentioned
on the following spread sheet index no.22 up to 25 x Quality
Management System (QMS) with the Inspection Certificate
material was contained an EN 10204 3.1and MTR was
validated by an Authorized representative-independent of
manufacturing department that found acceptable were
meets specification PMA no. 07707-PMA-105 Rev. B, PS-HRSG-
0004 Rev. D and ASME II Part A 2007 Edition 2008 Add.
Index
no.
QMS-ISO
9001:2000 by
Size Heat
number
MTR-
Certificate
date
9A2- 22
9A2-23
9A2-24
9A2-25

Lloyd Register.
with reg. no.
01SGI 6000236
Exp. date 31
May 2011
WN 4 x 150LB x S 40
WN 6 x 150LB x S 40
WN 6 x 300LB x S 40
WN 8 x 300LB x S 40


455A7
48A8
326A8
355A8
31/08/2007
13/05/2008
12/11/2008
30/06/2008


4. Review/verify the following status up dating Procedures and VT
competency personnel under EN 12952-6 and 13480-5 (As mentioned
on the Alignment meeting MOM dated 26 Aug 2009):

o Point 8: PWHT Procedure no. HT-010-0: To adjust
procedure/indicate the number of thermal couples required
by diameter of pipe in support of ISO 17663, pay close
attention tables 1, 2 and 3 with the updated document is
under internal verification before submit to AP-W via
SupplierNet.





o Point 9a: Material identification no. T9A2-PSP-03 Rev. 01 for ASME
incorporate with two strip system and EN material suggested by
AP-W can be uniquely identified using one strip (Unique colour)
and second strip for uniquely identifying the type/grade of the
materials with the updated document is under internal
verification before submit to AP-W via SupplierNet.

o Point 9c5: Verbal communication with APESI QCM that training for
personnel-VT Level II under EN 12952-6 and 13480-5 competency
are still on going for the QC-Personnel except for the following four
personnel were passed the QUIZ with after they have got in house
training:
o Hanafi
o Sumarno
o Joko Suwito
o Achmad Fauzi

o Point 13: Storage and Preservation procedure no. T9A2-PSP-04-00:
To review the procedure in section 2.3 and 4.1 of documents for
intent with the updated document is under internal verification.