Peningkatan Efektifitas Quality Control Project

melalui Implementasi QA / QC PROGRAM

April 2015

ASSET INTEGRITY MANAGEMENT, means:

DATA MANAGEMENT

EDMS
DOCUMENT CONTROLLER
QA/QC
NCR SYSTEM
RELIABILITY & INTEGRITY

RISK BASED INSPECTION (RBI)

RISK BASED CERTIFICATION (RBC)

RELIABILITY CENTERED MAINTENANCE (RCM)

RELIABILITY, AVAILABILITY & MAINTAINABILITY (RAM)

ASSET PERFORMANCE ASSESSMENT (APA)

FITNESS FOR SERVICE (FFS)

PIPELINE INTEGRITY MANAGEMENT SYSTEM (PIMS)

MAINTENANCE ASSESSMENT PROTOCOL (MAP)

SHUTDOWN & TURN AROUND (SDTA)

COMPLIANCE ASSURANCE
CERTIFICATION
PERMIT

MEETING OBJECTIVES
1. To have feed back and improvement for QA / QC Program
2. To validate and to ensure the proposed QA / QC Program meeting with
PGEs requirements and comply with applicable regulations
3. To know that QA / QC Program as Part of Asset Integrity Management
Process

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

Controller System
5. To know what is the meaning of QA (Quality Assurance) and QC
(Quality Controller)
6. To know where QA / QC Implementation

PROGRAM OBJECTIVES
Objectives of this program :
1. To ensure compliance with project requirements (target HSE, quality &

performance, schedule, cost)

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

3. Measurement Process (Key Performance Index)

4. As tools for main process:

Data Management Function As Built Drawings, Equipment No, PSV

No, MOC, PSM, CDM, PROPER

Reliability Function RBI, RCM, Safety Devices

Document Controller Function Traceability System

Compliance Assurance Function Certification, Color Coding, HSE

Program, Permit

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

2. Scope of QA / QC Program
1.
2.
3.
4.
5.

Piping
Mechanical
Civil
Electrical
Instrumentation & Controller

for following system (where applicable):

a)
b)
c)
d)
e)

Fluid Collection and Reinjection System

Geothermal Power Plant
Civil and Insfractures
Additonal Supply and Services
Transmission 24.68 km

WHAT IS QA / QC ?
(ISO 9000, 3.2.10 11)
_____________________________________________
QUALITY ASSURANCE
A part of quality
management focused
on providing confidence
that quality
requirements will be
fulfilled

QUALITY CONTROL
A part of quality
management focused
on fulfilling quality
requirements

WHAT IS QA / QC ?
(ISO 9000, 3.2.10 11)
_____________________________________________
These techniques and activities are agreed with customers and/or stakeholders
before project work is commenced.

QUALITY ASSURANCE

QUALITY CONTROL

A Strategy of Prevention

A Strategy of Detection

All activities that are designed to

determine the level of quality.

QC is a reactive means by which

quality is gauged and monitored.

It is focused on planning,
documenting and guidelines to
assure quality.
specifications and
industry or company standards.

It is undertaken at the beginning of

a project,

Activities
are
quality
plans,
inspection and test plans, the
selection of defect tracking tools

QA / QC PIPING SYSTEM an example

_____________________________________________
QUALITY ASSURANCE
Code
/Standard

No

Description

Material
Spec
Receiving
Storage and
Handling

ASME II,ASME
B36.10,ASME
B36.19M, etc.

Design

ASME B 31.1.

Welding
Procedure

Personnel

ASME IX

Ver.
Mill
Certificate
and
PMI (If
needed)
Stress
Analysis

QUALITY CONTROL
Code
/Standard

No

Description

Material
Receiving
Storage and
Handling

Approval
Procedure

Report

Integrity

ASME B 31.1.

Hydro test

WPS /
PQR
WPQT
3

Welding
Consumable
Control
Purity Gas
Fit Up
Welding
Inspection
Preheating
PWHT
Hardness

ASME II Part C
ASME B 31.1
ASME V

Ver.

Certificate
Electrode
Certificate
Gas
(Argon)
Report (Fit
Up, Visual)
NDE
(RT,PT,UT,
MT)

QA / QC PIPING SYSTEM an example

_____________________________________________
QUALITY ASSURANCE
Code
/Standard

No

Description

Cleaning
Before Paint

ISO 8501-1
SSPC

Approval
Procedure

Painting &
Coating

NACE

Approval
Procedure

Insulation

7
8

Pickling
Steam Blow
Reinstate

ASTM C1696

Ver.

Approval
Procedure
Approval
Procedure
Approval
Procedure

QUALITY CONTROL
No

6
7

Approval
Procedure

Description

Ver.
Report
Visual
Compare
ISO pic

Sand
Blasting

ISO 8501-1
SSPC

Painting &
Coating
Inspection

NACE

Ultra
Thickness
Measurem
ent

Insulation

ASTM C1696

Report

Pickling

Approval
Procedure

Endoscopic

Steam Blow

Approval
Procedure

Report
Target
Plate

Approval
Procedure

Line Check
Torque
Report

Code
/Standard

Reinstate

QA / QC MECHANICAL STATIC SYSTEM an example

_____________________________________________
QUALITY ASSURANCE
No

Description

Code
/Standard

Material
Spec
Receiving
Storage and
Handling

ASME VIII Div.

I & II
ASME II

Design

Fabricator
Pressure
Vessel

Welding
Procedure
Personnel

ASME VIII Div.

I&I
ASME VIII Div.
I & II

ASME IX

Ver.
Mill Cert
Certificate
Guarantee

QUALITY CONTROL
No

Description

Material
Receiving
Storage and
Handling

Approved
Drawing

ASME Stamp
U

WPS /
PQR
WPQT

Code
/Standard

Ver.

Report

Integrity

ASME VIII Div.

I&I

Hydro test

Fabricator

ASME VIII Div.

I & II

Expire
ASME
Stamp U

Welding
Consumable
Control
Purity Gas
Fit Up
Welding
Inspection
Preheating
PWHT
Hardness

ASME II Part C
ASME B 31.1
ASME V

Certificate
Electrode
Certificate
Gas
(Argon)
Report (Fit
Up, Visual)
NDE
(RT,PT,UT,
MT)

QA / QC MECHANICAL STATIC SYSTEM an example

_____________________________________________
QUALITY ASSURANCE
No

Description

Installation

Grouting

Code
/Standard

Ver.

QUALITY CONTROL
No

Description

Approved
Procedure
Manufacture
Standard

Approved
Procedure
Certificate
Grouting

Installation

Grouting

Final Check

Final Check

Code
/Standard
Approved
Procedure

Approved
Procedure

Ver.
Report
Orientation,
Leveling,
Elevation,
Centerline

Check
Material,
Surface
Preparation
, Mix of
Grout,
Curing,
Tightening
Anchor Bolt
Punch list

QA / QC MECHANICAL ROTATING SYSTEM an

example
_____________________________________________
QUALITY ASSURANCE
No

Description

Code
/Standard

Material
Spec
Receiving
Storage and
Handling

ASME VIII Div.

I & II
ASME II

Design

Installation

ASME VIII Div.

I&I

Ver.
Mill Cert
Certificate
Guarantee

Approved
Drawing

QUALITY CONTROL
No

Description

Material
Receiving
Storage and
Handling

Integrity

Code
/Standard

Report
FAT
ASME B 31.1.

Approved
Procedure

Installation

Ver.

Approved
Procedure

Perform
test
Report
Leveling,
Elevation,
Centerline
Report PreAlignment
First
Alignment
(after
grouting)
Final
Alignment

QA / QC MECHANICAL ROTATING SYSTEM an

example
_____________________________________________
QUALITY ASSURANCE
No

Description

Grouting

Final Check

Code
/Standard
Manufacture
Standard

Ver.

QUALITY CONTROL
No

Approved
Procedure
Certificate
Grouting
Approval
Procedure

Description

Code
/Standard

Grouting

Approved
Procedure

Check
Material,
Surface
Preparation
, Mix of
Grout,
Curing,
Tightening
Ancor Bolt

Final Check

Approved
Procedure

Punch list

Ver.

QA / QC CIVIL SYSTEM an example

_____________________________________________
QUALITY ASSURANCE
No

Description

Survey

Soil
Investigation

Code
/Standard

Excavation

Design

Ver.

Investigatio
n Existing
Facility
Approval
Procedure

QUALITY CONTROL
No

Description

Code
/Standard

Ver.

Survey

Report
Coordinate
s, Elevation

Soil
Investigation

Report
SPT,
DCPT,
Electric
Resistivity

Excavation

Report
Depth and
with
excavation,
Slope

ASCE 7

QA / QC CIVIL SYSTEM an example

_____________________________________________
QUALITY ASSURANCE
No

Description

Material
Spec
Receiving
Storage and
Handling

Code
/Standard
SNI 03-17292002

Foundation

Ver.

Grouting

Manufacture
Standard

Concrete
Work

ACI 207, ACI

301

No

Description

Code
/Standard

Ver.

Material
Receiving
Storage and
Handling

SNI 03-17292002

Report

Mill Cert

Approved
Procedure
Approved
Drawing

QUALITY CONTROL

Foundation

Report
Elevation,
Padding

Grouting

Approved
Procedure

Check
Material,
Surface
Preparation
, Mix of
Grout,
Curing,
Tightening
Anchor Bolt

Concrete
Work

ACI 207, ACI

301

Mechanical
Testing

Approved
Procedure
Certificate
Grouting

QA / QC CIVIL SYSTEM an example

_____________________________________________
QUALITY ASSURANCE
No

Description

Code
/Standard

Ver.

QUALITY CONTROL
No

Description

Code
/Standard

Ver.

Form Work

ACI 347
ACI 318

Mill Cert

Form Work

ACI 347
ACI 318

Material
Inspection

10

Reinforcing
Bar Work

ACI 301, ACI

315, ACI 318

Mill Cert

10

Reinforcing
Bar Work

ACI 301, ACI

315, ACI 318

Mechanical
Testing

11

Anchor Bolt

Mill Cert

11

Anchor Bolt

Mechanical
Testing

12

Steel Structure
Welding
Painting
Erection
Final

WPS,PQR,
WPQT

12

Steel Structure
Welding
Painting
Erection
Final

Report VT
NDE
Report
Paint thick
Report
Plumbness
, centerline,
elevation
Punch List

AWS D1.1
SSPC

AWS D1.1
SSPC