Document21

�

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 MTR’s 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 PMA’s 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 MTR’s 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”-6”x¾”x S XS 176668

9A2-

03B&C

5”x4”x1”x S XS 168930 &

1T32491

9A2-

03D

10”-6”x1”x S XS 1T34159

03E&F 3”x1½”x S XS 07/75718 &

06/74167

03G&H 6”x5”x1½” x S XS 07/76672 &

07/75718

20/07/2009

9A2-

04A

6”x5”x1½” x S XS 1T33083

9A2-

04B

24”x14”x1½” x S

XS

75473

9A2-

04C

APIQR

Registration

no. 0614 x

Expiration

date 10 Nov.

2011 and

registration

since 19 June

2006.

6”x2”x S XS 1T34165

20/07/2009

The above MTR’s 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-45º NPS 3” x S 40

LR-45º NPS 6” x STD

LR-90º NPS6” x S 40

LR-90º NPS8” x S 40

LR-90º 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 MTR’s 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 MTR’s 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


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-AQ–Cert.

with reg. no.

QUAL/2007/28

864 Exp. date

04-04-2010





LR-90º 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


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-45º NPS 14” x S 40

LR-45º NPS 14” x S 40

LR-90º 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.