Power Turbo-Systems/Power

Environment
Plants
SUPPLIER MONITORING INTERVENTION REPORT
IRN: T8A8-IR020



Expediting

Final Conformity Inspection







Q. Surveillance/Intermediate
Inspection

Pre-shipment Inspection





Project: ASTORIA II Unit: #301and #401
Equipment :
HRSG-Casing/C-Frame Modules
Equipment specification : Rev. :

Inspection & Test Plan : T8A8PSP-1 Rev.06-C-Frame Module Assembly
T8A8PSP-2 Rev.02-C Frame casing
T8A8PSP-3 Rev.01-Finned Tubes

Order No. : 100605 IO
Reference Contract No.: 0620
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 list on the page 2 of 4 bellows in this report.

Date of Intervention: 1, 3-4 June 2009.

WORKSHOP DELIVERY DATES (Ex-works) MANUFACTURING PROGRESS PERCENTAGE
Contractual Expected Realised
Supplier / Sub-supplier
Unit 301 : 12 Aug. 09
Unit 401 : 12 Aug. 09


14 July 09
12 Aug. 09


- Procurement :
- Manufacturing :
- Final testing :
Discrepancies report attached : Yes / No Discrepancies (Number off) : Major :
Minor :
SUMMARY: Next visit schedule is 10-11 June 2009.
All improper works on non pressure parts: C-frame & Boiler casing primer paint/Field Weld able primer,
rectification of cutting surface of Stub column for module 1A and visually spatter on C-frame after
painted have to be closed out before final inspection of each component.
The balance Mock up test report of finned tubes is not ready to offer for review during this visit. APESI
to speed up for completion of mock up test report.
APESI need to maintain all plastic caps being installed at all nozzles opening during storage of harps
assembly after hydro test. Two plastic caps were missed from nozzle opening of harps assembly at bay
6.
Actions: APESI has to be improved all works of non pressure parts to meets drawing and specification.

Attached Documents : None

Inspector/Date/Signature :
Condro Widiyarto/QA-APW Rep. 8 June 2009
Distribution :

Quality Coordinator/Date/Signature :

Report Reference: T8A8- IR0020



Power Turbo-
Systems/Power
Environment
Plants

QUALITY SURVEILLANCE / INTERMEDIATE INSPECTION


Reference
Document



Description / Action
Responsibl
e and
due date
1. SUMMARY/FINDINGS:
Proposed of this meeting:
The purpose of the meeting was to surveillance inspection witness of
fabrication of header, harps assembly, hydro test of harps assembly and
non pressure parts fabrication includes review non pressure part &
pressure parts quality documents/reports at PT. APESI Held for HRSG-C
Frame module assembly ASTORIA II project.

Attendees:
1) Gunawan Risdianto-APESI PM
2) Lucky R Prastiawan-APESI QCM
3) Luluk Utomo-APESI QC Inspector
4) Samsul & Fauzi-APESI QC Inspector
5) Condro Widiyarto-EURTREU Inspector-QA APW Rep.

Documents used to carry out this inspection was organized with the
following documents:
o ITP no.: T8A8PSP-1 Rev. 06-C Frame Module Assembly, T8A8PSP-2
Rev. 00-C Frame casing and T8A8PSP-3 Rev.00 Finned Tubes.
o EQS-7808-0004 Rev. B -Specification for material control & trace
ability
o Drawing for pressure parts and pressure parts

2. Shop surveillance inspection of Non Pressure parts and pressure Parts
2.1. Non Pressure Parts:

The following unit #301C-frame side panel module was observed during
shop inspection at Bay 4.2:
o Column stub pre assembly to unit #301 side panel C frame
module-1A that found gap 0 up to 1.5 mm on column C was
observed does not meet drawing no. 07808-1E2060 Rev. A

Fig. Column stub pre assembly to side panel module 1A with gap 0-1.5
mm on column C (Column D with gap 0 mm).

o Witnessed UT on unit #301 upper panel: In-flange to side panel
column C of C-frame module-1A and out-in flange column D & in
flange column-C module-1B that found indication does not meets
to AWS D1.1 table 6.2.




Fig. UT on roof panel (Flange-In) to side panel column F module-2B that
found indication in deep 16 mm (Thickness of flange 32 mm)

o Witnessed UT on unit upper panel-out flange to side panel
column C & in/out flange column D of C-frame module-1A
that found acceptable were meets to AWS D1.1 table 6.2.

Fig. UT on roof panel (Flange-Out) to side panel column F module-2B
that found acceptable.

o Witnessed MT examination on the welding of unit #301 floor
panel flange to side panel flange module-3A that found
acceptable, however on the column J found indication and
at the day was rectified that found acceptable.

o General visual inspection on the following C-frame panel after
primer painting of unit # 301 that found spatter on the gusset
plate to side panel & rectification on un-acceptable visual
welding of floor panel flange to side panel flange was
observed and touch up paint on the certain location is
required: All spatter was cleaned up by grinding and touch up
painting was done at the day that found acceptable.
MDL-3A-1-U301
MDL-3B-1-U301

Fig. Spatter and improper primer painting on side panel MDL-3A-1-
301 and MDL-3B-1-U301 was observed.




2.2 Pressure Parts-The following shop inspection during this surveillance visit:

T8A8PSP-1 Rev.06 item 4.0-Visual inspection (Final pass) of the following
stub to pipe header of manifold assembly: that found acceptable was
meets QCP-7.2 rev. 09 Visual Inspection of Weld and Code ASME
Section I PW-31, 33 and 35 requirements ((All of the irregularities of welds
were corrected by grinding).
o U301-ML11-P1/1
o U301-MU-12-P1/2
o U301-M12-P1/2

Fig. Performed visual inspection of unit # 301 Manifold assembly

T8A8PSP-1 Rev.06 item 4.0- Witness MT examination of the stub to pipe
header of manifold assembly: 301-ML-11-P1/1, 301-MU-12-P1/2 and 301-
M12-P1/2 that found acceptable was meets QCP-7.4 rev.12 Visual
Inspection of Weld and Code ASME Section I PW-31, 33 and 35
requirements and was performed by qualified MT level-2 personnel as
per SNT-TC-1A requirements (Sutopo MT Level-2 x expire date 12
January 2012 and Abdullah MT Level-2 x expire date 23 May 2011)


ITP ITP ITP ITP- -- -T8A8PSP T8A8PSP T8A8PSP T8A8PSP- -- -1 Rev. 06 item 5.0 1 Rev. 06 item 5.0 1 Rev. 06 item 5.0 1 Rev. 06 item 5.0 Witness Hardness test in the
following Manifold assembly (BM and WM of P5B manifold stub/End
Plate/Nozzle to manifold header after PWHT that found acceptable
were meets specification MS-HRSG-0008 and SOP-029:
Manifold # BM Hardness
values (HB)
WM hardness
values (HB)
Accept/Reject
301-ML-11-P1/2 208 - 219 227 - 258 Accepted
301-MU-12-P1/2 198 - 214 225 - 238 Accepted
301-MU14-P1/1 197 - 214 204 - 216 Accepted


Fig. Witnessed Pin BRINNEL hardness on Unit #301 manifold assembly (P5B
material) U301-MU-12-P1/2 at Bay 7.2.






o Spot witness of Liquid Penetrant Test (PT) on Harps Assembly unit
#401 HA-23B-24B,(> 10% PT as per Job routing no.), HA-73A and
HA-83A (100% PT) that found acceptable were meets
specification QCP 7.3 Rev. 16 and was performed by NDE
qualified personnel PT Level-II as per ASNT-TC-1A name Sutopo
certificate no. 93/PT/08 x expire date 12 January 2012.

Fig. Overview PT examination on unit #401 HA-83A

o Unit # 401 Harps Assembly dimensional inspection was
performed that found acceptable.
Harps
no.
Drawing No. Selected dim.
(mm) 3 mm
Actual dimension
(mm) Left/Right
Accept/
reject
HA-23B 07808-1E0160 Rev. A 21019 21021/21022 Accepted
HA-24B 07808-1E0160 Rev. A 21019 21022/21017 Accepted
HA-73B 07808-1E0161 Rev. B 21044 21044/21045 Accepted

Fig. Witness dimensional inspection before PWHT of Harps Assembly unit
# 401 HA-23B

ITP ITP ITP ITP- -- -T8A8PSP T8A8PSP T8A8PSP T8A8PSP- -- -1 Rev. 06 1 Rev. 06 1 Rev. 06 1 Rev. 06 item 5.0 item 5.0 item 5.0 item 5.0 Witness Hardness test: Witness Hardness test: Witness Hardness test: Witness Hardness test: Harp
Assembly #401 HA-73A - 75A with actual hardness found
acceptable were meets specification MS-HRSG-0008 Rev. G and SOP-
030 (MIC TEN) for tubes to header weld joint and SOP-029 (Pin Brinnel)
for nozzle/end plate to header:

Fig. Witness Hardness test: : : : Harp Assembly #401 HA-74A.




ITP-TA8APSP-02 Rev. 5 item 4.12-Unit 401- Witnessed hydro test on the
following Harps assembly:
o The potable water employed for hydro testing with Chlorine reading
is 50 PPM (The acceptable range is less than 100 PPM) and added
Protectsol 770 ferrous metal powdered corrosion inhibitor with the
concentration was checked = 880-920 mho by used of EP-10
Conductivity Meter: Accepted (The acceptable range is 800 1000
mho) and Conductivity meter during testing are calibrated in
accordance with the suppliers gauge control program.
o Harps Hydro tested in supported on a slope jig > 5 angle to ensure
adequate drainage of hydro test water and the component was
blown by air supply to remove excess water from bottom header
was observed : satisfactory.
o Witnessed includes verify calibration Pressure Gauges to the
following hydro test that found acceptable meets to specification
MS-HRSG-0003 Rev. 07 and drawing no. 07808-1E0160 Rev. A for DN
80 (No leakage or sweating was observed during the test period):
Unit #401
Harps
Assy. No.
Report no Pressure gage no.
and calibrate exp.
Date
Spec. Design
Pressure (DP) Test
Pressure (TP)
Actual
HA-16A,
17A & 18A
(DN80)
8A8-H-059
# 401
PSG-15: 15/6/09
PSG-17: 15/6/09
(Range 0-600 PsiG)
DP : 170 PsiG
TP : 255 PsiG
HT: min.15 mints.
DP: 180 PsiG
TP: 270 PsiG
HT: 35 mints.
HA-10B &
12B
(DN80)
8A8-H-060
# 401
PSG-108: 28/11/09
PSG-112: 28/11/09
(Range 0-2,000 PsiG)
DP : 500 PsiG
TP : 750 PsiG
HT: min.15 mints.
DP: 530 PsiG
TP: 785 PsiG
HT: 20 mints.
HA-73A &
83A
(DN100)
8A8-H-066
# 401
PSG-82: 29/10/09
PSG-85: 29/10/09
(Range 0-10,000 PsiG
DP : 2250 PsiG
TP : 3375 PsiG
HT: min.15 mints.
DP: 2300 PsiG
TP: 3500 PsiG
HT: 20 mints.
HA-66B
(DN100)
8A8-H-067
# 401
PSG-82: 29/10/09
PSG-85: 29/10/09
(Range 0-10,000 PsiG
DP : 2250 PsiG
TP : 3375 PsiG
HT: min.15 mints.
DP: 2300 PsiG
TP: 3500 PsiG
HT: 20 mints.
HA-74B &
75B
(DN100)
8A8-H-071
# 401
PSG-82: 29/10/09
PSG-85: 29/10/09
(Range 0-10,000 PsiG
DP : 2250 PsiG
TP : 3375 PsiG
HT: min.15 mints.
DP: 2300 PsiG
TP: 3500 PsiG
HT: 20 mints.

Fig. Observed hydro test of unit # 401 HA-74B-75B with actual TP 3500 Psig &
DP 2300 Psig

o Harps Assembly storage at out side of shop (at Bay 6) after hydro test
that found with out plastic cap on (Missed) certain location (Two
locations). APESI need to maintain all plastic cap was installed at
nozzles opening of harps assembly.




T8A8PSP-1 Rev.06 item 4.0 in process welding inspection: P5B Harps
assembly to P5A stub manifold (MU-11) Unit # 301 module assembly-2A
by GTAW welding with following items was verified/observed and
inspected: Accepted were meets Job routing J8A8-MD-200 Op. 130.
o WPS no. T5.5HH-025 Rev. 01 with supporting PQR no. APESI GTA-
5.5H-018
o Filler metal: ER90S-B3 x 2.4 mm & 3.2 mm
o Verify Pre heating >205 C was utilized and maintained
throughout entire welding cycle by tempil stick temperature
that found acceptable were meets approved WPS
o Welding was performed by qualified welder name Bahrul Ulum
(F-065) x last welded on 17 Feb. 2009 and Sutrisno (T658) x last
welded 03 Feb. 09: Accepted
o Calibrated welding machine WM-001 x expired 01 August 2009
and WM-023 x expire date15 August 2009: Accepted
o Grounding cable from calibrated welding machines was
attached directly to the parts being welded.
o Visual inspection was performed on the final pass that found
acceptable were meets specification QCP-7.2 Rev.9.
o Extend/re bake temperature 350 C x 70 minutes was performed
on the joint stub manifold MU-11 (P5A) BW-1 to harps nozzle HA-
72A (P5A) module-2A was verified that found acceptable were
meets WPS T5.5HH-025 Rev.01

3. Review The following APESI quality documents includes review Radiographic
film of splice joint:

Review NDE record:
o 11 sheet PT record no. T8A8-PT-401-40, 43 up to 52 for unit #401
Harps Assembly (Selection 10% of welded joint) that found
acceptable were meets specification MS-HRSG-0001 Rev. 11 by
qualified NDE PT level II Sutopo certificate no. 93/PT/08 expire date
12 January 2012,Yugi 33/PT/08 x 21 April 2011, Agus Hariyono and
Huda were evaluated by NDT Level III Adipadmo ID no. 126596
including practical examination that found acceptable were
meets QS-7507-0009 Rev. B.

Review PWHT chart record:
o 3 sheet PWHT charts: 905151 (U401 HA-81A & 83B), 905143
(U401HA-45B-47B) and 905138 (U401 HA-67A, 81B-82B, 905135
(U401 HA-40A-42A) were reviewed that found acceptable were
meets job routing J8A813A-200 Op.210, J8A812A-200 Op.130,
J8A812B-200 Op.130

4. Others: The following balance issued was not close out yet:

The balance buildup beam W8 x 67 x 3400 x 4 ea from PT MULCINDO:
EN Material S335 J2 being used for build up beam instead of A572
Grade 50. WPS with supporting PQR was approved by APESI and
followed review inspection and NDE reports for release/send of build up
beam to APESI

Balance MILL country origin for MTR from MILL ILSEN BURGER BROBBLECH
still needs APESI clarification/reply.

The balance of mock test report of finned tubes manufactured by APESI
is not ready to offer for review at this time surveillance visit.





Verify the RN09-089 (NCR 09-106): NCR was closed out, however to help
close any gap insulation that exist is still required.

Module-2B: improper primer painting on certain location on Floor panel
of C-frame module 2B was observed. APESI need touch up improper
primer before final inspection of C-frame.

Module 1A: improper flame cutting on the Stub column after machining
still observed that found not acceptable.

Field weld areas and exposed inside edges of casing plate with one (1)
coat of Deoxaluminate paint was not done yet on loose boiler casing
on the following casing side location of duct burner. Its does not meets
to the drawing 07808 Rev. B note9:
o Unit #301: BC-318-U301, BC-1-U301, BC-E-21-U301 and BC-E10-
U301
o Unit #401: BC-27-U401


5. Attached Photographs:

T8A8-IR020-1: Overview Module Assembly # 301 MDL-2A, 1A, 2B & 1B
at Bay 4.2 (Install and welding of manifold to harps assembly on
module-2A & 2B are in progress)
T8A8-IR020-2: Overview Module Assembly # 301 MDL-3A, 3B & 4B at
Bay 4.1
T8A8-IR020-3: Overview Boiler casing ceramic fiber insulation at Bay
2.1
T8A8-IR020-4: Overview SCR, Filler panel & duct burner assembly
#301/#401Bay 2.2