ED 00 CPL PRC 0021 Construction QC Procedure Rev.2

CONSTRUCTION QC PROCEDURE
FOR
B1MTBE & EGF EPC PROJECT
Issued 2018-OCT-10 Contractor Document No: ED-00-CPL-PRC-0021 Rev. 2 Page 2 of 24
REVISION HISTORY
Rev. Date Description of Change
• Attachment-1 ITP list is revised. (ITP for PC pile is added. Document

number is corrected for B1MTBE & EGF Project)
1 19-July-18
• Revised project document number based on project document numbering
procedure
• This revision up to CIVIL work which concerned from revision-0.
• Add Hand over flowchart as per Owner comment at page 10
• Attachment-1 ITP list have revised as following;
- As comment to Civil common works in ITP No. 0001~0105
- Add PC spun piling for Inspection and test Item and any concerned item.
- Revised to specific concerning procedure in all of Acceptance Standard
/Procedure column
2 10-OCT-18 - CIP pile ITP No. 0254 before concreting revised to Grade A and Owner
to witness as per PIM comment.
- Add Base Course for Road and Paving and revised to Responsibility
Matrix as per Owner comment.
- Drainage/ Fence and Gate revised at Responsibility Matrix as per Owner
comment.
- Drainage leak test marked to concrete works if any required
- Concrete works add to Before, During, Precast /Post concrete inspection.
- HVAC works revised at form inspection and/or Vendor forms
FOR
TABLE OF CONTENT
PAGE
1. GENERAL ..................................................................................................................... 5
1.1 Purpose ......................................................................................................................... 5
1.2 Definition........................................................................................................................ 5
1.3 Related Documents ....................................................................................................... 6
2. DOCUMENTS GOVERNING FIELD INSPECTIONS ..................................................... 6
3. RESPONSIBILITY ......................................................................................................... 7
3.1 CONTRACTOR ............................................................................................................. 7
3.2 FIELD QUALITY CONTROL MANAGER ....................................................................... 7
3.3 DISCIPLINE QUALITY CONTROL ENGINEER ............................................................. 7
3.4 DISCIPLINE SUPERVISORS ........................................................................................ 8
3.5 QUALITY CONTROL INSPECTORS ............................................................................. 8
3.6 SUBCONTRACTOR ...................................................................................................... 9
3.7 SUBCONTRACTOR INTERFACE ................................................................................. 9
3.8 LOG BOOKS or CONTROL SHEETS .......................................................................... 10
4. PROCEDURE .............................................................................................................. 11
4.1 INSPECTION ITEMS ................................................................................................... 11
4.2 WITNESSING .............................................................................................................. 11
4.3 INSPECTION NOTIFICATION ..................................................................................... 15
4.4 INSPECTION SCHEDULE........................................................................................... 16
4.5 INSPECTION REPORT ............................................................................................... 16
4.6 FUNCTION OF FIELD INSPECTION SUMMARY ........................................................ 17
5. NOTIFICATION OF COMPLETION OF INSPECTION WORK ..................................... 18
6. MEETING .................................................................................................................... 19
6.1 PRE-INSPECTION MEETING (PIM) ............................................................................ 19
6.2 QC MEETING .............................................................................................................. 19
7. QUALITY TRAINING ................................................................................................... 19

FOR
7.1 INTENT........................................................................................................................ 19
7.2 TRAINER ..................................................................................................................... 20
7.3 TRAINEE ..................................................................................................................... 20
7.4 TRAINING RECORD ................................................................................................... 20
8. SITE AUDIT ................................................................................................................. 20
9. MASTERPIECE ........................................................................................................... 21
10. QUALITY AWARNESS CAMPAIGN ............................................................................ 22
11. QUALITY MONITORING TOOLS AND CONTROL ...................................................... 22
12. GOLDEN JOINT .......................................................................................................... 24
13. ATTACHMENT ............................................................................................................ 24
Attachment (1) INSPECTION TEST PROGRAM (ITP) LIST ............................................. 24
Attachment (2) FIELD INSPECTION NOTICE (FIN).......................................................... 24
Attachment (3) FIELD INSPECTION WEEKLY SCHEDULE ............................................. 24
Attachment (4) FIELD INSPECTION REPORT FORM LIST ............................................. 24
Attachment (5) FIELD INSPECTION REPORT ................................................................. 24
Attachment (6) FIELD INSPECTION SUMMARY SHEET ................................................. 24
Attachment (7) HAND OVER FORM ................................................................................. 24
Attachment (8) FIELD INSPECTION REPORT (FIR) HANDLING ..................................... 24

FOR
1. GENERAL
1.1 Purpose
This procedure describes the general quality control and inspection coordination
activities to be performed by Contractor and Subcontractor with Owner and Indonesian
Government (DEPNAKER) involved at the project site during the construction for
Butene-1 and MTBE Project.
1.2 Definition
B1MTBE Butene-1 and MTBE Project
FEED Front End Engineering and Design
EPC Engineering, Procurement & Construction
PBI PT. Petrokimia Butadiene Indonesia
TOYO Toyo Engineering Japan
IKPT PT. INTI KARYA PERSADA TEHNIK
OWNER PT. Chandra Asri Petrochemical and Petrokimia

Butadiene Indonesia
CONTRACTOR IKPT
SUBCONTRACTOR Construction contractors, who is engaged by

CONTRACTOR for specific construction works under
a CONTRACT.
DEPNAKER Ministry of Manpower Department is authorities of

government Indonesia to verify and certify the Boilers
(all industries) and other equipment & facilities to be
operated in petrochemical industries.
Quality Control All those operations and techniques used to fulfill the
FOR
requirement of the project for quality.
Inspection Activity such as measuring, examining, testing,

gauging etc. to ensure one or more characteristics of
the work conform to the project specified
requirements.
Inspection and Test A document that is produced in order to identify for

Program (ITP) each discipline the inspection of equipment’s for the
project and how those inspections shall be checked
and recorded.
Quality Control Record A record of the results of planned inspection activities

(QCR)
Non Conformance (NC) A deviation report of products and/or process from the
specified requirements
Approval Action of officially agreeing to EPC Deliverables or

accepting them as satisfactory
Review Formal assessment or examination of EPC

Deliverables with the possibility or intention of
instituting change if necessary
Golden Joint (Tie in) System is not pressure tested after tie-in. Such
welded joint shall be inspected by Radiographic or
other accepted non-destructive examination method.
1.3 Related Documents

- ED-00-CPL-PEP-0001 Construction Execution Plan.
2. DOCUMENTS GOVERNING FIELD INSPECTIONS

The Field Inspections shall be performed in accordance with such TECHNICAL
DOCUMENTS as, but not limited to:
FOR
- Specifications and drawings.

- Procedures and manuals.
- Applicable codes and standards.
Subject to the Prime Contract and the CONTRACT, technical document(s) other than
the above listed may also be applicable and employed to govern Field Inspections.
Where contractual specifications, codes of practice or standards conflict, the more
stringent shall prevail.
3. RESPONSIBILITY
3.1 CONTRACTOR
Contractor shall coordinate with the Owner and Subcontractor, and Authority if
applicable, in order to maintain required quality level in the contract. Contractor shall
witness and/or monitor the tests and inspections performed by Subcontractor and
evaluate the results.
3.2 FIELD QUALITY CONTROL MANAGER

(1) Implement overall quality control of the construction works.
(2) Review and maintain Inspection and Test Plans for all stages of the construction
work.
(3) Establish and maintain quality procedures, where required, to ensure the
requirements of the Project are implemented in a controlled and systematic
manner.
(4) Review contractor/subcontract agreements for compliance with the applicable
specification and standards referenced in Section 1.3 of this procedure to ensure
the adequacy of the Subcontractor quality program.
(5) Report all quality issues, program, status and problems directly to the Field
Manager (FM).
3.3 DISCIPLINE QUALITY CONTROL ENGINEER

(1) Coordinate inspection activities within their discipline in accordance with the
relevant Inspection and Test Program (ITP).
(2) Ensure that inspection activities and acceptance criteria are clearly understood
by the Contractor/Subcontractor and Discipline Inspectors.
(3) Liaise with the Discipline Supervisors and the OWNER with regard to inspection
FOR
requirements and acceptance criteria.

(4) Discuss and resolve, where possible, problems relating to quality with the
OWNER discipline representative, always reporting back to the Field Quality
Control Manager.
(5) Verify and approve Quality Control Records within their discipline ensuring
records are generated accurately and expeditiously by the
Contractor/Subcontractor in accordance with the relevant ITP.
(6) Record and control all non-conformances raised within their discipline and
monitor the implementation of any corrective action requirements.
(7) Report any non-conformances found during inspection coordination with the QC
Inspectors to the Field Quality Control Manager.
(8) Establish and control of all signed off QCRs filing to ensure all relevant
documents are ready for handing over to the OWNER.
(9) Overall control of the QC Inspectors in their performance of inspection and
testing activities.
3.4 DISCIPLINE SUPERVISORS

(1) Check that all project documents that are maintained in the field are at the latest
revision before commencement of Contractor/Subcontractor work and during
construction.
(2) Continuously check and review the change status during the work.
(3) Perform continuous checks during construction such as workmanship,
dimensional checks, arrangement and alignment in accordance with the specified
requirements of the project.
(4) Ensure that the Contractor/Subcontractor prepares inspection and testing reports
continuously throughout construction together with QC Engineer/ Field Quality
Control Manager.
(5) Report any non-conformances found during construction to the Field Quality
Control Manager through the Field Manager.
3.5 QUALITY CONTROL INSPECTORS

(1) Perform inspection activities as instructed in accordance with the requirements of
the relevant Inspection and Test Plan.
(2) Continuously monitor the work to ensure that the specified requirements for the
FOR
project are being followed.

(3) Witness inspection and testing as instructed ensuring that the testing methods,
inspection methods and acceptance criteria are in accordance with agreed
procedures.
(4) Review all the necessary Quality Control Records for adequacy and verify
results.
3.6 SUBCONTRACTOR
(1) The Subcontractor shall be wholly responsible for performing quality control and
inspection activities to attain the required control of the quality on the project and
shall report its result to Contractor.
(2) To implement the quality control activities smoothly and effectively, the
Subcontractor shall establish QC organization and shall have capable and
sufficient numbers of QC personnel.
(3) The Subcontractor’s quality control activities shall be implemented in accordance
with the contract specified requirements.
3.7 SUBCONTRACTOR INTERFACE

It shall be the responsibility of each individual Contractor/Subcontractor to ensure all
construction works completed by them are handed over to another
Contractor/Subcontractor, so as to enable the next phase of construction works to
commence in an efficient and expeditious manner. To achieve this, the following hand
over procedure shall be implemented:
(1) The HAND OVER FORM in Attachment (7) hereto will be used to ensure that the
handover of sections between contractors is documented and recorded.
(2) The HAND OVER FORM is raised by SUBCONTRACTOR 'A', and signed. This
signature is stating that the section qualified on the form is completed in accordance
with the CONTRACT.
(3) SUBCONTRACTOR 'A', on completing the form, will present it to the Contractor
Construction Supervisor and QC Manager or his representative for verification.
(4) When the Contractor Construction Supervisor and QC Manager are satisfied that all
documentation and work are completed, the form will be presented to
CONTRACTOR 'B' for completion.
(5) SUBCONTRACTOR 'B' will review the form and inspect the site status for
FOR
compliance with the CONTRACT.

(6) If SUBCONTRACTOR 'B' rejects the hand over, he will enter the reason(s) in the
comments section of the form and return it to the Contractor QC Manager or his
representative, for assessment and resolution.
(7) When SUBCONTRACTOR 'B' accepts and signs the HAND OVER FORM, it will be
presented to the Contractor QC Manager or his representative, who will witness,
comment if required, and sign.
(8) Contractor QC Manager will file original. It shall be noted that the signature of the
CONTRACTORs/SUBCONTRACTORs concerned, or the CONTRACTOR signature,
is in no circumstances a release of the said CONTRACTORs/SUBCONTRACTORs
from their contractual obligations.
HANDOVER SEQUENT FLOWING
CONSTRUCTION
SUBCON ”A” QC CONTRACTOR SUBCON ”B”
CONTRACTOR
Reviewing /
Confirming
documentation
Documentation to Registering Site
Preparing / Site System Verification
Verification Site
Verification
If any requested to clarification
Accepted to
HAND OVER
3.8 LOG BOOKS or CONTROL SHEETS

To prevent duplication and to ensure that a unique and traceable numbering system is
provided throughout a CONTRACT for all FIELD INSPECTION NOTICES (FIN) as per
Clause 4.3, INSPECTION REPORT FORMS as per Clause 4.5, and HAND OVER
FORMS as per Clause 3.7, it shall be the responsibility of each individual
SUBCONTRACTOR to provide and maintain log books or control sheets. These shall
contain the following information:-
FOR
(1) FIELD INSPECTION NOTICE (FIN)

a) FIN number :( SUBCONTRACTOR No.)/0001 - infinity.
b) Date issued.
c) Contents/description.
(2) INSPECTION REPORT FORM
a) Report number :( SUBCONTRACTOR No.)/0001 - infinity.
b) Date inspection carried out.
c) ITP number.
d) Contents/description.
Note: Please refer to Attachment (8) for the detailed guideline on report
numbering
(3) HAND OVER FORM
a) Form number :( SUBCONTRACTOR No.)/0001 - infinity.
b) Date signed.
c) Contents/description.
4. PROCEDURE
4.1 INSPECTION ITEMS
Items subject to Field Inspection shall be as per the "INSPECTION AND TEST
POGRAM (ITP) LIST" in Attachment (1) hereto.
The CONTACTOR ITP shall serve as the guideline into further developing the detailed
requirement of the OWNER based on the CONTRACT and governing project
specifications. CONTRACTOR Quality Control group shall initiate the detailed check as
well as coordination among various departments and disciplines from CONTRACTOR
and OWNER in order to capture the overall project quality requirements.
4.2 WITNESSING
(1) The OWNER and CONTRACTOR respectively reserves the right to witness any
and all the INSPECTIONS that the SUBCONTRACTOR shall carry out pursuant
to this PROCEDURE and/or any other document forming a part of the
CONTRACT.
(2) Where CONTRACTOR or the OWNER elects to witness any of the INSPECTION
categories, the SUBCONTRACTOR shall provide the necessary facilities to
accommodate the request.
FOR
(3) Where the OWNER has waived the right to witness, CONTRACTOR shall
witness, then Subclause (4) of this Clause and Subclause (4) in Clause 4.3 shall
prevail. The INSPECTION shall be deemed to have been successfully
completed.
(4) INSPECTIONS subject to Grade "A" classification, where the right to witness has
been waived by the OWNER, CONTRACTOR shall witness. If no comments
have been made by the OWNER after examining the inspection report submitted
by CONTRACTOR, then after 2 days the CONTRACTOR shall be permitted to
proceed with the subsequent work sequence.
(5) Without prejudice to the general principle as per Sub-clause (1) of this Clause,
the Field Inspections hereunder are however categorized into the following three
Inspection Grades "A", "B" and "C". These categories shall be used in
conjunction with the Responsibility Matrix as to the specific roles of each involve
parties as defined in the ITP;
a) Inspection Grade "A"
All INSPECTIONS classified Grade "A" as a default shall require the presence of
the OWNER, or his representative, together with CONTACTOR, to witness and
sign for the inspection stage. This notes that the inspection is of paramount
importance and this may or may not be a Hold point.
If the OWNER’s role is marked as Hold and the OWNER or his representative
and CONTRACTOR did not waive the right to witness, such INSPECTIONS shall
not be carried out without the presence of the OWNER, his representative and/or
CONTRACTOR. Please refer to Clause 6.g for further explanation of Hold point.
b) Inspection Grade "B"
It is mandatory that all INSPECTIONS classified Grade "B", shall require the
presence of CONTRACTOR Inspector to witness and sign. These inspection
items may be subject to random inspection by OWNER.
c) Inspection Grade "C"
All other INSPECTIONS may be classified Grade "C". These shall be carried out
by the SUBCONTRACTOR and shall be subject to random inspection by
OWNER and/or CONTRACTOR.
(6) To further identify the specific responsibility of each party involved in the
inspection work, the following codes based on roles shall be used;
FOR
a) I - Inspection
Basically, all “I” or Inspection as defined in Section 1.2 of this procedure, are
to be carried-out by the SUBCONTRACTOR. The inspection also includes
testing and examination that are to be carried-out as part of the procedure to
check and verify the conformity of the completed construction work.
Verification and checks made by Vendor Supervisors or Third Party are also
deemed as Inspection and in this respect are also classified as “I” in the
responsibility matrix.
b) W - Witness
Witness points are on the part of OWNER (including Operation) and

SUBCONTRACTOR. These include but not limited to verification of the
completed work through visual inspection, observation of tests made and
review of results obtained pertaining to such tests. The involvement of
Licensor or representative from Local Government also falls under this
scope.
c) RW – Random Witness
Random Witness is similar to the scope of “Witness”, although the frequency

of attendance by OWNER or CONTRACTOR during inspection is minimized.
In usual situation, Grade “B” inspection allows random witness by Owner
and for Grade “C”, a random witness by either OWNER or CONTRACTOR
may be involved.
d) REV – Review
There are inspection items in the ITP that only requires submission of
documents that pertains to tests performed on materials, specimens or
completed construction works. These are reviewed by either OWNER or
CONTRACTOR based on the criticality of the document involved.
FOR
SUBCONTRACTOR is responsible in ensuring that required documents for

review are submitted promptly to OWNER and CONTRACTOR.
e) APP – Approval
Some documents relating to inspection require approval from OWNER or

CONTRACTOR. An inspection work requiring an approved procedure may
not be carried-out unless this approval is obtained from the designated party
as identified in the ITP. (Ex. Welding Procedure Specification, Procedure
Qualification Record, etc.)
f) T – Test
Some inspection works that are related to testing of specimen or samples

obtained from site is done in laboratories or third party testing agency (i.e.
Concrete strength test, compaction test, etc.). These are classified as tests
to note that actual work is to be performed by a different party in addition to
the inspection work carried-out by the SUBCONTRACTOR and subsequent
submission of the related documentation produced after the tests.
g) H – Hold
There are certain critical inspection stages that need to be fully witnessed by
Owner. This may vary depending on the extent on their involvement in the
project. For such item that requires mandatory presence of Owner’s
representative, these are designated as “Hold” point to indicate that no
inspection shall proceed without their attendance.
Note: All inspections that are classified as Hold point shall be clearly
understood by all parties. Close communication and sharing of information
shall be adhered so as to avoid any misunderstanding in carrying-out the
related tasks. It is advisable to closely communicate with OWNER regarding
this kind of inspection to avoid delay and cancellation which could then
create impact on the ongoing construction works.
FOR
4.3 INSPECTION NOTIFICATION

As for the respective INSPECTIONS classified Grade "A", "B" or "C", the
SUBCONTRACTOR shall be required to notify the OWNER and CONTRACTOR of the
scheduled inspections in the following manner:
(1) The Inspection Notification from the SUBCONTRACTOR to the OWNER and
CONTRACTOR shall be completed on form "FIELD INSPECTION NOTICE
(FIN)" in Attachment (2) hereto.
(2) The FIN shall be completed by the SUBCONTRACTOR and submitted to the
OWNER and CONTRACTOR within a notice period of not less than one (1)
working day.
(3) Notwithstanding the foregoing, where the presence of the officials of any local
authority is called for, the SUBCONTRACTOR shall be required to submit to the
OWNER and CONTRACTOR the Inspection Notification therefore not later than
ten (7) working days prior to the scheduled inspection date.
(4) The FIN under Sub-clause (1) of this Clause shall include the following
particulars:
a. Inspection item(s).
b. Inspection category, either Grade "A", "B" or "C".
c. Date, time, place and expected or scheduled duration of the
INSPECTION.
d. Requirement as to whether or not the presence of officials of the
concerned local authority (ies) is mandatory.
e. Others to be fore-notified, if any.
(5) The SUBCONTRACTOR may, as notified and scheduled, proceed with and
finish the INSPECTION irrespective of whether or not the OWNER and
CONTRACTOR Field Inspector(s) punctually attend at the time and place of the
INSPECTION, unless such a delay is previously communicated to the
SUBCONTRACTOR by the OWNER and CONTRACTOR, by an appropriate
means and in appropriate time.
FOR
Note: There may be circumstances during peak of construction work wherein

inspections in the same Discipline or type of work may come simultaneously in different
areas. Such kind of issue shall be resolved through close coordination and clear
arrangement of the schedule. Proper communication amongst the parties involved is
necessary to avoid any argument arising from this circumstance.
4.4 INSPECTION SCHEDULE

(1) Apart from the FIN as per Clause 4.3 "Inspection Notification" hereof, the
SUBCONTRACTOR shall submit to the OWNER and CONTRACTOR each week a
schedule for all the INSPECTIONS categorized by each Inspection Grade, which
the SUBCONTRACTOR plans to carry out in the subsequent one (1) week as per
the form "WEEKLY INSPECTION SCHEDULE" in Attachment (3) hereto. Any
changes to this inspection schedule, shall be informed on a daily basis to the
OWNER and CONTRACTOR Head of Quality Control, by the SUBCONTRACTOR
Head of Quality Control.
(2) The "WEEKLY INSPECTION SCHEDULE" shall contain the following information.
a. Inspection item.
b. Date, time and place of the intended INSPECTION.
c. Requirements as to whether or not the presence of officials of the concerned
local authority (ies) is mandatory.
d. Others to be fore-notified, if any.
e. Specification or procedure related to the particular INSPECTION.
(3) It shall be clearly understood that SUBCONTRACTOR shall have inspected the
completed work and found it acceptable, prior to offering the completed work for
CONTRACTOR or OWNER inspection (i.e. Formwork, Steel Structure Installation,
Welding Inspection, etc.). Only certain installations that may require to be tested in
situ shall be deemed allowable to be checked in the presence of all the parties
involved in the inspection (Non Destructive Tests, Insulation Resistance Test,
Pressure Test, etc.)
4.5 INSPECTION REPORT

(1) For INSPECTIONS carried out under all classifications, a "FIELD INSPECTION
REPORT", as per Attachment (5) hereto, together with any relevant drawings,
certification or technical information shall be submitted to the OWNER and/or
FOR
CONTRACTOR by the SUBCONTRACTOR at the time and place the inspection is

to be performed. The SUBCONTRACTOR shall also supply all the inspection
equipment necessary in order to complete the INSPECTION. A copy of each report
and its scanned file (pdf) shall be forwarded to the OWNER and CONTRACTOR
within a period of Seven (7) working days after the day of the INSPECTION was
performed.
Note: Scanning and storage of Field Inspection Report shall be clearly
discussed during the initial stage of the project in order to agree on the standard
practice and procedure that needs to be commonly followed by all
Subcontractors. Please refer to Attachment (8) for other details.
(2) The SUBCONTRACTOR shall retain copies of all inspection reports for his own
records.
(3) The originals of all inspection reports, test samples and radiographs shall be
retained by the SUBCONTRACTOR Head of Quality Control until the PLANT is
mechanically complete and accepted by the OWNER. At this juncture all quality
documentation packages shall be handed over to the OWNER.
Note: The hand-over of document to OWNER shall also be discussed and
finalized during the project initial stage.
(4) For the handling of FIR (i.e. Numbering, Filling-up, etc.), please refer to Attachment
(8).
(5) In case there are any comments or Punch list that may be resulting to the
observations made during the inspection, these shall be noted in the FIR and
separately registered for monitoring purpose. Please refer to Attachment (8) for
further explanation and related workflow.
4.6 FUNCTION OF FIELD INSPECTION SUMMARY

(1) In order to summarize the overall status and history of the INSPECTION
involvement upon a certain work item or as a whole, the CONTRACTOR Head of
Quality Assurance or the CONTRACTOR Head of Quality Control, whichever is
applicable as to a specific project, shall compile and employ a computer generated
FIELD INSPECTION SUMMARY SHEET, as per the sample in Attachment (6)
FOR
hereto. This will be made available to the OWNER and SUBCONTRACTOR upon
reasonable request, throughout construction of the facility.
(2) A The relative information as to the status of each single INSPECTION, classified
as "A","B" or "C" shall, upon completion, be entered into the computer QUALITY
CONTROL DATA BASE Program (QC Base) from which the Field Inspection
Summary Sheet is generated. Each Inspection report entry shall signify that :-
a. The INSPECTION has been duly performed and the status recorded.
b. The INSPECTION has been duly witnessed by the signatory.
c. The inspection report has been duly submitted to, and received by, the signatory.
(3) A complete print out of the FIELD INSPECTION SUMMARY SHEET will be
submitted to the OWNER and CONTRACTOR as part of the Turn-over package,
upon MECHANICAL COMPLETION of the facility.
(4) When any integral yet independent Unit, Section or System of the project is verified
by the relevant Field Inspection Summary as substantially complete, the
SUBCONTRACTOR shall request for Final Inspection by OWNER and
CONTRACTOR. This is a request that OWNER and CONTRACTOR confirm by
signature that such a Unit, Section or System, thereof is complete, and that the
documents submitted to OWNER and CONTRACTOR are the evidence proving that
every INSPECTION involved in the respective work items, which the TECHNICAL
DOCUMENTS require, have all been duly performed in accordance therewith and
successfully completed.
5. NOTIFICATION OF COMPLETION OF INSPECTION WORK

When the final FIELD INSPECTION SUMMARY SHEET containing the complete PLANT
(or the PERMANENT WORKS) or any unit, section or system in accordance with Clause
4.6 "FUNCTION OF FIELD INSPECTION SUMMARY SHEET", the SUBCONTRACTOR
shall issue to the CONTRACTOR a Notice advising of its readiness for the overall Final
Inspection.
CONTRACTOR shall review the relevant FIELD INSPECTION SUMMARY SHEET(s),

as referred to in the Notice, so that prior to the overall inspection, OWNER and
CONTRACROTOR will be well versed with the INSPECTIONS performed at each stage
of construction and with the results thereof.
FOR
The OWNER and CONTRACTOR shall perform an overall inspection of the PLANT (or
the PERMANENT WORKS) or any completed Unit upon notification from
CONTRACTOR,
6. MEETING
6.1 PRE-INSPECTION MEETING (PIM)
(1) Following an award of any construction contract, and prior to the start of any
construction or fabrication activity, a PIM shall be held between OWNER,
CONTRACTOR and SUBCONTRACTOR and to be chaired by CONTRACTOR
Head of Quality Control.
(2) The main purpose of this meeting is to orient the individuals about the project’s QC
procedure, quality objectives, anticipated authority requirements, Inspection and
Test Program (ITP), etc. It is important to commence with the construction with
sufficient knowledge of the quality that should become inherent characteristics in all
the completed works.
6.2 QC MEETING
(1) Weekly QC Meeting shall be established between OWNER, CONTRACTOR and
SUBCONTRACTOR at a designated time convenient for all the attendees. The QC
meeting is an important venue in discussing Quality concerns, recent Quality Alerts,
Non Conformities, etc.
(2) During peak time wherein many quality issues are raised and not expeditiously
resolved, the meeting may be held more than once a week between subgroups.
7. QUALITY TRAINING
7.1 INTENT
The intent of the training is to induct or educate inspectors, supervisors, foreman and
others of the following specific quality requirements, but not limited to;
(1) General Project Requirements and Procedures.
(2) Test and Inspection items.
(3) Documentation and Workflows.
(4) Specific working practices such as welding, painting, flange joints bolt tightening
torque control, handling of critical materials and equipment, special alloy steel
materials, etc.
FOR
(5) Quality Systems and Tools

(6) Masterpiece
7.2 TRAINER
Training will be carried out by the following person;
(1) CONTRACTOR Field Manager, Construction Manager, Supervisor, Quality Control
Manager
(2) Vendor or Manufacture’s Specialists
(3) OWNER’s Operation or Maintenance Specialists
7.3 TRAINEE
Inspectors, Supervisors, Foremen and others as necessary from CONTRACTOR and
SUBCONTRACTORs shall receive training prior to the start of work or during the
course of construction.
7.4 TRAINING RECORD

Training records shall be prepared and filed following each session. After completing
the training, a certification or sticker may be issued to the person who received the
training.
8. SITE AUDIT
The CONTRACTOR Quality Control Manager shall set-up an audit program, establish
set of checklists and perform audit with regards to the implementation of Project
Procedures as well as SUBCONTRACTORs quality system. The audit shall cover the
following minimum points;
• Implementation of related QC Procedures
• Documentation and Control
• Material Management
• Schedule Control and Planning
• Fabrication and Welding Procedures
• Testing and Control Procedures
• Control of Site Testing and Measuring Equipment/Instruments
• Relevant Certification Requirements
• HSE Policies
FOR
The audit shall be carried-out at regular intervals to ensure compliance to project

requirements and objectives. Follow-up checks and verification of preventive and
corrective actions should be carried-out in the form of quality surveillance audits.
9. MASTERPIECE
The use of Masterpiece may be implemented especially in areas/locations where
Owner quality expectations are strict and high. Masterpiece is an effective tool in
graphically showing the level of quality that is required to be achieved consistently by
Contractor/workers at a given stage of construction works.
Masterpiece is a sample of completed work for a related construction activity and can
be prepared in two options as explained below;
• On Site Sample: The masterpiece is produced based on an ongoing construction

activity. Photograph is taken on the completed item (normally the first work that is
carried-out for a new critical task i.e. excavation sloping/shoring, rebar and
embedded anchor bolt setting prior to concrete works, etc.) and this photo will be
developed into a Masterpiece document. The existing work is then used to orient
Workers as to the expected level of quality that is acceptable prior to concealing the
item and proceeding to the next activity.
• Objective Sample: Some items, especially small parts/component, can be
separately prepared in advance prior to the commencement of actual shop
fabrication or site installation activity. The sample will not be part of any permanent
plant component and can be kept and stored separately. One example is pipe
welding that will show the gap, cleanliness of the weld and visual appearance of the
fill. Aside from photograph sample, the completed item can be stored in the
Masterpiece Showroom and used as a sample for training and for Workers to follow
as a guide.
Should a particular project decide to implement the Masterpiece concept, the following
steps can be used as a simple guideline;
• Establish Masterpiece Plan and List
• Prepare Masterpiece (First work of Contractor)
FOR
• Put-up Masterpiece workshop or display area

• Carry-out training as per the Masterpiece
10. QUALITY AWARNESS CAMPAIGN

In order to increase Project quality awareness and to promote consciousness to all
workers, the CONTRACTOR Quality Control team shall establish a set of activities and
lead its implementation at Site. The key interests are as follows;
• QC Walkthrough – Joint walk down of OWNER, CONTRACTOR and

SUBCONTRACTOR’s representatives to conduct quality surveillance at site which
will focus on specific areas of concern. This shall be scheduled on weekly basis.
Any observations found shall be listed and critical concerns to be alerted to all
concerned to avoid recurrence.
• Quality Slogan – Selection of Quality Slogan that will be used as the theme for the
month. The slogan will be selected from submitted entries from
SUBCONTRACTORs. The slogan shall be posted on site bulletins boards, site
office and construction keys areas.
• Quality Bulletin – SUBCONTRACTORs may be requested to set-up Site Quality

Bulletin boards where information about quality campaign, trainings, masterpiece
sample, and QC related statistics can be posted.
• QC Personnel Identification – QC stickers shall be provided to OWNER,

CONTRACTOR and SUBCONTRACTOR QC personnel for a unified identification
at Site. The sticker shall be placed on the Safety Helmet.
• Quality Award or Recognition will be given to excellent group/team and individual

who contributed to Quality performance by complies with Quality rules, Quality
requirements, fulfill Construction target and quick correction action of finding.
11. QUALITY MONITORING TOOLS AND CONTROL

The day to day inspection activities are critical to the completion of each stage of
construction work. As much as possible, the inspection work shall never be a burden or
FOR
an obstacle into completing the construction work on schedule. The following tools can
be used to support the Quality objectives of the project in controlling, monitoring and
quantifying various areas of quality function in a systematic manner;
• Welding Control System (WCS) – is a computer system developed by

CONTRACTOR to monitor pipe welding works, NDT and Welder performance as
well as to provide support to piping installation inspection and Pressure Test control.
• Quality Control Database (QCBase) – is a Computer system developed by

CONTRACTOR to monitor the implementation of inspections at site and provide
support to plant turn-over documentation works. Following the establishment of the
ITP and subsequent update into the QCBase, the inspection matrix shall then be
established. Inspection Matrix is the list of required inspection against each Tag No.
This list is developed through QCBase and reviewed/finalized by QC Inspector or
Discipline Supervisors with support from Design Engineers if necessary.
• Non-Conformance Report (NCR) – is a method of documenting a non-conformity of

a product against the requirement. It is an effective tool in underlining flaws that
could affect the integrity of construction and which could also lead to schedule delay
and cost impact.
• Field Quality Alert – A form of reporting method to highlight an observation that

could potentially become a non-conformance. Repeated occurrence of such
observation may be elevated into NCR. This report is an important tool in
progressively addressing the observations at site as well as assessing the root
cause, providing solution and establishing methods to improve current procedures.
Lessons learned from such observation can be shared amongst all
SUBCONTRACTOR’s who are involved in similar activity.
• Welding Performance Control – Welding is one of the important tasks that is

carried-out in every project and the integrity and quality of welds depend heavily on
the skills and performance of each Welder. With the use of WCS, the welding
activities of each Welder can be monitored along with the RT repair rate that results
from poorly executed work. CONTRACTOR has a guideline in controlling the quality
FOR
of weld through the NDT reports as well as the resulting trend that can be generated
from the WCS database. The following figures can be used in judging Welders’
performance;
 RT Repair Rate (Joint Base): 5%
 RT Repair Rate (Film Base): 3%
12. GOLDEN JOINT

In order to meet requirements of Code or project specification, it is necessary that tests
be made upon the completed system and upon component parts of the finished system.
However, tie-in welds and girth weld joining length of pretested pipe or pipeline shall be
inspected by Radiographic or other accepted non-destructive examination method in
accordance with requirements (e.g. ASME B31,4 para 434.8.5 (a)(4)).
If system is not pressure tested after tie-in. after such inspection, the joint shall be
coated and inspected in accordance with requirements.
13. ATTACHMENT
Attachment 1 - INSPECTION TEST PROGRAM (ITP) LIST 14 Pages

Attachment 2 - FIELD INSPECTION NOTICE (FIN) 1 Page
Attachment 3 - FIELD INSPECTION NOTICE (WEEKLY SCHEDULE) 1 Page
Attachment 4 - FIELD INSPECTION REPORT FORM LIST 6 Pages
Attachment 5.1-FIELD INSPECTION REPORT (GENERAL) 4 Pages
Attachment 5.2-FIELD INSPECTION REPORT (CIVIL) 58 Pages
Attachment 5.3-FIELD INSPECTION REPORT (MECHANICAL) 56 Pages
Attachment 5.4-FIELD INSPECTION REPORT (TANGKAGE) 7 Pages
Attachment 5.5-FIELD INSPECTION REPORT (PIPING) 55 Pages
Attachment 5.6-FIELD INSPECTION REPORT (ELECTRICAL) 107 Pages
Attachment 5.7-FIELD INSPECTION REPORT (INSTRUMENT) 31 Pages
Attachment 5.8-FIELD INSPECTION REPORT SHEET (PAINTING) 4 Pages
Attachment 5.9-FIELD INSPECTION REPORT (INSULATION) 8 Pages
Attachment 5.10-FIELD INSPECTION REPORT (FIRE PROOFING) 3 Pages
Attachment 6 - FIELD INSPECTION SUMMARY SHEET 9 Pages
Attachment 7 - HAND OVER FORM 1 Page
Attachment 8 - FIELD INSPECTION REPORT (FIR) HANDLING 11 Pages

ED 00 CPL PRC 0021 Construction QC Procedure Rev.2

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CONSTRUCTION QC PROCEDURE

Issued 2018-OCT-10 Contractor Document No: ED-00-CPL-PRC-0021 Rev. 2 Page 2 of 24

Rev. Date Description of Change

• Attachment-1 ITP list is revised. (ITP for PC pile is added. Document

Issued 2018-OCT-10 Contractor Document No: ED-00-CPL-PRC-0021 Rev. 2 Page 3 of 24

1.1 Purpose ......................................................................................................................... 5

1.3 Related Documents ....................................................................................................... 6

2. DOCUMENTS GOVERNING FIELD INSPECTIONS ..................................................... 6

3.1 CONTRACTOR ............................................................................................................. 7

3.2 FIELD QUALITY CONTROL MANAGER ....................................................................... 7

3.3 DISCIPLINE QUALITY CONTROL ENGINEER ............................................................. 7

3.4 DISCIPLINE SUPERVISORS ........................................................................................ 8

3.5 QUALITY CONTROL INSPECTORS ............................................................................. 8

3.6 SUBCONTRACTOR ...................................................................................................... 9

3.7 SUBCONTRACTOR INTERFACE ................................................................................. 9

3.8 LOG BOOKS or CONTROL SHEETS .......................................................................... 10

4.1 INSPECTION ITEMS ................................................................................................... 11

4.2 WITNESSING .............................................................................................................. 11

4.3 INSPECTION NOTIFICATION ..................................................................................... 15

4.4 INSPECTION SCHEDULE........................................................................................... 16

4.5 INSPECTION REPORT ............................................................................................... 16

4.6 FUNCTION OF FIELD INSPECTION SUMMARY ........................................................ 17

5. NOTIFICATION OF COMPLETION OF INSPECTION WORK ..................................... 18

6.1 PRE-INSPECTION MEETING (PIM) ............................................................................ 19

6.2 QC MEETING .............................................................................................................. 19

7. QUALITY TRAINING ................................................................................................... 19

Issued 2018-OCT-10 Contractor Document No: ED-00-CPL-PRC-0021 Rev. 2 Page 4 of 24

7.2 TRAINER ..................................................................................................................... 20

7.3 TRAINEE ..................................................................................................................... 20

7.4 TRAINING RECORD ................................................................................................... 20

8. SITE AUDIT ................................................................................................................. 20

10. QUALITY AWARNESS CAMPAIGN ............................................................................ 22

11. QUALITY MONITORING TOOLS AND CONTROL ...................................................... 22

12. GOLDEN JOINT .......................................................................................................... 24

13. ATTACHMENT ............................................................................................................ 24

Attachment (1) INSPECTION TEST PROGRAM (ITP) LIST ............................................. 24

Attachment (2) FIELD INSPECTION NOTICE (FIN).......................................................... 24

Attachment (3) FIELD INSPECTION WEEKLY SCHEDULE ............................................. 24

Attachment (4) FIELD INSPECTION REPORT FORM LIST ............................................. 24

Attachment (5) FIELD INSPECTION REPORT ................................................................. 24

Attachment (6) FIELD INSPECTION SUMMARY SHEET ................................................. 24

Attachment (7) HAND OVER FORM ................................................................................. 24

Attachment (8) FIELD INSPECTION REPORT (FIR) HANDLING ..................................... 24

Issued 2018-OCT-10 Contractor Document No: ED-00-CPL-PRC-0021 Rev. 2 Page 5 of 24

B1MTBE Butene-1 and MTBE Project

FEED Front End Engineering and Design

EPC Engineering, Procurement & Construction

PBI PT. Petrokimia Butadiene Indonesia

TOYO Toyo Engineering Japan

IKPT PT. INTI KARYA PERSADA TEHNIK

OWNER PT. Chandra Asri Petrochemical and Petrokimia

SUBCONTRACTOR Construction contractors, who is engaged by

DEPNAKER Ministry of Manpower Department is authorities of

Issued 2018-OCT-10 Contractor Document No: ED-00-CPL-PRC-0021 Rev. 2 Page 6 of 24

requirement of the project for quality.

Inspection Activity such as measuring, examining, testing,

Inspection and Test A document that is produced in order to identify for

Quality Control Record A record of the results of planned inspection activities

Approval Action of officially agreeing to EPC Deliverables or

Review Formal assessment or examination of EPC

1.3 Related Documents

2. DOCUMENTS GOVERNING FIELD INSPECTIONS

Issued 2018-OCT-10 Contractor Document No: ED-00-CPL-PRC-0021 Rev. 2 Page 7 of 24

- Specifications and drawings.