Quality Control Manual Pt. Bara

PT.
BERKAH ANDALAN REKAYASA

Delivery With Quality
QUALITY CONTROL MANUAL
SHOP CONSTRUCTION AND FIELD

ASSEMBLY
Komplek Unimes Garden Regency Jl Immer Motor Blok E 19 Waru, Sidoarjo, 61254, Jawa Timur, Indonesia
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PT. BERKAH ANDALAN REKAYASA

Komplek Unimas Garden Regency,
Jl.Immer motor Blok E 19 Waru Sidoarjo, 61254
Telp. : 0813-1031-0553
Email : engsupport@baragroup.com
Website : www.baragroups.com
Doc. No. : QCM - 01

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Section : 0.1 TABLE OF CONTENT Page : 1 of 1
Section Description Rev Date
Cover Page 0
0.1 Table of Contents 0
1.0 QC Manual Control 0
2.0 Design Calculation, Drawing and Specification Control 0
3.0 Material Control 0
4.0 Production Control 0
5.0 Welding 0
6.0 Examination & Inspection Program 0
7.0 Calibration of Measurement and Test Equipments 0
8.0 Nondestructive Examination 0
9.0 Heat Treatment 0
10.0 Record Retention 0
11.0 Authorized Inspector 0
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12.0 Field Assembly 0
13.0 Repair and Alteration 0
14.0 Sample Forms 0
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Section : 1.0 QC MANUAL CONTROL Page : 1 of 1
1.1.SCOPE
This Section describes the applicability and control of the QC Program for Code construction
activities.
1.2. APPLICABILITY OF QC PROGRAM
a).This QC Manual is the primary document of the QC Program.
b).Upon agreement with the customer, portions of this Manual may be applied to the fabrication
of Non-Code items where Code Stamping is not a contractual requirement.
c). All the controlled copies of the QC Manual to be issued shall be serialized.
d).Uncontrolled copy may be issued (PT.BARA) PT.BERKAH ANDALAN REKAYASA at the

discretion of the company.
1.3. REVISION CONTROL
a). The Manual shall be revised by each Section except for the Sample Forms which are revised
by page.
b). Revision status of each Section and Sample Forms shall be shown on the Table of Contents,
Addition of information on Sample Forms will not require a revision to the manual. However,
deletion of information on Sample Forms is considered a revision.
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DESIGN CALCULATION,
Section : 2.0 DRAWING AND SPECIFICATION Page : 1 of 3
CONTROL
2.1. SCOPE
This Section describes work order and control of design calculations, drawings and
specifications and revisions thereto.
2.2. CUSTOMER SPECIFICATIONS
Design Specifications provided by the customer must be reviewed by the Design Engineer and
accepted by the Manufacturer from the Company Manager to verify compliance with the
requirements of the applicable Code. Engineers from the Company are responsible for further
clarification with the Customer for requirements that are unclear or do not comply with the Code
technique.
2.3. CONTROL OF CUSTOMER SUPPLIED DOCUMENTS
a).Design engineers are responsible for reviewing documents provided by customers to ensure
Code compliance.
b). Drawings and calculations provided by the Customer can be used for fabrication provided that
the technical review is adequate for fabrication requirements and must be stamped with
"Approved or Approved with notes", reviewed by Design Engineers and approved by
Manufacturing Managers before use.
c). The Manufacturing Manager must also know about receipt of drawings and calculations by
verifying the existence of the date, month, and year of the signature.
d). Revisions to Documents Provided Customers must be controlled in the same manner as the
originals.
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DESIGN CALCULATION,
CONTROL
e). DOCUMENT CONTROL (DRAWINGS, CALCULATION AND SPECIFICATION)
• Drawings, calculations and specifications must be prepared by the Design

Engineer, reviewed and approved by the Manufacturing Manager for Code
compliance.
• Images must contain definite information to ensure the right manufacturing
process.
• This information will consist of material specifications including class and grade,
NDE requirements, heat treatment, connection numbers, dimensions, pressure test
requirements, Welding Procedure Specifications, Code Section Edition and
Addenda, drawing numbers etc.
• Design calculations must include evaluating whether an impact test is needed or
excluded, the applicable Code and Supplementary Sections, calculation methods
and calculated thickness, etc.
• Design Engineers must verify compliance with applicable Codes, and then they
will be explained in the Manufacturer Data Report.
• Distribution of design documents must be handled by the Design Engineer.
• The Manufacturing Manager must keep a Document Checklist and record the
latest revisions for each contract. The Design Engineer must submit a new and
revised drawing to the Plant Manager and Quality Control.
2.4. COMPUTER AIDED DESIGN CALCULATION
a).When computer aided design calculations are used for the design of Code items, the Design
Engineer is responsible for the input of the correct design data and for verifying that the correct
output has been obtained and in compliance with Code.
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b).The Manufacturing Manager shall review Code Edition and Addenda to determine whether
standard designs and computer programs are affected or not.
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DESIGN CALCULATION,
CONTROL
2.5. FABRICATION DOCUMENTS
a). The Factory Manager is responsible for issuing applicable fabrication documents such as work
instructions. Images must be issued by the Manufacturing Technology Manager.
b). The fabrication documents with the revised level that will be used for fabrication must be
reviewed so that they do not reap the misunderstanding, and must be marked or recorded
documents that have received revisions that will later be listed on ITP.
2.6. INSPECTION AND TEST DOCUMENTS
a). Inspections and documents covering the manufacturing process, completion and quality records
with the revised level to be used for manufacturing must be registered at ITP.
2.7. REVISIONS OF DRAWINGS / DOCUMENTS
a).Revisions of drawings/documents shall be prepared, reviewed, approved and distributed in the

same manner as the original.
b).The revised area of drawings/documents except for typographical correction shall be identified
with a vertical line on the right hand margin and the area of pictorial information shall be
identified with appropriate method such as cloud mark and revision level.
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Section : 3.0 MATERIAL CONTROL Page : 1 of 5
3.1. SCOPE
This Section describes Procurement, receiving inspection and control of Code materials including
welding materials to ensure that only intended materials are used in Code construction.
3.2. PURCHASE REQUEST
Purchase Requests are prepared by Design Engineers for each contract, the amount of which is
approved by the Company Manager, as applicable. The person who agrees to the Material Purchase
Specification must ensure that the MPS covers all the requirements of the ASME Code Part II of the
Material Specification, the applicable construction Code and the Customer Specification, including
the material certification documentation requirements, so that the material meets the requirements.
acceptable for construction. and that all ordering information as required by the Material
Specifications indicated.
a). All raw material will be supplied by subcontractor shall be backed up by and comform to
their relevan mill / test certificate.
b). When material received from the mill does not satisfy the standart tolerance for camber,
profil, flatness or sweep corrective work by the use of controlled heating, chemical and
mechanical straightening, subject to the limitation of the standart, may be perform. It could
be done or shall be replace with a new one and precise one.
c). Steel material for fabrication shall not be heavily pitted or rusted.
d). Subcontractor shall provide the following document for record and control of material.
• Material List & Cutting Plan.

• Material Test report / Mill Certificate (Form the supplier)
• Delivery List
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3.3. RECEIVING INSPECTION
The Warehouse Officer will receive the material and prepare a Recipient Inspection Report. The
Recipient and Inspection Report together with the MTR will be forwarded to the QC Inspector to
receive the inspection.Using the Order and Purchase Code as a reference, the QC Inspector must accept
the inspection and then fill out the MIR. MIR will contain measurements for dimensions, heat
numbers, MTR numbers, material identification marks taken from materials and all other relevant
information. Company managers must approve MIR.
a). Upon arrival of the material at fabrication yards, warehouse section will inform QA/QC department
and project control to recheck the raw material. Scope of the inspection shall include visual
dimension, sharpness, thickness, heat no. or manufacture no.
b). Identification mark of material grade shall be clearly marked on all pieces of material including
those cut from the whole material it self. This identification marks shall remain clearly visible at
all times. Recomanded type of medium for identification marking shall be stamp, paint or crayons.
Subcontractor shall propose to contractor the method inspection.
c). Any non - conformance between client document and material received by PT………., QA/QC
department will inform with Quality Assurance confirmation (QAC).
d). When some material is not acceptable, the QA / QC department marks the material received in the
report by selecting one column that is already available.
e). Repair material shall client specification and repair procedure approve by client.
3.4. IDENTIFICATION OF ACCEPTED MATERIAL
The QC inspector must show acceptable material by attaching the tag "ACCEPTED" to the
material. When small parts are received, they can be placed on a tray, tub, or package and the
"ACCEPTED" tag / sticker will be installed on the tub, tray or package.
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3.5. MATERIAL CERTIFICATION

Material Certification, if required, will be reviewed by the QC Inspector for traceability of the
identification number and for compliance with the requirements of the ASME Code and Purchase
Orders. The signature and date of the QC Inspector on the material certificate will be proof that the
material certification review was carried out by him. The QC engineer must verify compliance with
the Code and re-certify the material produced to the specifications. The QC inspector reviews MIR
with material certification and he is responsible for making it available when requested. If further
material testing is required to be carried out at the time of receiving the inspection or during
manufacturing operations, the test must be prepared by the QC Inspector and the results must be
reviewed / approved by the QC Engineer and must be available when requested.
3.6. ISSUANCE OF MATERIAL
After completing and receiving the inspection received, the QC Inspector must record the results on
the MIR and will return the MIR to the Purchasing Officer and a copy to the Officer. Engineers will
only release to make material that is received and identified at MIR, and as specified in ITP.
3.7. STORAGE
Storage of ingredients The code in the store must be in the specified area. Store storage areas must
be on location to prevent material damage. Welding material will be stored according to the
manufacturer's recommendations in a clean and dry area and under the control of the Factory and in
the appropriate atmosphere when opened. Welding material must be stored, removed and controlled
in accordance with the Welding Material Control Procedure.
3.8. CUSTOMER SUPPLIED MATERIAL
For customer supplied materials, material test reports as required by the material specification and
Code shall be provided and customer supplied material will receive the same cycle of receiving
inspection, identification, certification and control according.
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3.9. IDENTIFIKASI MARKING

In case the original identification markings are removed or the material is divided into two
or more parts, one set of material identification shall be accurately transferred prior to cutting to
the location where the markings will be visible on the Code items, or a Coded Marking System
shall be used to assure identification of each piece of material during fabrication and subsequent
identification of the markings on the completed Code items.
Heat numbers or material identification markings shall be recorded on the MIR in the event
of machining or other operations which would cause the identification markings to be removed.
Upon completion of machining, the markings will be re-stamped or etched back onto the material.
This shall be verified by the QC Inspector.
• IDENTIFICATION MARKS
a). Transfer of identification marks (including heat no.) shall be check prior to cutting.
• MARKING
a). Giving the mark OK, if result of mark is correct.
b). After giving mark OK, we can do the next process.
• DIMENSION
a). Checking the MAL according the place.
b). “MAL” made the duplicated equipment as same as one from paper / polywood.
c). Identiti that the MAL has been made and chacked in accordance to drawing approval.
d). Only approval MAL will bbe used for fabrication process (marking, cutting, bending,
rolling, beveling).
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e). Proggresive dimensional check shall be conducted at stages before, during and after
the manufacturing process.
f). Dimensional marking shall be chacked prior to cutting, beveling, bending, and rolling.
After part or final assembling, all dimensional mark are to be reconfirmed for accuracy
prior to futher worksuch as reforming, etc. In wich the dimensional inspection shall
be conducted.
g). All measuring tools to be used for measuring and inspection shall be calibrated by an
authorized agenzy. The calibration record shall be kept as a QA record.
h). Check with measuring tools all dimensional of individual member / shop assemblies,
withing the specified tolerance.
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Section : 4.0 PRODUCTION CONTROL Page : 1 of 2
4.1 SCOPE
This Section describes the requirements in the control of production to ensure that every
production/fabrication process is performed in accordance with specified requirements and in the
correct sequence
4.2. INSPECTION AND TEST PLAN (ITP)
a). The ITP shall be prepared by the PPIC Engineer which shall contain all applicable processes
such as welding, NDE, heat treatment, inspection and test, etc. and all applicable procedures
to be used. The ITP shall also contain spaces for the designation of QC Inspector’s and
Hold/Witness/Review Points and for the indication of inspection, examination and test status.
b).The ITP shall be forwarded to the QC Engineer for the review and designation of QC
Hold/Witness points and approved by the QC Manager and Factory Manager.
c). The QC Manager shall submit the ITP, Drawings and any other Documents requested to the
AI so that he may assign his inspection points prior to start of fabrication.
d).The ITP shall be forwarded to the Production Supervisor including all applicable drawings
and procedures referenced on the ITP for execution and control of shop fabrication.
e). The revision to the ITP shall be prepared, reviewed and approved in the same manner as for
the original including AI review except that the processed page of ITP shall remain attached
to the revised page.
f). If additional Inspection Points are requested by the AI or customer, they shall be included.
Hold/Witness/Review Points shall not be deleted without approval of the QC Department
Manager, AI and/or customer.
g). Upon the completion of each operation, the Shop/Welding Foreman shall put his
signature/date on the applicable column to indicate the completed fabrication operation on
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Section : 4.0 PRODUCTION CONTROL Page : 2 of 2
the ITP. The Shop/Welding Foreman shall also record the identification number of materials
used and the ID No. of the Welders/Welding Operators who welded the joints on the ITP.
h). Upon satisfactory completion of their inspection points the QC Inspector/AI/Customer's

will sign-off on the applicable column of the ITP to indicate their acceptance.
i). Upon the completion of fabrication, the completed ITP and required reports shall be
submitted to the QC Engineer for review to assure that all the designated inspections have
been completed and conform to the applicable drawings, procedures and customer
documents.
4.3 NOTIFICATION TO THE AI
a). The QC Manager shall notify the AI of all Hold/Witness Points with reasonable advance
notice.
b). Fabrication operation shall not proceed work beyond the designated Hold points. In the
event that the AI consents to allow work to proceed through a specified AI Hold Point
without his presence, the QC Manager shall be responsible for documenting this agreement
on the ITP prior to beginning of the work so affected. The consent of the AI shall be
documented by his signature/date on the ITP in his subsequent visit.
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Section : 5.0 WELDING Page : 1 of 5
5.1 SCOPE
This Section describes the control of WPS, PQR, Welder qualification, welding material
distribution and welding processes. All welders shall be qualified in accordance with Section Ⅸ of the
ASME Code. All Welding Procedure Specification (WPS) shall be qualified in accordance. All
welding shall be performed in accordance with Section Ⅸ and with additional requirements of the
applicable Code Sections.
5.2 RESPONSIBILITY
Preparation of all Welding Procedure Specification and the Procedure Qualification Record shall
be the responsibility of the Welding Engineer. The certification of the PQR and WPQ will be the
responsibility of the QC Manager. The Production Supervisor is responsible for the control of all
welding materials. Issuance and storage of welding material will be the responsibility of Warehouse
Officer. The QC Inspector shall monitor all aspects of welding. It shall be the responsibility of Welding
Engineer to provide instructions and assistance to welders/welding operators to assure the full
compliance with the Code.
5.3 WELDING PROCEDURE SPECIFICATION
The Welding Engineer will be responsible for the preparation and qualification of Welding
Procedure Specifications and revisions to them.
When revisions to a WPS are required and the changes are limited to the nonessential variables,
the existing WPS shall either be revised showing a new revision level and date or a new WPS shall be
written. Any changes in essential or supplementary essential variables, when applicable, will require
a new qualification test. The Welding Engineer shall maintain a list of the WPSs which have been
qualified for ASME Code activities.
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The WPS designated on the drawing or weld map shall be made available to the Welders/Welding
Operators in the work area. The Welding Engineer shall give direction to the Welding Foreman and all
welders regarding the details of the WPS.
5.4 WELDERS / WELDING OPERATORS
The qualification of the welder / welding operator must be witnessed by the Welding Technician
at PT. BARA store. Only qualified welders are assigned to conduct code welding by the Welding
Foreman.
Each welder will be given an identification number after successfully completing his first
qualification test. If the welder goes from PT. BARA, the identification number is retired and will not
be transferred.
All names of eligible welders, identifiable numbers, positions that qualify, F-number, pipe
diameter, thickness, process and date of last work in the Process, etc. Will be stored in a Table from a
Certified Welder or Welding Operator. which must be updated by Welding Technicians every three
months. The Shop / Welding Foreman is responsible for the welding assignment and supervision.
Welding joints must be stamped with the welder's identification number at intervals of not more than 3
feet (1m) from welds made in steel plates 1/4 inch thicker and on non-iron plates 1/2 inch and deeper
in thickness, or identification numbers the welder is recorded in the Fabrication Sheet column in effect
by the Shop / Chief Superintendent with his signature. For the identification of welders on ships whose
wall thickness is less than 1/4 inch for steel material and less than 1/2 inch for nonferrous material,
suitable stencils or other surface marks must be used, or a record of the welder's ID must be made.
indicated on the Fabrication Sheet by the Shop / Las Foreman for each connection, which must be
available for AI.
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5.5 DOCUMENTATION OF TEST RESULT
The results of the qualification test shall be documented on the PQR or the WPQ as applicable.
When the testing is performed by an outside source laboratory, steps shall be taken to assure
that the test is performed on the correct specimen and these test reports shall be documented on the
PQR/WPQ by Welding Engineer. Test reports provided by the outside source laboratory shall be kept
on file by the Welding Engineer.
5.6 EXPIRATION AND RENEWAL OF QUALIFICATION
The performance qualification of a Welder or Welding Operator shall be affected when one of the
following conditions occurs:
a). When he has not welded with a process during a period of 6 months or more, his
qualifications for that process shall expire; unless, within the 6 month period, prior to his
expiration of qualification.
• The welder has welded with that process using manual or semiautomatic
welding, under the supervision and control of PT. BARA that will extend his
qualification for an additional 6 months.
• The welding operator has welded with that process using machine or automatic
welding, under the supervision and control of PT. BARA that will extend his
qualification for an additional 6 months.
b). When there is a specific reason to question his ability to make welds that meet the
specification, the qualification that support the welding he is doing shall be revoked. All
other qualification not questioned remain in effect.
c). Welder shall be re-qualified whenever a change is made in one or more of the essential
variables listed for each welding process. The Welding Engineer, QC Manager or the AI
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may require re-qualification of the welder when these reasons are found. All other qualifications not
questioned remain in effect. The WPS designated on the drawing or weld map shall be made available
to the Welders/Welding Operators in the work area.
The Welding Engineer shall give direction to the Welding Foreman and all welders regarding the
details of the WPS. Renewal of qualification shall be in accordance with QW-322.2 of the Code
Section IX.
5.7 WELDING MATERIAL DISTRIBUTION
The Welding Material Crib Keeper will be responsible for issuing and returning of welding
material using Welding Material Issue Card in accordance with the Welding Material Control
Procedure. Low hydrogen electrodes shall be properly identified and kept in atmosphere controlled
storage area under conditions complying with the manufacturer's recommendation. Low hydrogen
welding materials shall be dried in the heating oven before being issued for use in the shop according
to the manufacturer's recommended time and temperature.
Electrodes of controlled quantity shall be issued to Welders by the Welding Material Crib Keeper
and used within four hours, otherwise the remaining materials will be returned to the Welding
Material Crib Keeper. If portable holding ovens are used, this time may be extended to eight hours.
The low hydrogen electrodes once issued and returned will not be used for Code job. Welding
materials not requiring heated storage will be kept in clean and dry storage areas.
5.8 WELDING
The Head of Shop / Welding will assign the welder to code welding based on Fabrication Sheets,
WPS and drawings. He must instruct and supervise the welder during welding. The Shop / Welding
foreman must maintain the applicable documents for carrying out work in the workplace intended for
ASME Code work.
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5.9. USE OF SUBCONTRACTOR WELDERS
PT. BARA can involve individuals based on contracts or agreements for their services as welders
at shop locations and on site locations for fabrication provided all the following requirements are met.
• All Code construction is the responsibility of PT. BARA of all welders

• All welding must be done in accordance with PT. BARA welding procedures in
accordance with the requirements of Section IX.
• All welders must meet the requirements by PT. BARA complies with the
requirements of Part IX.
PT. BARA has minimal responsibilities including :
• Complete and exclusive administrative and technical supervision for all

welders by Foreman Workshop.
• The Shop / Welding Foreman has the authority to set and release the welder at
his discretion without the involvement of other organizations.
• The QC engineer is responsible for the assignment of the welder's
identification symbol.
• This program must be submitted to the AI who provides inspection services
for acceptance when used, by the QC Manager.
PT. BARA is responsible for compliance with the Code or parts thereof, including the
Certification stamp and providing Data Report Forms that are carried out correctly and signed by the
Inspector.
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EXAMINATION & INSPECTION

Section : 6.0 Page : 1 of 3
PROGRAM
6.1. SCOPE
This Section describes the control measures required in the examination and inspection during
material receiving inspection, in-process inspection, final inspection, pressure testing, stamping and
signing off the Manufacturer's Data Report.
6.2. RESPONSIBILITY
All shop fabrication activities and related to Code construction will be the responsibility of
Factory Manager. The planning and performing of examinations and inspections will be the
responsibility of the QC Manager.
6.3. INSPECTION IN PROCESS
The QC inspector must monitor the fabrication process, NDE and heat treatment operations,
and document the results of the inspection in the Fabrication Sheet and the corresponding report form.
The QC manager must notify the AI of his inspection points with adequate prior notice.
a). Prior the welding activity, welding procedure qualification test, welding procedure
specification, welding map, welder performance test and welder list shall be reviewed and
approvad by contractor and company.
b). All fabricated parts shall be inspected as to the following :
• Visual Inspection
• Weiding inspection shall ensure all parameter and condition.
• As per WPS / PQR and welder has been full fillet before welding, during
welding and after welding.
• Al welding will be visually inspected to check if that there are defect such
as undercut, crack, blow hole, slag inclusion, and fused spatter.
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PROGRAM
• All part shall be throughly cleaned. All dirty, welding electrode stubs and
foreign matter shall be removed.
• The leg size of fillet should be in accordance with the design stipulation.
• Formed corner of bracked shall be visual checked, and shall be no crack
or harmful defects is produced.
6.4. NDE
Non destructive examination (NDE) of pressure boundary weld and attachment weld to pressure
boundary shall be done in accordance with the approved NDE procedure.
The following documentation of NDE Personnel including subcontractor shall be kept on

file by Quality Control.
1). Name of certified individual.
2). Level of certification and test method.
3). Educational background and experience of certified individuals.
4). Statement indicating satisfactory completion of training in accordance with the

employer's written practice.
5). Name of certified individua
6). Level of certification and test method
7). Educational background and experience of certified individuals
8). Statement indicating satisfactory completion of training in accordance with the

employer's written practice.Results of the vision examination.
9). Current examination copy(s) or evidence of successful completion of examinations.
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PROGRAM
10). Other suitable evidence of satisfactory qualification when such qualification is used in
lieu of examinations.
11). Date of certification and/or re-certification and the dates of assignment to NDE.
12). Signature of the representative of the certifying agency.
13). The NDE written practice for the qualification and certification of NDE personnel
based on SNT-TC-1A current Code accepted edition.
c). When PWHT and hardness test is required , therefore subcontractor maintain these activities to
comply with the approved procedures.
6.5. PRESSURE TESTING
Internal pressure must be applied to the hydrostatic test pressure which at each point on the vessel
is at least equal to 1.3 times the maximum allowable working pressure multiplied by the lowest stress
ratio (LSR) for the pressure limit material where the vessel is built. The stress ratio for each pressure
limit material is the stress ratio the S value at the test temperature with the S voltage at the design
temperature. All loads that may be present during this test must be considered. Hydrostatic test
pressure readings must be adjusted to account for any static head conditions depending on the
difference in height between the space being tested and the measuring pressure.
A hydrostatic test based on a calculated pressure may be used by agreement between the user and
the Manufacturer. The hydrostatic test pressure at the top of the vessel shall be the minimum of the
test pressures calculated by multiplying the basis for calculated test pressure as defined in for each
pressure element by 1.3 and reducing this value by the hydrostatic head on that element. When this
pressure is used, the Inspector shall reserve the right to require the Manufacturer orthe designer to
furnish the calculations used for determining the hydrostatic test pressure for any part of the vessel.
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The requirements of above represent the minimum standard hydrostatic test pressure
required by this Division. The requirements of above represent a special test based on
calculations. Any intermediate value of pressure may be used. This Division does not specify
an upper limit for hydrostatic test pressure. However, if the hydrostatic test pressure is allowed
to exceed, either intentionally or accidentally, the value determined as prescribed in above to
the degree that the vessel is subjected to visible permanent distortion, the Inspector shall
reserve the right to reject the vessel.
6.6. INSPECTION PROGRAM FOR PAINTING.
a). All surface prepare for painting are to be inspected and the surface preparation standart and paint
used shall be reviewed and approved by contractor prior to the start of the work.
b). No work shall proceed at any stage of the job until the following stage inspection has been carried
out and approved :
• Before blasting :
- The surface shall cleaned form dirty, dust, and other foreign matter.
- The surface have cleaned shall be dried.
• After blasting :
- Grade surface preparation.
- Surface profile.
c). Improrer procedures during application, even though the specified total dry film thickness has been
achieved, shall be sufficient cause for complete removel of the applied material and re-application
using the specified procedure.
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CALIBRATION OF
Section : 7.0 MEASUREMENT & TEST Page : 1 of 1
EQUIPMENT
7.1. SCOPE
This Section describes the system for the calibration of examination, measuring and test equipment
used in the fulfillment of Code requirements.
7.2. RESPONSIBILITY
The QC Manager shall have the responsibility to assure that examination, measuring and test
equipment used in the fulfillment of Code requirements have been calibrated and are of proper type,
range and accuracy to accomplish the intended quality of the items. Calibration of NDE equipment is
the responsibility of the NDE Level Ⅲ. Calibration of equipment shall be accomplished by
government recognized calibration agency.
7.3. CALIBRATION FREQUENCY
The measurement and test equipment shall be calibrated, traceable to and controlled in accordance
with the national standards or the manufacturer's standard. Pressure gauges shall be calibrated against
a standard dead-weight tester. Pressure gauges shall be re-calibrated at any time when there is reason
to believe that they are in error. These pressure gauges shall be calibrated at least every 12 months.
The dead-weight tester shall be calibrated every three years. If any measurement or test equipment is
dropped or damaged so that there is a doubt in the accuracy of the equipment, it shall be recalibrated
immediately.
7.4. NDE EQUIPMENT
Calibration of NDT equipment shall be done by the NDE sub-contractor. The QC Manager will
review and verify these calibration records.
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NONDESTRUCTIVE
EXAMINATION
8.1. SCOPE
This Section describes the requirements for NDE and documentation of the results as required for
Code compliance. When Nondestructive Examination (RT, UT, MT, PT) is needed, it may be
subcontracted.
8.2. RESPONSIBILITY
QC Manager has the overall responsibility for successful performance of nondestructive

examination as required for Code compliance. QC Manager shall certify NDE Personnel. Preparation
of NDE Procedures, calibration of the NDE equipment, qualification of NDE personnel and
implementation of NDE for RT, UT, MT and PT will be the responsibility of NDE Level Ⅲ When
NDE is performed by a subcontractor, the QC Manager shall review the subcontractors written
practice, personnel qualification and certification records and the subcontractors NDE Procedures.
QC Manager is responsible for the qualification of VT Examiner and preparation of VT Procedure.
8.3. APPOINTMENT OF NDE LEVEL III
The QC Manager shall review the qualification and certification records for intended NDE Level
III personnel and, when satisfactory, write a letter to appoint a qualified NDE personnel as PT. BARA
appointed Level Ⅲ.
8.4. VT EXAMINER
VT Examiner shall be qualified and certified according to the written procedure
8.5. NDE PROCEDURES
NDE procedures must be written in accordance with Code requirements. This demonstration must
be documented by the signature on the cover sheet of the Procedure. The QC Manager must certify
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NONDESTRUCTIVE
EXAMINATION
the NDE Procedure in accordance with T-150 of Section Ⅴ. NDE procedures must be available for
NDE Inspectors in the work area. VT procedures must be provided by the QC Department.
8.6. NONDESTRUCTIVE EXAMINATION
The extent and method of NDE for Code items will be decided in accordance with the Code and
Customer specification by the Design Engineer and it shall be described on the fabrication drawing.
The QC Engineer prepares NDE map in accordance with the designated NDE requirements on the
drawing. Additional NDE may be required considering the fabrication process. Nondestructive
examination shall be based on the drawing and NDE Map and submit the NDE reports and film to the
QC Manager. NDE results will be documented on the appropriate NDE report forms. The QC Manager
will verify the results of NDE and if a defect is found, he will notify the results to the Factory Manager.
8.7. EQUIPMENT CONTROL
The appointed Level III personnel is responsible for the calibration and control of the NDE
equipment. He will maintain the list of the NDE equipment and calibration records which will be
reviewed by the QC Manager.
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Section : 9.0 HEAT TREATMENT Page : 1 of 1
9.1. SCOPE
This Section describes the requirements of heat treatment.
9.2. HEAT TREATMENT
The Design Engineer is responsible to prepare Heat Treatment Instruction that will determine the
scope of the heat treatment according to the requirement of Code, standards, and customer
specifications. The Manufacturing and Technology Manager approves the Heat Treatment
Instruction. The Manufacturing and Technology Manager will provide the heat treatment Instruction
to the QC Inspector. The Inspector QC shall assure the proper performance of the heat treatment by
witnessing, monitoring and document review i.e. furnace loading, method, heating and cooling rate,
time and temperature, the location and number of thermocouple, method of thermocouple attachment,
calibration of equipment used in the heat treatment, etc. Before performing the heat treatment, the
QC Inspector shall verify the identification marking, stamping or tagging on the item After
completion of the heat treatment, the QC Inspector shall make inspection to check the identification
marking and to verify that there is no damage or unacceptable deformation on the item.
9.3. RECORD
The QC Engineer shall review the heat treatment record and Time-Temperature Chart for
conformance with the requirements of the Heat Treatment Instruction, Code and customer
specification. The heat treatment record shall include date, Item identification, serial number of the
equipment used, Heat Treatment Instruction, heating rate, cooling rate holding time and temperature
and furnace loading (including location and number of thermocouples) as a minimum
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Section : 10.0 RECORDS RETENTION Page : 1of 2
10.1. Scope
This Section describes the requirements for retention of records.
10.2. RESPONSIBILITY
The QC Manager will be responsible for the retention of records.
10.3. RECORDS
PT. BARA shall maintain the documents as below :
1. Manufacturer’s Data Reports.
2. Manufacturer’s Partial Data Reports.
PT. BARA shall maintain the documents as below :
1. Manufacturer’s Data Reports / Manufacturer’s Partial data Reports.
2. Manufacturing drawings.
3. Design calculations.
4. Material Test Reports and/or material certifications.
5. Welding Procedure Specifications and Procedure Qualification Records.
6. Welder / Welding Operator Performances Qualification Records for each welder.
7. Reports NDT.
8. Repair procedure and records.
9. ITP.
10. Heat treatment records and test results.
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Section : 10.0 RECORDS RETENTION Page : 2 of 2
11. Post weld heat treatment records.
A copy of the Manufacturer’s Data Report shall be kept on file in a safe repository by QC
Manager. Retained records shall be made available to the Authorized Inspector Supervisors or to
review team designated by ASME.
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Section : 11.0 AUTHORIZED INSPECTOR Page : 1 of 2
11.1. SCOPE
This Section covers the interface between PT. BARA and the Authorized Inspection Agency (AIA).
11.2. INSPECTION AGREEMENT WITH AIA
PT. BARA shall maintain a written Inspection Agreement with an Authorized Inspection Agency
(AIA) which is accredited by the ASME. It is the QC Manager responsibility to immediately inform
ASME as soon as theagreement between AIA of record and PT. BARA is cancelled or changed.
11.3. FREE ACCESS
The AI and AIS shall have free access to all areas of the shop and field sites and documents from
PT.BARA including its vendors in order to perform inspection, monitoring and periodic audit.
The QC Manager shall provide full assistance to the AI Supervisor during his audit.
11.5. DOCUMENTS/QC MANUAL
The AI shall have free access to all documents and records required by the Code and those other
documents and records requested by him.
The QC Manual including subsequent revisions shall be acceptable to the AI. The QC Manager
shall distribute a controlled copy to AI at the shop and field site where Code activities are being
carried out.
11.6. INTERFACE WITH AI
The QC Manager (Site QC Manager for field sites) is the main contact with AI. He is responsible
for presenting or making available to AI all documents including Design documents, Manufacturing
Sheets, MDRs, etc. As required in other parts of this Manual. The QC manager must notify the AI of
his inspection points properly beforehand.
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Section : 11.0 AUTHORIZED INSPECTOR Page : 2 of 2
11.7. ASME CODE INSPECTION BY ANOTHER AIA (SECONDARY AIA)
When Customer request to PT. BARA for another AIA to perform inspection on their project
or Code jobs, or whenever the AIA of Record cannot provide coverage for inspection at field site, the
following provision shall be applied for Code Inspection.
• QC Manager shall contact with another AIA for written agreement of ASME Code inspection
at workshop and field activities.
• The AI of another AIA shall review and accept PT. BARA QC Manual prior to performing
any Code Inspection.
• When changes are made to the QC Manual by the secondary AIA, this changes shall be
subject to acceptance by the AI of AIA of Record.
• The AI of Secondary AIA shall perform all inspection activities required only for specific
project or Code job.
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Section : 12.0 FIELD ASSEMBLY Page : 1of 3
12.1. SCOPE
This Section describes responsibilities and measures to control field assembly. The quality related
activities not described in this section shall be in accordance with the requirements in the other
applicable Sections of this Manual.
12.2. RESPONSIBILITY
The Project Manager / Manager appointed by the General Manager or President Director takes
overall responsibility for the operation of the field site.
The Engineer is responsible for control of material and documents such as drawing, WPS, MTR,
etc. which are supplied by the shop.
The QC Engineer designated by the QC Manager takes responsibility for the Quality Control
activity at the site including in-Process inspection, control of NDE subcontractor and for preparing
the Manufacturer's Data Report.
12.3 MATERIAL CONTROL
Material shall be purchased, inspected and controlled in accordance with Section 4.0 . All the
material including welding material for Code construction at the field shall be supplied from the Shop
or directly from the vendor.
The QC Engineer shall be responsible to perform the receiving inspection at the field site. The
QC Inspector shall designate the material storage area in such a location as to prevent damage to the
material.
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Section : 12.0 FIELD ASSEMBLY Page : 2 of 3
12.4. DRAWING CONTROL
Drawing, specifications, etc. shall be supplied by the Manufacturing Technology Manager and
controlled as specified in Section 2.0 of this Manual. The Engineer will control the original or revised
drawings supplied by the shop.
12.5. PROCESS CONTROL
The Fabrication Sheet for field assembly work shall be prepared by the Engineer, approved by
the Project Manager or Site Manager and reviewed by the QC Engineer and site AI for the designation
of inspection points.
12.6. WELDING CONTROL
Welding Procedures and welders shall be controlled as described in Section 5.0 of this Manual.
The Welding Engineer shall supply the WPS.The QC Inspector is responsible for qualification of
welders and for preparation and maintenance of the Welder in the field. The Field Foreman is
responsible for assignment of welders and control of Welding Material Control Room at site. All
welding work and documentation will be performed in the same manner as in the shop.
12.7. INSPECTIONS
QC inspectors must monitor all construction processes and implement every inspection program
in the field. The Project Manager / Location Manager is responsible for all of that.
The QC engineer is responsible for notifying AI of upcoming Inspection points. When the
stamping code is required by the field site, the QC Site Engineer must control the application.
12.8. RECORD RETENTION
The QC Engineer will be responsible for the retention of records and forwarding the records to
the QC Manager of the shop. It is the responsibility of the QC Engineer to properly complete and
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Section : 12.0 FIELD ASSEMBLY Page : 3 of 3
certify the field construction portion of the MDR prior to presenting it to the AI.
12.9. CALIBRATION
Measurement and test equipment are calibrated and supplied by Factory Manager.
12.10. NONDESTRUCTIVE EXAMINATION
All NDE shall be controlled as specified in Section 9 of this Manual.
12.11. AUTHORIZED INSPECTOR
The QC Engineer will make all Code related document available to the AI. Please refer to
Section 11.0 of this Manual for all interactions with the Authorized Inspector (AI).
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Section : 13.0 REPAIR AND ALTERATION Page : 1 of 4
13.1. CONSTRUCTION STANDARD
When Original Equipment is constructed to the Code, Repairs and Alterations shall conform
insofar as possible to the section and edition of the Code most appropriate to the work performed.
When the Original Equipment is not constructed to the Code, Repairs and Alterations shall conform
insofar as possible to the edition of the Construction Standard or Specification most appropriate to
the work. Where use of Original Construction Code is not possible or practicable, other Codes,
Standards, Specifications including ASME Code with latest edition and addenda may be used
provided prior concurrence of the Inspector has been obtained. When applicable prior concurrence of
Jurisdiction and Owner shall also be obtained for use of Standards other that Original Construction
Standard.
• Dimension shown in the text, tables, and figures,whether given as decimals or fractions,
may be taken as decimals or fractions and do not imply any manufacturing precision or
tolerance on the dimensions.
• The Code does not fully address tolerances. When dimensions, sizes, or other parameters
are not specified with tolerances, the values of these parameters are considered nominal,
and allowable toler nces or local variances may be considered acceptable when based on
engineering judgment and standard practices as determined by the designer.
13.2. ACCEPTANCE INSPECTION
• The Inspector making the acceptance inspection shall be the same Inspector who
authorized the repair or alteration. Where this is not possible or practicable, another
Inspector may perform the acceptance inspection however, in all cases, the Inspector who
performs the acceptance inspection shall be an employee of the same organization as the
Inspector who authorized the repair or alteration.
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• The Inspector shall review the drawings, ensure the repair or alteration was performed
in accordance with the accepted code of construction or standard, witness any pressure
test or any acceptable alternative test method applied, ensure that the required
nondestructive examinations have been performed satisfactorily, and that the other
functions necessary to ensure compliance with the requirements of code have been
satisfactorily performed.
13.3. METHODS OF CORRECTION AND CHANGE
For all Repair and Change work, before starting the activity, the QC Manager must prepare and
agree to a Detailed Procedure that explains the Projected Scope of Work. This procedure includes at
least the Repair / Change methodology, the applicable Welding Procedure Specifications, the
proposed NDT method and the extent, Material, Pre-heat and Post-Welding Heat Treatment
requirements and Documentation requirements. Other special requirements from NBIC, the
Construction Code and the Owner must also be included. Based on this Procedure and other
applicable Images and Documents. The QC Manager must submit the following to the Inspector for
review and acceptance and allows him to show the inspection points on the Fabrication Sheet:
• Design Calculations, Drawings, Approved Material Specifications.

• Copy of original Manufacturer Data Report.
• Fabrication Sheet
• Repair / Change Procedure detailing the Projected Scope of Work.
• Applicable WPS, PQR and Welder Qualification Test Notes.
• NDE Proposal and Heat Treatment and Applicable Procedure.
The checks and tests required during repairs must comply with the Original Construction
Standards. However, if it is not possible or practical, alternative methods such as those permitted by
NB-23 and can be accepted by AI and the owner can be used. Inspectors must have access to inspect
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what is deemed necessary to ensure that the Inspection can be carried out, and to receive
Repairs and Amendments after the Final Inspection.
13.4. WELDING, NDE AND HEAT TREATMENT
Welding controls including qualification of Welding Procedures and Welders, control of

Welding Consumables, Welder’s identity & continuity control and shop/field welding controls for
Repairs and Alterations shall be in accordance with Section 5.0 of this manual. The Welding
Procedures and Welder’s Qualification shall conform to Original Construction Standard. If this is
not possible or practicable, WPS and Welders Qualified in accordance with ASME Code Sec. IX
can be used.
Records of approved WPS and Welder’s Qualification Tests shall be made available to
Inspectorfor his review and acceptance before carrying out welding work. Standard WPS shown in
2.3 of the NBIC can be used without supporting PQR for Repairs or for Performance Qualification.
Such WPS shall be documented and certified by QC Manager for use. When required, Owners or
Jurisdiction’s acceptance will be obtained for use of Standard WPS. NDE requirements including
Technique, Extent of Coverage, Procedures, Personnel Qualification and Acceptance Criteria shall
be in accordance with Original Construction Standard.
13.5. ACCEPTANCE AND INSPECTION OF REPAIR OR ALTERATION
Repair and Alteration shall be carried out as per the Procedure accepted by Inspector and all
the stages identified in the Fabrication Sheet shall be offered to him in accordance with his
designated inspection points. Before acceptance of any Repair or Alteration, the Inspector shall be
afforded right to satisfy himself that all the functions deemed necessary and in compliance with the
\
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requirements of the NBIC, have been performed.
Weld Repairs and Alterations shall be subjected to same NDE requirements as the Original
Welds. When this is not possible or practicable, alternative NDE methods acceptable to Inspector
and Owner or Jurisdiction as applicable may be used. NDE Personnel shall be qualified in
accordance with the requirements of Original Construction Standard. When this is not possible or
practicable, Personnel Qualified in accordance with NBIC adopted edition of SNT-TC-1A may be
used. Other NDE controls shall be as per Section 8.0 of this manual.
Preheat temperature requirements shall be as specified in the applicable WPS. Reference can
also be made to Table 2.5.1 of NBIC for recommended minimum preheat temperatures. PWHT shall
be performed as required by the Original Construction Standard or as per Original Manufacturer’s
Data Report. Local PWHT that is not specified by the Original Construction Code may be performed
as per NBIC with prior acceptance of the Inspector and when required by the Owner and Jurisdiction.
Under certain conditions, when PWHT in accordance with Original Construction Standard is
inadvisable or impractical, alternative methods of PWHT or Special Welding methods as described
in 2.5.3, Part 3 of NBIC and acceptable to Inspector may be used.
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Section : 14 SAMPLE FORM Page : 1 of 1
Index of Sample Form
Form No. Title Rev Date
1. MATERIAL INSPECTION REPORT 0

2. FINAL DIMENSIONAL REPORT 0
3. INSPECTION TEST PLANE 0
4. WELDING MAP 0
5. WELDING REPORT 0
6. HYDRO TEST 0
7. PAINTING SPECIFICATION 0
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MATERIAL INSPECTION Page : 1 of 1

Section : 14
REPORT Form No : 01
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Page : 1 of 1
Section : 14 FINAL DIMENSIONAL REPORT
Form No : 02
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Section : 14 INSPECTION TEST PLANE
Form No : 03
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Section : 14 INSPECTION TES PLANE
Form No : 04
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Section : 14 WELDING MAP
Form No : 05
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Section : 14 WELDING REPORT
Form No : 06
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Revision :
Date : WELDING REPORT Page :
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Section : 14 WELDING REPORT
Form No : 07
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Section : 14 PAINTING SPECIFICATION
Form No : 08
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Section : 14 PAINTING SPECIFICATION
Form No : 09
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Section : 14 HYDRO TEST
Form No : 10
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Section : 14 DOCUMENTATION HYDRO TEST
Form No : 11
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PT.

BERKAH ANDALAN REKAYASA

QUALITY CONTROL MANUAL

SHOP CONSTRUCTION AND FIELD

PT. BERKAH ANDALAN REKAYASA

Doc. No. : QCM - 01

Section : 0.1 TABLE OF CONTENT Page : 1 of 1

Section Description Rev Date

0.1 Table of Contents 0

1.0 QC Manual Control 0

2.0 Design Calculation, Drawing and Specification Control 0

3.0 Material Control 0

4.0 Production Control 0

6.0 Examination & Inspection Program 0

7.0 Calibration of Measurement and Test Equipments 0

8.0 Nondestructive Examination 0

9.0 Heat Treatment 0

10.0 Record Retention 0

11.0 Authorized Inspector 0

12.0 Field Assembly 0

13.0 Repair and Alteration 0

14.0 Sample Forms 0

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Section : 1.0 QC MANUAL CONTROL Page : 1 of 1

1.2. APPLICABILITY OF QC PROGRAM

a).This QC Manual is the primary document of the QC Program.

d).Uncontrolled copy may be issued (PT.BARA) PT.BERKAH ANDALAN REKAYASA at the

1.3. REVISION CONTROL

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2.2. CUSTOMER SPECIFICATIONS

2.3. CONTROL OF CUSTOMER SUPPLIED DOCUMENTS

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e). DOCUMENT CONTROL (DRAWINGS, CALCULATION AND SPECIFICATION)

• Drawings, calculations and specifications must be prepared by the Design

2.4. COMPUTER AIDED DESIGN CALCULATION

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2.5. FABRICATION DOCUMENTS

2.6. INSPECTION AND TEST DOCUMENTS

2.7. REVISIONS OF DRAWINGS / DOCUMENTS

a).Revisions of drawings/documents shall be prepared, reviewed, approved and distributed in the

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Section : 3.0 MATERIAL CONTROL Page : 1 of 5

3.2. PURCHASE REQUEST

• Material List & Cutting Plan.

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Section : 3.0 MATERIAL CONTROL Page : 2 of 5

3.3. RECEIVING INSPECTION

3.4. IDENTIFICATION OF ACCEPTED MATERIAL

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Section : 3.0 MATERIAL CONTROL Page : 3 of 5

3.5. MATERIAL CERTIFICATION

3.8. CUSTOMER SUPPLIED MATERIAL

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Section : 3.0 MATERIAL CONTROL Page : 4 of 5

3.9. IDENTIFIKASI MARKING

a). Giving the mark OK, if result of mark is correct.

b). After giving mark OK, we can do the next process.

a). Checking the MAL according the place.

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Section : 3.0 MATERIAL CONTROL Page : 5 of 5

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Section : 4.0 PRODUCTION CONTROL Page : 1 of 2