Inspection Report
Report No: 05 - 07/10/2015 (PT Gerbang) Date: 08.10.2015 Sheet 1 / 15
Project No: Manufacturer: PT. Gerbang Jakarta Indonesia
Project name: 9 Units of non-pressure vessels Equipment / Item No. :
Intermediate Inspection Production Test
Inspection Type Final Inspection Non Destructive Testing
Hydro Test / Leak Test NoBo Activities
Request for inspection
Inspection Basis
ASME B31.3
(Standards, Specifications):
A. Inspection Activities (for details see attached pages)
A1 Daily meeting (Activities planned, issues A13 Dye Penetrant Inspection
highlighted)
A2 Document review / Document approval A14 Radiographic Inspection / RT film review
A3 Checking Welding Procedure & Welder A15 Ultrasonic Inspection
Qualifications (WPS, WPQR/PQR & WQT)
A4 Checking NDT Personel Qualification A16 Eddy-Current Inspection
A5 Marking Transfer & Stamping; A17 Other NDE
Material Tracebility
A6 Witness Welding Procedure Tests, A18 Hardness Testing / Macro Testing
Welder Tests, Skill Test (ST),
Production Weld & Bend Tests etc.
A7 Machining of Parts A19 Coating Inspection
A8 Welding surveillance (Fit up, Visual etc.) A20 Mechanical testing
A9 PWHT (TC location, Heating rate, Holding time, A21 Intervention points actioned (Traveller, FTP, QCP)
cooling rate etc)
A10 Dimensional Check A22 Manufacturing Data Record Check
A11 Hydrostatic / Pneumatic Test A23 Expediting
A12 Magnetic Particle Inspection A24 Pre-shipment inspection
B. Inspector: C. Attached Documents
Kishnu NONE
D. Result of Inspection E. Brief description of reserves
Satisfactory
Accepted with remarks
Accepted with reserves
Not Satisfactory
F. Inspection Release Certificate: N/A
Written Diffusions
Date: 08/10/2015
-N/A
Signature:
Page 1 of 7
Inspection Activities
Activity
Result and comments related to inspections Remarks
No.
1. Documentation Review
a. Total of 8 MDR were given for review. 1 MDR for unit Sump Tank
SH-100 were not ready for review as fabrication was still on-going and
the QC have yet to compile its documents.
b. General findings reveal comments as per following.
i. All certificate of compliance or ASME Form 1-UA reveal
spelling mistakes on the Client INTEC Energy.
ii. WPS /PQR / WQT were satisfactory. Minor typo error found
in WPS. PT Gerbang to rectify and insert in MDR.
iii. Mill certs were satisfactory
iv. Material traceability reports were satisfactory.
v. NDT report and NDT personnel certificates were
satisfactory
vi. Dimensional reports were satisfactory.
vii. PT. Gerbang to ensure no discrepancies between welding
map, list of WPS, list of welders and NDT reports. To
A2/A4/ ensure all reports are traceable and linked between one
A22 another.
viii. PT Gerbang to insert approval status (signature/email copy)
regarding design calculations in MDR
ix. Hydrotest reports were satisfactory.
x. 6 units have yet to be hydrotested. Date 29 will be carry
1. Blocking Vessel hydrotest (Please find
2. Low Boiler Collection vessel attach our Procedure
3. Expansion tank Hydrotest)
4. Sump tank SH-100
5. Temperature blocking tank
6. Separator tank.
Report No: 05-07/10/2015 (PT Gerbang) Date: 08.10.2015 Page Page 2 of 7
Activity
Result and comments related to inspections Remarks
No.
2. Site Visit Visual Inspection and dimensional checks.
a. Sump Tank SH-50 ; not able to carry out full visual inspection Sump Tank not yet painting
because it was in the blasting/painting chamber; inaccessible. only preparation location
b. Dimensional checks were carried at random on units to verify with give cover tarpaulin
the dimensional reports. Were found to be satisfactory.
c. Welding visuals reveal comments that need rectification works
A8/A10 by PT.Gerbang before next phase of fabrication (Either
pressure test or painting)
i. Excessive spatters were found throughout SMAW
welds. Recommended to rectify via grinding.
ii. Mechanical damage/ dents were found on head and
shell side that requires weld touch up and grind
smooth.
iii. Undercuts were found and marked. To rectify via
grinding.
iv. Fillet weld sizes were satisfactory. Minor comments
required grinding.
v. SH-50 sump tank reveal insufficient fill on nozzle weld.
This have been communicated and to be rectified.
vi. Arc strikes were found and marked. Recommended to
rectify via grinding.
d. Minutes of Meeting was drafted out based on both
documentation and visual inspection findings and acknowledge
by both T.W.A and PT Gerbang.
This will be used as a reference to carry out the rectification
works.
Report No: 05-07/10/2015 (PT Gerbang) Date: 08.10.2015 Page Page 3 of 7
Pictures :
2. General view
1. Expansion tank
3. Undercuts 4. Close up of Pic 3
5. Spatters along weldment 6. Arc strikes - scattered across shell
Point 3 & 4. Undercut & Close up : - Remove weld by grinding
7. - Welding Repair ( Please find attach our welding Repair Procedure)
- Visual Inspection & Penetrant Test
Point 5 & 6. Spatter and Arc Strikes : - Remove Spatter and arc strikes by grinding
- Visual Inspection
Report No: 05-07/10/2015 (PT Gerbang) Date: 08.10.2015 Page Page 4 of 7
7. Manhole repad fillet weld to ensure 8. Mechanical damages on shell that requires
correct fillet weld sizes weld touch up
9. Dimensional checks 10.
12. Mechanical damage
11. Verified against dimensional reports
Point 7. All Leg Fillet Weld already check by welding gauge
Point 9,10 & 11. All Dimension Actual already verified by dimensional report
Point 8 & 12 . - rebuilt surface material by welding and after finish grinding flush
- Visual Inspection and Penetrant Test
Report No: 05-07/10/2015 (PT Gerbang) Date: 08.10.2015 Page Page 5 of 7
14. Undercuts on nozzle welds to grind
13. Low boiler collecting tank smooth
16. Tack welds that yet to be removed grind
15. Blocking vessel smooth
17. Fillet weld size checks OK according to 18. MFO Tank
drawing.
Point 14 . Undercut : - Remove Welding by grinding and welding repair
- Visual Inspection & Penetrant Test
Point 16. Tack Weld : - Remove Welding by grinding
Report No: 05-07/10/2015 (PT Gerbang) Date: 08.10.2015 Page Page 6 of 7
20. Arc stikes
19. Undercuts on fillet welds
Point 19 . Undercut : - Remove Welding by grinding and welding repair
- Visual Inspection & Penetrant Test
Point 20. Arc stikes : - Remove Welding by grinding
- Visual Inspection
All Vessel during process repair will be finish in 27 Oct 2015
Report No: 05-07/10/2015 (PT Gerbang) Date: 08.10.2015 Page Page 7 of 7
