FINAL REPORT OF APPRENTICESHIP (1) (1) (1) (Repaired)

FINAL REPORT
APPRENTICESHIP AT PT. SINGATAC BINTAN
QUALITY CONTROL DEPARTMENT
CREATED BY
MUHAMMAD IQRA RAMDAHAN

D321 12 265
DEPARTMENT OF OCEAN ENGINEERING

ENGINEERING FACULTY
HASANUDDIN UNIVERSITY
2016
VALIDITY SHEET
REPORT OF APPRENTICESHIP AT PT.SINGATAC BINTAN
PTSB (PT. SINGATAC BINTAN)
Name : Muhammad Iqra Ramadhan

Nim : D 321 12 265
Major : Department of Engineering
Has been carrying out apprenticeship for three months at PT.
Singatac Bintan on 18th July 2016 until 17th october 2016.
Bintan, October 2016
Reviewed By: Approved By:
Lead QA/QC Asst. Manager QA/QC PTSB

Coordinator / ISO
Management
Representative
Mr. Jesaya Sitepu Mr. Kumar
PREFACE
1
First of all, thanks to Allah SWT because of the help of Allah, writer
finished writing the paper entitled The Use of Methaphore right in the
calculated time.
The purpose in writing this paper is to fulfill the assignment that

given to complete studies of writer in Deapartment of Ocean
Engineering.
In arranging this paper, the writer trully get lots challenges and
obstructions but with help of many indiviuals, those obstructions could
passed. Writeralso realized there are still many mistakes in process of
writing this paper.
Because of that, the writer says thank you to all individuals who
helps in the process of writing this paper. Hopefully Allah replies all
helps and bless you all.the writer realized tha this paper still imperfect
in arrangment and the content. Thenthe writer hope the criticism from
the readers can help the writer in perfecting the next paper.last but not
the least hopefully, this paper can helps the readers to gain more
knowledge about Oil and Gas Construction Fabricator.
Bintan, October 2016
The Writer
2
TABLE OF CONTENTS
VALIDITY SHEET............................................................................................
PREFACE.......................................................................................................
TABLE OF CONTENTS..................................................................................
LIST OF FIGURES........................................................................................
LIST OF TABLE............................................................................................
TABLE OF APPENDIX.................................................................................viii
LIST OF ABBREVIATION..............................................................................
CHAPTER I INTRODUCTION.......................................................................
1.1. BACKGROUND..................................................................................
1.2. SCOPE OF WORK..............................................................................
1.3. PURPOSE OF APPRENTICESHIP.........................................................
CHAPTER II PROFILE AND SCOPE WORK OF COMPANY............................
2.1. COMPANY PROFILE............................................................................
2.1.1 Company Background.................................................................
2.1.2 Product & Services......................................................................
2.2. SCOPE OF QUALITY MANAGEMENT SYSTEM.....................................
2.2.1. Scope of Certification...............................................................
2.2.2. Permissible Exclusions..............................................................
2.2.3. Quality Policy of PT. SINGATAC BINTAN.....................................
2.2.4. Quality Objective of PT. SINGATC BINTAN.................................
2.3. ORGANISATION CHART OF PT.SINGATAC BINTAN..............................
CHAPTER III IMPLEMENTATION OF APPRENTICESHIP...............................
3.1. INTRODUCTION.................................................................................
3.2. PROCEDURE WORK OF QC................................................................
3.2.1. Receipt of Documents...............................................................
3.2.2. Customer Requirements...........................................................
3.2.3. QC Roles and Responsibilities...................................................
3.2.4. QC Inspection of Work and Records..........................................
3.2.4.1 Inspection and Test Plan........................................................
3.2.4.2 Welding Procedure Specification (WPS).................................
3.3. PRACTICAL WORK.............................................................................
3
3.3.1. Design......................................................................................
3.3.2. Procurement.............................................................................
3.3.3. Incoming Material Inspection....................................................
3.3.4. Fit-Up Inspection.......................................................................
3.3.5. Welding Process........................................................................
3.3.6. Welding Inspection...................................................................
3.3.7. Material Traceability.................................................................
3.3.8. NDT (Non Destructive Testing) Inspection................................
3.3.8.1........................................................................Penetrant Testing
74
3.3.8.2............................................................Magnetic Particle Testing
78
3.3.8.3.......................................................................Ultrasonic Testing
80
3.3.8.4..................................................................Radiographic Testing
82
3.3.9. Hydrostatic Test........................................................................
3.3.10. Final Dimension Inspection.......................................................
3.3.11. Painting Process........................................................................
3.3.11.1.....................................................................................General
85
3.3.11.2.......................................................Method of Painting Process
88
3.3.11.3.....................................................................Spray Application
92
3.3.11.4........................Repair of Damage, Welds and Defective Areas
92
3.3.12. Painting Inspection...................................................................
3.3.13. Non-Conforming (NC) Product Control......................................
3.3.13.1.........................................Non-conforming Purchased Product
94
3.3.13.2.........Non-Conforming Product During In-Process and Prior to
Shipment...........................................................................................
3.3.13.3....................Non-Conforming Product Detected after Delivery
96
4
3.3.13.4.....................................................................................Training
96
3.3.13.5...............................................................Internal Quality Audit
100
3.3.14. Customer Satisfaction............................................................104
3.3.15. Quality Records.......................................................................104
3.3.16. Manufacturer Data Book/ Manufacturer Data Report
(MDB/MDR).........................................................................................105
APPENDIX................................................................................................107
REFERENCE.............................................................................................151
LIST OF FIGURES
Figures.1 Logo of PT. Singatac Bintan..................................................................12
5
Figures.2Management System Certificate of PT.Singatac Bintan....................15
Figures.3 Sample of WPS........................................................................................53
Figures.4Pipe............................................................................................................ 55
Figures.5Plate........................................................................................................... 55
Figures.6Flat Bar...................................................................................................... 56
Figures.7Round Bar................................................................................................. 56
Figures.8Square Bar................................................................................................ 56
Figures.9Hollow........................................................................................................ 57
Figures.10Bulb Plate............................................................................................... 57
Figures.11Chanel..................................................................................................... 57
Figures.12Angle Bar................................................................................................ 58
Figures.13H-Beem.................................................................................................... 58
Figures.14I-Beem..................................................................................................... 58
Figures.15 Fitting..................................................................................................... 59
Figures.16Fit-up Inspection With Client...............................................................60
Figures.17Equiment of SMAW Process.................................................................63
Figures.18Electrode Rutile Flux.............................................................................64
Figures.19Electrode Basic Flux..............................................................................65
Figures.20Electrode CelluloseFlux........................................................................65
Figures.21Oven ,Qiuver of Electrode and Thermometer...................................66
Figures.22PPE of Welder......................................................................................... 68
Figures.23Equiment of SAW Process....................................................................69
Figures.24Fused Flux.............................................................................................. 70
Figures.25Agglomersted Flux................................................................................71
Figures.26Flux Oven................................................................................................ 71
Figures.27SAW Process........................................................................................... 72
Figures.28Liquid of Penetrant Testing.................................................................75
Figures.29Apply Penetrant by NDT Inspector.....................................................76
Figures.30Clean off penetrant by NDT Inspector................................................76
Figures.31Apply developer liquid and result of penterant testing by NDT
Inspector.................................................................................................................... 77
Figures.32Liquid of MPI Test ( White Contrast and Magnetic Ink )..................78
Figures.33 Yoke........................................................................................................ 78
Figures.34Burmah Castrol......................................................................................79
Figures.35MPI by NDT Man.....................................................................................79
Figures.36Equipment of UT....................................................................................81
Figures.37Training to use UT Equipment on Construction................................82
Figures.38Manufacturer Data Report.................................................................106
LIST OF TABLE
Table. 1Chart Organization of PT. Singatac Bintan.............................................18
6
TABLE OF APPENDIX
Appendix. 1 Sample of Inspection and Test Plan..............................................108
Appendix. 2Sample of Material Mill Certificate.................................................139
Appendix. 3 Sample of Material Verification and Inspection Report.............140
Appendix. 4Sample of Fit-Up Inspection Report...............................................141
Appendix. 5Sample of Welding Visual Inspection Report................................142
Appendix. 6Sample of Material Traceabilty Report..........................................143
Appendix. 7Sample of Ultrasonic Testing Report..............................................144
Appendix. 8Sample of MDR Index.......................................................................145
7
LIST OF ABBREVIATION
Abbreviatio
Description
n
PTSB : PT. Singatac Bintan
International Organization for
ISO :
Standardization
QMS : Quality Management System
AWS : American Welding Society
QC : Quality Control
HSE : Health, Safety and Environmental
ITP : Inspection and Test Plan
MDR : Manufacturer Data Report
NDT : Non Destructive Test
PQR : Procedure Qualification Record
WPS : Welding Procedure Specification
QCP : Quality Control Plan
QCR : Quality Control Requirements
H : Hold point
M : Monitoring Point
W : Witness Point
R : Review Point
A : Approval
WQTR : Welder Qualification Test Record
TQ : Technical Queries
MVIR : Material Verification and Inspection Report
MMA : Manual Metal Arc
SMAW : Shield Metal Arc Weld
MIG/MAG : Metal Inert Gas /Metal Active Gas
GMAW : Gas Metal Arc Welding
SAW : Submerged Arc Welding
ESW : Electro-slag Welding
TIG/TAG : Tungsten Inert Gas/ Tungsten Active Gas
8
GTAW : Gas Tungsten Arc Weld
AC : Alternative Current
DC : Direct Current
OCV : Open Circuit Volt
NC : Non-Conforming
MOM : Ministry of Manpower
PPE : Personal Protection Equipment
WSH : Workplace Safety and Health
9
CHAPTER I
INTRODUCTION
1.1. BACKGROUND
Ocean engineering is a relatively young, extremely varied and
remarkably exciting field of engineering. Oceans truly are the last frontiers
remaining on earth, and it is up to us as engineers to find ways to identify,
investigate and utilize ocean and coastal resources while at the same time
protecting them from the destructive effects of human activities.
While engineering has been around for hundreds of years, the term
"ocean engineering" has been in existence for only about 50 years.
However, there are certainly a myriad of engineering problems related to
our oceans that have existed for quite some time, most of which still need
attention! And since more than two-thirds of the earth is covered by
water, and more than 98% of the biological living space exists in the
oceans, wouldn't it make sense if at least two-thirds of engineers were
ocean engineers? We all know that this is not the case, and those who
choose ocean engineering have quite a collection of problems to solve.
Ocean engineering is a field of engineering that has many opportunities
within it to make an impact!
Therefore in this internship I wanted to deepen my knowledge about
the construction of marine structures in order to increase my knowledge
of the maritime industry and construction in the factory
1.2. SCOPE OF WORK

Some of the activity is carried out by author during follow
apprenticehip in PT.SINGATAC BINTAN are as follows:
1. Knowing the production process from start to finish offshore building
handed over to the owner
2. Reading a variety of images and visualizations associated with
construction of offshore building.
10
3. Obtain knowledge of the various inspections carried out such
inspections of materials, fit-up inspection, welding inspection and
etc.
4. Material Ceritification.
5. Knowing standard of safety in a company.
1.3. PURPOSE OF APPRENTICESHIP

1. Complementing the knowledge that I got in college and apply it on
the real work
2. Knowing the real condition of the inspection process an offshore
construction and knows all safety rules
3. Obtain a valuable experience and meet with surveyors competent to
give a lot of knowledge on me
4. Opening insight into the world of oil and gas and the area of work
that will be experienced after graduation.
5. Meet and completed courses at the Department of Job FTUH ocean
engineering in accordance with the applicable curriculum to
graduate as a scholar of Naval Architecture.
11
CHAPTER II
PROFILE AND SCOPE WORK
OF COMPANY
2.1. COMPANY PROFILE
2.1.1 Company Background
SINGATAC ENGINEERING PTE LTD was incorporated in Singapore in

March 1997. The Company specializes in Fabrication & Installation of Steel
& Piping Structures for Marine Engineering. Singatac is the registered
residential contractor for major shipyards in Singapore. Beside shipyards,
the Company services reputable ship owners and operators directly in
meeting their maintenance & emergency works. Singatac operates a
factory in Singapore fully equipped with gantry & overhead cranes, heavy
metal working equipments such as hydraulic press, hydraulic plate rolling,
lathes, boring/drilling machines and a complete range of welding & gas-
cutting equipments. Highly skilled and experienced workforce consisting
of about 200 Managers, Engineers, Supervisors & Workers are ready to
deliver high quality and competitive service to customers. Singatac has
established a new large scale production base in the Lobam, Bintan in the
Riau Province of Indonesia under PT Singatac Bintan. The production base
is located within the Bintan Industrial Estate, a designated Free Trade
Zone. Company Logo of PT. SIngatac Bintan can be seen in figure below.
Figures.1 Logo of PT. Singatac Bintan
12
2.1.2 Product & Services
Design, Fabrication & Supply of Structural Steel and Process Piping

(steel and stainless steel) including installation of machinery for
Marine, Industrial, Construction and Offshore Engineering uses
Metal Machining Shop for all kinds of unique, customized needs
Horizontal boring, milling, slotting, shaping, drilling and honing.
Emergency/Afloat Repairs of ships at Anchorage and on Voyage
Engine overhauling, repairs, mechanical work for all types of marine
and industrial purposes. Overhauling and repair of diesel marine and
industrial engines, gearboxes, pumps, winches, air compressors and
hydraulic assembly.
Metal fabrication, piping works and machine modifications in
accordance to customers design and specifications.
Desain, fabrikasi dan penyuplai struktur baja dan proses piping
( Baja dan Baja ringan) termasuk pemasangan sistem mesin-mesin,
industri, konstruksi bangungan lepas pantai
Tempat pembuat logam untuk segala macam jenis, yang dipakai
khusus, shaping, drilling
Perbaikan daruraat/perbaikan apung pada tempat labuh dan
pelayaran.
Pemeriksaan mesin, perbaikan, pekerjaan mesin konstrksi laut dan
industri yang dmaksud. Pemeriksaan dan perbaikan mesin diesel
bangunan laut dan mesin industri, gearbox, mesin pompa, mesin
derek, mesin udara dan perakitan hidaulik.
Fabrikasi baja, pekerjaan pipadan modifikasi mesin sesuai dengan
desain dan spesifikasi pemesan.
2.2. SCOPE OF QUALITY MANAGEMENT SYSTEM

The scope of our Quality Management System is to address the
requirements specified in the International Standard ISO 9001:2008. It is
a centralized one and is applicable to Singatac Engineering, Singapore and
PT Singatac Bintan, Indonesia.
Ruang lingkup dari sistem manajemen kualitas PT. Singatac telah di
atur dalam persyaratan yang di ttapkan dalam standar inter nasional ISO
13
9001:2008. Itu adalah sebuah keputusan dan diterapkan untuk PT.
Singatac Bintan Indonesia.
2.2.1. Scope of Certification

This section addresses the requirements of the Standard ISO
9001:2008 Sections 1.2 and 4.2.2.
The intended scope of certification for SINGATAC ENGINEERING PTE
LTD (Singatac) is described as follows:
Design, Engineering, Fabrication & Assembly of Steel
Structures &Equipment for Marine and Offshore
Industries.
Provision of Repair, Maintenance & Upgrading Services for
Ocean-Going Vessels.
Management system certificate of PT. SIngatac Bintan that has been

found comform to the quality management system standard by ISO
9001:2008 will be atched in below as follows:
14
Figures.2Management System Certificate of PT.Singatac Bintan
15
2.2.2. Permissible Exclusions
There is no exclusion identified from requirements of Standard ISO
9001:2008.All clauses of the standard are required to be followed in the
quality management system of Singatac.
2.2.3. Quality Policy of PT. SINGATAC BINTAN

The following page documents Singatacs Quality Policy,which
defines our commitment to quality and directs conformance to Singatacs
QMS.
Quality Policy
Singatac is committed to ensure that the companys Quality Policy
Statement meets the requirements of the Quality Management System
Standard ISO 9001:2008.
PT. Singatac Bintan berkomitmen untuk memastikan bahwa pernyataan
kebijakan kualitas perusahaan berrelasi dengan persyaratan pada Quality
Management System Standar ISO 9001:2008.
Singatacs Quality Policy is:
1.To conform to our products and services specifications;
2.To comply with the applicable regulatory and statutory
requirements;
3.To continually achieve high degree of customer satisfaction by
understanding and meeting our customer requirements and
their needs;
4.To develop strong and lasting relationships with our customers
and suppliers within the framework of clear contractual
relationships; and
5.To continually improve the effectiveness of our quality
management system.
16
Approved by:
Singatac top management shall ensure that the quality policy is

communicated and understood at appropriate levels in the organization
through staff briefings, training and other publications (e.g., notice board).
Our Policy Statements shall be reviewed at appropriate intervals to ensure
its suitability and adequacy.
Kebijakan kualiats PT. Singatac Bintan antara lain sebagi berikut
1. Untuk mencocokan produk perusahaan dan spesifikasi pelayanan
2. Untuk memenuhi regulasi yang dipakkai dan persyaratan
perundang-undangan.
3. Untuk melanjutkan penccapaian kepuasan yang tinggi kepada
pemesan susuai dengan persyratan pemesan dan kebuthan
mereka.
4. Untuk membangun hubungan yang kuat dan baik dengan
pemesan dan penyuplai dalam dengan struktur hubungan
kontrak yang jelas.
5. Untuk melanjutkan peningkatan efektifita dari quality
management system
2.2.4. Quality Objective of PT. SINGATC BINTAN
QUALITY OBJECTIVES
a) Operation Department
i. Pass rate for random NDT tests for all the shipyard, anchorage
repair and voyage repair projects min. 90%
ii. Pass rate for random NDT tests for the workshop projects - min
95%
iii. Fitting defects max. 10%
iv. Welding defects max. 10%
v. Adherence to Master Maintenance Schedule min. 90%
vi. Incidence of equipment breakdown due to unscheduled
maintenance Average 1 case per month
b) Purchasing Department
17
i. On-time delivery by vendors min. 95% of purchase orders
ii. Failure by vendors to comply with specification of purchase
orders max. 5% of purchase orders
c) Sales & Marketing Department
i. Achievement of minimum 80% Customer Satisfaction.
d) Training Department
i. Meeting yearly Training Plan min. 90% on Certification of Skill.
18
2.3. ORGANISATION CHART OF PT.SINGATAC BINTAN
Table. 1Chart Organization of PT. Singatac Bintan

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Thequality-
relatedresponsibilitiesandauthoritiesofpersonnelaredescribedbelow.
19
ManagingDirector
ManageandsuperviseSingatacs
processesandservicesaswellaslongterm
strategicplanningofcompany.
BoostSingatacsPolicyonqualityrelatedissues.
Reviewqualitypolicy,objectives andsetqualitydirection.
Direct the formulation of operational plans &policies. Set
goals, targets, proceduresandperformance&servicestandards.
ExecuteoperationactivitiesinaccordancewiththeQMSprocedures.
Review Singatacs performance and oversees all the
operational functions in SingatacEngineering
coveringthescopeofsales,fabrication, installation, and
services.
ResponsibleforthepreparationofSalesProposalandfollow-up.
Dealing with customers requirements and resolving
problems. Implement solutionsrelatedto
theproductsandservices.
Director
Overseeandmanagetheday-to-
dayadministrationactivitiesunderthecompany.
Ensure Operational Procedures, Standards and Guidelines are
followed and maintained.Initiateactionto preventoccurrenceof
non-conformityof SINGATACs
qualitymanagementsystemstandards.
IdentifyandrecordanyqualityproblemintheirUnitandundertakeco
rrectiveaction where required.
Controlfurtherprocessing,deliveryand/orinstallationof
nonconforming product/service
untilthedeficienciesorunsatisfactory conditions
havebeencorrected.Verifytheimplementationof
solutions.CarryoutQMS
managementrolesasassignedbytheManagingDirector.
Sourcingofsuppliersandevaluatesuppliersperformance.
Verify Purchase Requirements and instruct sub-ordinates to
20
prepare Purchase Order.ApproveandIssuepurchaseordertosupplier.
Ensurethatstaffaretrainedandareoperationallypreparedtohandlether
elevant SINGATACsprocessesatalltimes.
GeneralManager/YardManager
Execute operation activities in accordancewith theQMS
procedures and requirements.
Dealwithcustomeronresolvingday-to-
dayproductionissues.Ensureallsitesarepracticingwork-
sitesafetyandhousekeepinginstructions.
Projectmanagement.
Involve inreviewing customerrequirements andsupporting
Sales/Marketing Directorinpreparationofquotationandproposal.
AssistantGeneralManager
Execute Operation activities in accordance with the QMS
Procedures and requirements.
AssistandsupporttheGeneralManager/MDonOperationsactivities.
ResponsibleforcompanysOperationsManagement.
Dealwithsubordinateonresolvingday-to-dayoperationsissues.
Ensureallsitesarepracticingwork-
sitesafetyandhousekeepinginstructions.
Providestechnicalexpertiseanddirectionasnecessary.
Arrangeanddeploymanpowerforallprojectsandalsoco-
ordinatewithProject Managers/Engineersondayto-
daymanpowerrequirements.
ServeasProjectManagerforavarietyofspecialprojects;facilitate
project
activitiesandresolveissues;anddevelopandsubmitprojectrepo
rtsto the GeneralManager/MDandtheBoardofDirectors.
Plan, review, and evaluate the work of subordinate
management and professionalstaff.
Select,motivateandevaluatepersonnel;resolvepersonnelconcernsan
dissues andprovidefortrainingandprofessionaldevelopment.
Involvein reviewing customer requirements and supporting
Sales/Marketing Directorinpreparationofquotationandproposal.
Workerswelfare,appraisalandtrainingprogram.
21
SeniorAdministrationManager(PTSB)
Supervise on executingofadministrationactivities inaccordancewith
QMS procedureandrequirement.
Supervise preparationof Purchase Order asrequiredincluding
sourcing of quotation.
Superviseonexecutingofsecurityactivityforwholeareaintheyard.
Monitor and control whole activity related with HR, Logistic
&Warehouse, Security.
Giveadvisetosubordinatesintoimprovetheirdepartmentifneeded.
ProductionManager/AssistantProductionManager
DegreeorDiplomainEngineering
Goodanalyticalcapability&problemsolvingskills.
Effectivecommunication&interpersonalskills(Oral&written).
Haveproductionorprojectmanagementexperience(min.3yrs).
Possessorganizational&leadershipskills.
Havepositiveattitude&abletoworkinateam.
SeniorProductionManager
InadditiontojobandresponsibilityofProductionManager,
Supervise Maintenance department and other yard
management duties assignedbyYardManager.
Performreviewofequipmentfailureincidents.
Manageandcoordinatepreventivemaintenancework.
Performregularanalysisofassetperformancedata.
Verifyeffectivecorrectiveactionshavetakenplace.
Forecasting,budgeting,purchasing,andcostcontrol.
AssistantOperationManager
Degree or Diploma in Mechanical Engineeringwith
Minimum5Yearsof experience&above.
Knowledge of technical drawing, terms, symbols and Ability to
prepare MTO (MaterialTakeOff).
Communicationeffectivelyinwritingandspeaking.
Knowledge of work processes, operational sequences,fitting
and welding standards.
22
Monitor&controlSitesSupervisorsandtheirworkersondaytodayactiviti
es.
DailyprojectprogressmeetingandupdatingtoOperationManager.
CostMonitoring.
Abilitytoprovideeffectivesupervisionbygivingoutclearinstruction.
Managesubordinatesutilizingtheirtalentsandskills.
Abilitytoidentifyproblem,developalternativesolutions.
AbletomaintainthedocumentsaspertheISOneeds.
OperationManager/SeniorOperationManager
InadditiontorequirementsforAssistantOperationManager,
Degree or Diploma inMechanicalEngineering withMinimum 7
Years of experience&above.
ConductdailyprojectprogressmeetingandupdatetoDirector.
Provideongoingtrainings.
Ability to prepare quotations.Ability to negotiate with
customers on pricing matters.
AssistantProjectManager
Degree or Diploma in Mechanical Engineering with Minimum
5 Years of experience&above
Abletoread&understandallfabricationdrawingsofstructural&pielines
AbletopreparetheMTO&weightcalculationforanystructuraldrawings
Effectivecommunication&interpersonalskills(Oral&written)
Familiarwithallstagesofoperationsinexecutionofa fabricationproject
Enoughknowledgeabouttheweldingprocedurespecifications
tocarryoutthe project
Abletoread&explainthetechnicalrequirementsinthedrawingtoth
eproduction foreman&anyothers
Goodanalyticalcapability&problemsolvingskills.Possessorganization
al&leadershipskill.Havepositiveattitude&abletoworkinateam
Abletoplan&controltheoperationinaneffectivemanner
Abletoplan&controlallresourcesinaneffectivemanner
AbletomaintaindocumentsasperISOneeds
ProjectManager
InadditiontominimumrequirementsofAssistantProjectManager,
23
Abletohandlethetendersofvariousfabricationprojects.
SeniorProjectEngineer/ProjectEngineer
Min. Bachelors Degree in Engineering or Diploma with minimum 3

years of experience.
Abletoreadtechnicaldrawings.Understandthetechnicaldetailsrelate
dtothe job.AbletoprepareBillofMaterial.
Able tohandle theworkforce. Conversant in English. Able
tocommunicate effectivelywithOwner.
Determinationofprojectrequirementsandcontractreview.
BOM/ProjectSchedule/ProjectManagement.
PreparationofITP/PreliminaryMDRIndex/DDSR.
Co-ordinatewithdraftsmanforpreparationofshopdrawings.
ArrangeandissueofAFCdrawingforproduction.
Masterdrawinglistcontrol.
Budget/Costcontrol/ProjectCostclosing.
Co-ordination/Interfacewithcustomer.
PreparationofVariationOrder/TechnicalQueries.
LiaisewithQC/Commercial/MarketingPersonnel.
Preparationofquotation/DraftInvoice/Projectfile.
ProductionSuperintendent(PTSB)
MinimumBachelorsDegreeinEngineeringorDiplomawithminimum3yea
rsof experience.
Possess Englishlanguage proficiency, computer literacy, written
andoral
communicationskill,analyticalskill,problemsolvingskillandcustomerf
ocus.
Abletoreadtechnicaldrawings.Understandthetechnicaldetailsrelatedto
the job.AbletoprepareBOM(BillofMaterial).
ReportsdirectlytotheAssistantProductionManager
TakeovernewprojectfromProjectEngineeraftercontractawarded
Prepareand/orverificationofMTO(materialtakeoff)forprocurement.Tore
quest formaterialtopupifdeemnecessary.
Inchargeofprojecttechnicalclarificationwithclientduringfabricationst
age
Toclarifywithclientondetailofvariationorderduringprojectfabrications
tage
24
Toprovide variation order detail information (time, material &cost
impact) to
ProjectEngineerduringprojectfabricationstage
Inchargeofoverallmonitoring&expeditingofprojectdocumentationsub
mission toclient
Toprovideinputofweeklyreport&projectscheduletoPlannerforsubmis
sionto
Clientandinternalcirculation
Incharge of overallmonitoring of project documentation,
document/drawing controlanddistribution.
LiaisewithEngineeringforshopdrawingpreparation&distribution
InchargeofprojectfabricationworkinPTSB,whichincludemanpoweralloc
ation,
projectqualityandprojectprogressuntilcompletionoffabrication
Plan and control of production manhour to achieve target set by
Marketing
DepartmentandManagement
Plan&organiseoutsourcessuchascontractorsoranyotherserviceprovide
rsas requiredforthejob
Plan&controlofequipment,toolsandconsumablesfortheproject
Plan&liasewithQCforallinspectionactivities.
Plan&liasewithMaintenanceorShipwrightteamforallsupportrequirem
ent.
InchargeofloadoutactivityinPTSBincludingplan&workwithengineeringt
o preparetheliftingplan,RiskAssessmentforallliftingworks
Topreparedeliverydocuments,
suchasPackinglistforsubmissiontoProject
Engineer
ToundertakeanyotherassignmentorinhouseprojectasassignedbyPro
duction
Manager
Reviewandevaluateworkersandsubcontractorsperformanceandsubmi
treport tosuperior.
Conductriskassessment.
Trainingofworkers.
QAQC Manager / QAQC Assistant Manager

ReportstotheYardGeneralManager.
25
ResponsibleforQualityControlandAssurancefunctionsofPTSB
Ensures that production work quality is in accordance with
Contractual
RequirementsandRulessetbyRegulatory/CertificationBodies
IdentifiestrainingneedsofQualityAssuranceSectionstaffandwherene
cessary
(forQualityAssurancefunctions),thetrainingneedsofotherstaff.
InsistsqualityawarenessintheSINGATACthroughpromotionalactivitie
s
Investigates into non-compliance of SINGATAC and / or
Customers quality standards
Ensuresproperandup-to-
datedocumentationofqualityrelatedmatters.
Preparesandmaintainsthequalityassuranceprocedures
Investigates non-compliance and takes appropriate
corrective and preventive actions
Welding Engineer
PrepareandconductnewWPS/PQR
ConductWelderQualificationTest,includingendorsementofwel
derscertificates, extensionofvalidity
Conduct welding training for new welders, welding and
technical knowledge, welding consumable and lectures to
all level including sub-con, such as
Supervisor,weldingforeman,etc.
Preparing documents pertaining
toweldingforprojectsubmission,eg. Register
listforWPS/PQR,WQT,etc.
CompilingweldingstatisticandKPIofweldingdefectsandweldersperfor
mance
SurveillanceandVisualInspectionofwelding,analysisoffailureandcorr
ection
Deal withNDTCompany fortheprocedure correctness
ofPT/MT/UT/RT and relatedmatters
AnyothermattersdelegatedbyQA/QCMgr.
26
Quality Control Engineer

Education:B.EholderinMechanical,ProductionorManufacturingEngin
eering.
Min of 4 years experience worked as an inspector on structural
&piping fabrication,welding,inspection&testing.
Coordinateandcommunicatewithcustomer&thirdpartysurveyors.
PreparePQR&WPSbasedoncode.
Prepare&verifythequalityreports.ProficientinMSOfficesuite
KnowledgeinASNT-
LevelIIinLiquidPenetrant,MagneticParticles,Ultrasonic
andRadiography.
Familiarwithcodesofstandardandclassificationbodyrequirements.
TopossessweldinginspectorcertificationAWS/CSWIP-3.1.
QC Inspector/ QC Coordinator/ QC Assistant

Education:DiplomaholderinMechanical,ProductionorManufacturingE
ngineering.Minimumof2yearsexperienceworked.
Abletoreadthedrawings.ToInspect/verifymanufacturedpartsandpur
chased itemsperproductrequirements.

Performingqualitycheckssuchasdimensional,material,Fitup,visual,N
DT
Preparequalityreports.HaveknowledgeofMSOffice.
HSEManager/Superintendent/SafetyOfficer

MinimumrequiredDegreeinEngineeringofanydisciplineorequivalent.
Min 5 years of relevant working experience in Oil &Gas, Marine
Industries, PetrochemicalPlants,and/orShipyards.
Preferablycertifiedsafetyofficer.
27

WellversedwithHSErulesandregulationsincludingstatutoryregulatio
ns.
Possess English language proficiency, computer literacy,
written and oral
communicationskill,analyticalskills,problemsolvingskillsandcustom
erfocus.

ImplementeffectivelytheHSEManagementsystemtoachieveanaccid
entfree workingenvironment
EnsurecomplianceofstatutoryHSErulesandregulations
Conductsafetybriefing,auditandenforcesafetyrulesandregulations
Conductaccidentreporting,investigationandanalysis
Site assessment andinspectiontoensure conformance
withstatutory and companyregulations
Assist informulating and administering comprehensive accident
prevention program.
Contribute towards improvement in HSE Management
system through
campaigns,conductoftraininganddevelopmentofnewsystems
Assist in updating management/employees/contractors on all
HSE matters includinganynewlegislation

Assistintheinvestigationofallreportedincidentsandoccupationaldisea
ses

LiaisewithexternalpartiesincludingauthoritiesandcustomersonHSEm
atters.
TrainingofHSEinspectors.
EngineeringManager

28
ResponsibleforallpersonnelintheEngineeringdepartmentincludingh
iringand coordinatingwithotherdepartmentsandtheclient.
Overallplanningandsupervisingthedesignanddraftingworks
LiaisonwithProjectEngineer/Manager
AssigningworktoDesignerandDraftsman
Responsible for General Arrangement/ PLOT plans, Plant

Design andPresentationandcompletenessof finisheddrawings

CoordinatesMechanical,StructuralandElectrical&InstrumentationD
etailsfrom othergroups
CheckingandMarkingVendorsdrawing
Obtaininginformationformembersofthegroup
Establishing the number of drawings required for each job/ project
(drawing controlandregister)
Assigningtitlesforeachdrawingandmaintainingup-to-
datedrawingcontrolor
registerofdrawings,charts,graphsandsketchesforeachcurrentprojec
t.

Establishingadesigngroupfilingsystemforallincomingandoutgoingpa
perwork
Keepingacurrentman-hourscheduleandrecordofman-hours
ToprovideB.O.Mforallpipingmaterials.
PlanningManager

ToManageanddevelopoperatingplanningdepartmentactivityinrelati
ontoall aspectbothshortandlongtermto
ensurethatappropriateplanningconsentsare
obtained,costeffectively;andmaximumcontributionisachieved.
29

Managedailyandlongrangeplanning/schedulingWorkwithmanagem
ent in schedulingofcomponentswithvendorsandsuppliers
Ensurethatallcost,planninganddocument
controlreportsareprepared and
issuedinaccordancewiththeProjectCoordinationProcedure.

LiaisewithotherDepartmentsatallmeetingsrelevanttoprojectoperati
onsand
ensurethatthetimeandcostplansareupdatedtoreflectlatestinformati
on.
To supervise theimplemented projectplanningand scheduling tools
acrossmultipleprojectsandprogrammes(essential)

Tosuperviseandmaintaintheprojectplanandmasterschedulebasedo
ninput from projecttechnical/commercialfunctionsandcontractors

ManageandadvisethePlanneronprojectperformanceimprovementifn
eeded.
Planner

Todevelopandmaintaintheassignedprojectplanandmasterschedule
based
oninputfromprojecttechnical/commercialfunctionsandcontractors

Managedailyandlongrangeplanning/schedulingWorkwithmanagem
ent in schedulingofcomponentswithvendorsandsuppliers
Manage daily and long range scheduling while maintaining
30
productivity cost controls

Maintainproductionscheduleandassistinimprovingtheplanningproce
ss
Maintainscheduleswithsummaryreportsimmediatelyavailable.
Material Controller
Bewellorganizedandabletoprioritizeandmultitask
EnsureallmaterialsarereceivedandverifiedforagainstDeliveryOrder
SuperviseMaterialCoordinatorsandcoordinatetheirdailyactivities
Toaccuratelycontrolthestocksofrawmaterial
Tomanagetherawmaterialoffloadingprocess
InteractwiththePlannertounderstandmaterialdemandandforecast
PerformotherdutiesasrequiredbyManager
Designer/ CADEngineer

Producingstudiesandlayoutsofequipmentandpipingwhichmustbeec
onomic, safeoperableandeasilymaintained
Makinganynecessaryadditionalcalculationsforthedesign
Supervisingdraftsman
Checker

CheckingDesignersanddraftmansdesignanddetailsfordimensional
accuracy
andconformitywithspecification,P&IDs,vendorsdrawingsetc.
If agree with the Designer and/or Project Manager/Engineer,
may make improvementsandalterationstothedesign
Draftsman
31
Education:Diploma/B.E.
Minimum2yearsofexperienceindesign&drafting.
Abilitytoread&understandthedrawings.
AbilitytogenerateBillofMaterial(BOM).
AbilitytodoMaterialTakeOff(MTO)&MaterialPlanning.
Abilitytocreatedetailedproductiondrawingsforshopmanufacturing.
Abilitytocreatepreliminarydrawingsforquotationpurpose.
Producing detailed drawings from designers or project
Manager/Engineer sketches
Secondarydesignwork
Acquainting himself with the records, files, information sheets and
company practicesrelatingtothejob/project.
Shipwright Superintendent
DegreeinEngineeringorDiplomawithminimum3yearsofexperience.

PossessEnglishlanguageproficiency,computerliteracy,writte
nandoral
communicationskill,analyticalskillsandproblemsolvingskills.
ReportsdirectlytotheProductionManager
Managethelifting,quayside,yarddevelopment,blasting/paintingand
scaffolding operation

LiaisewithProductionorMaintenanceteamtosupportallprod
uctionor maintenanceworks.
Inchargeofonsitescrap&offcutmaterialmanagement

Plan&organisedailymanpowerandresourcesforthelifting,blasting
32
/painting, stagingandmooring(ifrequired)operation.

Inchargeofdistributionandcontrolofliftingpadeyesforanyliftingoperat
ion

Plan&organiseoutsourcessuchascontractorsoranyotherserviceprov
idersas requiredforthejob
Plan&manageanyyarddevelopmentormiscellaneouswork

Reviewandevaluatecontractorsperformanceandsubmitreporttosup
erior.
Trainingofworkers
Maintenance Superintendent / Maintenance Engineer (PTSB)

DegreeinMechanical,ElectricalorBuildingServicesEngineering.
Min5yearsofrelevantworkingexperience.
Possess English language proficiency, computer literacy,
written and oral communicationskill,
analyticalskillsandproblemsolvingskills..
ReportsdirectlytotheProductionManager
Manageallmaintenanceoftheyard'sequipmentandfacilities
Performreviewofequipmentfailureincidents.
Manageandcoordinatepreventivemaintenancework.
Performregularanalysisofassetperformancedata
Verifyeffectivecorrectiveactionshavetakenplace.
Forecasting,budgeting,purchasing,andcostcontrol
Reviewandevaluatecontractorsperformanceandsubmitreporttosupe
rior.
Trainingofmaintenancetechnicians
33
Maintenance Supervisor
Responsible
forRegularMaintenance,BreakdownMaintenanceandRepairof
equipments,toolsandtransportvehicles.
Co-ordinatewithexternalpartiesinrepair/maintenanceactivities.
Maintainmaintenancescheduleandrecords.
Keeptrackofequipment/toolsmovement.
Createpurchasingrequisition,maintenancerequisition.
KeeptrackofequipmentP.E.check,Calibrationofinstruments,
certificationof firefightingequipments.
ControlofLOTOtagsystemwhichisusedforrepairofmachineriesandel
ectrical works.

ReporttoIDAC(IndependentDamageAssessmentCentre)incaseoftra
nsport accident.
Conduct training on calibration/servicing/testing and Regular
Maintenance checklists.
Maintenance Technician/ Assistant

Shouldabletoidentifythemechanicaltools.
Shouldableto fillthechecklistformechanicalorientedequipments.

Shouldabletounderstandtheinstructionfrommechanicalfitterstodoth
ework.

Shouldabletocomplythesafetyrequirementswhenassemblinganddis
mantling theequipments.
Shouldabletoidentifythenameofsparepartsofequipments.
34
Shouldabletousethecorrecttoolsaccordingtoworkingprocedure.
Electrician
Shouldabletounderstandthebasictheoryofelectricalknowledge.
Should able to understand the basic knowledge of electrical
tools and accessories.
Should able to do minor electrical works like wiring connection,
Power point arrangement.
Shouldabletoidentifytheminorfaultyofelectricalequipments.
ShouldabletodotheconnectionforITorientedhardware.
Shouldabletostudytheelectricallinedrawings.
Shouldableto fillthechecklistforelectricalorientedequipments.
ShouldabletounderstandthemaintenanceschedulingchartforEquipm
ents.
Shouldabletowritetheservicereportforservicedequipments.
Electrician Charge man

Satisfyallcriteriaforelectrician.
Carryoutinsulation&continuitytest.
Cablerouteplanningonsite.
Organize&superviseallelectricalactivitiesatsite.
Abletounderstandroutinglayoutandterminationdrawing.
Assistant Manager (Logistics)

Responsibleforimport/exportshipment,purchaser,warehouse
andmarine operations.

CoordinationamongOperation,Project,SupplierandClienton
logistics arrangement.
35
Ensuresimport/exportdocumentationsaccordingtotheIndonesi
ancustoms requirementandcustomsaudit.
InventorycontrolfortheClientsmaterialstorageattheyard.
Carryoutvendorassessmentsandmaintainapprovedvendorlist.
Warehouseinventorycontrol.
ManagingShippingagencyandvesselin/out.

ResponsibleforShipsupplies,crewchangesandaccommodationarran
gement.

PerformotherdutiesassignedbytheOperationManager/SeniorOperati
onManagerthatrequired.
Technical Office / Assistant Technical Officer / Admin. Asst

(Purchasing)
ProcessPurchaseRequisition.

PreparePurchaseOrder,issuepurchaseordertosupplierandmonitord
elivery status.

AssistmanagementinassessingvendorsandmaintainApprovedVendo
rList.
Vendorcataloguesfiling.
Logistics Assistant
PreparedocumentsneededforLogistic/shipment
Coordinate with Project Manager, Purchaser, Customer,
Supplierand other
internalandexternalpartiesonLogistic/shipmentarrangements.
Stores Incharge
36
Responsible for day to day operation of stores activities, material
issue and receiving(mainstoreandallsitestores).
Control the maintenance of tools (especially hot work tools),
inventory / consumable check &issue, check onallequipments
issue out and incoming status.
Planandorganizethestoremanpowerfortheirdailyworks.
Helptoresolvestoreandotherdepartmentdiscrepancies.
Follow the QMS and SHMS requirement. Execute operation
activities in accordancewiththeQMSproceduresandrequirements.
ManagethesparesandmaterialsintheStores.
Carry out warehouse safety measures and ensure workers are
following the safetymeasures.
Supervisethestoremanonissuingandreceivinginspectionactivities.

Keepandmaintainequipmentmaintenancerecords.Anyotherdutiesas
signed.
Store Man
Keeptrackofmovementofitemsstoredinthestore.
Updatestockstatus.
CreatePurchaseRequisitionwhenrequired.
MonitordeliverystatusofPurchaseOrder.
Senior Marketing Manager/ Marketing Manager / Asst. Marketing

Manager
Degree in Marketing or other related fields with 3-5 years
professional experience.

Goodcommunicationandpresentationskills.Abletoliaisewithvendors
,dealers andretailers.

37
Dealingwithcustomersrequirementandresolvingproblems.Handlec
ustomer complaints.
Responsibleforthepreparationofsalesproposalandfollow-up.
Toproduceanannualmarketingplanandreportstomanagement
Conductmarketingvisit.
Tomanagethemarketingdepartment
budget,deliveryofallmarketingactivity withinagreed budget
Preparethemonthlysalesperformanceandreporttomanagement.
Marketing Executive
DiplomaholderinMarketingorotherrelatedfields

Atleast2yearsofexperienceinthemarinefield.ProficiencyinMS
Office applications. Meticulous,responsibleandabletomulti-
task.
Conductmarketingvisit.Updatecustomerdatabase.
FamiliarinhandlingProjectSalesandCostEstimation.
ReporttoManageronissuesfortheprogressoftheproject.Dealin
gwith customersrequirementandresolvingproblems.

Monitoringofcostanddeliverystatusofitemsandworkinprogress.Mo
nitoring
paymentprogressandensuringtimelypaymentfromcustomers

ConducttheCustomerSatisfactionSurvey.Marketsurvey,intelligenc
estudyand
competitoranalysis.Executeoperationactivitiesinaccordancewithth
eQMS proceduresandrequirements.
AssistMarketingManagerinexecutingmarketingplans,activitiesandstr
ategies.Performotherdutiesthatarerequiredandasassigned.
38
Administrative Manager/ HR Manager

ExecuteadministrationactivitiesinaccordancewiththeQMSprocedur
esand requirements.
Reports to the Director and provides administrative support to the
various divisions.
Administerthecompanystrainingplanandactivities
To provide accuratefinancialand accounting information to the
MD and
DepartmentManagers.
Administrative Assistant
ProvidedataanddocumentcontroltotheQualityManagementSystem.
Execute operation and administration activities in accordance

with the QMSproceduresandrequirements.
Filingqualityrecords.Handlepersonnelrelatedmattersandtraiingrecor
ds.
IT Executive
Professional Certificate/NiTEC, Diploma,
Advanced/Higher/Graduate Diploma,
Bachelor'sDegree,PostGraduateDiplomaor ProfessionalDegreein
Engineering(Computer/Telecommunication),
ComputerScience/Informationor equivalent

OneyearofworkingexperienceintherelatedfieldspecializinginIT/Com
puter-
Network/System/DatabaseAdminorequivalent.JobroleisSystemAd
ministrator orequivalent

39
ProvisionofITsupporttothelocalandremoteendusersrelatingtocompu
ter hardwareandsoftwareissue.
Administerdomainuseraccountsandgroupmemberships
Managethesharedfolderspermission.
Installandmaintainnetworkprinters/copiers.

EnsureWindowsclientsareinstalledwiththelatestMicrosoftpatchesan
dlatestAntivirusprogramandvirusdefinition.
Administerdatabackupandrestoration
Maintaincomputerhardwareandsoftwareinventory
Liaisewithvendorforhardwareandsoftwareprocurement
MaintainITSystempoliciesandprocedures
ProvideITtrainingtoendusers
Production Supervisor
DiplomainEngineering.
Abletoreadtechnicaldrawings.
Understandthetechnicaldetailsrelatedtothejob.
Abletohandletheworkforce.
ConversantinEnglish.
Shouldbeabletoplantheworkproperly.
Effectiveuseofman-powerandrawmaterial.
Supervisor
DiplomainEngineering.
Abletoreadtechnicaldrawings.
Abletohandletheworkforce.
ConversantinEnglish.
Shouldbeabletoplantheworkproperly.
Supervisor Assistant
40
Diploma Qualification with Minimum 3 Years of experience with
Engineering
works.BasiccommunicationknowledgeinEnglishwritingandspeakin
g.

Abletoreadbasictechnicaldrawing&workscopeandbasedonthattopr
epare materials.
Knowledge of work processes, production schedule, fitting
and welding
standards.MonitorProductionandfeedbacktohissuperioraboutworke
rsonday todayactivities.

ShouldhavecompletedSSSCsuccessfully.Abletofollow&adapttheper
mitto worksystem.Ableto
organize,controleffectively&handlesafelyaworkteamto
completetheworkintime.
WelderGrade1
Education:Primary6orequivalent.UnderstandsimpleEnglish.
Qualified3Gwelder(referto
WeldingCertificatesFilefordetailspecifications).

Abilitytoperformgrindingjobaswhenrequired.Abilitytooperatepower
tools suchasgrinders,CuttingTorch,chippinghammer,drills,etc.
Welder Grade 2
InadditiontominimumrequirementsofWelderGrade1,
Qualified4Gwelder(SMAWismust&FCAWatleast3Gposition).
Abletounderstandtheweldingsymbols.
Welder Grade 3
41
Qualified4Gwelder(SMAW&FCAW).
Qualified6GWelderor6GRwelder.

Qualifiedforspecialprocesswouldbeadditional(likeGMAW,GTAW&SA
W).
Abletocontrolawelder&grindersofasmallgroup(Upto10pax).
Minimumthreeyearsofweldingexperience.Abletoreadtheweldingsy
mbolfrom drawing.
Welder Grade 4
Minimumfiveyearsofweldingexperience,
Couldrunaprojectbyunderstandingallrequirementsofweldingasperdr
awing.
FitterGrade1
Education:MinimumPrimary6orequivalent.
Abilitytoperformvariouscuttingrequirementi.e.cutstraightline,cutcu
rveand
bevelcurvaturecutting,freehandbevelcutting&edgepreparation.
Abilitytoperformgrindingjobaswhenrequired.
Abilitytoperformoutfittingwork.UnderstandsimpleEnglish.
Twoyearsof fittingexperience.
Fitter Grade2
InadditiontominimumrequirementsofFitterGrade1,
Abilitytoperformgrindingjobaswhenrequired.
Abilitytomarktheplatesforthesimplestructure.
Fitter Grade3
42
Abilitytoreadthedrawingforthefitting&weldingrequirements.
Abilitytofitthepipestructures&
fitting.Abilitytohandletheprojectindividually
withaminimumworkgroupof(upto10pax).
Fitter Grade4

Abilitytohandletheprojectindividuallywithaminimumworkgroupof(u
pto20 persons).

Abilitytoperformthespecialtestlikefunctional,pressure,assembly&m
atting testasrequiredforthestructure.
Abilitytohandletheinspectionwiththethirdpartyinspectors.
Abilitytosupervisemultiracialworkforce.
Signalman& Rigger
Education:Primary6orequivalent.

AbilitytooperateGantrycraneandhavetheKnowledgeofRiggerSignals
andMaterialMovementBalancing.
HemusthavetheSignal&RiggerCertificate.
He must have the Knowledge of General Safety and Lifting
method Safety Requirements.UnderstandsimpleEnglish.
TwoorThreeyearsofworkingexperienceinrelatedfield.
Blaster
AbilitytooperatetheBlastingEquipments.
HemusthavetheBlastingCourseCompletionCertificateorExperience.
43

HemusthavetheKnowledgeofGeneralSafetyandBlastingmethodSafe
tyRequirements.
UnderstandsimpleEnglish.
ThreeorFouryearsofworkingexperienceinrelatedfield.
Painter
Education:Primary6orequivalent.UnderstandsimpleEnglish.

AbilitytooperatetheSprayPaintingEquipmentsandmusthavetheKno
wledge ofCheckingtheMicronsLevelintheJob.
HemusthavethePaintingCourseCompletionCertificateorExperience.
Hemust havetheKnowledge ofGeneral SafetyandPaintingmethod
SafetyRequirements.
ThreeorFouryearsofworkingexperienceinRelatedfield.
Machinist
Education:SecondaryLevelorITIorequivalent
Ability to operate varioustypes of Machines Such as Lathe,
Drilling, MillingMachineetc.
AbilitytoReadtheMachine Drawings andhavetheKnowledge
ofMachiningTolerances.

MusthavetheKnowledgeofVariousMachiningProcessandMachiningTo
ols.
HemusthavetheKnowledgeofGeneralSafetyRequirements.
ThreeorFouryearsofworkingexperienceinrelatedfield.
Time Keeper
Education:MinimumSecondary8orequivalent.UnderstandsimpleEngli
44
sh.

Identificationbadgeissueandkeeprecord.Timesheetpreparationand
maintain record.Notificationformspreparationandmaintainrecord.

Thumbscandatasmailingtomainoffice,Projectnumberupdateinthu
mbscan file.
Documentscollectionandsending.Planningandarrangement
forTransportof workers.
Mouldloft
Education:MinimumSecondary8orequivalent.
Understandingoftechnicaldrawinganditsterms.
Knowledgeaboutshipstructures,partsetc.
Knowledgeaboutbasicfittingstandards.
Knowledgeaboutshiplinesplantable.
Abilitytoperformmarking ofstructures bytakingmeasurements
insiteorby readingengineeringdrawing.
Fairer
Understandingofoutfittingdrawing.

Knowledgeonthematerialgrade/commonconsumablesusedforfabric
ation.
KnowledgeaboutSafeworkmethod/safetyawarenesswhiledoingjob.
Qualifiedfittergrade2.
Knowledgeofthermalaffectconsequencesandmaterialproperties.
Abilitytocarryoutfairingthestructuretorequiredform.
45
HaveknowledgeofAutoCAD(2D,3D)&MSOffice.
ShouldhaveBasicknowledgeofDesignAspects.
Stager

Education:Primary6orequivalentwithoneorTwoyearsofworkingexpe
rience inRelatedfield.
Ability to understand about the work requirement and location
with simpleEnglish.

EveryStagermustneedbasicScaffoldingerecterCertificateorPasstoc
onstruct atower&hangingframescaffoldwithoutriggers.
He must need the Knowledge of General Safety &Hazard
analysis Requirements.
General Worker
Ability to operate power tools such as grinding Machine and Baby
GrindingMachine.
HemusthavetheKnowledgeofGeneralSafetyRequirements.
OneorTwoyearsofworkingexperienceinrelatedfield.
Staging Supervisor
Understanding of work requirement and based on that able to
teach/ guide stagers.
Complete skill about all types of scaffold and material preparation

based on
erectionsize.Knowledgeabouttheerect&Dismantleprocedure/dimen
sionas perMOMregulation.
46
Mustcomplete(MMSC)marinemetalscaffoldingc
ourse.

PersonabletoErect/Dismantlestaging&estimationknowledge,alsoco
mplete
workintime.Alwaysknowaboutthebasicsafetyrequirement,emptyta
nkentry,
gasfreepermitssoeasytoleadworkerswithoutanyincident/accident.
Training Superintendent

Min.BachelorsDegreeorDiplomawithminimum3yearsofworkingex
perience.

Abletoreadtechnicaldrawings,understandthetechnicaldetailsrelate
dtothe companyactivities.
Designanddeveloptraining
programsforweldersandothertradetraining as required.
Maintaintrainingprogramscurrentandconductingap
praisals.

Trackcurrentindustrytrainingrequirementwithintheorganiza
tionneeds.

Developimprovedmethodtomeettrainingandfacilityobjectivesandg
oalsas required.
Assist line management in identifying potential training needs
base on organizationwork-relatedtask.
Help long-term improvement of employees skill, enabling them to
fulfill their potentialwithintheorganization.
47
CHAPTER III
IMPLEMENTATION OF
APPRENTICESHIP
3.1. INTRODUCTION
Name of Company : PT. Singatac Bintan
Business Entity : Privite Companies
This apprenticeship is carried for 3 months with date detail is as
follows:
Date: 18 July 18 October 2016

Place: PT. Singatac Bintan
Basic time of Work:
Monday Thursday : 08.00 16.00 ( Break time 12.00

13.00 )
Friday : 08.00 17.00 (Break time 11.30
13.30 )
Saturday : 08.00 13.00
In apprenticeship implemtation at PT. Singatac Bintan, there are

many department that have responbility and with scope job diverse, such
as HSE department, QA/QC deparment, Production deparment and ect.
For other department can be seen at organization chart of PT. Singatac
Bintan. From all of department in above, I take apprenticeship in QA/QC
Department.
48
3.2. PROCEDURE WORK OF QC
The Quality Control Department monitors and measures the
products throughout the execution of the project and finally the finished
product, before handing over to the customer.
Departemn Quality Control berfungsi untuk memonitor dan
mengukur barang mulai dari tahap pembuatan sampai dengan tahap
akhir pekerjaan barang sebelum diserahkan kepada pemilik barang.
3.2.1. Receipt of Documents

QC Engineer will receive the controlled copy of Engineering
Drawings, Project Schedule, Specifications, Inspection & Test Plan (ITP)
and Preliminary Manufacturers Data Report (MDR) from the Project
Engineer. Inspection and Test Plan gives the inspections and tests to be
carried out for a particular project based on customer requirements.
Penerimaan dokumen
Qc engineer akan menerima kopian gamabar teknik kontrol , jadwa
pekerjaan, spesifikasi, rencana inspeksi dan pengetesan (ITP) dan laparan
pendahuluan pembangunan dar project engineer. ITP memberikan
penjelasan tentang tata cara inspeksi dan pengetesan dilakukan selama
pekerjaan proyek berdasarkan persyaratan pelanggan.
3.2.2. Customer Requirements

QC Engineer will review the engineering drawings for dimensional
level and tolerance, percentage of NDT required and painting
requirements. The customer generally states his technical requirements
of the product in the General Notes column in the drawings. The General
Notes in engineering drawings will usually include,
Structural Steel Code
Grade of Steel Materials
Certification of the Material
Grade of Bolts and Nuts
49
NDT Percentage for Butt Joint, Full Penetration Joints
Fabricator Supply of Material
Persyratan pelanggan
Qc engineer akan meninjau kembali gambar teknik pada tingkatan
dimensi dan toleransi yang diberikan, persentasi dari Non
Destrucyive Test yang dibutuhkan dan persyaratan pengecatan.
Pelanggan secara umum menyebutkan persyaratan teknikal dari
barangnya di kolom catatan umum pada gambar. Adaun catatn
pada gambar teknik tersebut biasnya mencakup antara lain
Regulasi struktur baja
Grade material baja
Sertifikasi material
Grade baut dan murt
Oersentasi NDT untuk sambungan pengelasan
Pabrik yang menyuplai material
When there is a customer requirement, the customer or his

representative shall be afforded the right to inspect the purchased
product at vendorspremises and at project site.
3.2.3. QC Roles and Responsibilities

1. Organizing Inspection, Testing and Examination of all products and
components as specified in the Inspection Test Plan or
Requirement of the customer.
2. Verification of raw materials traceability and identification such as
a) Engraving
b) Hot Stamping
c) Stenciling
d) Painting
3. Verify the Fit-Up based on fabrication drawings
4. Carry out visual inspection based on NDT requirements
5. Liaising with Authorized Inspector and customer for Inspection/
50
Testing
6. Preparation of Dimensional Reports, MDR, WPS/PQR based on ITP,
WQR, NDT Procedure Requirement
7. Final Dimensional Check Report. Verifying the Painting Procedure
& documenting painting report
8. Prepare Load Test/ Pressure Test/ Function Test/ Weighing Reports
9. Implementing Corrective Action for discrepant parts
Peran dan Tanggungjawab QC

Mengorganisasi pemerikasaan, pengetesan dan pengujian dari
semua barang dan komponen seperti yang ditetapkan pada ITP
atau Persyaratan dari pelanggan.
Menmverifikasi material dan mengidentifikasinya
Memverifikasi pekerjaan fit up berdaarkan pada gambar fabrikasi
Melakukan inspeksi visual perdasarkan pada persyaratan NDT
Bekerja sama dengan inpektor yang berwenang dan pelanngan
dalam melakukan inspeksi/pengetesan
Menyiapkan laporan dimensi, MDR, WPS/PQR berdasarkan prosedur
persyaratan ITP,WQR NDT.
Pengecekan laporan akhir dimensi. Memverifikasi prosedur
pengecata dan dokumen laporan pengecatan
Menyiapkan load test/pressure test/fuction test/weighing test
Melakukan perbaikan terhadap bagian yang tidak sesuai dengan
persyaratan.
3.2.4. QC Inspection of Work and Records

1. Submission of Drawings, ITP, WPS, PQR to Client / Third
Party Inspector
A. The QC Inspector with the help of Project Manager shall present
the Issue For Approval drawings, design calculations, welding
51
procedure specification (WPS), procedure qualification records
(PQR), welder qualification records (WQR) and inspection & test
plans (ITP) to the Client or Third Party Inspector for review and
endorsement and to indicate their hold, witness or review points.
B. Client / Third Party Inspector or Project Manager (PrM) will sign
and date the inspection and test plan and the applicable
document to acknowledge review. Any question, raised by the
Client or Third Party Inspector concerning the drawings or
calculations shall be resolved with the Design Engineer.
2. Identification and Traceability of Inspection

QC Engineer/ Assistant should indicate inspection status on the
product by writing on it as Fit up OK, Welding Inspection OK, Final
Dimension OK or Reject. When identical products are fabricated and
inspected, the inspected product should be suitably identified with a
unique number and result of inspection. Ex. 11130F-1 Fit up OK, 11130F-
2 Weld Inspection OK.
Pekerjaan Inspeksi Quality Control dan Laporan
1. Penyerahan gambar, ITP, WPS, PQR kepada Client/ Inspektor Pihak
Ketiga
a. Inpektor Quality Control dengan bantuan project manager akan
menyerahkan gambar Issue for approval, kalkulasi pendesaianan,
spesifikasi prosedur pengelasan (WPS), laporan hasil kualifikasi
prosedur (PQR) , laporan hasil kualifikasi pengelas WQR dan
rencana pemeriksaan dan pengetesan (ITP).
b. Inspektur Cilent/Pihak ketiga atau project manager (PrM) akan
menandatangani dan memberi tanggal pada ITP dokumen yang
dipakai untuk ditinjau kesesuainya.
Jika ada pertanyaan, inspektur cliet/pihak ketiga tentang gambar
atau perhitungan akan terselesaikan oleh desaign engineer.
2. Identifikasi pencatatan inspeksi
Qc engineer/ assitant seharunya menandai status penginspeksian
pada produk dengan menuliskan ok apabila sudah di inspeksi atau
rejek jika ada kesalahan yang terjadi. Ketika mengidentifikasi produk
yang difabrikasi dan diinspeksi, penginspeksian produk seharusnya
52
sesui dengan uniqe number dan hasil inspeksi yang telah dilakukan
sebelumnya.
3.2.4.1 Inspection and Test Plan

Inspection and Test Plan is Specific sections of QCP that identify and
define inspection sequences. It is prepared in accordance with the
corresponding ITP of QCR and with all the applicable contractual,
engineering and vendors requirements. The ITP provide references to
applicable procedures, acceptance criteria, documentation, quality
records and inspection attendance to be performed, in chronological
order, from initial inspection, throughout final inspections and mechanical
completion. The ITP provide reference for the Inspection Forms to be
used.
In ITP, there are several points involvement code when carry out
inspection. The code points are as follows:
A. H Hold point
A Hold point is defined as a point in the manufacturing or testing
cycle beyond which it is not permitted to proceed without the
presence of a nominated party, unless written confirmation of non
attendance has been received. Only the organization responsible for
the hold point may waive the hold point. Approval to waive specified
hold points shall be documented before continuing work beyond the
designated hold point.
B. M Monitoring Point
A Monitor point is defined as a random / progressive inspection of
an activity identified in the Inspection and Test Plan. No notification
is required, however an agreed visit protocol shall be established
with the supplier / Subcontractor.
C. W Witness Point
A Witness point is defined as a point in the manufacturing or

testing cycle where Contractor and Company must be given the
option to attend. For repetitive activities witnessing of a percentage
53
sample of the total may be agreed. If nominated party does not
attend, the Subcontractor may proceed with the works.
D. R Review Point
A Review point is defined as a point in the manufacturing or

testing cycle at which a record of the activity is required. Contractor
and Company is required to review / endorse these records, which
shall be presented for review at the earliest opportunity, preferably
before the next activity.
E. A - Approval
An Approval point is defined as point of the manufacturing or

testing cycle where Subcontractor is required to submit certificates
for approval.
For sample, Inspection and Test Plan will be attached in appendix
1.
3.2.4.2 Welding Procedure Specification (WPS)

Welding Procedure Specification (WPS) is the formal written
document describing welding procedures, which provides direction to the
welder or welding operators for making sound and quality production
welds as per the code requirement. The purpose of the document is to
guide welders to the accepted procedures so that repeatable and trusted
welding techniques are used. A WPS is developed for each material alloy
and for each welding type used. Specific codes and/or engineering
societies are often the driving force behind the development of a
company's WPS. A WPS is supported by a Procedure Qualification Record
(PQR or WPQR). A PQR is a record of a test weld performed and tested
(more rigorously) to ensure that the procedure will produce a good weld.
Individual welders are certified with a qualification test documented in a
Welder Qualification Test Record (WQTR) that shows they have the
understanding and demonstrated ability to work within the specified WPS.
54
For sample, rpoert of welding procedure specification is attached as
follows:
Figures.3 Sample of WPS
55
3.3. PRACTICAL WORK
The following inspections are carried out by QC at various stages.
3.3.1. Design
The project Enginering team is responsible of the Engineering work.
CONTRACTOR AFC drawings and project specification are transformed into
Engineering deliverables such as shop drawings, work procedure and etc.
Engineering output which are the shop drawings are the reviewed
and approved by PTSB Engineering who have the competency and
authority to do this.
For any changes that primarily impact design, Project Engineer shal
raise Technical Query (TQ). The changes in the TQ Shall only be
implemented based on the CONTRACTORs response the TQ.
Reference Document
CONTRACTORs AFC drawings
Shop Drawings
Technical Queries
3.3.2. Procurement
The procurement of materials and service shall be in accordance
with written Singatac procedures as listed below. This includes
Qualification, Selection and Evaluation of sub-contractors and sub-
suppliers.
During document procurement stage the required Quality level,
test stage, examination level, inspection requirement shall be clearly
identified and include in procurement document. Customer approval of
sub suppliers for criyical item shall be received prior to placement of
order.
Reference Procedure:
Singatac-OPS-PM-02 Purchasing
Singatac-OPS-PM-07 Vendor Evaluation
3.3.3. Incoming Material Inspection

Quality Control Personnel should check the purchased raw material
to ensure that fabrication information such as material selection
56
conforms to the approved design drawings. Material Specification
Register Form is used to describe the raw materials like material
description, specification, heat number and identification number.
Anggota Quality Control harus mngecek material dasar yang dibeli
untuk memastikan bahwa informasi fabrikasi seperti pemilihan material
sesuai dengan desain gambar yang tlah disetujui. Formulir registrasi
Spesifikasi material digunakan untuk menggambarkan material dasar
seperti gambaran material, spesifikasi, heat number dan nomor
identifikasi.
QC material inspector must has a mill certificate when carry out
inspection. For example, (mill certificate attached in appendix 2.)
Inspektor QC material harus mempunya mill certificate ketika
melakukan inspeksi. Sbegai contoh mill sertifikat akan dilampirkan pada
lampiran 2
For evidence, Materials whom I inspect during apprenticeship in
singatac are as follows in bellow.
Sebagai dokumentasi, material yang prnah saya inspek selama
aging di singatac adalah sebagai berikut.
Sebagai contoh
1. Pipe
Figures.4Pipe
2. Plate
57
Figures.5Plate
3. Flat bar
Figures.6Flat Bar
4. Round bar
Figures.7Round Bar
5. Squere bar
58
Figures.8Square Bar
6. Hollow
Figures.9Hollow
7. Bulb plate
Figures.10Bulb Plate
8. Chanel
59
Figures.11Chanel
9. Angle Bar
Figures.12Angle Bar
10. H-beem
Figures.13H-Beem
11. I-beem
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Figures.14I-Beem
12. Fitting (elbow, flange,end cup, straight tee, reducer tee,
excentric reducer, concentric reducer)
Figures.15 Fitting
After all material has been inspected by QC material, the material

has to be made a report of material as reminders when the material will
61
be used for construction, QC material will check the material from this
report whether material has been inspected or not . This report is called
MVIR (material verification and inspection report). For Sample, (MVIR
report will be attached in Appendix 3.)
Sterelah material telah diinspek oleh QC material, material harus
dicatat dalam sbuah laporan sebagai pengingat ketika material akan
digunakan untuk konstruksi, QC material akan mengecek materialdari
laporan ini apakah material telah diinspek atau belum. Laporan ini disebut
MVIR ( Laporan verifikasi dan inspeksi material). Sebagai contoh, MVIR
akan dilampirkan pada lampiran 3.
3.3.4. Fit-Up Inspection

QC Inspector has to check whether the detailed drawings with
connection details conform to the design information provided and the
applicable codes and standards for manufacturing.
QC inspector harus mengecek apakah detail gambar dengan detail
sambungan sesuai dengan informasi desain yang disediakan dan
standar code yang diterapkan untuk manufaktur.
Fit-up inspection includes visual inspection, dimensional checks
after cutting, edge preparation, bevel angle, root gap, weld face of the fit-
up job. Fit up Report is used to record dimensions at the fit up stage. The
tolerance limit has to be mentioned clearly in the Fit Up report. The QC
Engineer shall self-check the Fit up Report against the drawing to ensure
its correctness before signing it. For Sample, Fit up inspection report will
be attached in appendix 4.
Fit up inspeksi termasuk visual inspeksi, pengecekan dimensi stelah
pemotongan, persiapan bevel, gap root, permukaan penggelasan dari
pengerjaan fit up. Laporan fit up digunakan untuk pencatatan dimensi
pada tahap it up. Batas toleransi harus disebutkan secara jelas dalam
laporan fit up. QC Engineer akan mengecek sendiri fit up report yang
tidak susai dengan gambar untuk memastikan kebenarannya sbelum
menandatangininya. Sebagai contoh , laporan fit up inspection akan
62
terlampir pada lampiran 4
If any variation found in the measurements against dimensions in

the drawings, the QC Engineer/ Assistant will inform the Project Engineer
who shall communicate with the Production Superintendent. All the
variations found must be corrected by the production and verified by the
QC Engineer before proceeding to next stage.
Jika ada perbedaan ditemukkan dalam pengukuran yang tidak
sesuai dimmensi pada gambar, QC Engineer/ perwakilannya akan
menginformasikan kepada projek engineer yang akan bicarakan dengan
production superintendent. Semua perbedaan harus dibenarkan oleh
pihak produksi dan diverifikasi oleh QC Enginer sebelum dianjutkan ke
tahap berikutnya.
The evidence when I carry out fit up inspection in PT. Singatac
Bintan will be attached in picture bellow.
Figures.16Fit-up Inspection With Client
63
3.3.5. Welding Process
QC will identify Welders, Welding Operators and Tack Welders who
are qualified in conformance with the requirements of the specified code.
QC shall keep a record of qualification of all Welders, Welding Operators
and Tack Welders and such other information as may be required. QC
shall make certain that the size, length and location of all welds conforms
to the requirements of the code & to the detailed drawings and that no
unspecified welds has been added without approval.
Qc akan mengifentifikasi welder, operator welding, yang telah
dikualifikkasi berdasarkan dengan persyaratan dari spesifikasi aturan. QC
akan mencatat kualifikasi semua welder, dan welding operatordan
inormasi lain yang mungkin dibutuhkan. QC akanmemastikan bahwa
ukuran, panjang dan lokasi semua pengelasan sesuai dengan
persyaratan code dan detail gambar dan bahwa tidak ada pengelasan
yang ditambah tanpa ada persetujuan.
1. Electrode Usagepenggunaan Elektroda

QC shall make sure electrodes are used only in the positions and
with the type of welding current and polarity of which they are classified.
QC akan memastikan elekroda yang digunakan hanya dalam posisi
dan dengan tipe arus dan polarity yang diklasifikasikan ileh welder.
2. Welding Related QC Functions

Current Welder qualifications and position of joint configuration in
compliance with welders qualifications
Kualifikasi arus dari welder dan posisi dari tipe sambungan dalam
memenuhi permintaan kualifikasi welder.
Joint fit up in compliance with WPS
Correct consumable as per WPS
Correct Preheat as WPS
Verify if Inter-pass temperature monitoring is performed
64
Fit up joinan dalam permintaan wps
Consumable yang benar sesuai WPS
Panas yang benar sesuai dengan WPS
Verifikasi jika monitoring temperature ditunjukan
Base on what I get when i take apprenticeship in PT.SINGATAC
BINTAN, definition of welding and kinds of welding process will be
explained clearly as follows:
Berdasarkan apa yang saya depatkan ketika magang di PT.
Singatac bintan, definisi pengelasan dan jenis-jenis dari welding proses
akan dijelaskan dibawah ini secara jelas sebagai berikut:
A union between pieces of metal at faces rendered plastic or liquid
by heat,pressure or both.
Proses pengelasan adalah penyatuan material baja pada permukkan
yang dibuta plastis atau cair oleh panas, tekanan atau keduanya
A. Possible energy sources
Sumber energy yang dapat digunakan
Ultrasonic
Electron beam
Friction
Electric resistance
Electric arc
Ultrasonic
Sinar electron
Friction
Listrik Bolak balikk
Busur listrik
B. The four essential factors for fusion welding

Empat factor dasar untuk peleburan pengelasan
1. Fusion is achieved by melting using a high intensity heat source

2. The welding process must be capable of removing any oxide and
contamination from the joint
3. Atmosphere contamination must be avoided
4. The welded joint must possess the mechanical properties required
by the specification being adapted
Peleburan dicapai dengan pelelehan mengunakan sumber panas
dengan intensitas tinggi.
65
Proses pengelasan harus mampu menghilangka proses oksidasi dan
kontaminasi dari sambungan
Kontaminasi dengan atmosfer harus dihindari
Pengelasan sambungan harus mempunyai property mekanikal yang
dibutuhkan oleh spesifikasi yang sedang digunakan.
Welding is regarded as a joining process in which the work pieces
are in atomic contact
Pengelasan adalah proses pengubungan sambungan dimana
material yang bekerja dalam kontak rekasi kimia.
A. Solid state processes
Forge welding
Friction welding
B. Fusion welding processes

Oxy-acetylene
MMA (SMAW)
MIG/MAG (GMAW)
TIG/TAG (GTAW)
Sub-arc (SAW)
Electro-slag (ESW)
Accordance with explaination in above, I just know three process of

welding are as follows:
Sesuai dengan penjelasan di atas, ketika melakukan magang,
diperusahaan itu menggunakan beberapa proses pengelasan dalam
pengerjaan fabrikasi. Adapun jenis-jenis proses pengelasan tersebut
adalah sebagai berikut.
1. Manual Metal Arc Processes (MMA)

The MMA welding Process was first developed in the late 19th
century using bare wire consumables.
MMA is a simple process in terms of equipment
The process can by used in AC, DC+ or DC-
The process is a manual process and demands a high skill from
the welder.
The process is widely used throughout the welding industry both
for shop and site working conditions
66
Proses pengelasan MMA pertamakali dibuat pada abad ke-19
menggunakan konsumebel kawat terbuka.
MMA mengunakan perlatan sederhana
Prosesn ini dapat menggunakan arus listrik AC, DC+ atau DC-
Proses ini dikerjakan secara manual dan dibutyuhkan welder
dengan skil yang tinggi.
SMAW process have a simple equipment than of other welding procees.

The equipment of Smaw process is described such as picture in below:
Proses MMA mempunyai peralatan yang sederhan dibandingkan dengan
proses penfgelasan yang lain. Adapaun contoh perlengkapanpada proses
ini digambarkan seperti dibawah ini.
Figures.17Equiment of SMAW Process
A. MMA Welding Variables

Variabel Pengelasan MMA
a) Voltage
The arc voltage in the MMA process is measured as close to the arc
as possible. It is variable with a change in arc length
Voltase dalam proses MMA diukur sedekat mungkin busur las. Ini
adalah variable yang berubah mengikuti panjang busur.
67
b) O.C.V.
The open circuit voltage is the voltage required to initiate, or re-

ignite the electrical arc and will change with the type of electrode
being used e.g 70-90 volts
Ovc adalah voltase yang dibutuhkan untuk permulaan, atau
menyalakan kembali busur dan akan berubah berdasarkan tipe
elekroda yang digunakan dengan range 70-90.
c) Current
The current used will be determined by the choice of electrode,

electrode diameter and material type and thickness. Current has
the most effect on penetration.
Arus yang digunakan akan ditentukan oleh pemilihan elektroda,
diameter elektroda dan tipe material dan ketebalan. Arus yang
paling berdamapak dalam penetarasi.
d) Polarity
Polarity is generally determined by operation and electrode type e.g

DC +ve or DC ve
Polarity pada umumnya ditentukan oleh operasi dan type elektroda
menggunakan sumber listrik DC+ve atau DC-ve
B. The three main electrode covering types used in MMA welding

Tiga type elektroda utama yang digunakan pada proses
pengelasaan MMA
a) Rutile - general purpose
A general purpose electrode, which gives the best appearance and

is easy to use. Drying-easy 100C for one hour and stored at
68
ambient for shelf life. Rutile flux ends in 2,3,4. For example , can be
seen picture bellow:
Sebuah elektroda Rutile, memberiikan penampilan yang sangat
bagus dan sangat mudah digunaka. Proses pengeringinya
menggunakan temperature 100 derajat selama satu jam dan
disimpan dalam kotak penghangat untuk menjaga temperaturnya.
Elektroda dapat diketahui dengan melihat kode pada elektroda
dengan nomor Akhiran 2,3,4. sebagai contoh, elkroda type rutile
dapat dilihat pada gambar dibawah ini.
Figures.18Electrode Rutile Flux
b) Basic - low hydrogen
Drying-bake 450C for one hour and store at 150C for shelf life (in a
calibrated oven. Issue-issued is small batches in heated quiver
(70C). rebake discard after record number of rebakees, normally
three times only. Basic Flux ends in 5,6,7,8. For example , can be
seen picture bellow:
69
Figures.19Electrode Basic Flux
c) Cellulose - deep penetration/fusion
Usually used in stovepipe welding (vertical down). High Hydrogen,

therefore high voltage, therefore high penetration. No drying
required, store in dry condition. Cellulose Flux ends in 0,1. For
example , can be seen picture bellow:
Figures.20Electrode CelluloseFlux
Before electrode is used for welding construction, electrode has to

preheated first in electrode oven. After that , if temperature
received by electorede has been sufficient, electrode taken out
from oven and save it in quiver with temperature 70C to keep
temperature elctorede constant in order that result of welding can
be suitable. Oven and quiver of electrode will attached in picture
below.
70
Figures.21Oven ,Qiuver of Electrode and Thermometer
C. Checks When MMA Welding
a) The welding equipment
A visual check should be made on the equipment to ensure it is in

good working order
b) The electrodes
Checks should be made to ensure that the correct specification of

electrode is being used, the electrode is the correct diameter and in
good condition. In the case of basic fluxed electrodes ensure the
correct heat treatment is being carried out before use e.g Baked at
350C, holding 150C, quiver temps 70C.
Cellulose and rutile electrodes do not require pre-baking but should
be stored in a dry condition.
71
c) OCV open circuit volts
A check should be made to ensure that the equipment can produce
the OCV required by the consumable and that any voltage selector
has been moved to the correct position.
d) Current & polarity

A check should be made to ensure the current type and range is as
detailed on the WPS.
e) Other variables
Checks should be made for correct electrode angle, arc gap and
travel speed.
f) Safety
Welder Safety equipment is kind of most important when carry out

welding to protect welder from incident and make welder be sequre
being work. Safety equipment of welder attached in below as
follows.
Figures.22PPE of Welder
D. Advantages and Disadvantages

a) Advantages
Field or shop use
Range of consumables
72
All positions
Portable
Simple equipment
b) Disadvantages
High welder skill required
Low operating factor*
High levels of fume
Hydrogen control (flux)
Stop/start problems
2. Submerged Arc Welding Process (SAW)

Submerged arc welding was developed in the Soviet Union during
the 2nd world war for the welding of thick sections
The process uses amps in the range of 100 to over 2000, which
gives a very high current density in the wire producing deep
penetration and high dilution
A flux is supplied separately via a flux hopper in the form of
either fused or agglomerated
The arc is submerged beneath the flux layer and no eye
protection is required
The process is normally mechanised.
SAW process have a simple equipment than of other welding procees. The
equipment of Smaw process is described such as picture in below:
Figures.23Equiment of SAW Process
73
A. Submerged Arc Welding Fluxes
a) Fused Flux
Flaky appearance
Lower weld quality
Low moisture intake
Low dust tendency
Good re-cycling
Very smooth weld profile
Figures.24Fused Flux
b) Agglomerated Flux
Granulated appearance
High weld quality
Addition of alloys
Lower consumption
Easy slag removal
Smooth weld profile
Figures.25Agglomersted Flux
74
Figures.26Flux Oven
B. advantages and Disadvantages

a) Advantages
Low weld-metal cost
Easily automated
Low levels of ozone
High productivity
No visible arc light
Minimum cleaning
b) Disadvantages
Restricted welding positions
Arc blow on DC current
Shrinkage defects
Difficult penetration control
Limited joints
The evidence when I carry out welding inspection in PT. Singatac

Bintan will be attached in picture bellow.
75
Figures.27SAW Process
3.3.6. Welding Inspection

When QC do welding inspection, there are many thing that must be
carried out by qc such as follow :
Ketika QC melakukan inspeksi pengelasan ada beberapa hal penting
yang harus dilakukan oleh QC yaitu sebagaiberikut:
QC shall inspect welding process. It shall,

Check quality and condition of filler materials to be used
Check Joint Fit-up
Check finished weld appearance
Check weld size
Check fillet size
Arrange NDT and monitor it
Monitor post weld heat treatment (PWHT) if required
Prepare weld Inspection Reports.
QC akan menginspek proses pengelasan
Memeriksa kualitas dan kondisi dari material yang digunakan
Mengecek fit up
Mengecek tampilan pengelasan yang sudah selesai
Mengecek ukuran pengelasan
Mengecek ukuran fillet
76
Menyiapkan NDT dan memastikannya
Memastikan proses PWHT jika dibutuhkan
Menyiapkan laporan inspeksi pengelasan
Welding inspection is carried out to check the porosity, pin hole,

slag and crack. Welding Visual Inspection Report will be used to fill up the
results. For sample, Wleding visual inspection report will be attached in
appendix 5.
Inspeksi pengelasan dilakukan untuk mengecek prositi, pin hole,
slag dan crack. Laporan inspeksi pengelasan akan digunakan untuk
mengisi hasil darin pengelasan. Sebagai contoh, laporan isnpeksi
pengelasan akan di lampirkan pada lampiran 5.
3.3.7. Material Traceability

In regard to materials, traceability refers to the capability to
associate a finished part with destructive test results performed on
material from the same ingot with the same heat treatment, or to
associate a finished part with results of a test performed on a sample from
the same melt identified by the unique lot number of the material.
Destructive tests typically include chemical composition and mechanical
strength tests. A heat number is usually marked on the part or raw
material which identifies the ingot it came from, and a lot number may
identify the group of parts that experienced the same heat treatment (i.e.,
were in the same oven at the same time). Material traceability is
important to the aerospace, nuclear, and process industry because they
frequently make use of high strength materials that look identical to
commercial low strength versions. In these industries, a part made of the
wrong material is called "counterfeit," even if the substitution was
accidental.
For sample, Material Traceability report will be attached in
appendix 6.
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3.3.8. NDT (Non Destructive Testing) Inspection
NDT inspection is carried out as per customers requirement. QC
Engineer will highlight the locations in the drawing at which NDT has to
be done. NDT is carried out by the subcontractor according to [AWS D1.1
or ASME].
According to project requirements, Radiographic Test (R.T),

Ultrasonic Test (U.T), Magnetic Particle Test (MPI), DYE Penetration Test
(DPT) are carried out by the subcontractors in the presence of Welding
Foreman and QC. The NDT reports are submitted by the subcontractor to
QC. QC will review NDT reports and identify repair joints with defect.
Upon completion of correction works, QC shall check at repair joints to
ensure that all repairs are rectified. The defective areas are subjected to
the same type of NDT to verify the acceptance of repair areas. The final
results are recorded in the Weld & NDT Map. For sample, NDT inspection
report will be attached in appendix??
A welding inspector should have a working knowledge of

NDT methods and their applications, advantages and
disadvantages.
Four basic NDT methods
Magnetic particle inspection (MT)
Dye penetrant inspection (PT)
Radiographic inspection (RT)
Ultrasonic inspection (UT)
3.3.8.1. Penetrant Testing

Dye penetrant inspection (DPI), also called liquid penetrant
inspection (LPI) or penetrant testing (PT), is a widely applied and low-cost
inspection method used to locate surface-breaking defects in all non-
porous materials (metals, plastics, or ceramics). The penetrant may be
78
applied to all non-ferrous materials and ferrous materials, although for
ferrous components magnetic-particle inspection is often used instead for
its subsurface detection capability. LPI is used to detect casting, forging
and welding surface defects such as hairline cracks, surface porosity,
leaks in new products, and fatigue cracks on in-service components. There
are 3 liquid used to do penertant testing, the liquid is as follows.
Penetrtant Liquid Developer

Liquid
Cleaner Liquid
Figures.28Liquid of Penetrant Testing
1. Typical sequence of operations to inspect a weld

a) Pre-Cleaning
Ensure surface is very Clean normally with the use of a solvent.
b) Apply penetrant
After the application of the penetrant the penetrant is normally left
on the components surface for approximately 15 minutes (dwell
time). The penetrant enters any defects that may be present by
capillary action. Process apply penetran liquid in the field can be
seen in picture attached bellow.
79
Figures.29Apply Penetrant by NDT Inspector
c) Clean off penetrant

After sufficient penetration time (dwell time) has be given the
penetrant is removed, care must be taken not to wash any
penetrant out off any defects present. To clean pentrant liquid,
inspector use cleaner liquid. Process clean off penetrant will be
attached in picture below .
Figures.30Clean off penetrant by NDT Inspector
d) Inspection / development time

Inspection should take place immediately after the developer has
been applied any defects present will show as a bleed out during
development time. After full inspection has been carried out post
cleaning is generally required. Process apply developer liquid and
result of penterant testing can be seen in photo below.
Defect
80
Figures.31Apply developer liquid and result of penterant testing
by NDT Inspector
2. Advantages and Disadvantages

a) Advantages
Simple to use
Inexpensive
Quick results
Can be used on any non-porous material
Portability
Low operator skill required
b) Disadvantages
Surface breaking defect only
little indication of depths
Penetrant may contaminate component
Surface preparation critical
Post cleaning required
Potentially hazardous chemicals
3.3.8.2. Magnetic Particle Testing

Magnetic particle Inspection (MPI) is a non-destructive testing (NDT)
process for detecting surface and slightly subsurface discontinuities in
ferromagnetic materials such as iron, nickel, cobalt, and some of their
alloys. The process puts a magnetic field into the part. The piece can be
magnetized by direct or indirect magnetization. Direct magnetization
occurs when the electric current is passed through the test object and a
magnetic field is formed in the material. Indirect magnetization occurs
when no electric current is passed through the test object, but a magnetic
field is applied from an outside source.
MPI have several equipment is used when do inspection welding .
thw equipment are yoke white contrast, and magnetic ink liquid. Before
carry out MPI, NDT man need to check sensifity of yoke use Burma Castrol
and weinging test to equipment calbratiio use block calibration of MPI. The
equipment of MPI will be attached in below clearly.
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Figures.32Liquid of MPI Test ( White Contrast and Magnetic Ink )
Figures.33 Yoke
Figures.34Burmah Castrol
1.Typical sequence of operations to inspect a weld
Clean area to be tested

Apply contrast paint
Apply magnetisism to thecomponent
Apply ferro-magnetic inkto the component during magnatising
Iterpret the test area
Post clean andde-magnatise if required
The evidence when I follow NDT man to inspect welding

construction with use MPI method is as follows picture below.
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Figures.35MPI by NDT Man
Advantages
Simple to use
Inexpensive
Rapid results
Little surface preparation required
Possible to inspect through thin coatings
Disadvantages
Surface or slight sub-surface detection only
Magnetic materials only
No indication of defects depths
Only suitable for linear defects
Detection is required in two directions
3.3.8.3. Ultrasonic Testing

Ultrasonic testing (UT) is a family of non-destructive
testing techniques based on the propagation of ultrasonic waves in the
object or material tested. In most common UT applications, very short
ultrasonic pulse-waves with center frequencies ranging from 0.1-15 MHz,
and occasionally up to 50 MHz, are transmitted into materials to detect
internal flaws or to characterize materials. A common example
is ultrasonic thickness measurement, which tests the thickness of the test
object, for example, to monitor pipework corrosion.
1.Typical sequence of operations to inspect a weld
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Surface and sub-surface detection
This detection method uses high frequency sound waves,
typically above 2MHz to pass through a material
A probe is used which contains a piezo electric crystal to transmit
and receive ultrasonic pulses and display the signals on a
cathode ray tube or digital display
The actual display relatesto the time taken for the ultrasonic
pulses to travel the distance to theinterface and back
An interface could be theback of a plate material or a defect
For ultrasound to enter amaterial a couplant must be introduced
between the probe and specimen
Figures.36Equipment of UT

Advantages
Rapid results
Both surface and sub-surface detection
Safe
Capable of measuring the depth of defects
May be battery powered
Portable
Disadvantages
Trained and skilled operator required
Requires high operator skill
Good surface finish required
Defect identification
Couplant may contaminate
No permanent record
84
The evidence when I carry out UT inspection in PT. Singatac Bintan
will be attached in picture bellow.
Figures.37Training to use UT Equipment on Construction
For sample , report of ultrasonic testing will be attached in

appendix 7.
3.3.8.4. Radiographic Testing

The principles of radiography
X or Gamma radiation is imposed upon a test object
Radiation is transmitted to varying degrees dependant upon the
density of the material through which it is travelling
Thinner areas and materials of a less density show as darker
areas on the radiograph
Thicker areas and materials of a greater density show as lighter
areas on a radiograph
Applicable to metals,non-metals and composites
Advantages
Permanent record
Little surface preparation
Defect identification
No material type limitation
Not so reliant upon operator skill
Thin materials
Disadvantages
Expensive consumables
85
Bulky equipment
Harmful radiation
Defect require significant depth in relation to the radiation beam
Slow results
Very little indication of depths
Access to both sides required
3.3.9. Hydrostatic Test

Hydrostatic test is the testing method to know leaktightness of
welding and connection with the help of pressurized of water as a means
to test the leaktightness of welding. Hydrostatic test is commonly used
leaktightness test of piping installation.
When the piping construction has been finished then hydrostatic test is
carried out to test leaktightness of welding at each connection of pipe and
all connection that use flange to ensure that there is no a leak in each
connection.
1. Basic principles
The basic principle of Hydrostatic Pressure Test is to use water that

is in the pipeline to be tested as a medium for detecting leaks by
applying pressure on the water.
2. Equipment of Hydrostatic Test
a) Water Pump: to fill the water in the pipe that will be tested.
b) Water Hose: its use to complement of water pump equipment.
c) Test pump: to give a pressure in the pipe that will be tested with
step increase /pumping the water in the pipe. Test pump must
have a capacity minimum 50 kg/cm2
d) Blank Flange: its used to close the pipe that will be used and as
the place to fill water and connection place for test pump
3. Pre-Testing
a) Which one piping installation that will be tested, limit the testing
area with give marking on pipe in order that can easily to check
the leak later.
86
b) Ensure all valve, flange and gasket/packing has been installed
correct.
c) Ensure all packing has been installed have a hole in the middle,
in other word , its not closed.
d) All valve has been installed must be fully opened.
e) Install blank flange In the end of pipe that will be tested
f) Connect the test pump at end of blank flange
4. Testing
a) Fill the water in the pipe that will be tested until full.
b) Connect the test pump and pressure gauge.
c) Fill the test pump with water.
d) Do water pumping in the pipe that will be tested In order the
water has pressure enough by way of moving the lever that is on
test pump device in order the water in the test pump is pumped
in the pipe will be tested.
e) Check pressure gauge, if pressure has been enough then stop the
pumping. If pressure has not been enough and water in test
pump has been empty then do additional water and do it again
till the pressure enough.
f) Check all connection of welding and connection of flange. If there
are a leak in the connection, water will be seen and blow out
from pipe has been tested.
3.3.10. Final Dimension Inspection

Final Dimension Inspection Final Dimension Inspection will be carried
out after completing all welding to check the final dimensions. This
inspection includes length, width, height, diagonal dimensions of the end
product and for machined items like pipes & bending parts the checking
will include dimensions, angle, radius and bending degree whichever is
applicable. Results are recorded using Dimensional. The tolerance limit
has to be mentioned clearly in the report. The QC Engineer shall self-
check the Final Dimension Inspection Report against the drawing to
ensure its correctness before signing it.
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3.3.11. Painting Process
3.3.11.1. General
Paint application shall be started, interrupted and completed at a
proper time taking into consideration the schedule for the related work so
that it never has as detrimental effect on the overall schedule (or the
schedule for the related work) nor the integrity of the coating applied.
1. All surfaces to be coated shall be cleaned (surface prepared) prior to

application of paint.
2. Blast cleaned surfaces shall be primed within four hours after surface
preparation to prevent rust formation. Applicator shall measure and
record local conditions of temperature, humidity before & during
blasting, during painting & curing.
Paint shall not be applied to surfaces under the following

conditions:
During rain, fog, or when dust is in suspension in the air,
When steel temperature is less than 3 above

surrounding airs dew point,
When relative humidity is above 85%, except for

inorganic zinc silicate up to 90%,
3. All paint shall be thoroughly using mechanical stirrer to give uniform

consistency before use. The grade and quantity of thinners shall be
agreed with the paint supplier; excessive thinning will be a cause for
rejection of the work. Paints supplied as more than one component
shall be thoroughly mixed in the proportions laid down by the supplier
and applied within the specified time limit after mixing ("pot life").
88
4. Coatings containing heavy or metallic pigments that have a tendency
to settle shall be kept in suspension by a mechanical agitator or
stirrer.
5. No paint shall be used in which after the given shelf life the vehicle
has set hard and which cannot be readily re-incorporated by correct
mixing. Similarly, no paint shall be used which has jellied or which
has thickened to such an extent that too much thinner is required to
bring it brushing consistency.
6. Painted surfaces shall not be handled until the paint has dried
thoroughly. Similarly, no coat shall be applied until the preceding coat
has dried. (Refer to the product data sheet for the minimum
overcoating interval).
7. No paint shall be force dried under condition, which will cause

checking, wrinkling, blistering, formation of pores, etc.
8. Paint shall be protected from rain, condensation, contamination, and

snow/freezing until the entire surface has dried.
9. Force ventilation shall operate continuously throughout the paint

application and curing period for internal surfaces.
10. Provisions shall be made to protect workmen form toxic hazards and
to prevent fires and explosions.
11. Paint application by spraying shall not be carried out in windy

weather or near equipment (especially rotary/sealing) or surfaces of a
contrasting colour unless the latter are properly protected from the
spray.
12. The paint shall be applied evenly to produce a smooth coating of the
required uniform thickness and free of pores or defects. Extra care
89
shall be taken to when applying paint to the edges, corners, welded
parts and crevices in order to obtain the required film thickness.
Overspray, skips, runs, sags and drips should be kept to a minimum.
13. Stripe coatings is an essential part of good painting practices that

should be carriedout to areas where adequate coverage by spraying
cannot be achieved. It shall be applied at all edges, corners, welded
seams, crevices and any difficult areas, e.g. at frames and stiffeners
in tanks and internal areas. Stripe coating is to be applied by brush
or roller only and before the full coat application.
14. When dilution is required to facilitate application, painters must cut

the paint with the thinner specified by the paint manufacturer, and
the maximum quantity recommended for each method of application
must not be exceeded.
15. Wet and Dry film thickness shall be in accordance with the paint
specification and manufacturer instructions. The procedure for
measurement of dry film thickness shall be in accordance with ISO
19840
16. If the specified dry film thickness has not been met, additional
coat(s) shall be applied in accordance to the paint manufacturer
recommendation.
17. Each coat of paint shall be applied within the allowable painting
interval. Refer to the paint product data sheet
3.3.11.2. Method of Painting Process

The method of applying the protective coatings is devided of airless
spray , Air spray (conventional) and Brush
1. AIRLESS SPRAY
90
Airless spray is a method of application, which does not directly use
compressed air to atomise the coating sprayed. Hydraulic pressure is
used to atomise the fluid by pumping it at high pressure through a
small precision orifice in a spray nozzle.
The required hydraulic pressure is usually generated by an air

powered pump having a high ratio of fluid pressure to air input
pressure. Pumps with rations between 20:1 and 60:1 are available,
perhaps the most common being around 45:1.
Generally the pumps are driven by compressed air or electric or

gasoline motors.
The chief advantages of airless spray are: -
1. High build coatings can be applied without thinning.
2. Very rapid application is possible, giving an economic advantage.
3. Compared to conventional spray, overspray and bounce-back are

reduced, leading to reduced losses of material and less dust and
fume hazards.
The tips, through which the paint is forced to achieve atomization,

are precisely constructed from tungsten carbide. The atomized fan
is produced by a slot ground on the face of the orifice. Various orifice
sizes together with different slit angles are available. The choice of
tip is governed by the fluid pressure to give atomization couples with
the orifice size needed to give the correct fluid delivery rate. The
fluid delivery rate controls the film thickness applied.
Different slot angles produce spray fans of different widths. The

selection of a particular fan width depends on the shape and size of
the structure to be painted. Choice of the width is also related to
91
orifice size. For the same orifice size, the paint applied per unit area
will be less than the wider the spray fan.
Airless spray equipment normally operates at fluid line pressures up

to 352 kg/cm (5,000 p.s.i) and should always be used in accordance
with the manufacturers operating instructions and safety
precautions.
Generally, tips with an orifice size 0.23-0.33mm (9-12 thou) are

suitable for coatings to be applied at approximately 50 microns (2
mils) wet film thickness.Tip sizes from 0.33-0.48mm (13-19 thou) for
wet film of 100-200 microns (408 mils) and 0.4809.79 (19-31 thou)
for 3200 microns (8 mils) and above. Heavy duty mastics which are
applied at very high film thickness may need tips with orifices as
large as 1.02-1.52mm (40-60 thou). Refer to the product data sheets
for the correct size of tip used.
There are several designs of tips available, the choice of which
depends upon the finish required, the ease of application and ease of
clearing blockages from the tips. With some products, the decorative
effect achieved with airless spray is not as good as can be achieved
by conventional spray. However, airless spray application is now
widely acceptance as a convenient method of applying high
performance protective coatings.
2. AIR SPRAY
This is a widely accepted, rapid method of coating application in

which paint is atomized by a low pressure air stream. Conventional
air spray equipment is relatively simple and inexpensive, but it is
essential to use the correct combination of air volume, air pressure
and fluid flow to give good atomization and a paint film free from
defects.
If conventional spray application is not controlled correctly, large
losses of paint can result from overspray and rebound from the
92
surface in addition to problems such as poor flow, sagging and pin
holing. The major disadvantage of conventional air spray is that high
build coatings can generally not be applied by this method as most
paints have to be thinned to a suitable viscosity for satisfactory
atomization, and so lose their high build properties.
Pressure feed tanks or pressure pots are commonly used in
association with low pressure air stream (conventional) spray guns, to
provide a means of delivering paint at a regulated pressure from a
tank, through a fluid hose to a spray gun.
A length of air hose from the compressed air supply is connected to
an air pressure regulator on the tank lid. Some air bleeds through the
regulator at an adjusted pressure into the tank but most of the air
passes the regulator and reaches the spray gun through a second
length of air hose to atomize the paint as it is sprayed. The air, which
has entered the tank, forces paint from it to the gun through a length
of fluid hose. Paint in the tank can be prevented from settling by
means of an agitator driven by hand or by a compressed air motor.
3. BRUSH
Brush application may be used the following circumstances:

- When areas cannot be properly coated by spraying for any
reason.
- Above ground level when it is considered that loss of paint under
prevailing conditions is excessive and progress of work has to be
maintained and personnel in or near the work site or plant or
equipment property, may be affected by spray particles.
- For touch-up or repairs to localised damaged paint or areas of
incorrectly applied paint.
- Where the manufacturer considers the coating material suitable

for brush application.
93
- For applying the initial coat of paint to corners, edges, crevices,
holes, welds or other irregular surfaces prior to spray application.
Brushes used in brush application shall be of a style and quality that

will permit proper application of paint.
The brushing shall be done so that a smooth coat, as nearly uniform
in thickness as possible, is obtained. There should be no deep or
detrimental brush marks. Paint shall be worked into all crevices and
corners. Runs and sags shall be brushed out.
During application of each coat all areas such as corners, edges,
welds, small brackets, bolts, nuts and interstices shall receive
additional paint to ensure that these areas have at least the
minimum specified dry-film thickness and to ensure continuity of
coating
3.3.11.3. Spray Application

Hose and containers shall be thoroughly cleaned before addition of
new materials. The spray gun shall be held no closer than 200mm or
more than 600mm from the surface to be coated and shall always be held
at right angles to the surface. Each spray shall overlap the previous pass;
large surfaces shall always receive passes in two directions at right angles
to reach other.
Each coat is to be applied uniformly and completely over the entire
surface. All runs and sags shall be brushed out immediately or the paint
shall be removed and the surface be-sprayed.
Before spraying each coat, all areas such as corners, edges, welds,
small brackets. Bolts, nuts and interstices shall be pre-coated by brush to
ensure that these areas have at least the minimum specified dry-film
thickness.
3.3.11.4. Repair of Damage, Welds and Defective Areas

All damages and defects to the coating shall be repaired and touched
up accordingly.
94
1. Film Defects
Film defect is defined as defects that do not reveal the substrate steel
and would include, although would not be limited to following:
Missed areas and under thickness
Incorrect colour, gloss level
Poor opacity and hiding power
These defects may be repaired by application of additional coat of

coating concerned.
Dry (over) spray and poor finish and texture
Sagging, drips and runs
These defects shall be repaired by removing the defect by abrasion

with grit paper and re-application of the coatings.
Inadequate adhesion
Pinholes and holidays
Cracks and Flaking
These defects shall require the complete removal of the coating prior
to repair.
1. Coating damage not exposing the substrates
Damage to the coating that does not reveal the substrate shall
prepared by abrading the area to sound material. The coating shall
be chamfered back at an angle of 45 over a minimum of 20mm
from the edge of the original damage. If sound material is not
found within 20mm, the abrasion shall continue until sound
material is encountered. The coating system shall then be re-
applied strictly in accordance with the paint specification.
2. Coating damage exposing the substrate - including welds
95
Damage that reveals the substrate shall be prepared in accordance
with the original painting specification and shall/may include blast
cleaning or power tool cleaning (refer to paint specification repair
procedure). The cleaning shall continue for a distance not less than
25 mm into sound undamaged surrounding coating.
On completion of preparation and cleaning, the damaged area shall
be made good using the same numbers and the same materials as
was originally required by the paint specification.
(Note: Surface tolerant coating may be used as repair primer over
power tool cleaned surfaces).
3.3.12. Painting Inspection

Painting inspection will be carried out to check the thickness of
microns of the painting DFT. The results are recorded using the Painting
Inspection Report or Paint Maker Report issued by Paint Maker Inspector, if
possible. The tolerance limit has to be mentioned clearly in the report.
QC will check the following things in the painted material:
Blast profile measurement
Dew point and humidity
Wet film thickness of paint coating
Final dry film thickness of paint coating
3.3.13.Non-Conforming (NC) Product Control

All the dimensions should be as per drawing. If any deviation found
which needs additional work and new material to correct it, NCR has to
be raised by the party who detects it. The Production Superintendent/
Production Supervisor/ Project Engineer have to investigate the root-
cause of nonconformance and take necessary corrective action.
NCR is divided into several parts are as follows:
3.3.13.1. Non-conforming Purchased Product
96
1. Parts
Non-conformance may be detected during receiving inspection by the

Store personnel, verification inspection by Quality / Welding Inspector,
Quality Control Engineer or by Production Superintendent/ Foreman before
start of work. Depending on the result of evaluation and circumstances,
the non-conformance may be:
Accepted
Returned to Vendor
Disposed
All rejected products shall be returned to the vendor when found not
acceptable. Should there be reasons to leave the non-conforming products
in the companys premises, the Store personnel shall ensure that these
are segregated to prevent inadvertent use and appropriately identified.
Details of the non conformance and the disposition shall be recorded
on the copy of the vendors delivery document. The Purchaser shall liaise
with the vendor for disposition of nonconforming purchased products.
2. Equipment
Upon detection of non-conformance during receiving inspection, the

Project Engineer/ Production Superintendent/ Maintenance Engineer
whoever placed the purchase requisition shall evaluate the non-
conformance. Depending on the results of evaluation and circumstances,
the non-conformance may be:
Accepted
Returned to Vendor
Disposed
If the equipment is rejected and has to be returned to the vendor, the

details of non-conformance and the disposition shall be recorded on the
copy of the vendor delivery document and receipt control procedure in
SINGATAC-OPS-PM-05 Storage of Products should apply. Should there be
reasons to leave the non-conforming products in the companys premises,
the Store Supervisor / Assistant shall ensure that these are segregated to
97
prevent inadvertent use and appropriately identified. The purchaser shall
liaise with the supplier for the disposition.
3.3.13.2. Non-Conforming Product During In-Process and

Prior to Shipment
During production process whenever variation from the drawing is
found in the in-process product, depending on the seriousness of the
variation, it can be identified as non conforming product.
Upon detection of non-conforming product/ service, the Project
Manager/ Project Engineer shall be informed by Quality Control Engineer/
Production Superintendent. They will evaluate the condition of the non-
conformance and decide on the disposition, proposalshall be submitted to
Buyer for approval. The product may be recommended for scrap or rework
to serviceable condition.
Buyer shall be notified of the intension to carry out all approved
correction action such as rework and/ or repair.
3.3.13.3. Non-Conforming Product Detected after Delivery

This applies to customer return of product / services only. If the
customer raises NCR using his NCR form, corrective action shall be taken
and that NCR closed. In the event that the customer just informs non-
conformance either orally or by email, then it shall be recorded and filed
in Customer Complaints file. Corrective action shall be taken and the non-
conformance corrected and closed
3.3.13.4. Training
Employees that are not qualified to perform a task based on

previous experience will be trained to perform new processes. An
experienced or trained individual will perform this training. The training
can be done by external or internal trainer(s).
1. New employee Orientation
98
All new employees are given an Orientation Training on
administrative, safety and ISO matters. Orientation will be carried out by
HR Executive where employee is briefed on the overall company structure,
management rules & regulations, use of personal protection equipment
(PPE) and other administrative matters. Workplace safety video clip show
will be arranaged by concerned department Manager. Briefing on ISO
quality policy, objectives, relevant ISO procedures and work Instructions
will be carried out by concerned Manager/ his designate. Upon completion
of orientation program. New employee orientation form shall be filled up,
signed by the new employee and passed to the Admin.staff(Training) The
annexure of this form shows the relevant ISO procedure and work
instruction for each position.
On-the-job training is conducted by immediate Supervisor to enable
staff to familiarise with the job functions and job responsibility. The
duration and extent of on-the-job training may vary and it will be decided
by the department head,who will take into consideration the new
employees experience, qualification and aptitude. New staff are normally
attached to a more senior staff and assigned simple tasks as a start to
familiarise him/her with the job procedures. Training Record shall be used
to record skills acquired as a result of internal training provided for fitter,
welder and other trades.
2. Identification of Training Needs

In the beginning of every year, General Manager/ Yard Manager and
Training Superintendent at Bintan will identify the training needs of
employees. Training needs could be identified in view of the following :
Ministry of Manpower Requirement/ Workplace Safety and Health
Requirement
Introduction of new Machines / Equipment/ Software
Changes in Job Responsibilities
Lack of skilled personnel
Technological Change
Diversification of Business
99
a) MOM required training for SE, Singapore
Every new employee in the workshop must go through,
Shipyard Safety Induction course for general trade
Safety course for hot work trade
Every project supervisor must go through,
Shipyard supervisor safety course
Every crane operator must go through,
Rigger & signaller course
Every forklift operator must go through,
Forklift operator course
Every scaffold erector must go through,
Marine metal scaffold erector pass course
Every scaffold supervisor must go through,
Marine metal scaffolding for Supervisors course
b) Welder Qualification
All welders must have welding certification according to
Responisibility and Authority of Singatacs Quality Manual. The
company will make sure the worker has already acquired the
necessary welding certification and it is renewed six months once
before putting him to perfom welding job. Copies of welding
certificates are maintained by Admin. Staff (Training) in Singapore
and by Welding Engineer in Bintan.
3. Annual Training Plan
1. The General Manager / Yard Manager and Training
Superintendent shall prepare Annual Training Plan for fabrication,
anchorage and QAQC employees to meet MOM (Ministry of
Manpower), WSH (Workplace Safety and Health) and quality
requirements. They shall forward training plan to the respective
Admin.staff(Training) with a copy to the Managers of Fabrication,
Anchorage and QAQC.
100
2. General Manager/ Yard Manager are responsible for the execution
of Training Plan. They will identify employees to be sent for the
training courses through their supporting line of Managers and
Training Superintendent. Admin. Staff (Training) will check for
course provider, schedule, fees, method of payment etc. and
arrange for providing training course. The employee who attends
the course has to submit Employee Training/ Skills Upgrade
Application to him who will then make course registration.
3. For fees payment to the training service

provider,Admin.staff(Training) will raise Purchase Requisition, get
approval from HR Manager/ GM and pass to Purchasing
department. Upon receiving invoice from the course provider, he
will pass it to Purchasing department for onward forwarding to
Accounts department to make payment.
4. Training Objective is stated as follows:
Meeting Annual Training Plan min. 90% of Certification of Skill
The Annual Training Plan should be executed with a pass rate of
minimum 90%. That means if employees are sent for 100 training
courses, they should pass minimum of 90 training courses and
get the necessary skills & certificates. Example: Employees are
sent for 50 training courses as per training plan and passed out
40 courses. Then the pass rate is (40/50)*100 equals to 80%. The
failed employees have to be resent for the training courses in
order to achieve the required 90% pass rate. That is, atleast
another 5 employees need to pass the courses and get the
required skills. General Manager/ Yard Manager is responsible to
achieve Training objective(s) of the company.
5. Admin.staff(Training) shall prepare a report according to

completed training or pending training by course and send to
GM/ Yard Manager once in six months with a copy to Admin.
101
Manager at Singapore and Training Superintendent at PT
Singatac Bintan.
3.3.13.5. Internal Quality Audit
1. PURPOSE
To define a procedure for conducting Internal Quality Audits at

planned intervals to determine whether the quality management system
is effectively implemented and maintained.
2. SCOPE
This procedure covers Singatacs quality management system which

complies to requirements of the standard ISO 9001:2008 established
through documented manual, procedures and work instructions.
3. RESPONSIBILITY
a) The Management Representative shall be responsible for
preparing the internal audit schedule, appointment of auditors
and ensure that timely corrective actions are taken.
b) The appointed auditor shall be responsible for conducting the
audit and reporting to the Management Representative of the
audit findings.
c) The auditee or the party responsible shall take timely corrective
action on deficiencies found during audit.
4. PROCEDURE
a) Planning the Audit Schedule

The Quality Management System shall be fully audited atleast
once a year by internal audit team. The planning of audit
schedule should take into account the quality issues that have
risen in the preceding audits and ensure that potential weak
areas are being paid more attention than stable areas. The
102
audit schedule shall be planned in such a way as to avoid
peak period which may clash with other interests.
The results of previous audits shall be examined to identify

regular trouble areas. These areas should be scheduled for
extra audits.
Activities where significant new or changed procedures have

been implemented should be scheduled for audit before bad
habits have time to become entrenched.
Taking into account the audit needs and staff availability, the
Management Representative shall prepare an Audit Schedule.
It shall define Audit Criteria, Scope, Frequency and Methods.
b) Formation of Audit Team

The Management Representative shall appoint the auditors.
The auditors shall not audit their own work. Auditor shall be
trained to conduct quality system audit, and where possible,
have some technical background on the area to be audited.
The auditor shall review previous Audit Reports relevant to the
audit, review the requirements of the Quality Management
System and plan for the audit. The auditor may prepare his/
her notes and checklist for the audit to be carried out by
him/her and make use of it as a guideline.
c) Conducting the Audit

The purpose of an internal audit is to ensure that the Quality
Management System is suitable, adequate and effective. The
audit must be conducted in a spirit of cooperation and
goodwill. The auditor must examine the area being audited
and ensure that the Quality System is being fully implemented
and used in a positive manner. Specific evidence must be
obtained to prove that the system is working. This evidence is
in the form of properly completed documentation as defined in
each procedure. Where felt necessary review each procedure
clause and ensure it was completely followed.
103
Where the Quality System is not working well or there appears
to be a poor attitude to the system or parts of the system then
the auditor shall make an observation which can be used to
improve the system.
The auditor must not accept evidence handed to them. He must

locate own evidence. The following is a guide for the auditors carrying out
the audit.
A. The Auditor shall use the Audit Checklist as a Guideline to carry
out fact finding and not fault finding in the system. Auditors shall
be objective in questioning the Auditees.
B. The Auditor shall ask the Auditee to briefly run down the
procedure and stop for clarification if necessary.
C. The Auditor shall ask for and verify the work evidence (such as
reports, records, minutes, instructions, etc) whenever necessary.
Auditor shall select the samples.
D. The Auditor shall selectively question the staff's job at that
moment while maintaining the routine activities.
E. The Auditor shall use the basic human senses such as Sight,
Hear, Smell and Touch to detect any irregularities in theactivities
being monitored.
Where deficiencies are identified then they shall be recorded in the

Audit Summary Report. The deficiency shall be categorised as follows:
Major - Significant nonconformance requiring major corrective
action or exposing the company to unacceptable risk.
Minor - Minor nonconformance not affecting the effectiveness
of the system but requiring corrective action.
Observation Potential problems / risks/ inefficiencies/ Failure
to follow best practice but not requiring corrective action.
The auditor shall obtain agreement from the auditee on the

nonconformances raised. Upon completing the audit, the auditor shall
104
summarise the findings in the Audit Report. Any major nonconformance
shall be highlighted.
d) Corrective Action
The auditee shall investigate into the non-conformances, recommend

and take the appropriate corrective actions and inform the auditor within
the agreed time.
e) Follow-up Actions
The auditor shall follow up with the audit findings and
corrective actions to satisfy himself of the action taken. When
the corrective actions are satisfactory the auditor shall close
the Corrective Action.
When corrective action requires long period for implementation
the auditee or the auditees management shall propose a plan
for the corrective action. The auditor shall take note of such
nonconformances and verify the effectiveness in the next audit.
The completed Audit Report shall be handed to the
Management Representative for filing.]
f) Measurement, Analysis, and Continuous Improvement
Any findings will be monitoried analyzed periodically to identify

systematic problem and potential areas for further improvement and
continous improvement effort.
Singatac shall collect and analyse appropriate data to demonstrate

the suitablility and effectiveness of Quality Mangement System and to
evaluate where continual improvement of the effectiveness of the Quality
Management System shall be made.
g) Management Representative
105
The Management Representative shall be responsible for ensuring
that the Quality System of the Company is implemented and maintained.
He/She shall constantly check the work of the Internal Audit Teams and
provide guidance to improve the internal auditing function. He/ She shall
discuss the audit findings during management review.
3.3.14.Customer Satisfaction
PTSB shall monitor information relating to CONTRACTOR perception
as to whether PTSB has met their requirements. Customer satisfaction
survey will be performed after FAT in addition to continuous monitoring
during project execution stage.
Customer feedback will be analyzed by Project Manager and report
shall be raised to Managements attention, if action(s) required.
3.3.15.Quality Records
All inspection and testing reports shall be indexed, filed,
documented and kept updated by QC Deparment in an orderly manner.
These record shall reflect full traceability to the actual inspection
activities.
Reference Document:
PS-15001F-M01-MDR-001 PT. SINGATAC-MDR Index
PS-15001F-M01-QCR-001 Manufacturing Data Report Book
3.3.16.Manufacturer Data Book/ Manufacturer Data Report

(MDB/MDR)
1. The QC Inspector shall create a project specific Manufacturers

Data Report (MDR). All project specific QC documents shall be
collated, continually updated and maintained in the file. Upon
completion of the project all material certificates, partial data
reports, examination, testing, heat treatment, manufacturing
procedures, users design specifications and manufacturers design
106
report shall be submitted to Third Party Inspector or Client for
review and endorsement.
2. Upon completion of a project the QAQC Manager/ Project Manager

shall prepare and issue the required copies of the MDR including
any electronic copies to the client as per contractual
requirements. The QAQC Manager/ Project Manager shall maintain
the original copy unless otherwise specified in the contract.
3. Upon compilation of the applicable forms, the QC inspector shall

sign and date the form prior to submission to the Client/ Third
party Inspector for his review and endorsement.
4. Upon completion of the forms, the QC Inspector shall make a copy

for his file (MDR) and the original submitted to the customer if
contracted scope requires it.
For sample, Index of Manufacturer Data Report will be attached in

appendix 8and Photo MDR will be attached in below.
Figures.38Manufacturer Data Report
107
\
APPENDIX
108
Appendix. 1 Sample of Inspection and Test Plan
INSPECTION INVOLVEMENT
REFERENCE DOCUMENTS
INS. ACCEPTANCE
INSPECTION ITEM INSPECTION
DOCUMENT DOC. NO Singatac 3RD Party Clien Client
NO CRITERIA
REPORT
TITLE t1 2
.0 Pre-Production Meeting Documents H H H
Prior To PS-15001F-M01- -
Fabrication ITP-001
ITP Fabrication PS-15001F-M01-FP-
Methodology
008
Procedure PS-15001F-M01-FP-
Project Quality
002
Plan PS-15001F-M01-FP-
Material Control
003
& Traceability
Procedure PS-15001F-M01-
Welding FP-019
Procedure -
PS-15001F-M01-
Specification &
FP-020
Register
Welders
Qualification PS-15001F-M01-
List & Records FP-023
Welding
Consumable
PS-15001F-M01-
Control
HSE-001
Procedure
HSE plan PS-15001F-M01-
Project schedule
109
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
SCH-001
2.0 PS-15001F-M01- -
Preparation & Approval SDRL
FP-001
of Procedures Procedures H R R
110
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
3.0 Preparation & Approval Welding
PS-15001F-M01-FP-
of FAB/AFC/ WELD MAP Procedure
019
DWGS & WPSS Specification & PS-15001F-M01-FP-
AWS D1.1
Register 027
Confirm the
NDT Procedures
ASME IX
latest revision Ultrasonic
drawings are Testing Subsea
PS-15001F-M01-FP-
being used procedure Structural
Check approved Magnetic 028
Steel welding Shop
WPS as per WPS Particle Testing
Specification Drawings
NDT Matrix
register PS-15001F-M01-FP- MWA Fabrication
Subsea Weld &
026 Specification H M/R M
Structural NDT
Tether System
Steel welding Map
Fabrication
Specification 220802DUST03002
Fabrication Specification
Gravity Base
Specification 220802DUSG03201
Tether System Fabrication
220802DUSG03218 Specification
Fabrication
Specification
Gravity Base
220802DUSG03202
Fabrication
Specification
111
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
Control and monitoring Subsea

measuring devicesand Structural Steel
3.1 Test Equipments welding
calibration Specification
Welding machine
Backing ovens Calibration
Quivers Fabrication - H M/R M/R
records
Inspection and Specification
testing
equipments
NDE Offshore
Equipments., structure
construction
4.0 NDT Technicians NDE Personnel ASNT-TC-1A, Approved H R R

LEVEL II Certificates
Qualification &
Check that technicians
Register List ASME V/AWS
have relevant valid
Subsea
D1.1 Mock up Test
qualifications before
Structural Subsea
starting NDT activities
Steel welding Structural
Mock up test
Specification Steel welding
Fabrication
112
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
Specification Specification
MWA Fabrication
Specification
ASME/AWS
Welding
Procedure
AWS D1.1
Specification & ASME IX
Previously Qualified Subsea
Register
WPS Subsea WPS
Structural
5.0 Structural Steel welding PQR H R R
Confirm previously
Steel welding Specification WPS Register
qualified WPS is listed
Specification MWA Fabrication
on approved register
Fabrication Specification
Specification
5.1 WPQT Welding

AWS D1.1 WPS
ASME VIII
Procedure PQR H H W
Check material ASME IX
Specification & WPS Register
traceability
Check Bevel Register
preparation
Welding
Check & record welding
Qualification H
parameter ( Ampere,
Procedure
voltage, heat input,
113
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
Travel speed, etc)
NDT
Mechanical test
Previously Qualified Welders

6.0 Welders Qualification
List & Records AWS D1.1
Confirm welder ID
Welder
against welder register ASME IX
Qualification Welder
Confirm welder is
Procedure Subsea Register
qualified for specific
Subsea
Structural Welder H R R
welding to be
Structural
Steel welding Certificates
undertaken
Steel welding
Specification
Welder log
Specification MWA Fabrication
Fabrication
Specification
Specification
6.1 AWS D1.1 Welder H H W

WQT Welding
Procedure ASME IX Register
Confirm welder ID
Specification &
against welder register
Check bevel preparation Register Welder
Welder
as per approved WPS Certificates
114
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
Check welding Procedure
parameter as per Qualification H
approved WPS Record
Visual inspection Welders
NDT
Qualification
NDT Reports
List & Records
BS EN Material H W M/R
7.0 Material Receiving Material Control
10204:2004 Receiving
Inspection &Traceability
BS EN 10164
Procedure ISO898- Inspection
Carry out receiving
Handling, Structural Steel Reports
inspection to ensure
Storage & Welding
materials are handled
Preservation Specification
and stored in
Procedure
accordance with Subsea
approved Structural
procedures/manufactur Steel welding
es instructions. Specification
Check Mill Fabrication
certificates/Material Specification
grade/size heat
number is correct as
115
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
per purchase
order/packing list.
Visual inspection
Dimensional check
8.0 Welding Consumable Welding

Consumable
Check consumables are
Control Log Books
stored in accordance
Procedure Consumable
with manufactures
Subsea Receiving
recommendations. AWS D1.1
Structural
Check consumable Inspection H M/R M/R
Steel welding ASME IX
certificates against Reports
Specification
batch numbers confirm
Fabrication
traceability and
Specification Certificates
compliance.
Approved H M/R M/R

9.0 Inspection Marking/ Material Control Mill Certs
Drawings Fit Up report
Heat no and Traceability & Traceability
Procedure Shop Drawings
Handling,
Storage
&Preservation
Procedure
Subsea
116
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
Structural
Steel welding
Specification
Fabrication
Specification
10.0 Rolling Shell Tank & Subsea Subsea

bending Gutter Plate Structural Structural
Steel welding Steel welding
To check / verified mill
Specification Specification
cert prior to rolling /
Fabrication MWA Fabrication Rolling /
bending
Specification Specification Dimensiona
Check dimensional prior H W
Dimensional Dimensional
to bending l Test M/R
Control Control
Fiber elongation (more Report
Procedure Procedure
then 5%) Calculation
and NDT reports
11.0 Bevel / Joint Welding Welding Fit Up report H M M
Preparation Welding
Procedure Procedure
Specification & Specification summary
Inspect weld fit up and
Register & Register Report
alignment is correct NDT Report
Fabrication Shop AWS D1.1
117
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
Drawings
Ensure correct bevel is ASME VIII
Subsea
ASME IX
being used as per
Structural
latest revision drawing
Steel welding
and WPS.
Specification
Visual Lamination
Fabrication
check
Specification
NDT after surface
Grinding
12.0 Fit-Up Inspections Welding
Procedure
Check weld joint fit
Specification &
up/alignment against
Register
latest approved
revision drawing. Approved Welding
Check dimensional
Drawings Procedure Fit Up Report
before welding Dimensional
Specification Dimensional H W M/R
Control & Register Report
Procedure AWS D1.1
ASME VIII
Subsea
Structural
Steel welding
Specification
13.0 Welding Inspection Welding Welding Welding H M M
118
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
Inspect and verify Procedure
condition,certification Specification &
and calibration of all Register
welding machines and
Fabrication Shop Procedure summary
equipment.
Drawings Specification
Check weld joint fit Report
Welders & Register
up/alignment before
AWS D 1.1
Qualification
welding.
WPS should be posted Register And Identify
Welding Control Approved WPS
at site preheat and
Procedure Drawings Numbers
interpass temperatures
should be monitored to Subsea ASME VIII
confirm code Structural ASME IX Welding
compliance Steel welding Parameter
Welding parameter
Specification check report
check
Fabrication
Specification
AWS D1.1 Visual H W/ M

14.0 Visual Inspection Welding
(Table 6.1) Inspection R
Procedure
100% visual Inspection
Approved Report
Specification &
to be carried out on all
Register Drawings
welds.
119
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
Fabrication Shop
Drawings
15.0 NDE Examination AWS D1.1 NDE Reports H W/ M/R
For Buoyancy R
NDT Procedures
tank, Pad
Eyes, Seal NDT Matrix ASME V
Welds, GB Fabrication ASME VIII

Gussets and Tubular Specification
Partial Joint Penetration Tether

MPI Cat I 100% Fabrication
Cat II,III 50%
Cat IV,V 20% Specification
UT-Cat IV,V 20%
Full Penetration- RT/UT

Subsea
Cat I 100%
MPI Cat I 100% Structural
RT/UT Cat II,III 100% Steel welding
MPICat II,III 50%
RT/UTCat IV,V 20% specification
MPI- Cat IV,V 20%
RT+MPI 100 % for all

the long seams and
120
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
circumference seams
Dish head 1 on
buoyancy tank
For circumference
seams Dish head 2
UT+MPI 100%
Fillet Weld MPI 100%

All Weld -100% Visual
Inspection
NDE Examination NDT Procedures NDE Reports H W/ M
R
For Other Structure
AWS D1.1
Partial Joint Penetration

and Fillet welds
NDT Matrix
MPI Cat I 100%
Cat II,III 50% Subsea
Cat IV,V 20%
UT-Cat IV,V 20% Structural
Steel welding
Full Penetration-
specification
RT/UT - Cat I,II,III
GB Fabrication
100%
RT/UT- Cat IV,V 20% Specification
121
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
MPI Cat I 100% Tether
MPI Cat II,III 50%
Fabrication
MPI Cat IV,V 20%
Specification
All weld 100% Visual
Inspection.
16.0 Welding Repair Welding
Procedure
Check welding repair
Specification & H
location
W M/R
Register
Check visual and
Weld Repair Weld Repair
Carried out NDT
Procedure Report
(MPI)Inspection after
Approved WPS
gouging before Fabrication AWS D1.1
welding Specification Weld Repair
Procedure
GB Fabrication ASME VIII
Check buttering is Visual
Specification
within tolerance Inspection
Tether H
Report After W M/R
Check heat Fabrication
Repair
Specification
straightening
Procedure
H
W M/R
122
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
17.0 NDE After Repair NDT Procedures
Visual Testing
Visual Inspection
Procedure
After repair
Fabrication
NDE with original
Specification AWS D1.1
method and approved ASME VIII
NDT Reports H W M/R
procedure GB Fabrication ASME V
Specification
Tether
Fabrication
Specification
18.0 Load Test Load Test

Procedure
Check equipment
calibration cert. Fabrication
Check equipment / AWS D1.1
Specification
ASME VIII
tools condition Load Test
Refer to Load H W W
GB Fabrication Report
Test Procedure
Specification
Tether
Fabrication
Specification
123
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
19.0 NDE After Load Test NDT Procedures
Check visual Inspection Fabrication

after load test Specification
Check NDE after load
GB Fabrication AWS D1.1
test NDT Reports H W W
ASME VIII
Specification
Tether
Fabrication
Specification
Fabrication Shop Dimension H W M/R

20.0 Dimension Check AWS D1.1
Drawings AFC Drawings Report
Check over all
Dimensional
dimension
Control
Procedure
Fabrication
Specification
GB Fabrication
Specification
Tether
124
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
Fabrication
Specification
Fabrication Shop
21 Pad eyes and Lifting
Drawings
Trunnions
Dimensional
Weld Preparation Control
Weld joint fit up and Procedure
alignment Fabrication
Shackle Hole Specification

AWS D1.1
Diameterwithin 3mm GB Fabrication AFC Drawings Dimension
tolerance of the Specification H W M/R
Report
nominal diameter.
Tether
Final orientation 0.5 Fabrication
degrees and within Specification
6mm of the final
location
Visual Inspection
Ensure weld size

22.0 Production Test Subsea AWS D1.1 H
ASME VIII
Structural Steel
W W
welding
125
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
Specification Inspection
Reports
Fabrication
Specification
Offshore
structure
construction
Hydrostatic
23.0 FAT
Hydrostatic Test Test
Check for completeness
Procedure
of inspection reports Fabrication
prior to pressure Specification
testing ensure all
GB Fabrication
ASME VIII Hydrostatic
NDE has been carried H W H W
Specification
Test Report
out as per
Tether
requirements.
Check for dewatering / Fabrication
drying after hydro Specification
test
24.0 Release Note For Subsea AWS D1.1 H R/ M/R

ASME VIII W
Blasting and Painting Structural Steel
welding
126
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
Specification Inspection
Release Note
Fabrication
Specification
Offshore
structure
construction
25.0 NitrogenPurging & Pressurization Pressurizatio H H W

Pressurization Procedure n Report
To check equipment Cal Fabrication

Certificate Specification
To check and record the ASME VIII
pressure
Visual inspection to
detect any leak, at
the weld location
SIT Procedure Refer to SIT SIT Report H W W
26.0 SIT
Procedure
Fabrication
Electrical Continuity test
Check clamp installation Specification
Check overall system
GB Fabrication
127
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
trial fit Specification
Tether
Fabrication
Specification
27.0 Concrete Pouring and GB Fabrication Concrete H H W
GB Fabrication
Testing Specification testing
Specification
Report
Check concrete Material
Check concrete mixing
Concrete testing
28.0 Final Inspection As - Built Punch List H H W

Drawings Form
Check Final visual / AFC Drawings
AWS D1.1
dimension inspection Inspection
Check punch list Release Note
29.0 Final Weight Weighing & COG AWS D1.1 Weighing H W W
Weight Control Report
Control
Check equipment
Procedure
Procedure
calibration certificates
MID Water Arch
Record final weight
Fabrication
Specification
GB Fabrication
Specification
128
REFERENCE DOCUMENTS
INS. ACCEPTANCE
NO CRITERIA
REPORT
TITLE t1 2
Tether
Fabrication
Specification
Transportatio
30.0 Load Out & Sea - H W W
n & Load out
Fastening
Procedure
Check Inspection
Fabrication
Release Note
Specification
Refer to Load
GB Fabrication Out Procedure
Specification
Tether
Fabrication
Specification
31.0 Final Documents
Manufacturer's Manufacturer's
All final documents
Data Report Data Report
should be reviewed by MDR H H H
(As Built)
Quality department for
Index
completeness before
final hand over.
129
Appendix. 2Sample of Material Mill Certificate
130
Appendix. 3Sample of Material Verification and Inspection Report
131
Appe
ndix. 4Sample of Fit-Up Inspection Report
Appendix. 5Sample of Welding Visual Inspection Report
Appendix. 6Sample of Material Traceabilty Report
Appendix. 7Sample of Ultrasonic Testing Report
FINAL REPORT OF APPRENTICESHIP 2016
Appendix. 8Sample of MDR Index

Sub CD
Section Description Vol. No. Yes/No
Section No.
1 Introduction Y
Cover Page
137
Sub CD
Section No.
Table of Contents Detailed Indexes
2 Description of Equipment Y
Equipment Part list/ Tag Number

3 Surveillance Completion Notes Y
Certificate of Conformity issued by sub-contractor

Inspection Release Certificate signed by sub-contractor
and contractor.
4 Test Certification Y
Mid Water Arch System Load Test Reports

Post NDT Reports
SIT Reports (ECC)&Calibration Certificates for
instruments
SIT Reports (Weighing)&Calibration Certificates for
instruments
SIT Reports (Clamp Installation)
Gravity Base Load Test Reports
Post NDT Reports
SIT Reports (ECC)&Calibration Certificates for
instruments
SIT Reports (Weighing)&Calibration Certificates for
instruments
Trail Fit (Integration Test)
5 Code Compliance Certificates NA
Certificate of Compliance
6 Manufacturing Procedures (General for all) Y
Supplier / Subcontractor Document Register List
6.1 Y
(SDRL)
Health, Safety, Security, Environmental Management
6.2 Y
Plan
6.3 Project Quality Plan Y
6.4 Material Control & Traceability Procedure Y
6.5 Dimensional Control Procedure Y
6.6 Inspection and Test Plan for Structural Fabrication Y
6.7 Inspection and Test Plan for Blasting & Painting Y
138
Sub CD
Section No.
6.8 Inspection and Test Plan for Dish Head Forming Y
Inspection and Test Plan for Forging Material (For
6.9 Y
Swivel Pad eye)
6.10 Inspection and Test Plan for Tether Chain and Shackle Y
Tether Chain and Shackle Manufacturing Procedure &
6.11 Y
Drawings
6.12 Non-conformance Control Procedure Y
6.13 Document & Drawing Control Procedure Y
6.14 Fabrication Methodology Procedure Y
6.15 Handling, Storage & Preservation Procedure Y
6.16 Blasting & Painting procedure Y
6.17 Transportation and Load out Procedure Y
6.18 FAT - MWA Hydrostatic Test Procedure Y
6.19 FAT - Nitrogen Purging & Pressurization Procedure Y
6.20 FAT - Pad eye Load Test Procedure Y
6.21 FAT - Tether Chain Proof Load Testing Procedure Y
6.22 SIT Procedure Y
6.23 FAT - Electrical Continuity Check Y
6.24 FAT - Weighing and Center of Gravity (COG) Procedure Y
6.25 As Built Drawings Y
6.26 Welding Procedure Specification & Register Y
6.27 Welders Qualification List & Records Y
6.28 Welding Procedure Qualification Records Y
6.29 Weld Repair Procedure Y
6.30 Welding Consumable Control Procedure Y
6.31 NDT Matrix Y
6.32 NDE Procedure Ultrasonic Testing procedure Y
6.33 NDE Procedure Magnetic Particle Testing Y
6.34 NDE Procedure Visual Testing Procedure Y
6.35 NDE Procedure Dye Penetrant Testing Procedure Y
NDE Procedure Radiographic Testing Procedure Y
6.36
for Structure
139
Sub CD
Section No.
NDE Personnel Qualification & Equipment Y
6.37
Register List
6.38 Method Statement Y
7 Production Weld Records Y
Production test Reports

NDT Technician mock up test Report
8 Inspection, Test and NDE Reports
Mid Water Arch System (Base Frame +Gutter
8.1 Buoyancy Tanks)
Tag Number : xxxxxxx
Weld Map Drawings
Material traceability
Welding traceability documentation
Weld Repair Records
Fit up Reports
Visual Inspection Reports
Dimensional Reports
Radiographic Examination Reports
Ultrasonic Examination Reports
Magnetic Particle Inspection Reports
Dye-Penetration Inspection Reports
PWHT Reports
Hydrostatic Reports
Borescope Inspection Reports
Coating Procedure Qualification Reports
Painting Inspection Reports
Holiday test Reports
Adhesion test Reports
Nitrogen Purging and pressurizing Reports
As built Weights and COGs Reports
8.2 Gravity Base
140
Sub CD
Section No.
Weld Map Drawings
Weld Repair Records
Fit up Reports
Dimensional Reports
PWHT Reports
Concrete Pouring Reports
Compression test Reports
Concrete Pouring Repair Reports
8.3 Tri Plates
Weld Map Drawings
Weld Repair Records
Fit up Reports
Dimensional Reports
141
Sub CD
Section No.
PWHT Reports
8.4 Riser Clamps 4, 12 & 12.8 Inchs
Weld Map Drawings
Weld Repair Records
Fit up Reports
Dimensional Reports
PWHT Reports
9 Material Test Certificates(General for all) Y
Material Inspection Reports and certificates

Anode Certificates
Paint Material Certificates (ie,TDS,MSDS)
Paint Material Inspection Reports
Weld Consumable Certificates
Rigging Certificates
142
Sub CD
Section No.
10 Hazardous Area Certificates NA
Records/Reports
Y
11 Other Testing / certificates
Inspection Release Certificate
12 Vendor Technical Query(General for all) Y
Technical Query Register
13 Vendor Deviation Requests(General for all)
Deviation Requests
14 Non-Conformance(General for all) Y
Anomaly Report
Non-Conformance Register (Internal & External)
Non-Conformance Report
15 Others
Sub Vendor Document (MRB)
Chain
REFERENCE
1. Quality Management System of PT. SIngatac Bintan
2. ISO 9001:2008
3. AWS D1.1/D1.1M:2010Structural Welding Code-Steel
4. TWI (Training Welding Inspection ) Part 04 About Non-Destructive Test and Part
05 About Welding Process
5. Data Report of Inspection QC Inspector
6. www.wikipedia.org
7. Client Specification and Procedure
143

FINAL REPORT OF APPRENTICESHIP (1) (1) (1) (Repaired)

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FINAL REPORT OF APPRENTICESHIP (1) (1) (1) (Repaired)

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FINAL REPORT

APPRENTICESHIP AT PT. SINGATAC BINTAN

QUALITY CONTROL DEPARTMENT

MUHAMMAD IQRA RAMDAHAN

DEPARTMENT OF OCEAN ENGINEERING

REPORT OF APPRENTICESHIP AT PT.SINGATAC BINTAN

PTSB (PT. SINGATAC BINTAN)

Name : Muhammad Iqra Ramadhan

Has been carrying out apprenticeship for three months at PT.

Singatac Bintan on 18th July 2016 until 17th october 2016.

Bintan, October 2016

Reviewed By: Approved By:

Lead QA/QC Asst. Manager QA/QC PTSB

Mr. Jesaya Sitepu Mr. Kumar

The purpose in writing this paper is to fulfill the assignment that

Bintan, October 2016

1.2. SCOPE OF WORK

1.3. PURPOSE OF APPRENTICESHIP

2.1.1 Company Background

SINGATAC ENGINEERING PTE LTD was incorporated in Singapore in

Figures.1 Logo of PT. Singatac Bintan

Design, Fabrication & Supply of Structural Steel and Process Piping

2.2. SCOPE OF QUALITY MANAGEMENT SYSTEM

2.2.1. Scope of Certification

Management system certificate of PT. SIngatac Bintan that has been

2.2.3. Quality Policy of PT. SINGATAC BINTAN

Singatac top management shall ensure that the quality policy is

2.2.4. Quality Objective of PT. SINGATC BINTAN

Table. 1Chart Organization of PT. Singatac Bintan

Min. Bachelors Degree in Engineering or Diploma with minimum 3

QAQC Manager / QAQC Assistant Manager

QC Inspector/ QC Coordinator/ QC Assistant

Responsible for General Arrangement/ PLOT plans, Plant

Maintenance Superintendent / Maintenance Engineer (PTSB)

Maintenance Technician/ Assistant

Electrician Charge man

Assistant Manager (Logistics)

Technical Office / Assistant Technical Officer / Admin. Asst

Senior Marketing Manager/ Marketing Manager / Asst. Marketing

Execute operation and administration activities in accordance

Complete skill about all types of scaffold and material preparation

Date: 18 July 18 October 2016

Monday Thursday : 08.00 16.00 ( Break time 12.00

In apprenticeship implemtation at PT. Singatac Bintan, there are

3.2.1. Receipt of Documents

3.2.2. Customer Requirements

When there is a customer requirement, the customer or his

3.2.3. QC Roles and Responsibilities

Peran dan Tanggungjawab QC

3.2.4. QC Inspection of Work and Records

2. Identification and Traceability of Inspection

3.2.4.1 Inspection and Test Plan

A Witness point is defined as a point in the manufacturing or

A Review point is defined as a point in the manufacturing or

An Approval point is defined as point of the manufacturing or

3.2.4.2 Welding Procedure Specification (WPS)

Figures.3 Sample of WPS

3.3.3. Incoming Material Inspection

After all material has been inspected by QC material, the material

3.3.4. Fit-Up Inspection

If any variation found in the measurements against dimensions in

Figures.16Fit-up Inspection With Client

1. Electrode Usagepenggunaan Elektroda