RAPID PROJECT

Spot Inspection Report

Central Directorate Doc. No: 20180108-SIR-WLD-P30-0172
Objective: To Improve Weld Management Quality System at site area.
Venue: Date 08/January/2018
UPT 30/ CPP /MMHE-ATB Fab. Workshop, Pasir Gudang, Johor.
Start Completed
10:00am 13:30am
Date Time of e-mail
Invitation by email 03/Jan/2018 12:39
Report sent to CD Welding and Inspection Manager 09/Jan/2018 15:30
Report sent to PD Head of Quality and UPT QM 10/Jan/2018 17:18
Minutes by: Suhaimi Bin Hamidun

Attendee: -
NAME DESIGNATION E-MAIL
Mr. Suhaimi Hamidun CD SME/WE suhaimi.hamidun@rapid-ipmt.com
Mr. Hafiz Jamaluddin CD SME/WE Hafiz. Jamaluddin @rapid-ipmt.com
Mr. Zulkifly Alias Deputy Quality Director zulkifly.alias@petronas.com.my
Mr. Zulfaqar Mobaraya NDT Specialist pria57@gmail.com
Mr. Amir Azli QAQC Engineer amirazli.malkharid@petronas.com
Mr. Hussin Ali CPP Quality Manager
Mr. Ariffudin MMHE-ATB Welding Engineer

Summary of Observations:
Follow-
Recommended up /
No Observation Status
Corrective/Preventative Action Due
Date
Found Equipment pass certificate of Welding EPCC to get the Welding machine Area for
1 machine was overdue on 31 Dec 2017. calibrated accordingly. improvement
24/01/18

Found weld inspection box was not fill-up by

CD SME advice to QC inspector to monitor Area for
2 QC inspector. No info for welder name and
closely on this issue. improvement
24/01/18
NDT status.
Found Welding defects still not remove even QC Inspector needs to monitor closely on Area for
3 gouging until whole thickness. this issue. improvement
24/01/18

CD SME Advice root gap shall follow WPS

requirement. If no root gap, it will affect to Area for
4 Found fit-up joint with no root gap.
more back gouging and risk to welding improvement
24/01/18
defects such slag and LOF not fully remove.

Page 1 of 9
1. Spot Inspections/Surveillance:

UPTs / Complianc
Date / Time Requirements
EPCC / e Issue
ITB/PTS/Code/
No Contracto Finding Statement / Photo Remarks / Recommendation Register #
Complete Project
r/Area/ Start Yes No / Status
d Specification
Discipline

RAPID- FE1- TPX

UPT 30/
PIP- DES 0001- Pre briefing was conducted by MMHE QC
CPP
9008 , PTS Engineer regarding walkabout plan and
/MMHE-
31.38.01.31, PTS location to be check, also consent regarding
1.1
ATB Fab.
Workshop/
08/Jan/18
09:30 am
08/Jan/18
13:30 pm
30.10.60.18, PTS
34.51.11.30
safety requirement and this walkabout 
BUTADINE focusing on fabrication activities for the
&
STORAGE
ASME VIII
butadiene storage vessel A, B, C and D.
VESSEL
Division 2

Figure 1

UPT 30/ RAPID- FE1- TPX All ovens was calibrated and verified.
CPP PIP- DES 0001- Calibration certificate was available for
/MMHE- 9008 , PTS
easy reference and verification.
31.38.01.31, PTS
1.2
ATB Fab.
Workshop/
08/Jan/18
09:30 am
08/Jan/18
13:30 pm 30.10.60.18, PTS
34.51.11.30
EPCC was advised to ensure oven
temperature setting following according to

BUTADINE
STORAGE & the approved consumable control procedure
VESSEL ASME VIII required minimum 150 Degree Celsius in
Division 2 order to get sufficient heat to remove any
moisture inside the electrode.

Page 2 of 9
 Figure 2,3,4&5

UPT 30/
CPP
RAPID- FE1- TPX
PIP- DES 0001- EPCC need to improve the control and

/MMHE- 9008 , PTS
31.38.01.31, PTS
issuance record of backing and holding
ATB Fab. 08/Jan/18 08/Jan/18 electrode.
1.3 30.10.60.18, PTS Area for
Workshop/ 09:30 am 13:30 pm
BUTADINE 34.51.11.30 Improvem
STORAGE & Area of Improvement
ASME VIII ent
VESSEL
Division 2
 Figure 6&7

Found weld inspection box was not fill-up

by QC inspector. No info for welder name
and NDT status.
CD SME advice to QC inspector to monitor

closely on this issue.
RAPID- FE1- TPX
UPT 30/ .
PIP- DES 0001-
CPP
9008 , PTS
/MMHE-
31.38.01.31, PTS Area of Improvement Area for
ATB Fab. 08/Jan/18 08/Jan/18
1.4 30.10.60.18, PTS Improvem
Workshop/ 09:30 am 13:30 pm
34.51.11.30
BUTADINE
&
ent
STORAGE
ASME VIII
VESSEL
Division 2
 Figure 8&9

RAPID- FE1- TPX Found Welding defects still not remove

UPT 30/ even gouging until whole thickness.
PIP- DES 0001-
CPP
9008 , PTS QC Inspector needs to monitor closely on
/MMHE-
31.38.01.31, PTS Area for
1.5
ATB Fab.
Workshop/
08/Jan/18
09:30 am
08/Jan/18
13:30 pm
30.10.60.18, PTS
34.51.11.30
this issue.
Area of Improvement
 Improvem
BUTADINE
&
ent
STORAGE
ASME VIII
VESSEL
Division 2
Figure 10

Found joint with no root gap, CD SME

RAPID- FE1- TPX Advice root gap shall follow WPS
UPT 30/
PIP- DES 0001- requirement. If no root gap, it will affect to
CPP
9008 , PTS
/MMHE- more back gouging/back welding and risk
1.6
ATB Fab.
Workshop/
08/Jan/18
09:30 am
08/Jan/18
13:30 pm
31.38.01.31, PTS
30.10.60.18, PTS to welding defects such slag and LOF not  Area for
Improvem
34.51.11.30 fully remove.
BUTADINE
&
ent
STORAGE Area of Improvement
ASME VIII
VESSEL
Division 2

Figure 11
 SAW welding process in progress for the
weld joint on inlet ring connection. Welding
operator was advised to ensure welding
RAPID- FE1- TPX preparation is clean, followed as per WPS
UPT 30/
PIP- DES 0001- parameter and ensure preheat applied as per
CPP
9008 , PTS requirement stated in WPS in order to
/MMHE-
31.38.01.31, PTS
1.7
ATB Fab.
Workshop/
08/Jan/18
09:30 am
08/Jan/18
13:30 pm
30.10.60.18, PTS
34.51.11.30
ensure compliance mechanical properties
after welding. 
BUTADINE
STORAGE
& CD SME advice Qc inspector to monitor
ASME VIII closely on minimum preheating temperature
VESSEL
Division 2 and ensure welder understand properly with
WPS compliance.

Figure 12&13
Welding Process Control.

Welding machine was checked based on:-

-Calibration tag / sticker expired date
-Equipment / cable / earthing condition.
- -Equipment / cable / earthing condition
UPT 30/
CPP
RAPID- FE1- TPX
PIP- DES 0001- was secured and no visible damage was 
/MMHE- 9008 , PTS observed.
ATB Fab. 08/Jan/18 08/Jan/18 31.38.01.31, PTS
1.8 30.10.60.18, PTS -Found Equipment pass certificate of
Workshop/ 09:30 am 13:30 pm
BUTADINE 34.51.11.30 Welding machine was overdue on 31 Dec SH 006
STORAGE & 2017.
VESSEL ASME VIII
Division 2 Corrective action required:
-EPCC to get the Welding machine
calibrated accordingly.
 Figure 14&15

UPT 30/ RAPID- FE1- TPX Welding Consumable Controls.

CPP PIP- DES 0001-
/MMHE- 9008 , PTS
31.38.01.31, PTS -Found temperature / humidity device
1.9
ATB Fab.
Workshop/
08/Jan/18
09:30 am
08/Jan/18
13:30 pm 30.10.60.18, PTS
34.51.11.30
provided inside welding consumable 
BUTADINE control room.
STORAGE &
ASME VIII (Good Observation)
VESSEL
Division 2
Figure 16

Post Briefing To Address Finding Issues.

UPT 30/ RAPID- FE1- TPX
CPP PIP- DES 0001- Post briefing was conducted by CD SME WE,
/MMHE- 9008 , PTS UPT QAQC Engineer and MMHE-ATB team to
ATB Fab. 08/Jan/18 08/Jan/18 31.38.01.31, PTS address finding issue during spot inspection. The
1.10 30.10.60.18, PTS
Workshop/ 09:30 am 13:30 pm finding were summarizes as below:-
BUTADINE 34.51.11.30
& 1. EPCC need to ensure Saw flux and
STORAGE
ASME VIII electrode got sufficient heat as per
VESSEL
Division 2 procedure during baking and holding
processes.

Figure 17 2. EPCC need to ensure not uses same

 oven for baking and holding in order
to ensure good management of baking
and holding system.

3. EPCC need to improve the control and

issuance record of backing and holding
of electrode / SAW flux.

4. Fitter teams to ensure fit-up bevel

preparation comply with WPS. If no
root gap, it will affect to more back
gouging and risk to welding defects. If
gouger not performing correct gouging
method, the welding defects such slag
and LOF are not fully removed, it will
left in weld metal area and cause NDT
rejected again. It will waste time and
cost due to rework. CD SME WE was
highlighted to EPCC, to ensure root
gap and root face comply to WPS in
order to prevent weld defects occurred
in back gouging area.

5. Found weld inspection box was not

fill-up by QC inspector. QC inspector
need to update accordingly.

6. Found Welding defects still not

remove even gouging until whole
thickness. QC teams need to brief to
gouger how to gouge with the correct
method.
7. Found Equipment pass certificate of
Welding machine was overdue on 31
Dec 2017. QC team needs to improve
this issue. Ensure all welding machine
duly calibrated as per schedule.
Photo File Locations
Figure No Photo File Location
1-17 Z:\042F_MEETINGS_REPORTS_PRESENTATIONS\13. WIM Team\13.9 Site Photos\20180108\Suhaimi\Reduced