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SET No.1 DELIVERY FT-1002+03+04+05+06 5 - Units Loadout 24 July ‘16
SET 2 PRE-TRIAL FT-2002+03+04+05+06 JIG 1 - Yes JIG 2- Yes Tank Mounted
SET 3 WORKSHOP FT-3002+03+04+05+06+07 Fabrication Yes Layout & Cutting
SET 4 WORKSHOP FT-4002+03+04+05+06+07 ------ ----- No Activity
1. Trial Assembly Bank Cells No. 2 …… On progress monitoring & inspection ( Level – Plumb – Height ) Bridge Sections ( 5units ) ……………. 100% Complete awaits for Mounting Trial Header Air-Water Pipes ……………... 95% Complete awaits Flange to Flange Trial Mounting Donut Launder (Center) ……………... 100% Complete On-Going Top Tank Mounting Connecting + Downflow Duct ……….. 90% Complete full welding w/ dealt Hot works bolt holes flange
2. Poor painting repair and touch up are still hard to dealt with Quality during final intervention of inspection 3. Un-satisfactory results dealt during Huakai Packing stages without proper internal team and lack of
project team to issue an Outotec Packing Procedure – Improvement still be dealt hard for Quality 4. Handling damage of cargo are still hard to controlled by Huakai during movement packing & transfer 5. Rubber Liners team are hard to control dealt by quality which they are not properly coordinate to QC-OT 6. Delivery practice in accordance to Export Structural Steel need improvement by Supplier
7. OUTOTEC Workshop Jig & Production Inspection :
QC WORKSHOP 3 WORKSHOP 2 WORKSHOP 1 Outotec
VI Upper Section 2unit FU Baffle Plate FU Bridge Section x5 FW Dealt QC
VI Underflow Duct x5 FW Discharge Box FW Booster Cone FW -do- QC Legend : FW – Full welding on process, FU – Fit-up w/ Edge Preparation & Dimensional Checking as per drawing requirements, VI – Visual Inspection Include repair, rectification, grinding works, NDE – RT/UT/MT check. All visual rejection shall have value immediate repair as UC-PR-LOF-GAP-CUT-Poor OUTOTEC DEALT HARD TO IMPROVED HUAKAI QC
Fit-Up still minor improvement with improper edges preparation dealt by workshop team of HUAKAI Large GAP control due cutting, improper level still to be dealt not more than 3mm during Fit-Up Tack weld by Fit-up are still Not satisfactory, rejected to be removed dealt by HUAKAI QC Tankwall welding are stringent critical run requirement by weaving or string bead poor practice Non-conformance visual inspection during excavation wall weld gouging found with linear porosity Poor welding control to distribution of welding gas shielding protection to minimized porosity dealt QC Deformation of Tank plate during assemblies and mounting – repair required NDT-MT required to grinded weld on top section & Lifting Lug - witness required Tank Rim Pad Plate for mounting Bridge found to be deform not properly level – repair required Assembly process has been improved to be completed at workshop fit-up and welding prior trial Overhead welders HK105 & HK107 has been verified test qualification witness by OT – Accepted SAW + FCAW repair procedure still No WPS & PQR – Urgent Required Poor stop-start, poor surface profile, porosity, poor weld, incomplete weld, heavy weld – dealt QC All post weld by Huakai are category D far from level category C but cosmetics complete it accepted Pipe Welding are improved by GTAW + FCAW but work damage by improper surface grind & clean Grinding by Cosmetics are still hard to improve by Huakai as traditional practice dealt improvement No Release Report by Outotec Quality where QC dealt by Punch Listing & Improvement closed out
IMPROVEMENT FOUND BY HUAKAI
Process of section Upper Tank with Donut Launder Fit-up + Welding Dimensional checking found acceptance to level ±3mm control prior welding Blasting works are properly coordinated and results satisfactory with immediate repair Top coating works verify acceptable with +15% over coat during verification acceptance QUALITY CONTROL dealt by HUAKAI QC will immediately repair by visual & on the spot tolerance
MEETINGS Regular weekly MOM ( OUTOTEC Quality to HUAKAI Project / QC ) is basis of QC Information only. MOM – Week 30th by Outotec QC dealt with delivery conformance & 2nd Batch Pre-Trial Project meeting by Outotec – Negative information query to QC between Huakai & OTSH Project OUTOTEC QA/QC will incorporate every meeting on Health, Safety and Environment (HSE) at
regular per workshop & yard, Meeting on QUALITY ASSURANCE & CONTROL will be held every regular interval every FRIDAY under the Minutes of Meeting (MOM).
COORDINATION Meeting under by HUAKAI & OUTOTEC PROJECT Team has no direct copy of information PER monthly minimum purposed – No record of information plan & priority for production and quality in terms of Status of Project, Quality, Quantity, Technical Discussion, Progress of work, Delivery and Gant Chart scheduling and other remaining works.
HSE Safety Points – Continuously informed in terms of HSE in Workshop No.3 & Yard of HUAKAI OUTOTEC QA/QC INSPECTION Points
- Regular Walk Through, Surveillance & Monitoring - Weekly Report & Non-Conformance Record - Punch Listing activities performed under unsatisfactory - Manufacturer’s Data Record ( MDR ) Review
This inspection, examination or testing carried out by Outotec or the customer shall not relieve the supplier of any of his obligations of expert manufacturing according to Outotec and specification. The supplier shall be solely responsible for accuracy, quality and completeness of his work and supply, subject to technical data and specifications.