wika mp prosedur rev. 2

8/10/2019 Wika Mp Prosedur Rev. 2

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PT. WIJAYA KARYAEngineering Division

No. Dok : WIKA-DIP-ENG-PM-MP01 No. Rev : 00

CD ENGINEERING

TITTLE : QUALITY PROCEDURE OFMECHANICAL AND PIPING

Date Applied :

1 September 2014

Form Changes : - No

Because Changes : - No

Because Changes : - No

APPROVED By

PPD DIVISION KNOWING By

NamePositionSignature

Date

Dwi SusenoManager Of Engineering DIV

1 Oktober 2014

Hendra JayusmanGM DIP

1 Oktober 2014

DISTRIBUTION

NUMBER OF

COPIES

RECIPIENTS /

PROJECT

NUMBER OF

COPIES

RECIPIENTS /

PROJECT


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PT. Wijaya KaryaJalan D.I. Panjaitan Kav. 9 Jakarta


Title : QUALITY PROCEDURE OF MECHANICALAND PIPING

Date Applied : 1 September 2014

1. PURPOSE

The purpose of this Procedure is to describe the requirements for Mechanical &Piping Engineering work to be implemented for a Project execution.

2. SCOPE

This Procedure applies to the Mechanical & Piping Engineering discipline to set out

engineering work execution process.for PT Wijaya Karya (Persoro) Tbk- EngineeringDivision.

3. REFERENCES

(1) WIKA-ENG-PM-03.05 Prosedur Engineering Quality System Pada Nalar BisnisEPC

(2) WIKA-ENG-PM-03.04 Design Quality Control Pada Nalar Bisnis EPC(3) WIKA-ENG-PM-02.03 Prosedur Design and Build(4) WIKA-ENG-PM-02.01 Prosedur Design Struktur(5) WIKA-ENG-PM-03.03 Prosedur Supervisi Engineering(6) WIKA-PEM-PM-05.02 Prosedur Pengendalian Dokumen dan Rekaman

4. DEFINITION

(1) WE WIKA Engineering Division(2) PS Project Secretary(3) QA Quality Assurance(4) PM Project Manager(5) PE Project Engineer(6) PPC Project Planning & Control

5. RESPONSIBILITY

Responsibilities and Authorities of the Mechanical & Piping Engineering Section areas follows:


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5.1 HOD

The Head of Department (HOD) is responsible to ensure that entire Projectinvolving his department can be handled by department team member in a goodquality, on schedule, and within budget. This will include having a good plan forman hour consumption and man power requirements, scheduling, and budgeting.HOD is also responsible for the development of his department to balance theCompany growth by planning and executing the team development program. Insome condition where Company has a small Project only, HOD may responsible as

Project Lead Engineer.

Particular Job Description of HOD is:

- Define man hour estimation for Project execution during proposal.- Supporting Business Development Department to obtain new Project,

technically.- With PPC, forecasting Project Schedule and calculating the man power

requirements/man power loading.- Selecting and assigning Project Discipline Team including Project Lead

Engineer, Engineer, Designer and Drafter.- With PPC Engineer, analyze each of the Personnels loads and ens ure job

distribution is executable for all Personnel.- Overseeing the overall Project achievement in his department and with Project

Lead Engineer take necessary action if a deviation against plan has occurred.- Give instruction to Project Team Member directly or through Project Lead

Engineer for required action during Project execution.- Reporting to Engineering Director of overall Project achievement by his

department.- Prepare and execute a team development program which includes coaching,

mentoring, training, or other methods which are effective for all personnel.- Actively supporting HR for recruitment whenever required, to ensure that all

Personnel meet with the given requirements, are capable to perform the worksin a good Quality and within Schedule.

- Give appraisal for all department Personnel as per HR standard format andbased on their actual behavior, performance, and achievement.

5.2 Project Lead Engineer

The Project Lead Engineer is responsible to execute the Project Engineering workwith daily control of overall production of Deliverables to ensure that all Project

Works meet Quality requirements and are completed on schedule. The ProjectLead Engineer is also responsible to control that the requirements of the WE


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Procedures are fully implemented and maintained throughout the execution of thedesign engineering work for which he is responsible and shall undertake thefollowing activity:- Understanding the project scope of work including its philosophies and

technical requirements.- With PPC Engineer, plan & submit schedule and estimation of the man hour

consumption for all Deliverables.- With PPC Engineer, monitor daily the progress achievement.

- Overall coordination of internal Discipline Engineers, Designers, and Drafters inhis Section.

- Advise to the Engineer in his/her Section on the Job execution philosophy.- Advise to the Engineer in his/her Section on the Corrective Actions as required- Guiding the Engineer, Designer, or Drafter in his/her Section for Deliverables

development and incorporating Client comment as per requirements.- Coordination at a managerial level with other Sections, Project Team, Client,

Vendor, Etc.- Clarification & Confirmation on the Input Data from the issuing sources and

send it to Engineers / Designers in his/ her Section for Design work.- Approval of all the Design Input / Output document prepared by Engineers in

his/her Section.- Supervision to the Engineers in his/her Section on the Design Engineering

Quality.- Control of Schedule in respect of his/her Section responsibilities.- Coordination between his/her Engineering Section and other Sections.- Control and Approval of all the design change under his/her Section scope of

work.- Control of the distribution of all output data produced by his/her Section.- Together with the Document Controller in Project Team to control his/her

Sections Documents. - Participating inter Discipline meetings or appoints Engineer from within his/her

Section as a Reviewer of these meetings..- Reporting to HOD for project achievement

- Supporting HOD for manpower development, recruitment, and appraisal.

5.3 Engineers

Engineers are responsible to carry out the following activities under the supervisionof the Project Lead Engineer.


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- Quality Control within the Mechanical& PipingEngineering group ScheduleControl of his assigned activities.

- Resolving Incomplete or conflicting items in input/output data and inform toProject Lead Engineer.

- Prepare Plot Plan, Mechanical Data Sheet, Equipment List, MechanicalRequisition (MR), MTO, Mechanical Specification (including press are vessels,pumps, compressors, and other rotating equipment), Detail Drawing, ShopDrawing (if required by check), and Calculation, All the work will be under the

supervision of the Project Lead Engineer.- The Product will be checked by a second Engineer (not Originator), if a second

Engineer is not available the Project Lead Engineer will check and approve.- Check of all Product prepared by Designers.- Preparation of Change Request (NPPC and other change note).- Supervision of the Designers and CAD Operators.

5.4 Designer

The Designer is responsible to carry out the following activities under thesupervision of the Engineer.- Quality Control Schedule Control of the assigned activities.- Review of input data and clarify to Engineer prior to start the Designers work. - Prepare Pressure Vessel, Detail Scantling Drawing by Designer.- under the supervision of the Engineer.- These Products will be checked by the Engineer and will be approved by Project

Lead Engineer.- Check all CAD Operator Output.- Review plot plan and piping plan in PDMS and 2D drawing

5.5 CAD operators

The CAD Operators are responsible to carry out the following activities under thesupervision of the Engineer.- Review of the CAD input data and clarify to Engineers prior to start the

drafting.- Input all data to CAD system.- Self checking the CAD product in term of quality control.


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6. WORK INSTRUCTION

6.1 General

This Procedure defines how to control the Mechanical & Piping Engineering workperformed by the Mechanical & Piping Engineering Discipline (hereinafter calledthe Discipline).

This Procedure supports the WIKA-ENG-PM-03.05 Prosedur Engineering Quality

System Pada Nalar Bisnis EPC , and it is referred to, WIKA-ENG-PM-03.04 DesignQuality Control Pada Nalar Bisni s EPC .

If an application version of this Procedure is requested by Client in Contract thenthis Procedure is tobe used as the backbone format and a Project Specific,Mechanical & Piping Engineering Procedure for Project is to be prepared byProject Lead Engineer, checked by Engineering Manager and approved by ProjectManager (or PE).These changes should not conflict with the requirements of the Quality Manual.

6.2 Design Planning

6.2.1 Team Assignment

In response to the Project Execution philosophy set by the responsible ProjectTeam and followed by a Project Kick Off meeting, the Project Lead Engineer willdetermine the Mechanical & Piping Engineering team and assign an Engineer orEngineers. The Project Lead Engineer shall prepare Work Assignment and SchedulePlan.

This Work Assignment and Schedule Plan will be checked by HoD and approved byProject Manager.

6.2.2 Planning of Mechanical and Piping Design Engineering Work

6.2.2.1 Scope of Work

Scope of work for the Mechanical & Piping Engineering Discipline is as follows:

(1) Verification of the data and information given by client.


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(2) Preparation of Mechanical & Piping Data Sheet (Vessel, Tank, Pump,Compressor, Manual Valve, Expansion Joint, Strainer, InsulationFlange, etc.)

(3) Preparation of Equipment/ Piping Material Class Specification(4) Preparation of Mechanical & Piping Calculation (Strength/wall

thickness, Piping Stress Analysis, HVAC, BTU, etc.). PurchaseSpecification (for EPC Project only).

(5) Preparation of Material Equipment List

(6) Preparation of Detail Drawing.

6.2.2.2 Engineering Work Flow

Mechanical & Piping engineering work is performed basically according to:Chart 5 : Work Flow for CalculationChart 6 : Work Flow for Mechanical & Piping Data SheetChart 7 : Work Flow for Equipment/Material SpecificationChart 8 : Work Flow for Material Take-Off

Chart 9 : Work Flow for Material RequisitionChart 10 : Work Flow for Design Change Control

6.2.2.3 Responsibilities and Authorities

The Mechanical & Piping Engineering Execution Organization is shown in chart 1

6.2.3 Design Interface between Sections

Design Interface between the Disciplines, related Disciplines and the Project Teamis shown in Chart 3 which is shows a typical interface and the arrow line shows thedirection of the information transferred among the related Disciplines.

After the Mechanical & Piping Engineering Product are issued to other Disciplines,and when the other Disciplines find difficulties in performing their Design, theProject Lead Engineer to resolve the difficulties.

The Design information from the Mechanical & Piping Engineering Discipline are tobe in written , it can be used as inter Discipline correspondence.

All interfaces among the related Discipline shall be controlled by the Project LeadEngineer.


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6.3 Design Input

The Design Input is to be clarified and documented at the early stage of theMechanical & Piping Engineering work. The Design Input is defined by therequirements of the Contract, the laws and the Standards quoted in the Contract.

The Design Input for the Mechanical Design Engineering works are as follows:

- PFD

- P&ID

- Design Basis

- Equipment Sizing

6.4 Design Output and Validation

The Design Outputs are the Design Products which are completed during theMechanical & Piping Engineering stage or those which are the required on ofPurchasing, Fabrication and Construction activity.

The Design Output is to be of the required quality to satisfy the contractrequirements.

The Design Outputs of the Mechanical & Piping Engineering works are as follows.(Refer to Section 6.2.2.1)

- Data Sheet

- Equipment List

- Equipment/Piping Material Class Specification

- Mechanical Requisition- Material Take Off

- Detail Drawing

- Shop Drawing

- Calculation/Analysis

- Wall Thickness for Vessel/Tank,Pipe

The kinds of Design Outputs to be prepared by the Mechanical & Piping EngineeringDiscipline are informed by the Project Lead Engineer to the Project Team. These


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Design Output documents are to be listed up by the section inDrawing/Specification List .

Design Output validation given by Client if the Engineering Products meet withClients requirement . The Client will sign on the Engineering Product as DesignValidation.

For FEED (Front End Engineering Design) Projects: the Client will opt whether tosign or not (if applicable).

6.5 Design Verivication

Quality Assurance Audit of Design will be carried out according to the DesignVerification Procedure. In order to ensure that the Design Output of Disciplinemeets with the Design Input requirements, the Design shall be verified through thefollowing Design Verification Procedure.

- Inside Discipline Review

- Cooperative Review for all design output (refer to 6.4). These review use interDiscipline check sheet form.

The definitions to be applied to this function are as follows:

Approval : Authorization by the discipline that design output has beenreviewed and meets the requirements.

Check : An activity to assure that the design output satisfies thedesign input requirements.

The Verification activities of assigned Personal on Various Design Products are

summarized in table 2 and attached work flow chart.

6.5.1 Internal Discipline Review

A Design Output Review is performed within the Discipline. The Review isperformed by on Engineer who did not originate the Product. The Inter DisciplineCheck Sheet can be used for the Internal Discipline Review.

6.5.1.1 Approval

a) The Approvers signature represents the Disciplines endorsement of the


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quality of that document (Product).

b) The Approver examines that the contents of the Products are in accordancewith the Project requirements.

6.5.1.2 Checking

The Checkers signature represents the Design Verification as to the correctnessof Originators work as follows:

(1) The use of current, valid input data as a basis of Originators work. (2) Conformance to the specifications and supplemental documents such as

minutes of meeting, letter, facsimile, etc.(3) Conformance to the Mechanical & Piping lEngineering Procedure and other

Design Practices

6.5.1.3 Originator

(1) The originators signature represents that the Product is self checked

regarding the accuracy and completeness.(2) The Originator of a Document performs the assigned Engineering Work by

referring to the Design Procedures and practices of the following :(a) Practices, codes, and regulations specified in the contract.(b) Mechanical & Piping Engineering Procedure.(c) Vendor Data & Reference Technical Book.(d) Instruction given by the Project Lead Engineer

6.5.2 Cooperative Review for Drawing

For a Project where all Disciplines are to be included in addition to the InternalSection Review, where the Drawing is originated, the Drawing is also to bereviewed by the other Disciplines, before issuing to the Client. This reviewperformed by Disciplines within WE is defined as Inter -Discipline Review.

6.5.2.1 Inter Discipline Review

The Inter Discipline Drawing Review is carried out basically by the followingDiscipline:

(a) Discipline in charge of the Process design(b) Discipline in charge of the Instrument Engineering


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(c) Discipline in charge of the Electrical design(d) Discipline in charge of the Mechanical design

6.5.2.2 Inter Discipline Review Result

(a) When Mechanical, or Piping drawing meets the Project requirement, theDrawing will be issued for comment to Client through Project Team

(b) When Mechanical, or Piping Drawing does not meet the Project requirement,

Drawing will be revised.6.5.2.3 Incorporating Client Comments and Issuing for Clients approval

(a) After receiving Clients comments, any clarification is to be carried by wayof a meeting with Client out and Comment is to be finalized. This result is tobe documented as minutes of meeting, letter or facsimile.

(b) After incorporating the agreed Comments, the revised Drawing is preparedby the Designer, checked by the Engineer, and approved by the Project Lead

Engineer. For revised Calculation Report, it is prepared by Engineer andchecked and approved by Project Lead Engineer.

6.6 Design Change

The Design Change Control flow is referred to Chart. 6.

6.6.1 Revision of the Design Document

Design Change is to be shown in revising on the original document and identifying

the point revised.6.6.2 Verification of the Design Change

The Design Change is to be verified by the Discipline Engineer. The sameVerification Procedure as describe in paragraph 6.5 is applied to the design change.Design change shall be in writing through Project Correspondence, MOM, etc.

6.7 Non Conformance Product, Corrective Action, & Preventive Action

To record Non Conformance Product, Corrective Action & Preventive Action followEngineering Procedure.


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7. ATTACHMENTS

7.1 Work Assignment and Schedule Plan7.2 Table 1A Drawing List7.3 Chart 1 Mechanical & Piping Engineering Execution Organization7.4 Chart 3 Work Flow for Calculation7.5 Chart 4 Work Flow for Drawing7.6 Chart 5 Work Flow for Mechanical Data Sheet

7.7 Chart 6 Work Flow for MTO7.8 Chart 7 Work Flow for MR7.9 Chart 8 Design Change Control Flow7.10 Table 1 The Split Mechanical & Piping Engineering Work


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CHART 1 MECHANICAL ENGINEERING EXECUTION ORGANIZATION

MECHANICAL DISCIPLINEENGINEER

PROJECT LEADMECHANICAL ENGINEER

MECHANICAL & PIPINGDESIGNER

MECHANICAL & PIPING DRAFTER & 3DMODELLING

MECHANICAL & PIPING HOD

PROJECT LEAD PIPINGENGINEER

PIPING DISCIPLINEENGINEER

PDMS ADMINISTRATOR

3D MODEL


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CALCULATION &SELF CHECK

FINAL CHECK

Chart 3. WORK FLOW FOR CALCULATION

Y

N

DESIGN DATASUBMISSION

DESIGN CRITERIADEVELOPMENT

BY WHO HOW

LEAD ENGINEERENGINEERINGDOCUMENT

LEAD ENGINEERWORK ASSIGMENT

AND SCHEDULEPLAN

ENGINEERSIGN THECALCULATION

LEAD ENGINEERSIGN ON THECALCULATION SHEET

PROJECT MANAGER TRANSMITTAL

CONFIRMATION &INSTRUCTION TO

ENGINEER

ISSUE FOR APPROVALCALCULATION TO CLIENT

CLIENT'S APPROVAL

DATA SHEET DESIGNDATA INPUT

PROJECT MANAGER ANDMECHANICAL & PIPING HOD

MEMO

CLIENTSIGN ON THECALCULATION SHEET

LEAD ENGINEERREVIEW ONCALCULATION,MINUTE OF MEETING

N

Y


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Chart 4. WORK FLOW FOR DRAWING

DESIGNED

INPUT TO CAD

Y

N

FINAL CHECK

REQUIREINSTERDISCIPLINE

CHECK

INTERDISCIPLINE CHECK RESULT

ISSUE FOR APPROVAL TO CLIENT

CLIENT'S APPROVAL

ISSUE FOR CONSTRUCTIONTO CLIENT

N

Y

CHECK

Y


BY WHO HOW

LEAD ENGINEER MEMO

LEAD ENGINEER WORK ASSIGNMENT AND SCHEDULE PLAN

DESIGNER DRAFT

CAD OPERATOR INPUT TO ELECTRONICFILE

DESIGNER SIGN THE DRAWING

ENGINEER SIGN THE DRAWING

LEAD ENGINEER SIGN THE DRAWING

LEAD ENGINEER IDC FORM

ENGINEER COMPILE ALL COMMENT

PROJECT MANAGER OR

ENGINEERING MANAGERTRANSMITTAL

CLIENT SIGN THE DRAWING(If applicable)

LEAD ENGINEER REVIEW ON DRAWING,MINUTE OF MEETING ETC

PROJECT MANAGER ORENGINEERING MANAGER

TRANSMITTAL

CONFIRMATION ANDINSTRUCTIONTO ENGINEER

CHECK

Y

N

YN

REVISI AS PER IDC COMMENT


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Chart 5. WORK FLOW FOR MECHANICAL DATA SHEET

INPUT DATA ON DATA SHEET AND SELF CHECK

FINAL CHECK

ISSUE FOR CONSTRUCTIONDATA SHEET TO CLIENT

ISSUE FOR APPROVALDATA SHEET TO CLIENT

CLIENT'S APPROVAL

Y

Y

N


BY WHO HOW

LEAD ENGINEERWORK ASSIGNMENT ANDSCHEDULE PLAN

ENGINEER

ENGINEER CALCULATION SHEET

SIGN ON THE DATASHEET

SIGN ON THE DATA SHEETLEAD ENGINEER

PROJECT MANAGER ORENGINEERING MANAGER

TRANSMITTAL

LEAD ENGINEERREVIEW ON DATA SHEET,MINUTES OF MEETINGETC

CLIENT SIGN THE DATA SHEET

PROJECT MANAGER ORENGINEERING MANAGER TRANSMITTAL

Y

CONFIRMATION ANDINSTRUCTION TO

ENGINEER


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Chart 6. WORK FLOW FOR MECHANICAL MATERIAL TAKE-OFF

REVIEWED

FINAL CHECKOK ?

MTO DOCUMENT SENDTO CLIENTOR TO BE USED AS A BASIS FOR PURCHASING

N

DESIGN DATA FROM APPROVEDFOR CONSTRUCTION DRAWING

DEVELOP PIPINGMECHANICAL MTO

BASED ON DRAWING

BY WHO HOW

DESIGNER MTO FORM

ENGINEER SIGN ON MTO

LEAD ENGINEER SIGN ON MTO

NOTE :1. LEGEND : MTO = MATERIAL TAKE OFF

Y

PROJECT/ENGINEERINGMANAGER

TRANSMITTAL


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Chart 7. WORK FLOW FOR MECHANICAL REQUEST FOR QUOTATION

CHECKED

DEVELOP MR

BY WHO HOW

ENGINEER

LEAD ENGINEER

STANDARD RFQ FORMAT

PROJECT MANAGER ORENGINEERING MANAGER TRANSMITTAL

ISSUE RFQ TO CLIENT & TO PROCUREMENT

DEPARTEMENT

SIGN THE PRODUCT

NOTE :

1. LEGEND = MR = MATERIAL REQUIS2. THE REQUEST FOR QUOTATION IS APPLICABLE FOR

EPC PROJECT

NO

YES

DESIGN INPUT FOR RFQ SUCH AS :

- SPECIFICATION- DATA SHEET- DRAWING- MTO


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TABLE 1 THE SPLIT OF MECHANICAL & PIPING ENGINEERING WORK

No. DOCUMENT DESIGNER ENGINEER LEAD ENG.

TEAM ASSIGNMENT

1 Work Assignment and Schedule Plan - P (Note 1 & 3)

DESIGN OUTPUT

2 Mechanical Data Sheet P C (Note 2 & 3)3 Equipment Specification P C (Note 2 & 3)4 Mechanical Requisition P A (Note 3)5 Material Take Off P C A (Note 3)6 Specification of Piping, Valve, and Fitting P C (Note 2 & 3)7 Equipment Detail Drawing P C A (Note 3)8 Shop Drawing P C A (Note 3)9 Equipment List P C (Note 2 & 3)

10 Calculation P C (Note 2 & 3)

LegendP : PreparedC : CheckedA : Approve

Note

(1) Checked by Project Manager & Approved by Engineering Manager(2) CHECKED can be considered as APPROVED (3) If the Project Project Lead Engineer is not available, Engineering Manager will act

as Project Project Lead Engineer