KALPATARU PROJECTS INTERNATIONAL LIMITED

(Oil & Gas Division)

Quality Management System Internal Audit Report

In compliance with requirements of

ISO 9001:2015 [KPTL-IMS-M 001, Rev. 8. Dt. 15.06.2023]

Corporate Office
71, Kalpataru Synergy, Opp. Grand Hyatt,
Santacruz (East), Mumbai 400 055.
Maharashtra.
Project Name : PNCPL (NRL) Part-C1 & C2

Location : Guwahati, Mangal Doi & Tezpur, Assam

Audited Date : 26/12/2023 to 30/12/2023

Type of Audit : Internal Audit

Audit Medium : Visit at project site, interaction with team.

Audit Duration : 4 Days

ISO Coordinator : Sh. Surender Bogum

Internal Auditor : Sh. Ramesh Muthusamy

Auditee : Mr. Project Site Team

Good Highlights Positive Point Improvement Required Observation Non Conformity Action

Nil 48 5 06 04
 Kalpataru Projects International Limited
Oil& Gas Division
Internal Audit Report

Format No: IMS-QA-IA-05, Rev-02, Dt: 15.06.2023,

(Oil & Gas Division)
Reference Documents: (Select as applicable) Reference Documents: (Select as applicable)
KPIL-IMS-M 001, KPIL-EnMS-M-001,
REV.8. Dt.15.06.2023 YES / NO REV.1. Dt: 15.06.2023 YES / NO
Scope of Standards covered in this Audit: (Put  on below standards which are covered in this audit)

QMS (ISO 9001:2015)

Report No. IA-NRL C1&C2_2023_DEC Date of Audit 26.12.2023 to 30.12.2023

Department
PNCPL Part-C1 & C2, Project Auditee(s) Project Site Team
/Project Name

Guwahati,
Audit duration,
Location Mangal Doi & 4 Days Auditor(s) Ramesh Muthusamy
(days / hrs)
Tezpur (Assam)

Quantity Complete Statements

Good practices Nil Nil

Opportunities for Improvement-5

Refer attached Annexure -01 supporting
improvement Observation-6

Nonconformities 4 Refer attached Annexure -01 supporting

Signature of Signature of
Auditee Auditor

Review / Opportunities for Improvement

Nonconfomities Reviewed in MRM: No. Date:
Closure Improvement actions

Status of
findings

Review on: Date: Date: Date: Date:

 KALPATARU PROJECTS INTERNATIONAL LTD (Oil & Gas Division)
Audit Finding Sheet - Annexure-I (Attachment to Internal Audit Report) Audit Date: 26.12.2023 to 29.12.2023
Purcheser / Contractor : M/S Kalpataru Projects International Ltd Document No : KPIL-QA-IA-010, Rev-01, Dt: 26.12.2023 to 30.12.2023
Project : PNCPL, Part-C1 & C2 & CCG Office Audit Location: Mangal Doi, Tezpur & CCG Office, Assam
Type of Audit : Quality Management System Internal Process Audit
Audit Programme Manager : Sh. Surender Bogum
Name of Int. Auditor : Ramesh Muthusamy
Name of Auditees : KPIL Site Team (As per the attached attendance sheet)
Reference
Deapartment / Finding
Sr. No Details of Sample checked Description of Findings document / Requirement Photo (If applicable)
Activity Category
Clause No.
Welding electrode issue register:
MIV No: 02189 Electrode issued after approval and Material storage
Material Store,
1 Dtae: 25/12/23 recommendation of user, record maintained, Positive and Handling
Mangal Doi
SAP issue no: 4915746343 timely updated and reconcialiation process found Procedure
in linear order
The personnel was not aware about FIFO, materail Improvemen
Material Store, Awareness of store IMS, Support, 7.2 Necessary training/awareness to
2 issue and receipt control and materail wastage t
Mangal Doi assistanec Personnel competency be given on materail management
control Required
Checked for awareness of toxic / non toxic and
Material Store, Competency of store Helper flammability of materal was found aware, also IMS, Support, 7.2
3 Positive
Mangal Doi Mr. Viswajit Das knows the procedure of operating fire extinguisher competency
and emergency response plan
IMS, Operation,
Though tagging system are implemented for Improvemen
Material Store, Identification and 8.5.2 Identification Tagging system to be maintained
4 identidfication / traceability some of fitting items t
Mangal Doi traceability of pipe fittings and traceability and regular basis
are found without tags Required
competency
Spillage of waste lubrication oil on ground obsered
IMS, 6.1.2 Lack of focus on aspect & impact,
Material Store, Storage of fuels: that leading to enviromnent impact was not
5 Observation Environment similar observation to be identified
Mangal Doi Waste lubrication oil identified by site HSE team with action plan.
Aspect and reoccurance to be controlled.
Scrap like used welding consumables, grinding &
IMS, 8. Operation,
Material Store, Scrap Materail recovery & buffing wheels, electrode stub ends, gloovses etc
6 Positive Waste
Mangal Doi storage condition. has been recovered and stored at designated place
Management
in segreggated condition.

Adeqaute support to be provided

Material Store Materail Storage and steel materails shall be free
Storage of 6" conduit pipes found inadeqauate
7 and Yard, Steel materail storage and Handling from ground contact in order to
support
Mangal Doi Procedure avoid ingress of rain water, debris
and corrossion.

Non
Confirmity
Action
 Reference
Deapartment / Finding
Sr. No Details of Sample checked Description of Findings document / Requirement Photo (If applicable)
Activity Category
Clause No.
Action

Adeqaute support to be provided

Material Store Materail Storage and steel materails shall be free
8 and Yard, Steel materail storage 24" line pipes stacked without support (gunny bag) and Handling from ground contact in order to
Mangal Doi Procedure avoid ingress of rain water, debris
and corrossion.

Adeqaute support to be provided

Material Store Materail Storage and steel materails shall be free
24" bare line pipes & 6" conduit pipes stacked with
9 and Yard, Steel materail storage and Handling from ground contact in order to
in adeqauate support
Mangal Doi Procedure avoid ingress of rain water, debris
and corrossion.

There is no evident of signed document or training

HR & Requested for sample of Job Proof of communicating the JD to
awareness document from site in order to
10 Administration, Descreption assigned at the Personnel to be maintained on
communated the Job Descreption assigned to the Non IMS, 7.5,
Mangal Doi time of Personnel Joining record
Personnel during the time of joining at site Confirmity Documented
HR & Requested for drinking Action Information
No report or record found for water testing or
11 Administration, water suitability report or Reocrd to be maintained
checking the drinking water suitability
Mangal Doi monitering
HR & New joiners record backup
12 Administration, availability sampled Verified and found in order Positive
Mangal Doi Fitter : Mr. Santosh Yadav
Updation of site hindrance
Planning, Mangal register. Site Hindrance reported through DPR. Client signed record to be
13 Observation IMS, Planning
Doi Daily Progress Report No. However client signed record to be maitained maitained
343 25.12.23
Planning, Mangal Requested list of updated P Equipment ldetails are reported through DPR.
14 Positive IMS, Planning
Doi & M equipments Daily Equipment deployment status are traceable.
 Reference
Deapartment / Finding
Sr. No Details of Sample checked Description of Findings document / Requirement Photo (If applicable)
Activity Category
Clause No.
Interface between the
intrested parties Quality Vs
Planning input / output,
Planning, Mangal Interface found with effective communication, IMS, Internal
15 effective communication, Positive
Doi status and reports were shared on regular basis. Communication
stringing/mainline/tie-in
chart, status of pipe book
and next day plan.
IMS, 5.3
Planning, Mangal Found updated and displayed.
16 Project Organogram Positive Organization roles
Doi Department wise organogram also found updated
& responsibilities
Requested updated list of
17 Civil, Mangal Doi List found updated with revision number Positive
Procedures & ITPs
IMS, 8.2.2,
Sample Work Procedure:
Determining the
Document no.
18 Civil, Mangal Doi Approved procedure available Positive requirements for
KPTL/NRL/EIL/PNCPL/CIV/JP-
product and
05
services
Status of claibration of IMS, 8.7, Control
Document not available for monotoring the Instrument list to be prepared and
19 Civil, Mangal Doi instruments / machines Observation of non conforming
calibration calibration to be monitered
used for testing & inspection products
Checked for control of
IMS, 7.5.3, Control
drawing revision and Inward drawing revision found updated where as Drawing issuance status /index to
20 Civil, Mangal Doi Observation of Documented
distribution to sub no evidence / record for sub-contractor issuance. be maintained
Information
contractor
Sample Cube test report:
Report No- KPTL-EIL-NRL- Test result found satisfactory, ITP followed and IMS, Product
21 Civil, Mangal Doi Positive
SNPL-GEN-028. report maintained as per the requirement Realization
Dt: 17.04.23
Sample of Sub Contractor
Planning, Mnagal MOM Record for IMS, 7.4,
22 MOM record available and found in order Positive
Doi M/S Hind Enterprises Communication
MOM Dt: 30.10.23
Electrode stub end scrap collection observed and
proper utilization of electrode noted.

LPG source available for pre-heating.

IMS, Product
Weld Joint No- 1241 free Tie- DG set ground earthing provided for safety.
23 Positive Realization,
in
Approved WPS
NRL C1, Free Tie- Welding earthing lead place on pipe found as per
in Welding the recommendation.

During hot pass welding current measures 145

Amps & 148 Amps which is inline to WPS.
Welder ID Card for IMS, 8.1
24 Mr. Sujeet Baranwal-W19 Certified Identity Card proof available at site Positive Operational
Mr. Udhayjeet Singh-W07 planning & control
 Reference
Deapartment / Finding
Sr. No Details of Sample checked Description of Findings document / Requirement Photo (If applicable)
Activity Category
Clause No.
Weld Numbering as per the Procedure template.
25 Weld joint no. KM1235M78 Positive
Pipe details were properly transferred on the
external surface of mill coating using paint markers

Welded HDD string has been found properly rested

Supporting of welded pipe
26 with adequate height using gunny bags in order to Positive IMS, Product
string
NRL C1, Mainline facilitate easy NDT and joint coating works Realization,
Welding Approved Work
Welder ID Card for
Procedures
27 Mr. Parma Mahto-W17 Certified Identity Card proof available at site Positive
Mr. Ajay Ojha-W01
Feeler gauge, temperature gun, High Low gauge
and Universal weld gauge was available with Site
Availibility of Inspection
28 Quality Engineer. Positive
instruments at site
All instruments found in usable condition with
valid calibrations
Correctness of report input verified for sample
welder no.69 and found matching.
IMS, 9.1,
Register has been maintained for day to day NDT
Monitering,
results of each welder.
29 Positive measuring,
Reports are updated upto date.
Verified Sample Welder analysis and
Repair percentage found well controlled -1.9%
Performance Report for evaluation
NRL C1, Quality which was found within the maximum permissible
Week 16/12/2023 to
benckmark.
22/12/2023
IMS, 9.1, cummulative repair% to be
Improvemen Monitering, maintained per welder wise for
Suggested cummulative repair% to be maintained
30 t measuring, knowing the performance of
per welder wise.
Required analysis and individual welder over period of
evaluation time
IMS, PQP & SOP
Inspection instrument Instrument Calibration index well maintained upto Calibration of
31 NRL C1, Quality Positive
calibration monitoring date inspection
instruments
IMS, 9.1,
PTC record and Status well maintained, the Monitering,
Production welding Test
32 NRL C1, Quality performance were found consequetively with Positive measuring,
coupon Record
satisfactory results analysis and
evaluation
IMS, 7.5,
Verified WPS/PQR, EQT and All records has been properly maintained upto
33 NRL C1, Quality Positive Documented
PTC Records date with Client approved
Information
It has been observed site office that all ISO
Non IMS, 7.5.3, Control
certificates and Company corporate policies are Latest Version of document to be
34 NRL C1, Quality Context of the Organization Confirmity of Documented
not upgraded up to the latest version which are to updated and displayed.
Action Information
be displayed.
Report shall contain name of
Verified sample Quality tool The available record shows training has been IMS, 9.1.2, trainer / instructor and after
35 NRL C1, Quality box talk training record. conducted periodicaly, however no eveident of Observation Evaluation of training the report shall be
Dt: 24.12.2023 & 15.11.2023 instructor and evaluation done after training. compliance reviewed by Qulaity Manager or
feed back form to be maintained.
 Reference
Deapartment / Finding
Sr. No Details of Sample checked Description of Findings document / Requirement Photo (If applicable)
Activity Category
Clause No.

Verified sample of ITP Reports of Repair weld visual, DPT, UT, after repair
IMS, Product
36 NRL C1, Quality compliance for repair weld RT & UT compliance found in order and complied Positive
Realization
joint KM1262M17 ITP requirement

IMS, 8.5.2,
Verified Pup Pipe Pup pipe left out and consumption detail
37 NRL C1, Quality Positive Identification and
traceability detail traceability details found maintained
Traceability

Verified Sample Inspection

reports for compliance
IMS, 7.5,
Trenching Report no. 60, Dt: All mandatory fields are found filled with required
38 NRL C1, Quality Positive Documented
12.12.2023 data and copllying to the ITP requirement
Information, ITPs
Lowering Report no.60,
Dt:19.12.2023
Material storage
Welding Consumable
39 Store, Tezpur Verified and found as per SOP requirement Positive and Handling
reconciliation
Procedure
Material storage
Storage of Welding
40 Store, Tezpur Verified and found as per SOP requirement Positive and Handling
consumable
Procedure
Material on rack shall be stored in
Material of Plant & Machinery items like filters,
Material storage hardless condition, excessive
Storage of other spares are found excessive stacking on rack from
41 Store, Tezpur Observation and Handling height stacking items are to be
consumable materail which material fall from height hazards are
Procedure shifted to alternate rake / suitable
observed.
location
Piping materails like flanges, fittings, stud nuts are
Materail traceability on pipe stored on pellets in seggregated condition and IMS, Identification
42 Store, Tezpur Positive
fittings proper tagging was provided for easy identification & Traceability
and avoiding mixup
Cylinders to be stored at suitable
It has been observed LPG gas clinders are stored
location having adequate
inside the store godown in which there was no
ventilation, Tag/label to be
ventilation other than the entrance door. Non HSE Plan, Storage
provided designating
43 Store, Tezpur Storage of Gas cylinder No identification for EMPTY/FILLED clyinders. Confirmity of flammable
EMPTY/FILLED identification.
In same room other flamable materials like foam Action materail (fuels)
Other flammable materails shall
pig, polythene packed materail are stored adjcent
not be stored on adjection location
to the gas cylinders.
and to be shifted to other location.
 Reference
Deapartment / Finding
Sr. No Details of Sample checked Description of Findings document / Requirement Photo (If applicable)
Activity Category
Clause No.
Film processing chemical solution time table
register well maintained.

Dark Room temperature measured 18 Deg C which

was found as per the requirement.

Chemical solution tanks and film loading desk

arrangements are found in order.

Reference Weld Defective chart found displayed.

Audit on Radiography Work,
NDT Dark Room, IMS, Radiography
44 Dark Room base facility and API 1104 acceptance criteria were found displayed Positive
Tezpur Testing Pro cedure
film processing for ready reference.

IQI sets for 10 ISO 16 & 6 ISO 12 was found

available in adequate quantity.

For densitometer Sr. No. JR08, found in working

condition with calibration validity maintained due
on 15.02.2024.

Validity of Survey meter & Dosimeter verified and

found calibrated.
Sample RT report no.1080, Report found with all required checks are done IMS, Radiography
45 NDT, Tezpur Positive
Dt: 26.12.2023 and recorded as per ITP requirement Testing ITP
Material storage To be stored with polythene
RT Film Digitizer, Film scanning machine found improper handling,
46 Scanner Equipment and Handling wrapped and placed inside cartoon
Tezpur no cover and heavy dust settlement are observed.
Non Procedure box
It has been observed at site office that all ISO Confirmity
IMS, 7.5.3, Control
certificates and Company corporate policies are Action Latest Version of document to be
47 Quality, Tezpur Context of the Organization of Documented
not upgraded up to the latest version which are to updated and displayed.
Information
be displayed.
Verified Sample weld visual All mandatory fields are found filled including
48 Quality, Tezpur report no. 600, Dt: alignment sheet no, welding consumable batch no. Positive IMS, Welding ITP
26.12.2023, and found as per the ITP requirement
IMS, 7.5,
WPS/PQR/EQT/PTC Found updated and Client approved record
49 Quality, Tezpur Positive Documented
document files maintained in order.
Information
All calibration report are suggested
Calibration of instruments carried out , index
IMS, PQP & SOP to be reviewed by Quality Engineer
maintained upto date. Improvemen
Verified list of calibrated Calibration of and signed on report with
50 Quality, Tezpur However there are no evident on confirming the t
instruments inspection conformance to the calibration
usability of instruments with respect to the Required
instruments result for usability in order to avoid
calibration result.
last moment rejection of
Verified sample Tool box
Quality tool box talk conducted and record IMS, Support, 7.2
51 Quality, Tezpur talk / training report Dt: Positive
maintained in order. competency
26.12.2023
IMS, 8, Operation,
NRL-C2, Site Ch: Verified fied joint coating Checked preheating and found 65 Deg C, DFT 150
52 Positive Field joint coating
KM1414 work on joint KM1414 M57 micron and found as per procedure requirement
procedure
 Reference
Deapartment / Finding
Sr. No Details of Sample checked Description of Findings document / Requirement Photo (If applicable)
Activity Category
Clause No.
All inspection inspection instruments found
available in working condition with valid
calibration. IMS, 7, Resources,
NRL-C2, Site Ch: Verified fied joint coating
53 Coating visual of joints KM1414 M55, M56 & M57 Positive Field joint coating
KM1414 work
found satisfactory. procedure
Closure patch position maintained 10 / 2 'O' clock
position
The coating waste like primer mixing pot, pad &
NRL-C2, Site Ch: Verified for EHS compliance IMS, Hazard
54 foam brush found collected properly & disposal Positive
KM1414 at coating work Material Disposal
found in order
Welding earthing found properly utilized as per the
recommendation and procedure.
Weld joint numbering found inline to the
Welding job
NRL-C2, Mainline Ch: 1429, Joint no. KM1429, procedure.
55 Positive procedure and
Welding M18 Minimum first filler found completed before taking
WPS
the break.
Above observation are inline to the WPS and Weld
numbering procedure
Welding
NRL-C2, Mainline Welding consumable found properly handled using consumable
56 At Ch: 1429 Positive
Welding tin and stored inside paywelder. handling and
storage procedure
Found client approved Identity card available at
site.
At ch:1429, Verified sample Welding job
NRL-C2, Mainline Welding hood utilized properly.
57 Welder Identity for W NO. Positive procedure and
Welding Preheating carried out through induction coil is as
69 & W No.71 WPS
per approved WPS.
LPG source available for interpass heating.
Verified welding consumable batch no
Welding job
E6010 3.2MM-18437130
procedure and
NRL-C2, Mainline E8010P1 4.0MM- 18500713
58 At Ch: 1429 Positive WPS, IMS Product
Welding Correlated with electrode box, welding report and
realization, Risk
EQT report found in order.
assessment
Welded pipe string end provided with night cap
Civil IMS, 7.5,
Report No- SV-05/BW-25, Report found as per ITP and due approval taken
59 Documentation, Positive Documented
Dt: 10 2023 from Client
Tezpur information
Civil IMS, 7.5.3, Control
Traceability of Drawing issue Document control index maintained with revision
60 Documentation, Positive of Documented
to Sub-Contractor number.
Tezpur Information
Team to be motivated and
Human Resource Identificatio of training needs and communication Improvemen
IMS, Training, communication through notice
61 / Administration, Training to the team to be improved at site level, training t
Competency board and mail circulation are
Tezpur schedule to be adhered. Required
suggested
 Reference
Deapartment / Finding
Sr. No Details of Sample checked Description of Findings document / Requirement Photo (If applicable)
Activity Category
Clause No.
Project inward technical document index status
maintained with traceability, where as commercial
correspondance status /index to to be maintained IMS, 7.5.3, Control Planning document / index can be
Planning,
62 Document Transmittal Index upto date. Observation of document and shared at all levels in order to
Guwahati
From KPIL Planning Manager to the sud-ordinate record communication easier.
level status to be shared to spread offices in order
to avoid communication gap.
Planning, Plan Vs Actual Progress
63 Back up / Supporting input data found available Positive IMS, 6, Planning
Guwahati monitoring / measurement