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Xstrata Technology Pty Ltd ABN 65 118 727 870 Level 4, 307 Queen Street, Brisbane, Queensland 4000 Telephone: +61 7 3833 8500. Facsimile: +61 7 3833 8555 www.xstratatech.com
Rev No. 0
TABLE OF CONTENTS
1. 2. 3. PURPOSE AND SCOPE............................................................................................................................ 3 DEFINITIONS........................................................................................................................................... 3 QUALITY PLAN LEVEL DEFINITION........................................................................................................ 4 3.1 3.2 3.3 3.4 4. Level A - No Traceability (NT) ............................................................................................................ 4 Level B - Partial Traceability (PT)......................................................................................................... 4 Level C - Full Traceability (F) .............................................................................................................. 5 Quality Plan Level by Equipment Type ............................................................................................... 7
MANUFACTURING DATA REPORT (MDR) REQUIREMENTS GUIDELINES ............................................. 7 4.1 Indices.............................................................................................................................................. 7 4.1.1 List of Contents ........................................................................................................................ 7 4.1.2 User Guide ............................................................................................................................... 7 4.1.3 Section Contents List ................................................................................................................ 7 4.1.4 Sub-Section Contents List ......................................................................................................... 7 4.2 Presentation ..................................................................................................................................... 8 4.2.1 Compilation ............................................................................................................................. 8 4.2.2 Collation ................................................................................................................................ 10 4.2.3 Paper Sizes ............................................................................................................................. 10 4.3 Example MDR Structure- Table of contents...................................................................................... 11 Witness Points ................................................................................................................................ 13 Hold Points..................................................................................................................................... 13 Example Inspection and Test Plan (ITP) (Template)............................................................................ 14 Example Quality Plan (Template) Level C.......................................................................................... 15
5.
SUPPLIER / FABRICATOR INSPECTION AND TEST Work REQUIREMENTS.......................................... 12 5.1 5.2 5.3
6.
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1.
2.
DEFINITIONS
An inspection, test or measure point in the manufacture/construction process beyond which work may not proceed without release being granted by an identified party. Activities such as measuring, examining, testing, gauging one or more characteristics of a product or service and comparing these with specified requirements to determine conformity. A formalised plan describing how, when and where the characteristics of products/works will be inspected, tested or measured to provide evidence that design, regulatory and contractually specified requirements have been met. A volume or number of volumes compiled by Suppliers/Contractors, containing records, certification and objective evidence of compliance with requirements appertaining to material, equipment or installation work for the project. Stock-in-trade items such as lengths of steel, piping, grating, handrails, bolts etc. The project person(s) nominated by the Project Manager to be responsible for the establishment and management of the Project Systems and QA regime (or specific part/function thereof).
Hold Point
Inspection
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Traceability
Verification Point
Witness Point
Work Package
The ability to trace the history, application or location of an item by means of recorded identification (AS/NZS ISO 8402) i.e. The systematic planned and documented approach to produce records to provide trails back from a completed product to the sources of materials, details of batches or lots, the equipment used, the operators involved, dates, times, details of conditions and other pertinent information. A stage in the sequence of the manufacture/ construction process where inspecting and/or testing is performed by personnel whose responsibility it is to determine the acceptability of product/works and to record inspection and test data. A stage in the sequence of the manufacture/ construction process where a party may formally witness the actions of another party in carrying out inspection and test activities. Equipment or item/s made from material by way of manufacturing or fabrication processes or methods, by a manufacturer or fabricator to a technical specification, code, drawing and /or process requirement.
3.
3.1
3.2
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All identifiable materials and components shall be fully traceable to receipt certification via unique identifications during the manufacturing stage only. Similarly, welds shall be traceable to welder qualifications and procedures during the manufacturing stage only. All non-destructive examination records shall however be fully traceable to the relevant component or part. The following documentation is required: (i) ITPs (ii) Technical Queries (iii) Non Conformance Reports (iv) Corrective Action Requests (v) Concession Requests (vi) Material Certificates (vii) Welding Procedures (Structural, Piping, etc.) (viii) Welder Qualification Records (ix) Test to Destruction Records (impact tests, tensile & compressive tests, ductility tests, etc.) (x) Non Destructive Examination Records (Ultrasonic Tests, Radiography Tests, Magnetic Particle Tests, Dye Penetrant Tests, Hardness Tests, Cleaning and Pressure Testing etc.) (xi) Heat Treatment Records (xii) Coating Inspection Records (xiii) Inspection Release Reports (xiv) As-Built Drawings (if requested as part of the project scope) (xv) Vendor Equipment Datasheets (performance curves, installation, operating and maintenance documentation, vendor test certificates, etc.) (xvi) Mechanical setup and test records (linear/angular travel, clearance, rotational freedom, etc.) (xvii) As constructed critical dimensions record
3.3
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Documented manufacturing and quality history of all identifiable materials, components and welds include the following: ITPs Inspection Authority Certificate of Compliance, where appropriate (pressure vessels, cranes, etc.) (iii) Technical Queries (iv) Non Conformance Reports (v) Corrective Action Requests (vi) Concession Requests (vii) Inspection Release Reports (viii) Material Certificates (Structural, Piping, Fittings, Valves) (ix) Heat Numbers (for Pressure Vessels and Pressure Piping) (x) Weld Maps (xi) Welding Procedures (Structural, Piping) (xii) Welding Procedure Qualification Records (xiii) Welder Qualification Records (xiv) Welding Consumable Register & Certificates (for Pressure Vessels and Pressure Piping) (xv) Weld/Material/NDE traceability sheets (for Pressure Vessels and Pressure Piping) (xvi) NDE Personnel Certification (for Pressure Vessels only) (xvii) Test to Destruction Records (impact tests, tensile & compressive tests, ductility tests, etc.) (xviii) Non Destructive Examination Records (Ultrasonic Tests, radiography Tests, Magnetic Particle Tests, Dye Penetrant Tests, Hardness Tests, Compaction Tests, Air Tests, etc.) (xix) Production Test Plate Records (for Pressure Vessels only) (xx) Heat Treatment Records (xxi) Leak Test Records (xxii) Dimensional Verification Records (xxiii) Hydrostatic Test Records (for Pressure Vessels and Pressure Piping) (xxiv) Calibration Certificates (xxv) Surface Preparation and Humidity Records (xxvi) Coating Inspection Records (xxvii) As-Built Drawings (if requested as part of the project scope) (xxviii) Vendor Equipment Datasheets (performance curves, installation, operating and maintenance documentation, vendor test certificates, etc.) (xxix) Mechanical setup and test records (linear/angular travel, clearance, rotational freedom, etc.) (xxx) As constructed critical dimensions record (i) (ii)
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3.4
The QA Requirements for the following types of equipment or fabrications are detailed below: Equipment Type Quality Plan Level Level A Level B Level C Partial No Traceability Full Traceability Traceability Pressure vessels and pressure parts X Process Equipment (Static) X Process Equipment (Dynamic) X Conveyor Equipment X Pumps X Valves - Safety X Valves - Other X Structural Steelwork and Platework X Process Instruments and Control Devices X Electrical Equipment X
4.
4.1 4.1.1
Indices
List of Contents The List of Contents shall be placed at the beginning of the MDR. A typical MDR structure is shown in item 4.3. A List of Contents should show the Volume, Part and Section information. If the index is revised, it shall be re-submitted for review.
4.1.2
User Guide For complex goods or work, the Supplier/Contractor should provide a User Guide detailing how the traceability and identification system works, how to locate materials in an assembly and how to relate records to materials or other records. The guide shall be submitted for review along with the MDR List of Contents. The guide should be placed immediately after the List of Contents.
4.1.3
Section Contents List A Section Contents List - specific to the Section, should be placed immediately following section dividers. This list shall identify the contents of the Section to Sub-section level.
4.1.4
Sub-Section Contents List The Supplier/Contractor should provide a Sub-Section Contents List if considered necessary by the Company Representative or the Supplier/Contractor. This list shall identify the contents of the sub-section to the commencing page number of individual documents. Such lists are usually required when traceability is a requirement.
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4.2 4.2.1
Presentation
Compilation MDRs should be compiled in new, hard covered, D type, four ring, white, plastic folders with external pockets for front cover and spine. A full sized title page and spine title strip should identify folders. The folders contents should not be longer than the folder and should be clamped in place with a four ring spring clamp. When the folder (complete with contents) is laid flat, the outer edge should not be higher than the bound edge. MDRs should be compiled in Parts, eg. In the case of a purchase order for three separable items, each item shall have its documentation maintained in a Part of the MDR. Parts shall be given a numeric identifier. Parts are in turn broken down into sections at discipline level as listed below. Only those sections, which are applicable to the material/equipment/work being supplied or carried out, shall be included. For sections of the report that are not applicable state N/A on the list of contents. Section A - Inspection Release Certificate, Inspection Waiver and ITP Include a copy of the Inspection Release Certificate signed by or on behalf of the Companys Representative. When the equipment/material/work does not require Company Representatives inspection, include a copy of the correspondence received from the Companys Representative indicating a waiver of Company Representatives Inspection. Signed-off Inspection and Test Plans shall also be included in this section. Section B - Material Certificates and Material Test Reports For Purchase Orders or Contracts requiring material traceability, this section shall contain a list identifying material certificates/test reports with their part, piece or item number and is to include a copy of the certificate/reports referred to on the list. The list shall show the Supplier/Contractors drawing no. of each part/piece of equipment or bulk material item number identified with: (i) Certificate / report number, line item - page number. (ii) Heat, lot, plate number, etc. For Purchase Orders / Contracts which do not require material traceability a register of material certificates/test reports shall be sufficient. Section C - Certificate of Compliance This section shall contain certificates of compliance to the purchase order requirements and to the applicable codes and standards for fabricated pieces of equipment. Section D - Welding Records This section shall include a list of accepted welding procedure specifications (WPS), welding procedure qualifications (PQR), weld maps, welding traceability control sheets, and results of production weld tests.
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Section E - Welder and Welding Operator Records This section shall include a list of qualified welders and welding operators, date of qualification, welder identification number, and name of the qualifying authority. Section F - Non-Destructive Testing Records In this section include a list, map or summary of all the non-destructive testing performed. Reference shall be made to the test locations on the equipment/materials/work. Include all certificates/reports that are issued for non-destructive testing performed. Include a summary sheet for all non-destructive testing personnel and their qualifications. Section G - Painting and Coating Copies of reports of all surface preparation and coating applications shall be included in this section. Section H - Heat Treatment Records This section shall include certificates and properly scaled charts for all heat treatment performed, including reference to equipment identification number and date of heat treatment. Section I - Dimensional Records Record of final dimensional checks and flange surface finish inspections shall be included in this section. Section J - Non-Conformance Reports and Concessions Non-conformance reports, technical queries, and all approved concessions shall be included in this section. Section K Pressure/Leak Test Records This section shall include hydrostatic and/or pneumatic test records, proof test certificates and valve body/seat/leak test certificates. Section L General Test Records This section shall include reports of mechanical running test, mechanical functional tests, performance tests, and noise level tests. Section M - Electrical Certificates and Reports In this section the following shall be included when relevant. (i) Electrical and electronic equipment certification schedule and other certificates and reports. (ii) Electrical Material Statement of Compliance. (iii) Electrical Certification - Hazardous operation. (iv) Other test reports required by the specifications.
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Section N - Instrumentation Certificates and Reports In this section include the following when relevant. (i) Instrumentation equipment certification schedule. (ii) Instrumentation Certification - hazardous operation. Section O Drawings In this section include a copy of complete as-built drawings, if required as part of the project scope. Section P - Miscellaneous Certificates, Reports and Records This section shall include all requested certification, reports, records and other data, which are not covered by other sections. Section Q - Statutory Documents for Cranes, Hoists and Lifts List and copy of all statutory documentation shall be included in this section. Section R - Documentation for Pressure Vessels and Heat Exchangers, and Other Statutory Requirements List and copy of all statutory documentation shall be included in this section. 4.2.2 Collation The MDR should be collated as Volumes, each folder being a volume with a volume number identifying the total number of volumes, eg. Volume 1 of 6. Each volume shall clearly show: 1. Project Name; 2. Purchase Order/Contract Number; 3. Supplier/Contractor name; 4. Project Equipment/Material/Work; 5. Volume Identification, (i.e. Volume 1 of 10; Volume 2 of 10); 6. Part numbers covered in the Volume. 4.2.3 7. Paper Sizes Standard ISO-A series paper is required for all MDR data i.e. A1, A2, A3 or A4. The preferred size for drawings and schedules is A3. The preferred size for Certificates and Reports is A4. Where the use of A4 or A3 size sheets leads to the illegibility of the drawing details, a larger Asize (that corrects the problem) may be used. When A1 or A2 size data is provided, it shall be folded to A4 size and placed in suitable four hole plastic pockets within the folders. Folded data should have the title block uppermost and visible
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4.3
Volume
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Volume
Part
Section N
Description Instrumentation Certificates and Reports Instrumentation Equipment Certification Schedule Instrumentation Certification - Hazardous Operation Other Compliance Reports Drawings As-Built Drawings Miscellaneous Certificates, Reports and Records Instrument Calibration Certificates (relevant during fabrication Vendor Data for Instruments and Gauges Others Statutory Documents for Cranes, Hoists and Lifts Cranes, Hoists and Lifts Statutory Documents for Pressure Vessels, Heat Exchangers an Others Inspection Authority Certificate Design Calculations and Assumptions
5.
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5.1
Witness Points
As a minimum, Witness Points shall be nominated for: Welding The QAE shall nominate appropriate Witness Points for the Weld Procedure Specifications and Welder Qualification Records. If these processes are not included in the ITP, the QAE shall ensure that the Supplier / Fabricator revises their ITPs to include these processes. Sub assemblies the QAE shall nominate a Witness Point at the final inspection of each sub assembly. If this process is not included in the ITP, the QAE shall ensure that the Supplier / Fabricator revises their ITPs to include this process.
5.2
Hold Points
As a minimum, hold points shall be nominated for: The final inspection, and/or shop testing, prior to the delivery of the equipment. Specific critical dimensions or other attributes will be nominated as such on Supplier or Xstrata General Arrangement drawings. (This is where the equipment or fabrications will interface on site with other equipment or fabrications, and/or where they need to comply with transport limitations such as containerisation) These will be classified as a client (XT) hold point. If this process is not included in the ITP, the QAE shall ensure that the Supplier / Fabricator revises their ITPs to include this process.
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Rev No. A
5.3
Stage 01 02 03 04 05 06 07 08 09 10
Activity Review Material Certification, Chemical Analysis And Mechanical Tests Review Weld Procedures And Qualifications For Piping Raw Material Identification (Castings) Inspect Casting And Fabrication Casting Repair, If Applicable. Weld Procedure Approval Mark Off For Machining (castings) Inspect All Critical Dimensions Hydrostatic Test (Pressure Parts) Prepare/Paint To Contract Specification Final Inspection And Review Of Documentation
Fabricator H H
Vendor
ISO 9001 ISO 9001 ISO 9001 ISO 9001 Supplier Instruct Supplier Instruct Supplier Instruct ISO 9001 ISO 9001
Suitability for fabrication prior to welding Cast Number on casting and identify certification Visual and dimensional to drawing Suitability for repair prior to welding Dimensional Dimensional Structural integrity of casting and fabrications freedom from leaks Visual and Paint thickness Visual, Dimensional and Certification
Material certificate and drawing Casting and Fabrication drawing Applicable standards Drawing Notes on GA Contract drawing
H H H H H H R
Purchase Order
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6. 6.1
QUALITY PLAN REQUIREMENTS (FULL TRACEABILITY- LEVEL C) Example Quality Plan (Template) Level C
Sheet 1 of 1
ISSUE DATE H = MANDATORY HOLD POINT/100% WITNESS. APPROPRIATE REPRESENTATIVE MUST ATTEND W = WITNESS POINT NOT MANDATORY. APPROPRIATE REPRESENTATIVE TO BE INFORMED BUT IF NOT IN ATTENDANCE WORK TO PROCEED R= REVIEW OF DOCUMENTS/RECORDS.
Fabricator
Vendor
Records Insp. Records Certificates Dimensional Certificate Certificate of Conformity Manufacturing Data Records
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