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XSTRATA TECHNOLOGY LIMITED

TECHNICAL SPECIFICATION PMA-XT-SP0009


QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS
Revision 0 Date Revised 25-Jan-10 Description/Comment Originator Approved for Use C. Hanna Signatures Checked B. Boucher Approved H. Joubert

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

TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No.: PMA-XT-SP0009

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.

QUALITY PLAN REQUIREMENTS (FULL TRACEABILITY- LEVEL C) ...................................................... 15 6.1

Xstrata Technology Pty Limited ABN 65 118 727 870

QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

25-Jan-10

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TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No.: PMA-XT-SP0009

Rev No. 0

1.

PURPOSE AND SCOPE


The purpose of this procedure is to define the quality assurance requirements for the equipment and material that may be procured for Xstrata Technology (XT) Projects. This specification shall be used to determine the level of Quality Plan required for the equipment being supplied and the contents that are required in the Manufacturing Data Report (MDR). This procedure shall also be used to determine the traceability level for the equipment being supplied. The level of Quality Plan shall be entered into the Quality Assurance Requirements Register, along with the frequency of inspection required. The Quality Assurance Requirements Register shall be controlled and updated by the Project Manager or their nominated representative.

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

Inspection and Test Plan (ITP)

Manufacturers Data Report (MDR)

Material Quality Assurance Engineer (QAE)

Xstrata Technology Pty Limited ABN 65 118 727 870

QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

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TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No.: PMA-XT-SP0009

Rev No. 0

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.

QUALITY PLAN LEVEL DEFINITION


The QAE shall review the equipment to be supplied as part of the Work Package and assign the Quality Plan Level as shown below.

3.1

Level A - No Traceability (NT)


A documented statement by the material/component supplier, fabricator or vendor, (drawn up as a result of inspection and tests carried out by personnel authorised by the supplier/fabricator/vendor and who may be involved in production), demonstrating that the product conforms to the requirements of the supply contract / purchase order, without mention of any test results, is required. This documented statement shall also be the MDR. Proof of traceability of materials, components and welds is not required. The following documentation is required: Concession Requests (if applicable) As-Built Drawings (if applicable)

3.2

Level B - Partial Traceability (PT)


An Inspection and Test Plan (ITP), drawn up and issued by the supplier, fabricator or vendor, and reviewed and approved by the QAE, is required. This ITP shall demonstrate that the product has met or exceeded all of the requirements specified in the supply contract. The ITP shall ensure that all the documentation required for the MDR is part of the inspection and testing process. An MDR, as required under the supply contract, shall be provided (refer to item 4 for guidelines for the MDR requirements).

Xstrata Technology Pty Limited ABN 65 118 727 870

QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

25-Jan-10

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TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No.: PMA-XT-SP0009

Rev No. 0

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

Level C - Full Traceability (F)


A Quality Plan, drawn up and issued by the supplier, fabricator or vendor, and reviewed and approved by the QAE, is required. The Quality Plan shall include procedures for design (where applicable), procurement, subcontracting (where applicable), manufacture, pre-delivery testing, delivery, erection (where applicable), and commissioning (where applicable). ITPs, as in Level B above, are required for manufacturing and fabrication processes. An MDR, as required under the supply contract, shall be provided (refer to item 4 for guidelines for the MDR requirements). Documented manufacturing and quality history of all identifiable materials, components and welds via test reports, material certifications, etc. which have been nominated in the approved ITP and MDR list of contents. These records shall be fully traceable to the relevant component or part on the finished product and shown using marked-up as-built drawings or isometrics and separate traceability sheets for welding and non-destructive examination records.

Xstrata Technology Pty Limited ABN 65 118 727 870

QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

25-Jan-10

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TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No.: PMA-XT-SP0009

Rev No. 0

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)

Xstrata Technology Pty Limited ABN 65 118 727 870

QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

25-Jan-10

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TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No.: PMA-XT-SP0009

Rev No. 0

3.4

Quality Plan Level by Equipment Type

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.

MANUFACTURING DATA REPORT (MDR) REQUIREMENTS GUIDELINES


MDRs (in varying detail) are required for quality plan levels A, B and C. The Suppliers / Vendors shall include all relevant data which they are contractually obliged to supply under their Supply Contract or data that they normally collect as part of their manufacturing process, and include this data in the relevant MDR Section.

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.

Xstrata Technology Pty Limited ABN 65 118 727 870

QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

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TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No.: PMA-XT-SP0009

Rev No. 0

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.

Xstrata Technology Pty Limited ABN 65 118 727 870

QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

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TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No.: PMA-XT-SP0009

Rev No. 0

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.

Xstrata Technology Pty Limited ABN 65 118 727 870

QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

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TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No.: PMA-XT-SP0009

Rev No. 0

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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TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No.: PMA-XT-SP0009

Rev No. 0

4.3

Example MDR Structure- Table of contents


Part Section A A-1 A-2 B B-1 B-2 B-3 B-4 B-5 C C-1 D D-1 D-2 D-3 D-4 D-5 E E-1 E-2 F F-1 F-2 F-3 G G-1 H H-1 I I-1 I-2 J J-1 J-2 J-4 K K-1 K-2 K-3 K-4 K-5 L L-1 L-2 L-3 L-4 M M-1 M-2 M-3 M-4 Sub-Section Description Inspection Release / Inspection Waiver Inspection Release Report Completed ITPs Material Certificates / Test Reports Structural Steel Pipe Fittings Valves Others Certificate of Compliance Certificates of Compliance Welding Records Welding Procedure Specifications and Register Procedure Qualification Records and Register Weld Maps and Traceability Records Consumable Register and Certificates Production Test Plate Records Welder and Welding Operator Records Welder Register Welder Qualification Records and Renewals Non-Destructive Testing Records NDE Maps and Traceability Records NDE Reports - UT, RT, MT, PT, Hardness Tests, etc NDE Personnel Register Painting and Coating Surface Preparation and Painting Records Heat Treatment Records Heat Treatment Records Dimensional Records Dimensional Verification Records Flange Facing Inspector Records Non-Conformance Reports and Concessions Non-Conformance Reports Approved Concession Reports Concession Records Pressure Test Records Hydrostatic Test Records Pneumatic Records Proof Test Certificates Valve Body / Seat / Leak Test Certificates Air Test Records Mechanical and Performance Test Records Mechanical Running Tests Mechanical Functional Tests Performance Tests Noise Level Tests Electrical Certificates and Reports Electrical and Electronic Equipment Certification Schedule, etc Electrical Material Statements of Compliance Electrical Certifications for Hazardous Operations Other Test Reports
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Volume

Xstrata Technology Pty Limited ABN 65 118 727 870

QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No.: PMA-XT-SP0009

Rev No. 0

Volume

Part

Section N

Sub-Section N-1 N-2 N-3

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

O O-1 P P-1 P-2 P-3 Q Q-1 R R-1 R-2

5.

SUPPLIER / FABRICATOR INSPECTION AND TEST WORK REQUIREMENTS


All basic test work required will be specified in standard specifications pertaining to the equipment being supplied. Any specific requirements in terms of test work, or inspections, will be listed in the project specific equipment specifications. All test work carried out, on equipment supplied to XT, must comply with Australian Standards, as a bare minimum. Should any more onerous test work be required, it will be detailed in the project specific equipment specifications. All test work must be planned and the activities listed in the ITP for the equipment. ITPs are required for Quality levels B and C. The QAE shall also determine the critical aspects of the manufacturing or fabrication of the item/s, as part of that work package. Notwithstanding the Quality Plan Level the witness points and hold points are to be addressed when reviewing ITPs. All Supplier / Fabricator ITPs are to reviewed and approved by the QAE. The QAE shall include Verification Points, Witness Points or Hold Points on the Supplier / Fabricator ITPs, based the what the QAE determines are critical dimensions and processes in manufacture or fabrication. The Supplier/Fabricator must give the QAE Engineer at least 1 weeks notice prior to any test work or inspections that are specified as witness or hold points in the ITP.

Xstrata Technology Pty Limited ABN 65 118 727 870

QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

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TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No.: PMA-XT-SP0009

Rev No. 0

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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QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

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TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No. PMA-XT-SP0009

Rev No. A

5.3

Example Inspection and Test Plan (ITP) (Template)


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. AP = REVIEW AND APPROVAL OF TECHNICAL DOCUMENTS BEFORE COMMENCEMENT OF MANUFACTURE Castings & Fabrications Procedure Ref. Stage Involvement Client End (XT) User AP AP R R AP/H R H R H H H H W W W Records Report Material Certificate Approved WPs Material Certificate Certificate of Conformity Approved WPS Certificate of Conformity Certificate of Conformity Test Certificate Paint Certificate Certificate of Conformity Data Book

Product Inspection and Test Plant for Xstrata Technology


PURCHASER: END USER: CONTRACTOR: PRODUCT: DESCRIPTION: Xstrata Technology ISSUE DESCRIPTION FIRST ISSUE CLIENTS COMMENTS ADDED

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

Quality Characteristic Material Certificates comply with application specification

Acceptance Criteria Purchase Order applicable material specification

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

Xstrata Technology Limited ABN 87 009 661 447

PMA-XT-SP0009 - Quality Assurance Requirements for Procured Items

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TECHNICAL SPECIFICATION QUALITY ASSURANCE REQUIREMENTS FOR PROCURED ITEMS

Document No. PMA-XT-SP0009

Rev No. A

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.

Product Quality Plan for Xstrata Technology


PURCHASER: END USER: CONTRACTOR: PRODUCT: DESCRIPTION: Stage 01 02 03 04 05 06 07 08 09 10 11 12 Activity Contract Handover and Review Review Design Requirement Submit design data to statutory authorities and client Develop Inspection and Test Plant Develop GA drawings and submit to client Award sub contract/supply orders Issue AFC drawings Expedite Inspect all purchased items on receipt including certification prior to part issued for assembly Final Inspection. Shop assembly. Confirm critical dimensions, aspects Packing, Marking and Preservation Review Manufacturing Data Records Procedure Ref. ISO 9001 ISO 9001 ISO 9001 ISO 9001 ISO 9001 ISO 9001 ISO 9001 ISO 9001 Contract schedule Visual, Dimensional and Certification Visual, Dimensional, Cleanliness and Nameplate Adequacy of packing , Preservation and Identification Records and Certification Contractual delivery dates Purchase Orders and Drawings Drawings and Contract Specifications To Approved Specification Release Certificate Contract Requirements R H H Compliance with drawings, specs. Contract Crane codes R Quality Characteristic Compatibility of order and specifications with Tender Documents Acceptance Criteria Tender Documents Stage Involvement Client End (XT) User R R R R R R R R H H W W W H W W R R R EOHT Crane Xstrata Technology ISSUE DESCRIPTION FIRST ISSUE CLIENTS COMMENTS ADDED

Records Report Acknment of Order Data Book

Fabricator

Vendor

Submission ITP Drawings P.O.

Records Insp. Records Certificates Dimensional Certificate Certificate of Conformity Manufacturing Data Records

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PMA-XT-SP0009 - Quality Assurance Requirements for Procured Items

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