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Quality control
in
construction!
 Accountability
 Tracability
 Reliability
 Customer
satisfaction

QA/QC ISO 9001


Technical Support Quality Management Cost
System Requirements Impact

We specialize in the following oil, gas,


power, and infrastructure Construction This web site was set up to assist International construction projects
projects, we can provide expert technical Investment Consortiums, Construction specify in contract documents how and
support. We can visit your overseas Companies/ Suppliers and inspection when segments of the project are to be
construction project and immediately personnel to become familiar with the handed over to the customer. It is
implement our benchmarked best practices ISO 9000:2000 (International Standards apparent that significant cost impact
and get your construction quality back on organisation) and the implementation of and loss of profit margins is attributed to
track. Our experienced QA/QC construction this standard in the Construction, projects that do not have the minimum
support team can be available on a fast Petrochemical Oil /Gas and Power quality and constructability systems in
track short term visit from 7 days to 25 industries. Sample construction place prior to the commencement of the
days. We can provide your Company with a procedures have been developed as a project.
24 hour response to your enquiry. base, for project implementation.
Project QA/QC
Control of Bids Implementation
Subcontractors

Project bid documents contracts and


Well over 90% of companies or
customer specifications define the
The use of numerous sub-contractors and organisations implement the standard
quality control and quality assurance
suppliers on major construction projects because of the pressure from their
requirements of the project. It is
who do not comply with client specifications customers. When introducing the
common practice for suppliers to be
will result in the issue of (nonconformance standard into an organisation there is a
assessed by audit not only on their
reports) resulting in significant additional requirement within the standard that the
capability and track record to complete
cost impacts and schedule delays. company only purchases services and
the project but also on their ISO 9001
products from quality assured sources.
quality systems.
The Project Mission Statement
Owners - Investment Performance

Customers - Product Quality, Low Maintenance Costs,

Prime Contractors - Project Completion on Time Within Budget, Customer Satisfaction

Employees - Career, Work Satisfaction

Suppliers - Continuing Business

Society - Responsible Stewardship

The purpose of this Web Site is to Provide International Quality Management Services
on Major Lump Sum Turn Key Construction Projects around the world for Oil Gas and
Power Generation Industries, based on ISO 9001 Quality Assurance Quality Control
Standards and the customers specific contractual requirements.

The intent of qaqc-construction web site is to provide the user strategic information and
tools to implement Project Quality Management Systems without reinventing the
proverbial wheel.

While considerable effort has been made to make the web site user friendly, interesting
and informative it was apparent that back room or supporting information was required
to give the site viewer more detailed information, this can be obtained in the premium
section of the web site for members that would like access it.

qaqc-construction.com web site specialises in the following:


1. Provide guidance to Owner Consortium Investment Organisations Construction Companies and suppliers for the
Implementation of Quality Management Systems.
2. Provide construction companies information and technical expertise in the field of Quality Management Systems so
that they have the competitive edge when tendering for mayor lump sum turnkey Engineering, Procurement and
Construction projects
3. Provide electronic database for Quality Documentation that can be adapted for As-built Turn Over Packages and
Performance Guarantees.
4. Implementation of Quality Management System Procedures covering the specific requirements of the Customers
Contract, obtaining customer approval for Project Implementation
5. Provide Quality Assurance Quality Control personnel and Inspectors for Project System Management implementation
for Civil, Mechanical, Electrical, and Instrumentation construction site disciplines.
6. Provide Quality Management Consulting Services.
7. Provide on site Internal and External Auditing services.
Product Manufacturing Projects Needs for Quality
1] Procedures & Specifications Implementation
2] Codes & Standards Mission Statement
3] ASME Certification Planning & Scheduling
4] NDT Procedures Constructability Program
5] Inspection & Test Plans Audits
6] Material Inspections Training
7] Pre Inspection Kick Off Meeting
Quality Management Savings
Purchased Materials & Equipment Virtually No Rework
Inspection Requirements Zero Punchlists
1] Overshort & Damage Report Project Completed Under
2] nonconformance Report Budget And On Time
3] Preventative Maintenance Schedules Company Annual Savings
4] Control Of Customer Supplied Product Motivated Employees
Customer Satisfaction

4.1] Management Responsibility 4.12] Inspection


4.2] Quality System & Test Status
4.3] Contract Review 4.13] Control Of
4.4] Design Control Non-
4.5] Document & Data Control LEVEL 1 Conforming
4.6] Purchasing QUALITY Product
4.7] Control Of Customer ASSURANCE 4.14] Corrective
Supplied Product COMPANY POLICY &
4.8] Product Identification MANUAL Preventive
& Traceability Action
4.9] Process Control supplied to the customer 4.15] Handling
4.10] Inspection & Testing usually at bid stage Storage Packing
4.11] Control Of Inspection
Measuring & Test Equipment LEVEL 2 Preservation &
QA MANAGEMENT Delivery
PROCEDURES 4.16] Control Of
Quality
supplied by Records
subcontractor unless 4.17] Internal
otherwise agreed Quality Audits
4.18] Training
LEVEL 3 4.19] Servicing
QC INSPECTION 4.20] Statistical
PROCEDURES Techniques
NDE PROCEDURES
METHOD
STATMENTS

LEVEL 4
QC INSPECTION
CHECK SHEETS
Click here to goto Construction Inspection & Test Plans and Inspect.

Hold & Witness Have all subcontractors defined their Inspection Points Witness and Hold Points? Does the
Points Defined Test Plan define the scope of the customers Technical requirements.

Are there any off site suppliers/vendors that require


Subcontractors
Inspection & Test Plan coordination on site to complete
Involvement
any installations?

Ensure any and all Third Party Inspections are


Third Party
coordinated and defined in the Inspection & Test
Inspection
Plans.

Ensure all the project scope is defined in the Test Plan.


Project Scope
This is especially important because the Test Plan is
Agreed & Defined
the document that validates the project.

Point of Contacts Does the Inspection & Test Plan identify all the inspection bodies, subcontractors and
Defined vendors working on the site?

The Reason Why

The Quality Control Inspection Plan (QCIP) is the master document that controls the quality of the project
requirements. It can either control all sub contractors on site or control each subcontractor individually. The QCIP
must be in place and agreed by all concerned parties prior to the commencement of any construction activities.

Quality Training

Training of the site QC inspectors into their specific duties and involvement in the inspection activities must be
conducted prior to the commencement of any construction work.

The Requirements

The requirements of the QCIP must identify the following:

 The quality targets to be achieved in relation to the customers projects technical and contractual requirements.
 The specific assignments and responsibilities of the involved inspection parties.
 The specific procedures, methods and work instructions to be applied
 Methods for dealing with revisions and changes of the QCIP during the progress of the project
 Reference to inspection check sheets for each construction discipline

QCIP Example

Below is an example of a project Quality Control Inspection Test Plan.

Quality Control Inspection & Test Plan

COMPANY NAME
Description of Activity
Inspect
Witness
Hold
Review

Rev No Date

Approved Date Sign

Quality Control Inspection & Test Plan


ACTIVITY PROCEDURE CHECK LEVEL OF VERIFYING INSPECTED COMMENTS
POINTS ACCEPTANCE DOC BY
2 Tell me
3 what Tell me, what
4 construction construction Tell me,
5 activity. procedure what are Tell me, what
6 you are going your is your level of Tell me,
to use to inspection acceptance?
7 what Who is
describe your check (i.e. Contract inspection
8 activity? going to Are there
points? Specification documents inspect the
9 any other
Drawings you are item and requirements
10 Client going to when? that need to
11 Procedures). use to be stated?
12 verify the
13 inspection
activities?

Construction Site Inspection and Test Plans

How Do I Control 1000 to 30000 construction workers on large construction projects and still provide what the
customer wants?
(and)
How do I verify when the contractors Construction Department says the project finished?
(and)
How do I Know, if all the quality control inspections have been completed and there are no outstanding punch-lists?
(and)
Ho w do I know, is the as-built condition correct and in accordance with the approved (Issued for Construction
Drawings)?
(and)
How do I know, if there is any design changes that effect the operating process?
(and)
How do I prevent construction mistakes and having to complete rework, then losing my profit margins?
Note: (Quality Plans may be used to control the following interrelating processes:

 FEED-Front End Engineering


 EPC-Engineering Procurement and Construction Projects
 Commissioning
 Mechanical Completion
 Project Turnover

Use Construction Quality Control Inspection and Test Plans Purpose and scope
The purpose of an Inspection and Test Plan is to put together in a single document that records all inspection and
testing requirements relevant to a specific process. On a construction contract the process is likely to be a
construction activity, element of work, trade work or providing a product section. An Inspection and Test Plan
identifies the items of materials and work to be inspected or tested, by whom and at what stage or frequency, as well
as Hold and Witness Points, references to relevant standards, acceptance criteria and the records to be maintained.
Inspection and Test Plans, when properly implemented, help ensure that, and verify whether, work has been
undertaken to the required standard and requirements, and that records are kept.

Glossary

Hold Point - A 'hold' point defines a point beyond which work may not proceed without the authorisation of the
customer of customers representative.

The customer of customers representative might be an agency's or other or a regulatory authority (such as a council,
Third Part Testing Authority Surveillance - Intermittent monitoring of any stage of the work in progress (whether by
the service provider or customer). Self inspection - Where the service provider performing the work verifies the quality
progressively often with the aid of checklists. Work area - A discrete section of the whole work, usually defined by
location, where any trade work or activity would be completed before it moves onto another area. Examples include a
wall, a room, a building, a length of pipeline between manholes and the like.

Roles and Responsibilities

There are no set rules as to who, contractor's organization, should document Inspection and Test Plans. It is
appropriate, however, that they receive input from those with a good technical and practical knowledge of, and
experience in, the activities involved. The use, understanding and acceptance of ITPs by inspectors and other
personnel will generally be contractor if they are involved in their preparation. The Contractor is responsible for
ensuring that all the required Inspection and Test Plans are prepared, including those covering work or processes to
be carried out by its subcontractors. While it is preferable sub contractors prepare the ITPs for their own work, in the
final analysis some may require the contractors involvement. A senior representative of the contractor would be made
responsible for approving Inspection and Test Plans, and any subsequent amendments, prior to their submission or
submission of compliance/conformity certification to the customer. The contract conditions would define the
submissions to the customer and any responses required.

Overview

The following steps are involved in documenting Inspection and Test Plans for a construction contract: -

Step 1 Read the contract documents (including the technical specifications) and prepare a list of any discrepancies,
ambiguities, missing information and standards of materials and/or workmanship that it is considered are
inappropriate.

Step 2 Contact the customer and resolve the issues listed as a result of Step 1.

Step 3 Examine the scope of work and divide it into separate areas requiring an Inspection and Test Plan (where not
already prescribed in the contract documents). As a general guide it is normally most convenient to document a
separate Inspection and Test Plan for each trade or work area/section.

Step 4 Note the Hold and Witness Points required by the customer (including as listed in the contract documents).

Step 5 Review the contract documents again and note the requirements that have the most impact on the quality of
the finished work. For each ask the question "What will be the consequences if it is not made sure this is right?" Be
certain to include any references to tests, submitting information to the customer, obtaining approvals and Hold and
Witness Points.

Step 6 Determine from Step 5 which items or aspects of each inspection will need to be recorded on checklists and
prepare these.
Step 7 Discuss the checklists with those directly involved with the work and obtain their input. This input should
particularly be directed at identifying those issues that have caused problems (and involved extra costs) in the past,
and therefore warrant checking at the earliest opportunity to avoid unnecessary and costly rectification.

Step 8 Prepare each Inspection and Test Plan to reflect the requirements of the contract documents. Reference the
ITP in the Quality Management Plan and cross-reference to the other related ITPs.

Step 9 Issue each Inspection and Test Plan and/or associated certification to the customer for consideration within a
reasonable period prior to commencing the work described in the Plan and adjust them to suit any comment received
(or act as otherwise required in the contract documents).

Step 10 Decide how best to divide the whole of the work into work areas for control purposes and indicate these
locations either on a schedule (with reference to grids and levels) or by marking up drawings.

Step 11 Prepare and issue checklists for each work area and identify them according to location.

Step 12 Train those directly involved with each of the ITP in their use. Formalise a procedure for the notification of
Witness and Hold Points to the appropriate person(s).

Step 13 Carry out inspections and tests in accordance with the Inspection and Test Plans, provide notices to the
customer and/or regulatory authorities for Hold or Witness Points, as designated or applicable, and record the results
on checklists.

Inspection And Test Plan Supporting Information

Record the following contract particulars on each of the Inspection and Test Plans: - Quality Management Systems
Guidelines

 Contract Name
 Contract Number
 Description of process/activities for that particular Inspection and Test Plan.

Inspection and Test Plans General

Description of operation or stage of work requiring inspection or test Because 100% inspection and testing in most
cases is neither practical nor desirable, it is necessary to adopt a testing frequency and sampling process which
provides a representative indication of the work to suit the risks involved.

Inspections and tests are often best done after a number of separate activities, but prior to a major one that will cover
up previous work. Contractors and subcontractors would carry out preliminary tests to assist in obtaining an early
indication of conformity.

Inspections and tests vary to suit the risks and work involved this is completed by referring too prevous lessens
learned files and experaince of the technical personnel that are completing the ITP. Remember, the ITP provides
information to the site construction personnel as to what the customer has said what they want, (In the contract of
Project Specification)

The "what to test", "how to test" and "when to test" is governed by: -

 What the work is and how complex it is


 Accessibility for inspections and sampling
 Consequences of failure, including as follows:
 Cost of remedial work
 Effect on construction program
 Accessibility for rectification
 Disruption to use of building or structure
 Consequential damage to other elements
 Threat to safety of workers and public
 Availability of resources.

The type, timing and frequency (the what, when and how often) of inspections and tests are best determined in
conjunction with the consideration of the characteristics to be verified. Characteristics of inspection/test/approval
The characteristics of a work item can be defined as "a distinguishable property of an item, material or process".
Examples of characteristics are colour, texture, size, strength, flatness, alignment, capacity and the like.

The characteristics to be verified will frequently determine the stage at which the inspection or test must take place if
the potential for subsequent nonconformities is to be avoided. This further work might also cover up or deny access
for the purposes of verifying certain characteristics. Some characteristics can only be considered after one particular
operation and before another, such as the inspection of steel reinforcement after installation but prior to the pouring of
concrete.

Stage/frequency

The inspection/test stage/frequency will often be determined by the requirements of the contract documents or by the
type of inspection and/or test and the characteristics under consideration, as outlined above. In the latter case
however, there is the potential for a considerable range in what constitutes the most appropriate frequency and
sampling process. It is suggested that a representative sampling of the work to suit the risks involved be used as a
guide initially. Thereafter, frequencies would be increased and processes reviewed for'problem' work activities and
decreased where consistent conformity was evidenced.

QC Inspection Check Sheets

Records are essential to quality management because they provide the documented evidence necessary to verify
that a product/service is in accordance with the contract requirements. The records would be in various forms, and
would include the checklists, test certificates, certificates of compliance/conformity, survey data, written approvals
and the like. Inspection and Test Plans would help define the records required and will comply with Project payment
milestones and as-built turnover documentation.

Project Specifications Codes and Standards

The standards against which conformity is measured can take various forms. The most common source is usually the
contract technical specification. Other standards would often be referenced in this document, and may include any of
the following: -

 Contract documents/specification generally


 Contract drawings
 Approved workshop drawings and/or calculations
 Approved technical details/procedures
 Approved samples and/or prototypes
 Regulatory requirements
 Australian Standards
 International Standards
 Standard specifications
 Manufacturers' recommendations

Acceptance criteria

Acceptance criteria would normally be defined in the contract documents (either directly or by reference to other
standards such Inernational Codes and Standards). Where this is not the case it would be necessary to identify them
and possibly to agree them with the customer. It is preferable to establish acceptance criteria with the customer
(where they are not specified or clear) to agree the yardsticks (such as test panels/sections or previous work) against
which a product/service is to be declared conforming or nonconforming.

Inspection Test procedures

For many inspections/tests, the methods employed will be specified or self evident and determined by the
characteristics being examined. In other cases, however, the precise manner in which the inspection/test is carried
out would need to be identified and described. A clearly described test procedure will usually be necessary to help
achieve consistent and reliable results. A typical test procedure using statistical techniques might, for example, cover:
-

 reference to work areas/lots or batches


 frequency of sampling
 Quality Management Systems Guidelines 5
 method of taking samples
 method of conducting a test (including conditions)
 qualifications of test personnel and equipment calibration/condition/specification
 method of documenting results.

In some cases it may be possible to satisfy the requirements simply by referencing the requirements of the Code &
Standard.

Hold and Witness Points

It is the contractors and subcontractors responsibility to identify the Hold and Witness Points (with the people
responsible for the inspection/test/endorsement and other requirements) that are required for its contractors and
subcontractors employees doing the work. The contractor would do this to the extent that is necessary to be confident
that the work is being carried out to the standards required. The customer usually retains the option to inspect the
work at any stage and may identify Hold and Witness Points requiring the customer's attendance. When preparing an
ITP, the word "Surveillance" would be shown against all selected inspection or test points that are not otherwise
covered by Hold or Witness Points.

QC Inspection Checklists

As noted in with some work, the logical stage to carry out an inspection or test is often after a number of separate
activities, but prior to a major one that will cover up previous work. It is often useful to complete checklists at such
stages and with each inspection and test where they will, in effect, summarise the procedures that have, and should
have, taken place up to the particular point in the work process. QC Inspection Checklists are useful reminders to the
person doing the work of all the matters that are to be addressed. They are used to confirm all the matters have been
attended to. They are also reminders to the person inspecting the work of all the matters that should be checked. A
QC Inspection Checklist also gives an opportunity to record any special or unusual conditions under the contract, and
draw these to the attention of the people doing the work. For example, special precautions for protecting existing
work, notifications to the public, and other matters that might not normally be required for the particular trade or
activity, may be included.

The fact that QC Inspection Checklists exist, and that their use and content have been verified, would give a
customer confidence that the person doing the work is aware of all the important steps, attributes and matters to be
addressed, and the standards that should be complied with, and that conformity is being verified.

Inspection and Test Plan QC Inspection Checklist

The following typical checklist for Inspection and Test Plans has been designed to assist customers in assessing the
Contractors ITPs. It may also assist service providers in developing their ITPs, as a guide to the content of ITPs. The
customer may specify other items that would be addressed in the contactors ITPs to support the control of risks.

Overview Check List for Inspection and Test Plans


Have ITPs been developed for all the relevant contract activities? (Clause 4.2)
Are there ITPs for each activity affecting quality? (Clause 4.2)
Are all the Plan documents identified and their revision status shown? (Clause 4.2.3)
Are all the Plan records legible, readily identifiable and retrievable? (Clause 4.2.4)

5 MANAGEMENT RESPONSIBILITY

Does the service provider identify and include all customer requirements in ITPs the contract quality representative
nominated in the ITPs? Do the ITPs nominate the person responsible on site for all key and related construction
activities?

6 RESOURCE MANAGEMENT

Do the ITPs identify the resources proposed to carry out inspections and tests?
Do the ITPs include the minimum required qualifications and experience of the people that are to carry out
inspections and tests?
Do the ITPs identify the required equipment, facilities and supporting services?
Do the ITPs identify each critical working environment?

7 PRODUCT REALISATION

Are the ITPs updated to reflect changes to customer requirements?


Do the ITPs identify inspections and tests to verify/validate design?
Do the ITPs identify the inspections and tests required to ensure the products/services meet the requirements?
Do the ITPs reflect the control of conditions required for inspection and testing? (Clause 7.5)
Do the ITPs identify whether the monitoring and measuring devices are calibrated specification? (Clause 7.6)

8 MEASUREMENT, ANALYSIS AND IMPROVEMENT

Does the contractor plan and implement in the ITPs the monitoring, measurement, and analysis needed to
demonstrate the conformity of all work?
Does the contractor state in the ITPs who is responsible for receiving, in-process and final
inspection and testing for all work activities and for closing out work areas?
Do the ITPs include the methods for indicating when nonconformity control is initiated and for closing out work areas?
Have inspection and test forms been developed and implemented for recording inspection and testing for each
activity? (each stage in a process may be on separate but linked forms)
Receiving inspection
Do the ITPs define responsibility for verifying conformity of the supplied product before using it in the constructed
works?
Do the ITPs adequately address the inspection and testing requirements for the supplied product before it is used in
the constructed works?
In-process inspection Do the ITPs define responsibility and provide for in-process inspection and testing? Do the ITPs
adequately address the inspection and testing requirements for all the products/services during construction of the
works? Final Inspection and Testing
Do the ITPs define responsibility and provide for final (or acceptance) inspection and testing?
Does the service provider have a method and define responsibility in the ITPs for final review of all inspection/test
results to confirm that all inspections and tests have been carried out to completely verify conformity for each work
area?

QC Inspection Check Sheets

Do the ITP forms indicate:


all the inspection and testing required by the customer?
inspections and tests to verify and validate design (where applicable)?
inspection and tests required for the supplied product before it is used in the works?
inspection and tests required for the products/services during construction of the works?
who performs the inspection or test and at what stage of the contract work?
how each inspection or test is to be carried out and recorded? (such as a documented testing procedure or by
reference to a standard test method) the acceptance criteria and frequency of testing, including customer's
requirements?
(reference to a contract specification clause alone may not be acceptable the record reference verifying conformity of
materials/product or preceding work?
who reviews inspection/test results, evaluates whether work conforms, determines what to do next if work does not
pass a required inspection or test, and closes out completed and conforming work areas? when statistical analysis of
test results is required?
provision for confirmation that all inspections and tests have been carried out to completely verify the conformity in
each work area?

QC Contruction Procedures (overview)


Click here to goto QC Construction Procedures

Mechanical QC  PROTECTION, PRESERVATION. & MAINTENANCE


OF EQUIP.
Procedures  BOLTING
 COLD-CUTTING & PREPARATION FOR HOT WORK
 SCAFFOLDING
 CAR-SEALING OF VALVES
 RIGGING
 GAS RELEASE PROCEDURE
 SITE HANDLING & IDENTIFICATION OF PIPING
MATERIAL
 PIPING DEMOLITION
 PIPING FABRICATION
 PIPING INSTALLATION
 PRESSURE TESTING OF PIPING
 PRESERVATION OF EQUIPMENT
 HOT-TAPS
 TIE-INS
 FLUSHING OF HYDRAULIC OIL CONTROL SYSTEM
 SPACER INSERTS SOCKET WELDS
 SITE HANDLING & IDENTIFICATION
 PRE-INSTALLATION OF MECHANICAL EQUIPMENT
 INSTALLATION OF MECHANICAL EQUIPMENT
 ROTATING EQUIPMENT ALIGNMENT
 ROTATING EQUIPMENT ALIGNMENT
 PREPARATION OF ROTATING EQUIPMENT FOR
OPERATION
 TUBE ROLLING PROCEDURE
 CONTROL OF SITE WELDING
 PREHEAT AND INTERPASS HEATING
 HEAT TREATMENT
 POST WELD TREATMENT (UNDER AND ABOVE
GROUND PIPING)
 DEMOLITION OF ELECTRICAL EQUIPMENT
 CONDUIT INSTALLATION
Civil Stuctural QC  SITE HANDLING & IDENTIFICATION STRUCTURAL
MATERIALS
Procedures  STRUCTURAL DEMOLITION
 STRUCTURAL FABRICATION
 STRUCTURAL INSTALLATION
 SITE HANDLING AND IDENTIFICATION OF CIVIL
MATERIALS
 SURVEYING
 SITE PREPARATION
 CIVIL DEMOLITION
 DISPOSAL OF WASTE MATERIALS
 EXCAVATION
 DEWATERING
 BACKFILLING
 FORMWORK
 CONCRETE REINFORCEMENT
 CONCRETE POURING
 CONCRETE CURING
 GROUTING
 CONCRETE REPAIR
 ASPHALTING
 CONCRETE FLOOR CONSTRUCTION
 BUILDING MASONRY WALL CONSTRUCTION
 DRY WALL CONSTRUCTION
 BUILDING ROOF CONSTRUCTION
 BUILDING CEILING CONSTRUCTION
 DOORS AND WINDOWS INSTALLATION
 BUILDING INSULATION
 WATERPROOFING
 WALL AND FLOOR FINISHES
 RAISED FLOORING INSTALLATION
 PRE CAST BUILDING CONSTRUCTION

 DEMOLITION OF ELECTRICAL EQUIPMENT


Electrical QC Procedures
 STORAGE, HANDLING & IDENTIFICATION OF
ELECTR. MAT
 CONDUIT INSTALLATION-
 CATHODIC PROTECTION INSTALLATION
 CABLE PULLING
 GROUNDING SYSTEM INSTALLATION
 DUCT BANK INSTALLATION
 ELECTRIC MOTOR INSTALLATION
 GENERATOR INSTALLATION
 SWITCHGEAR INSTALLATION
 TRANSFORMER INSTALLATION
 BATTERY UPS SYSTEM INSTALLATION
 JUNCTION BOX INSTALLATION
 MOTOR CONTROL INSTALLATION
 LIGHTING SYSTEM INSTALLATION
 CONTROL PANEL INSTALLATION
 RELAY INSTALLATION
 BREAKER INSTALLATION
 CABLE TESTING
 GROUNDING SYSTEM TESTING
 MOTOR TESTING
 SWITCHGEAR TESTING
 TRANSFORMER TESTING
 BATTERY TESTING
 CONDUIT SEAL POURING
 MULTI WAY SWITCH INSTALLATION
 TERMINATION & SPLICING HV CABLES
 IN-PLANT COMMUNICATION SYST INSTALLATION

Instrumentation QC  SITE HANDLING & IDENTIFICATION OF


INSTRUMENTATION
Procedures  DEMOLITION OF INSTRUMENT
 INSTRUMENT PREINSTALLATION CALIBRATION
 INSTRUMENT INSTALLATION TRANSMITTER
TRANSDUCERS
 INSTRUMENT INSTALLATION CONTROL VALVES
 INSTRUMENT INSTALLATION SWITCHES
 INSTALLATION OF SAFETY RELIEF VALVES
 INSTRUMENT INSTALLATION ANALYZERS
 INSTRUMENT INSTALLATION INDICATORS
 MISCELLANEOUS INSTRUMENT INSTALLATION
 FIELD PRESSURE TESTING OF INSTRUMENT
PIPING
 INSTRUMENT LOOP CHECK
 FIRE ALARM SYSTEM INSTALLATION TESTING

Coating QC Procedures SITE HANDLING & IDENTIFICATION OF COATING


MAT
 COATING
 TAPE WRAPPING (PIPING)
 HEAT SHRINK SLEEVE (PIPING)
 SURFACE PREPARATION FOR INSULATION
 CLADDING
 CONCRETE FIRE PROOFING
QC Check Sheets (overview)

Click here to goto QAQC Inspection Check Sheets and Inspect.

Using QC Inspection Checklist for As-built Verification and Mechanical Completion

A checklist is a structured form or questionnaire for collecting and analyzing data. This is a generic tool that can be
adapted for a wide variety of purposes. Collecting and analyzing data is important for identifying and understanding
problems and thus making appropriate changes to solve these problems.

Prospective Users
Inspection checklists are useful on construction projects that wants to improve quality and productivity, reduce defect
rates, and reduce re-work.

Problem Addressed:

 Increasing or high frequency of product faults.


 High rates of defective products requiring repair or re-work.
 High levels of waste materials.
 Low productivity.
 Verification documentation for as-building of the project for project turnover.

Process
This practice requires line managers and quality control staff to collect information about the number and sources of
defects in the construction process. Information about the number, causes and frequency of the defects are recorded
in the checklists and tallied to show totals. These totals can then be analyzed to see the times most defects are
made, the types of defects and the most common causes of defects. This information can then be used to reduce
defects.

Steps in implementation

1. Decide what construction activity will be observed or inspected.


2. Identify the period to be observed or inspected. This period should be relevant to the problem.
3. Develop a standard table or form for each type of construction activity based on criticality.
4. Name the columns and rows in the table.
5. The checklist form is usually an A4 sheet with a table with rows indicating types of defects and columns indicating the
time the mistakes are detected. The QC inspector fills in the number of defects of each type in the cell of the relevant
defect and time period. This checklist helps to identify the major types of defects.
6. Make standard format check sheets available each construction activity.
7. Discuss the results and draw conclusions.
8. Discuss possible actions for improvement.
9. The inspection checklists should be stored in a safe place.
10. The summary the inspection check sheet can be used as input for a quality improvement program. The checklist
totals can be used to identify which errors are most common, and to try to prevent these errors in the future. Workers
may need additional training or guidance in order to avoid making such errors.
11. Resources Required
o Line managers and QC quality inspectors' involvement.
o Check sheets.
o Document controller

Challenges and pitfalls


 Staff may feel they have more work to do.
 Difficulty in maintaining efforts to collect information.

Positive Impact

 Helps to record all faults and sources of faults.


 Saves money by helping to eliminate major sources of defects.
 Bench mark best practices for quality improvement.
 Transparent and honest reporting

Indicators for monitoring

 QC Check sheets form created and made available.


 QC Check sheets filled, summarized and discussed.

QC Check Sheets (overview)


Click here to goto Construction Inspection & Test Plans and Inspect.

Have all subcontractors defined their Inspection Points Witness and


Hold & Witness Hold Points? Does the Test Plan define the scope of the customers
Points Defined Technical requirements.

Are there any off site


suppliers/vendors that require
Subcontractors
Inspection & Test Plan
Involvement
coordination on site to complete
any installations?

Ensure any and all Third Party


Third Party Inspections are coordinated and
Inspection defined in the Inspection & Test
Plans.

Ensure all the project scope is


defined in the Test Plan. This is
Project Scope
especially important because the
Agreed & Defined
Test Plan is the document that
validates the project.

Point of Contacts Does the Inspection & Test Plan identify all the inspection bodies,
Defined subcontractors and vendors working on the site?
The Reason Why
The Quality Control Inspection Plan (QCIP) is the master document that controls the quality of the project
requirements. It can either control all sub contractors on site or control each subcontractor individually. The QCIP
must be in place and agreed by all concerned parties prior to the commencement of any construction activities.

Quality Training
Training of the site QC inspectors into their specific duties and involvement in the inspection activities must be
conducted prior to the commencement of any construction work.

The Requirements
The requirements of the QCIP must identify the following:

 The quality targets to be achieved in relation to the customers projects technical and contractual requirements.
 The specific assignments and responsibilities of the involved inspection parties.
 The specific procedures, methods and work instructions to be applied
 Methods for dealing with revisions and changes of the QCIP during the progress of the project
 Reference to inspection check sheets for each construction discipline

QCIP Example
Below is an example of a project Quality Control Inspection Test Plan.

Quality Control Inspection & Test Plan

COMPANY NAME
Description of Activity

Inspect
Witness
Hold
Review

Rev No Date

Approved Date Sign

Quality Control Inspection & Test Plan


ACTIVITY PROCEDURE CHECK LEVEL OF VERIFYING INSPECTED COMMENTS
POINTS ACCEPTANCE DOC BY

2 Tell me
what
3 construction Tell me, what
activity. construction
4 procedure Tell me,
you are going what are
5 to use to your Tell me, what
describe your inspection is your level of
6 check acceptance? Tell me,
activity?
points? (i.e. Contract what
7 Specification inspection Who is
Drawings documents going to
8 Client you are inspect the Are there
Procedures). going to item and any other
9 when? requirements
use to
verify the that need to
10 be stated?
inspection
11 activities?

12

13

Construction Site Inspection and Test Plans


How Do I Control 1000 to 30000 construction workers on large construction projects and still provide what the
customer wants?
(and)
How do I verify when the contractors Construction Department says the project finished?
(and)
How do I Know, if all the quality control inspections have been completed and there are no outstanding punch-lists?
(and)
Ho w do I know, is the as-built condition correct and in accordance with the approved (Issued for Construction
Drawings)?
(and)
How do I know, if there is any design changes that effect the operating process?
(and)
How do I prevent construction mistakes and having to complete rework, then losing my profit margins?
Note: (Quality Plans may be used to control the following interrelating processes:

 FEED-Front End Engineering


 EPC-Engineering Procurement and Construction Projects
 Commissioning
 Mechanical Completion
 Project Turnover

Use Construction Quality Control Inspection and Test Plans - Purpose and scope
The purpose of an Inspection and Test Plan is to put together in a single document that records all inspection and
testing requirements relevant to a specific process. On a construction contract the process is likely to be a
construction activity, element of work, trade work or providing a product section. An Inspection and Test Plan
identifies the items of materials and work to be inspected or tested, by whom and at what stage or frequency, as well
as Hold and Witness Points, references to relevant standards, acceptance criteria and the records to be maintained.
Inspection and Test Plans, when properly implemented, help ensure that, and verify whether, work has been
undertaken to the required standard and requirements, and that records are kept.Glossary
Hold Point - A 'hold' point defines a point beyond which work may not proceed without the authorisation of the
customer of customers representative.

The customer of customers representative might be an agency's or other or a regulatory authority (such as a council,
Third Part Testing Authority Surveillance - Intermittent monitoring of any stage of the work in progress (whether by the
service provider or customer). Self inspection - Where the service provider performing the work verifies the quality
progressively often with the aid of checklists. Work area - A discrete section of the whole work, usually defined by
location, where any trade work or activity would be completed before it moves onto another area. Examples include a
wall, a room, a building, a length of pipeline between manholes and the like.

Roles and Responsibilities


There are no set rules as to who, contractor's organization, should document Inspection and Test Plans. It is
appropriate, however, that they receive input from those with a good technical and practical knowledge of, and
experience in, the activities involved. The use, understanding and acceptance of ITPs by inspectors and other
personnel will generally be contractor if they are involved in their preparation. The Contractor is responsible for
ensuring that all the required Inspection and Test Plans are prepared, including those covering work or processes to
be carried out by its subcontractors. While it is preferable sub contractors prepare the ITPs for their own work, in the
final analysis some may require the contractors involvement. A senior representative of the contractor would be made
responsible for approving Inspection and Test Plans, and any subsequent amendments, prior to their submission or
submission of compliance/conformity certification to the customer. The contract conditions would define the
submissions to the customer and any responses required.

Overview
The following steps are involved in documenting Inspection and Test Plans for a construction contract: -

Step 1 Read the contract documents (including the technical specifications) and prepare a list of any discrepancies,
ambiguities, missing information and standards of materials and/or workmanship that it is considered are
inappropriate.

Step 2 Contact the customer and resolve the issues listed as a result of Step 1.

Step 3 Examine the scope of work and divide it into separate areas requiring an Inspection and Test Plan (where not
already prescribed in the contract documents). As a general guide it is normally most convenient to document a
separate Inspection and Test Plan for each trade or work area/section.

Step 4 Note the Hold and Witness Points required by the customer (including as listed in the contract documents).

Step 5 Review the contract documents again and note the requirements that have the most impact on the quality of
the finished work. For each ask the question "What will be the consequences if it is not made sure this is right?" Be
certain to include any references to tests, submitting information to the customer, obtaining approvals and Hold and
Witness Points.

Step 6 Determine from Step 5 which items or aspects of each inspection will need to be recorded on checklists and
prepare these.
Step 7 Discuss the checklists with those directly involved with the work and obtain their input. This input should
particularly be directed at identifying those issues that have caused problems (and involved extra costs) in the past,
and therefore warrant checking at the earliest opportunity to avoid unnecessary and costly rectification.

Step 8 Prepare each Inspection and Test Plan to reflect the requirements of the contract documents. Reference the
ITP in the Quality Management Plan and cross-reference to the other related ITPs.

Step 9 Issue each Inspection and Test Plan and/or associated certification to the customer for consideration within a
reasonable period prior to commencing the work described in the Plan and adjust them to suit any comment received
(or act as otherwise required in the contract documents).

Step 10 Decide how best to divide the whole of the work into work areas for control purposes and indicate these
locations either on a schedule (with reference to grids and levels) or by marking up drawings.

Step 11 Prepare and issue checklists for each work area and identify them according to location.

Step 12 Train those directly involved with each of the ITP in their use. Formalise a procedure for the notification of
Witness and Hold Points to the appropriate person(s).

Step 13 Carry out inspections and tests in accordance with the Inspection and Test Plans, provide notices to the
customer and/or regulatory authorities for Hold or Witness Points, as designated or applicable, and record the results
on checklists.

Inspection And Test Plan Supporting Information


Record the following contract particulars on each of the Inspection and Test Plans: - Quality Management Systems
Guidelines

 Contract Name
 Contract Number
 Description of process/activities for that particular Inspection and Test Plan.

Inspection and Test Plans


General

Description of operation or stage of work requiring inspection or test Because 100% inspection and testing in most
cases is neither practical nor desirable, it is necessary to adopt a testing frequency and sampling process which
provides a representative indication of the work to suit the risks involved.

Inspections and tests are often best done after a number of separate activities, but prior to a major one that will cover
up previous work. Contractors and subcontractors would carry out preliminary tests to assist in obtaining an early
indication of conformity.

Inspections and tests vary to suit the risks and work involved this is completed by referring too prevous lessens
learned files and experaince of the technical personnel that are completing the ITP. Remember, the ITP provides
information to the site construction personnel as to what the customer has said what they want, (In the contract of
Project Specification)

The "what to test", "how to test" and "when to test" is governed by: -

 What the work is and how complex it is


 Accessibility for inspections and sampling
 Consequences of failure, including as follows:
 Cost of remedial work
 Effect on construction program
 Accessibility for rectification
 Disruption to use of building or structure
 Consequential damage to other elements
 Threat to safety of workers and public
 Availability of resources.

The type, timing and frequency (the what, when and how often) of inspections and tests are best determined in
conjunction with the consideration of the characteristics to be verified. Characteristics of inspection/test/approval The
characteristics of a work item can be defined as "a distinguishable property of an item, material or process".
Examples of characteristics are colour, texture, size, strength, flatness, alignment, capacity and the like.

The characteristics to be verified will frequently determine the stage at which the inspection or test must take place if
the potential for subsequent nonconformities is to be avoided. This further work might also cover up or deny access
for the purposes of verifying certain characteristics. Some characteristics can only be considered after one particular
operation and before another, such as the inspection of steel reinforcement after installation but prior to the pouring of
concrete.

Stage/frequency
The inspection/test stage/frequency will often be determined by the requirements of the contract documents or by the
type of inspection and/or test and the characteristics under consideration, as outlined above. In the latter case
however, there is the potential for a considerable range in what constitutes the most appropriate frequency and
sampling process. It is suggested that a representative sampling of the work to suit the risks involved be used as a
guide initially. Thereafter, frequencies would be increased and processes reviewed for'problem' work activities and
decreased where consistent conformity was evidenced.

QC Inspection Check Sheets


Records are essential to quality management because they provide the documented evidence necessary to verify
that a product/service is in accordance with the contract requirements. The records would be in various forms, and
would include the checklists, test certificates, certificates of compliance/conformity, survey data, written approvals
and the like. Inspection and Test Plans would help define the records required and will comply with Project payment
milestones and as-built turnover documentation.Project Specifications Codes and Standards

The standards against which conformity is measured can take various forms. The most common source is usually the
contract technical specification. Other standards would often be referenced in this document, and may include any of
the following: -

 Contract documents/specification generally


 Contract drawings
 Approved workshop drawings and/or calculations
 Approved technical details/procedures
 Approved samples and/or prototypes
 Regulatory requirements
 Australian Standards
 International Standards
 Standard specifications
 Manufacturers' recommendations.
Acceptance criteria
Acceptance criteria would normally be defined in the contract documents (either directly or by reference to other
standards such Inernational Codes and Standards). Where this is not the case it would be necessary to identify them
and possibly to agree them with the customer. It is preferable to establish acceptance criteria with the customer
(where they are not specified or clear) to agree the yardsticks (such as test panels/sections or previous work) against
which a product/service is to be declared conforming or nonconforming.Inspection Test procedures

For many inspections/tests, the methods employed will be specified or self evident and determined by the
characteristics being examined. In other cases, however, the precise manner in which the inspection/test is carried
out would need to be identified and described. A clearly described test procedure will usually be necessary to help
achieve consistent and reliable results. A typical test procedure using statistical techniques might, for example, cover:
-

 reference to work areas/lots or batches


 frequency of sampling
 Quality Management Systems Guidelines 5
 method of taking samples
 method of conducting a test (including conditions)
 qualifications of test personnel and equipment calibration/condition/specification
 method of documenting results.

In some cases it may be possible to satisfy the requirements simply by referencing the requirements of the Code &
Standard.

Hold and Witness Points


It is the contractors and subcontractors responsibility to identify the Hold and Witness Points (with the people
responsible for the inspection/test/endorsement and other requirements) that are required for its contractors and
subcontractors employees doing the work. The contractor would do this to the extent that is necessary to be confident
that the work is being carried out to the standards required. The customer usually retains the option to inspect the
work at any stage and may identify Hold and Witness Points requiring the customer's attendance. When preparing an
ITP, the word "Surveillance" would be shown against all selected inspection or test points that are not otherwise
covered by Hold or Witness Points.

QC Inspection Checklists
As noted in with some work, the logical stage to carry out an inspection or test is often after a number of separate
activities, but prior to a major one that will cover up previous work. It is often useful to complete checklists at such
stages and with each inspection and test where they will, in effect, summarise the procedures that have, and should
have, taken place up to the particular point in the work process. QC Inspection Checklists are useful reminders to the
person doing the work of all the matters that are to be addressed. They are used to confirm all the matters have been
attended to. They are also reminders to the person inspecting the work of all the matters that should be checked. A
QC Inspection Checklist also gives an opportunity to record any special or unusual conditions under the contract, and
draw these to the attention of the people doing the work. For example, special precautions for protecting existing
work, notifications to the public, and other matters that might not normally be required for the particular trade or
activity, may be included.

The fact that QC Inspection Checklists exist, and that their use and content have been verified, would give a
customer confidence that the person doing the work is aware of all the important steps, attributes and matters to be
addressed, and the standards that should be complied with, and that conformity is being verified.
Inspection and Test Plan QC Inspection Checklist
The following typical checklist for Inspection and Test Plans has been designed to assist customers in assessing the
Contractors ITPs. It may also assist service providers in developing their ITPs, as a guide to the content of ITPs. The
customer may specify other items that would be addressed in the contactors ITPs to support the control of risks.

Overview Check List for Inspection and Test Plans


Have ITPs been developed for all the relevant contract activities? (Clause 4.2)
Are there ITPs for each activity affecting quality? (Clause 4.2)
Are all the Plan documents identified and their revision status shown? (Clause 4.2.3)
Are all the Plan records legible, readily identifiable and retrievable? (Clause 4.2.4)

5 MANAGEMENT RESPONSIBILITY
Does the service provider identify and include all customer requirements in ITPs the contract quality representative
nominated in the ITPs? Do the ITPs nominate the person responsible on site for all key and related construction
activities?

6 RESOURCE MANAGEMENT
Do the ITPs identify the resources proposed to carry out inspections and tests?
Do the ITPs include the minimum required qualifications and experience of the people that are to carry out
inspections and tests?
Do the ITPs identify the required equipment, facilities and supporting services?
Do the ITPs identify each critical working environment?

7 PRODUCT REALISATION
Are the ITPs updated to reflect changes to customer requirements?
Do the ITPs identify inspections and tests to verify/validate design?
Do the ITPs identify the inspections and tests required to ensure the products/services meet the requirements?
Do the ITPs reflect the control of conditions required for inspection and testing? (Clause 7.5)
Do the ITPs identify whether the monitoring and measuring devices are calibrated specification? (Clause 7.6)

8 MEASUREMENT, ANALYSIS AND IMPROVEMENT


Does the contractor plan and implement in the ITPs the monitoring, measurement, and analysis needed to
demonstrate the conformity of all work?
Does the contractor state in the ITPs who is responsible for receiving, in-process and final
inspection and testing for all work activities and for closing out work areas?
Do the ITPs include the methods for indicating when nonconformity control is initiated and for closing out work areas?
Have inspection and test forms been developed and implemented for recording inspection and testing for each
activity? (each stage in a process may be on separate but linked forms)
Receiving inspection
Do the ITPs define responsibility for verifying conformity of the supplied product before using it in the constructed
works?
Do the ITPs adequately address the inspection and testing requirements for the supplied product before it is used in
the constructed works?
In-process inspection Do the ITPs define responsibility and provide for in-process inspection and testing? Do the ITPs
adequately address the inspection and testing requirements for all the products/services during construction of the
works? Final Inspection and Testing
Do the ITPs define responsibility and provide for final (or acceptance) inspection and testing?
Does the service provider have a method and define responsibility in the ITPs for final review of all inspection/test
results to confirm that all inspections and tests have been carried out to completely verify conformity for each work
area?

QC Inspection Check Sheets


Do the ITP forms indicate:
all the inspection and testing required by the customer?
inspections and tests to verify and validate design (where applicable)?
inspection and tests required for the supplied product before it is used in the works?
inspection and tests required for the products/services during construction of the works?
who performs the inspection or test and at what stage of the contract work?
how each inspection or test is to be carried out and recorded? (such as a documented testing procedure or by
reference to a standard test method) the acceptance criteria and frequency of testing, including customer's
requirements?
(reference to a contract specification clause alone may not be acceptable the record reference verifying conformity of
materials/product or preceding work?
who reviews inspection/test results, evaluates whether work conforms, determines what to do next if work does not
pass a required inspection or test, and closes out completed and conforming work areas? when statistical analysis of
test results is required?
provision for confirmation that all inspections and tests have been carried out to completely verify the conformity in
each work area?

Audit

AUDIT Audit Schedule Prepare your audit schedule. Normally internal audits
PREPARATION every 3 months

Audit Plan Review the contract scope and prepare your


questions in accordance with ISO system elements.

Audit Notification Complete correspondence to all parties concerned


notifying them of audit. This is normally completed
two weeks prior to the audit.

CONDUCT AUDIT Audit Opening Meeting Conduct audit open meeting with all parties
concerned. Explain the system elements that are
going to be audited. Introduce other members of the
audit team.

Conduct Audit Make sure departmental engineers have not left the
office for site.
Record your answers and be polite.
Audit report Audit reports are completed within three working
days and the initial findings are discussed in the
Audit close out meeting. Internal Audits are normally
completed every three months.

AUDIT CLOSE Resolution of non Make every effort to identify possible


OUT conformance reports nonconformances. Try and make clear the audit is a
and corrective actions business tool that benefits every one.

Audit close out Lead audit completes audit close out meeting and
meeting highlight the scope and results on the audit.

AUDIT REPORT Distribution of Audit Distribute your audit report to all the members of the
DISTRIBUTION Report audit opening meeing. Discuss with management
ways and means to improve performance.

Vendor Inspection

Quality Procurement Planning


In order for the construction planning scheduling not to be delayed it is essential for Project
suppliers to be:
Assessed
Approved
A procurement Quality Planning Schedule is completed itemizing the project vendor
inspections that need to be completed for the scope of the project.

Customers Approved Suppliers List


If the Project proposed suppler is not already on the customers approved list then the suppler
Quality Management system must be assessed to see if they can provide products on time,
within budget and meeting the project quality requirements.

Customers Generic Product Inspection Matrix


To prevent nonconforming equipment and materials being installed on the Project the
acceptance inspection activates are required to be itemized to ensure all precautions are
taken. Inspections can be at the place of manufacture or at material receipt.

Most major construction companies have Product Inspection Matrixes that define what the
minimum quality requirements the suppler must provide to the customer. These are normally
standard formats that are issued for every purchase product that the company purchases, (as
below).
In order to prevent nonconforming equipment and materials being installed on site
the acceptance inspection activities are required to be itemized and formalized to
ensure all possible precautions are taken. Inspections can be undertaken at the place
of manufacture or upon material receipt.

Vendor Inspection
Requirements for Scope

Rev Date

Code Number

Project

Test & Inspection Against

1 Visual Inspection By Purchaser

2 Check Inspection Reports And Certificates By Purchaser

3 Reports And Certificates To Be Provided

1 Material Test Report

2 Heat Treatment Reports

3 Welders Qualification Reports

4 Welder Qualification Reports & PQR'S

5 Workmanship, Material Defects, Dimensions

6 Compliance With Purchase Order

7 Paint Specification
8 Quality Control Manual, QC Plan, System Implementation

9 Check NDT Reports and Weld Maps

10 Check Hydrostatic Testing Reports

11 Check Vendors Design Documents

12 Check Approval Status Of Submitted Documents

Project Supplier Evaluation (assessment)


Prospective Project Suppliers are assessed by audit to ascertain if they are capable to provide
quality products. A quality questionnaire is sent to the suppler, on he basis of this the
customers rating system is applied.

An acceptable audit and rating system evaluation will decide if the customer wishes to place a
Purchase Order with the nominated supplier. Quality Control Requirements,
Customers Purchase Orders

The customers Purchase Orders must provide the supplier with the correct information to
provide the product the customer specified. To do this the Customer must assure himself
purchased product is inspected during its manufacture utilizing a Project Specific Supplier
Inspection and Test Plan.

The customer must therefore have a Quality Management System that provides the supplier
with all the relevant information to complete his contract on time and within schedule. Once the
suppler is accepted the following requirements are stated in the Purchase Order:

 The seller will operate a quality management system that meet the requirements of ISO 9000
during the contracted scope of the work.

 The buyer reserves the right to evaluate and audit the implementation of the quality system.

 The buyer reserves the right to request the supplier to provide formal records of certificates
for any activity associated with the sellers work.

 ALL Documentation shall be in the original source state or true copy of the original. Copies
shall be of reproducible quality or they shall be considered unacceptable. Data transposition
form the original is not acceptable.

 All documentation shall uniquely identify all sheets with:

i.The Purchase Order Number


ii. Tag number or Item Code

Purchase order consists of:


- Technical purchase order package
- Vendor Data and Erection Manuals
- Description of Non Material Requirements (NMRs)
- Terms & Conditions according to Contract and depending on value of risk
- Quality Requirements
- Quantities and prices
- Delivery conditions
- Marking Instructions
- Delivery Instructions
- Payment Terms
- Delivery Dates
- Warranties
- Performance guarantees

Quality Plan Requirements


All bidders must submit with their bid, a Quality Plan specifically developed to the requirements
of the request for quotation.

This plan will integrate the practices and procedures contained in the Seller's Quality Control
Manual/System with the Request for Quotation requirements. The Detailed Quality Plan
specific for a Purchase Order will include, but not be limited to the following:

 The suppler will attend a quality kick off meeting with the purchaser prior to the
commencement of the work

 Administrative data such as suppliers name, location, and shop order number, tag number,
item description, etc.

 An effective date and/or revision number.

 A complete listing of Quality Control activities to be performed including, but not limited to,
types of inspection, factory tests, control of welding processes, nondestructive examination,
and seller witness and hold points.

 Provisions for Buyer, Owner, and/or their agents witness and hold points.

 Listing of other major fabricated or subcontracted services.

 The quality attributes if not identified in the suppliers Quality Plan, must be addressed in the
Seller's Quality Manual/System (i.e.procedures/instructions, drawings, etc.):

 Specific references to technical specification requirements and applicable codes and


standards referenced in the specifications included in this Purchase Order and Contract.

 Acceptance and rejection criteria to be used for inspection and tests.

 The types of documents that will be used to record inspection and test results.

 Sub-suppler responsibilities including the level of source and receipt inspection to be


performed for mayor suborder items and subcontracted services.

 Suppliers agrees that Inspection Status Reports on production will be issued bi-weekly.

Customers Vendor Inspection Assignment Package


Once the Purchase Order is finalized an approved the Customer must verify by inspection the
product meets the customers requirements. Inspection Assignment Packages are completed
itemising the specific items for inspection the Vendor Assignment Package should contain the
following information:

 An Inspection Assignment Letter Indicating:

 The approved Inspector name

 Supplier's address
 Suppliers Contact name

 Procurement Inspection Report

 Copy of Purchase Order Nonmaterial Requirements List (NMR)

 Customers Generic Quality Requirement Plan

Once the Inspection Assignment Package has been completed bi-weekly inspection reports
are completed by the customers Approved Inspector, any quality deficiencies are corrected and
inspection waivers are reviewed and agreed.

Inspection Assignment Packages are retained for the project As-built Files.

Piping Hydrostatic Testing (overview)


Test Preparation

NEW - Click here to purchase our new piping


hydrostatic test pack!

1. Pressure source and test gauge should be upstream of check valve. If


pressure source is downstream, check valve should have flapper removed
or jacked?up. (Pressure must be released downstream of check valve after
test completion.)

2. Ensure that test blinds installed are the Correct thickness. Ensure that
all items such as control valves, relief valves, rupture disks, orifice plates,
diaphragm instruments, expansion joints, etc., which could be damaged
during pressure test have been removed or isolated, as indicated on the
pressure test flow diagram. Ensure that equipment, such as filters, which
have internals that may be damaged during pressure.

3. Ensure that all items such as control valves, relief valves, rupture disks,
orifice plates, diaphragm instruments, expansion joints, etc., which could be
damaged during pressure test have been removed or isolated, as indicated
on the pressure test flow diagram.

4. Ensure that equipment, such as filters, which have internals that may be
damaged during the pressure test are either blocked from test or that
internals have been removed.

5. Check all temporary supports that have been called for on the pressure
test flow diagrams, piping arrangement drawings or spool drawing to ensure
that they have been properly installed.

6. Ensure that equipment, such as compressors, which must not be


included in the field tests have been properly blocked off with the casing
drain open.

7. Check open and closed position of all valves.

8. Check for proper installation of vents and drains.

9. Verify chloride content of test water when testing stainless steels.

Testing:

1. The pressure test gauge shall normally be located at grade near the test
pump.

2. Pressure test gauges shall be calibrated to ensure accurate readings.


Gauges should be tagged with the date they were last calibrated.

3. Care must be exercised not to exceed pressure test specified on the


pressure test data.

4. When conducting a pneumatic test, it is essential that the contract


specification for pneumatic testing be adhered to in order to avoid creating a
safety hazard.

5. Pneumatic test systems must include double block valves with a bleeder
valve between them to safely isolate the pressure source (by closing block
valves and opening bleeder to atmosphere) when incremental and final test
pressures are attained.

Test Completion:

1. Care shall be exercised in controlling the rate of draining from vessels in


respect to inflow of air through the vent to assure that a vacuum is not
applied.

2. CAUTION: Prior to commencing drainage, ensure that all vents are


open with plugs and blind flanges removed.

3. After drainage, remove all temporary blinds and blanks, temporary


support, and temporary testing connections.

4. Reinstall all items that were removed for test. Ensure that line
Specification gaskets and bolts are being used when reinstalling these
items.

5. Remove all shipping bars from expansion joints.

6. Remove Stops from spring hangers and check cold settings.


CONTENTS OF HYDROSTATIC
TEST PACKAGES

Cover sheet
Description of Line Test

Safety Check Sheet

Pipe Work Pre test


Check list

Hydrostatic Test Report


As- Built File

Monitoring During Testing


Data Sheet

Pressurize
Welding Travel
Check Sheet

Heat Treatment
Check Sheet
Turn over Dossier

Hardness Testing Report

Blow, Flush & Chemical


Cleaning Check List

Flushing & Cleaning


Check List
Punch List Check Sheet
NDT Reports

Why this subject


During hydrotesting and pressure testing operations incidents sometimes happen. This Safety
Feedback Notice provides some typical examples which can be used an an aid in highlighting
the hazards and dangers involved are what are often seen as routine operations.

Details of 5 incidents.

1. Hydro-test of a new vertical vessel.

click here

The root cause of the incident is not fully known but there was some thought that hydrotesting
with "very cold" water was a contributing factor.

Fortunately no injuries occured.

2. Filling of a vertical tank.

click here

The filling of the tank was made with water from a fire hydrant.

The top the tank blew off becuase the relief valve could not displace the air fast enough for the
volume of water that was being pumped in.

Fortunately no injury happened, but an operator was on top of the tank a few seconds before.

3. Emptying of a vertical tank.

click here

The collapse of this tank happened while it was being emptied. A plastic sheet protecting the
roof was trapped in the vent; hence a vacuum was caused.

There was no injury. It should be noted that this type of incident is not that unusual.

4. Sphere collapse.
click here

The accident happened during the filling of a bar 2000 m LPG sphere. Its legs collapsed. One
person was killed and one seriously injured.

At the time of the accident, the sphere was approximately 80% full of fresh water.

The vessel’s last hydro-test was 10 years ago and the last inspection of its legs was 5 years
ago.

Severe corrosion of the legs under the concrete fire protection was the main cause. The
corrosion occurred due to water ingress between the concrete and the steel legs.

The water protective cap located over the concrete was not sufficient to keep water out. After
the accident, it was verified that the steel legs had thickness reductions of up to 8mm, with
piting holes of up to 10cm .

After analysis and tests, it has been found that the following factors caused the collapse:

 Water caps over the fire-proofing concrete were of poor design thereby letting water penetrate
between the steel beams and the concrete.
 Vertical cracks in the concrete let water in.
 Repairs had been done to the concrete, but with poor workmanship.
 The concrete had not adhered to the old concrete, again letting water in.
 The deluge system had been tested with salt water, increasing the possibility of corrosion.

5. Emptying of a gear box.

click here

To speeed up the removal of 250l of oil from a gear-box, the guage hole was plugged and the
breather was connected to the 6 bar air network.

The gear box exploded, and threw missiles around seriously damaging surrounding piping and
structure. Fortunately there was no injury.

SPECIFIC RECOMMENDATIONS

For each case the specific recommendation are generally obvious:

1st incident : Water tempearture is critical when hydro testing. TFE specification (GS PVV 211)
states taht both metal and water temperature during pressure testing shall be maintained at
least at 16ºC or at least 10ºC above the impact test temperature of the metal.

2nd and 3rd incidents : Venting systems shall be inspected and checked before filling and
emptying operations.

4th incident : Is a maintenance problem? Before testing an old vessel, a complete inspection
must be performed visually and with NDT. This inspection shall include the vessel, nozzles,
appurtenances, and supporting structures.

5th incident : obviously a gear-box is not pressure vessel, but productivity may lead to a risky
attitude.

Non-Destructive Testing Mechanical (overview)

The successful application of mechanical nondestructive testing inspection methods requires that

1 The test system and procedure be suited to both inspection objectives and types of flaws.
2 The operator has sufficient training, experience and is qualified.
3 The standard for acceptance is defined.

The most commonly used non destructive testing methods used for the inspection of ferrous and none ferrous steels
on construction site's comprise the following:

Radiographic This inspection method is used for the This inspection method can
Testing inspection of carbon steel for the identify the following welding
investigation of welding defects on the defects, pipe mismatch, lack of
surface and sub surface. The penetration lack of fill, undercut,
advantages of this method is that cavities. burn through, slag
there is a permanent record for as inclusions, lack of fusion, porosity,
built purposes. Approval certification cracking, tungsten inclusions.
is required to use this equipment on
site.

Liquid- This inspection method is used for the This inspection method can
Penetrant inspection of carbon steel for the identify the following defects, all
Testing investigation of welding surface and type of surface cracks ,porosity,
surface cracking.The advantages of shrinkage areas, laminations.
this method is that it is easy to use
and very portable. Operators are
required to be certified.

Magnetic- This inspection method is used for the This inspection method is can
Particle inspection of carbon steel for the identify the following
Testing investigation of welding surface and defects,subsurface defects.
surface cracking. The advantages of
this method is that it is easy to use
and very portable. This method is
especially suitable for surface carbon
steel microcracking. Operators are
required to be certified.
Ultrasonic This inspection method is used for the This inspection method can
Inspection inspection carbon steel for the identify the following defects,
Testing investigation of welding defects. cracks laminations, cavities, flakes
Operator approval certification is pores bonding faults, inclusions,
required in order to use this internal flaws, measure thickness
equipment on site. and corrosion.

Hardness This inspection method is used for It is normally stated in the contract
Testing checking the hardness of the heat specifications the hardness value
effected zone after post weld heat this inspection method has to
treatment of welded connections. meet.

Calibration (overview)

Prepare Master List of


Inspection, Measuring
and Test Equipment

- equipment name/identification number


- holder of equipment for recall purpose
- frequency, criteria of acceptance, range of tolerance date of calibration
- work instruction or procedure for calibration, to be in-house or external calibrated recall date.

Ensure inspection, measuring, and test equipment is calibrated against


Certified/Reference Equipment having a known valid relationship to
Internationally or Nationality Recognized Standards.

Ensure Inspection, Measuring, and Test Equipment that is out of calibration is


withdrawn from use.

There are only nine types of inspection, and test measurement conducted to
verify the performance of installations at commissioning or service.These are:
- dead weight tester
- temperature measurement
- linear measurement
- current rating of equipment
- the resistance of a current carrying loop
- the insulation resistance of a current carrying loop
- electrical voltage measurement
- water flow rates for hydrant systems
- hydraulic pressure for pipe installation
The calibration of any instrument will be considered invalid if any of the following situations occur.

- expiry any period as shown on the label


- excessive electrical overload
- tampering
- excessive mechanical shock

If an equipment is found to be out of calibration, the validity, and critically of previous recorded results must
be assessed by the calibration controller, or his delegate. This assessment and any resulting actions must
be documented.

Welding Procedures (overview)

The cost impact of not being able to control the Method Statement
quality of welding and repair rates can be
substantial. This will and can cost the contractor
considerable delay in the completion of the project. Welding of Piping and
Thereafter invoking contractual penalties. Resulting Structural Components
in the loss of profit margins and later arbitration.
1) Welders shall only work within the limit of
their qualification range.

Approvals prior to the commencement of welding 2) Welding supervisor/welders shall ensure


operations. that "Welding Procedure Specification"
(WPS) selection is taken from the approved
matrix for each specific line class/application
accompanying each WPS.

3) Withdraw consumables only from


Welding Procedure Specifications.
designated welding stores and endorse
Procedure Qualification Reports.
initials on the "Welding Consumables
Welder Certification Certificates.
Distribution Form" maintained by the issue
Welding Consumables.
clerk.
NDT Company.
NDT Operators.
4) Withdraw only sufficient quantities of
NDT Procedures.
welding consumable for a four (4) hour
Radiation Safety.
period of work.
Post Weld Heat Treatment Company.
Post Weld Heat Treatment Procedure. 5) All low-hydrogen welding electrodes shall
Welding Inspection Personnel. be maintained in heated "portable rod
Welding Repair Procedure. caddies". The lid of the caddie should be
closed following the withdrawal of each
withdrawal electrodes.

6) Low-hydrogen electrodes shall only be


conveyed to the job site in heated "portable
Welding Defects Defined rod caddies".

7) At shift change, all "rod caddies" must be


returned to the originating welding store for
checking. All issued and unused low-
hydrogen electrodes shall be scrapped.
DEFECT CAUSE

Pipe off set mismatch Pipe misalignment 8) The technical requirements of the
"Welding Procedure Specification" (WPS)
Lack of root penetration Welding technique must be followed at all times.

Insufficient root fill Welding technique 9) Pre-heat and interpass temperatures


shall be monitored using "Tempil Stiks" or
Excessive penetration Welding technique calibrated "digital" temperature by
pyrometers. greater than the nominal wall
External undercut Excessive amps/volts thickness. ii) For flanges, use the thickness
corresponding to two (2) higher wall
Internal undercut Excessive amps/volts thickness ranges greater than the nominal
wall thickness.
Internal concavity Welding technique
10) Pre-heat values shall be taken
Root burn through Welding technique calculated and WPS assuming a value of
0.42 CE (Carbon Equivalent). Wall
Lack of root penetration Weld joint set up thickness values shall be selected as
follows:
Interpass slag inclusions Weld technique, grinding,
cleaning

Elongated slag inclusions Weld technique, grinding, a) For pipe-pipe, use the actual wall
cleaning thickness.

lack of side wall fusion Weld technique, b) For pipe-to-fitting or fitting-to-fitting.


amps/volts to low
c) For fittings (other than flanges), use the
Interpass cold lap Weld technique next higher wall thickness range a sufficient
period of time to ensure an Oxygen content
Scattered porosity Weld technique of less tan 0.5%. When available, "purge
monitoring devices" shall be used.
Cluster porosity Weld technique,
insufficient wind cover d) Backpurge shall be maintained for a
minimum of four (4) passes. Pipe bungs
Root pass aligned Weld technique, (purge dams) shall be left in place until
porosity insufficient wind cover completion of the joint.
Transverse crack Insufficient wind cover,
e) The end of partly used filler wire shall be
lack of pre-heating & post
snipped off prior to use.
weld heat treatment of
weld joint. Material
f) Maintain the tip of the filler rod within the
problem.
gas shroud during welding to avoid
Longitudinal crack Insufficient wind cover, contamination.
g) Interpass temperatures for these
lack of pre-heating & post
weld heat treatment of materials is critical. The welder shall check
the temperature prior to the next pass. All
weld joint. Material austenitic stainless welds on this project will
problem. be tested for "Ferrite" content therefore,
cleanliness during fabrication and
Longitudinal root crack Insufficient wind cover, monitoring of interpass temperatures will
lack of pre-heating & post have a direct effect on test results.
weld heat treatment of
weld joint. Material h) Only approved "iron-free" cutting and
problem. grinding disks shall be used.

Tungsten inclusions Weld technique i) Only approved marking materials


(sulphur, chlorine free etc.) are to be used.

j) All material handling devices and


equipment shall be adequately
protected/lined, to prevent the possibility of
carbon "pick-up" (i.e. workbench, transport
trucks, supports etc.).
Welding Process Metology
k) Wherever possible, tools shall be colour
coded to prevent cross-use with other
material types.

Welding Procedures to avoid hydrogen induced 11) Pre-head shall be applied through the
cracking. full thickness of the joint and checked from
the opposite side wherever possible.

12) For repair welds, the pre-heating


temperature shall be 500 C (1220 F) above
that used for the original weld. Maximum
To control cracking when completing the welding pre-heat for repair welding is 1500 C (3020
procedure the following factors must be considered. F).

13) approved WPS. Internal misalignment


for butt joints shall not exceed 1.5 mm
(1/16'').
- Combined thickness of the material to be welded
- Carbon equivalent values 14) Deposit the root pass and six (6)
- Hydrogen scales successive passes or 1/3 of the weld
- Welding arc energy volume prior to interruption (allowing to cool
to ambient temperature).

15) Buttering (build-up) is permitted as


follows:
Codes and Standards That are most Commonly
Used on Construction Projects a) Buttering shall not exceed the lesser of
10 mm or 1/3 base metal thickness.

b) If buttering will exceed 10 mm or 1/3


base metal thickness then this shall be
witnessed by the customer and the area
Codes and Standards That are most Commonly shall be tested by PT/MT following
Used on Construction Projects completion of buttering but before final
welding of the joint.

16) Backwelding is permissible for all


applications, so long as the same electrodes
ASME Boiler and Pressure Vessel Code
and process is used as for the fill pass.
Clause Section
17) The following points shall be observed
Power boilers I when fabricating/welding stainless and non-
Pressure vessels VIII, DIVISION 1 ferrous materials:
Pressure vessels VIII, DIVISION 2
Heating Boilers IV a) Weld preps and filler materials shall be
Nondestructive Ex V degreased using an appropriate solvent.
Welding & brazing IX
qualifications
b) Weld prep surfaces shall be buffered
using flapper wheels.

c) Argon hoses shall be checked for any


American Pipeline Institute loose connections or leakage etc.

API 1104 Welding Pipelines & related facilities d) Fit up geometry shall be in accordance
with the applicable, approved WPS.
API 650 Welded Steel Tanks for Oil Storage
e) Bridge tacks to be used. Avoid tacking
AWS D1.1 American Welding Society directly on to the adjacent pipe wall. Bridge
tack within the fusion faces of the joint
ANSI American National Standards Institute wherever possible.

f) Prior to welding, the backpurge shall be


set up in accordance with the approved
B31.1 Power Piping WPS for a sufficient period of time to ensure
B31.2 Industrial Gas & Air Piping an Oxygen content of less tan 0.5%. When
B31.3 Petrolium Refinery Piping available, "purge monitoring devices" shall
B31.4 Oil Transportation Piping be used.
B31.5 Refrigeration Piping
B31.6 Chemical Industrial Piping g) Backpurge shall be maintained for a
B31.7 Nuclear Power Piping minimum of four (4) passes. Pipe bungs
B31.8 Gas Transmission & Distribution Piping (purge dams) shall be left in place until
Systems completion of the joint.

h) The end of partly used filler wire shall be


snipped off prior to use.

i) Maintain the tip of the filler rod within the


gas shroud during welding to avoid
contamination.

j) Interpass temperatures for these materials


is critical. The welder shall check the
temperature prior to the next pass. All
austenitic stainless welds on this project will
be tested for "Ferrite" content therefore,
cleanliness during fabrication and
monitoring of interpass temperatures will
have a direct effect on test results.

k) Only approved "iron-free" cutting and


grinding disks shall be used.

l) Only approved marking materials


(sulphur, chlorine free etc.) are to be used.

m) All material handling devices and


equipment shall be adequately
protected/lined, to prevent the possibility of
carbon "pick-up" (i.e. workbench, transport
trucks, supports etc.).

n) Wherever possible, tools shall be colour-


coded to prevent cross-use with other
material types.

Materials Detection Depth Orientation Access Remote Automated


NDT Technique
applicable capability Sizing Evaluation problem Detection detection

Liquid penetrant All Surface No No Yes No No

Ultrasonic All Volumetric Yes Yes Limited Yes Yes

Radiography All Volumetric Yes Yes Yes No Yes

Magnetic Surface, near-


Magnetic No No Yes No No
Particle surface

Magnetic Surface, near-


Magnetic Yes Yes No Yes Yes
Fluxleakage surface

Surface, near-
Eddy current Conducting Yes yes Yes Yes yes
surface

Acoustic
All Volumetric Yes No No Yes Yes
Emission

Surface, near-
Thermo-graphy All No Yes No Yes Yes
surface

Visual All Surface No No Limited Yes Yes

Suface
XRD Conducting Yes No Yes No No
Stresses

Potential drop Conducting Surface Yes No Yes No Yes

Engineering and Construction Codes and Standards

ASME IX - American Society of Mechanical Engineers


ASME IX - B 31.3 PROCESS PIPING
ASME IX - B 31.1 POWER PIPING
Material (P numbers) will assist the Welding Engineer to complete the Welding Procedure Specification prior to the
mechanical testing of the Procedure Qualification Report.

P-numbers Material Composition

1 Carbon Steel

3 Up to 1/2% Cr and up to 1/2% Mo

4 1 to 2% Cr, 1% Mo Alloy Steel


5A 2 to 3% Cr, 1% Mo Alloy Steel

5B 5 to 10% Cr, 1% Mo Alloy Steel

5C All 5A and 5B Materials heat treated to 85ksi+

6 Martensitic Stainless Steel

7 Ferritic Stainless Steel

8 Austenitic Stainless Steel

9 2 to 5% Ni Alloy Steel

10 Mn-V, Cr-V, 9%Ni, High Cr Alloy Steels

11 Low Alloy Steel, Quenched and Tempered to 95ksi+

21 1.2% Mg or Mn alloy Aluminium

22 1.2% Mn, 2.5% Mg, 0.25% Cu Aluminium

23 1.3% Mg, 0.7% Si, 0.25% Cr Aluminium

25 1.5% Mg, 0.8% Mn, 0.15 Cr Aluminium

31 Copper

32 Admirally, Naval, Aluminium brass, Muntz Metals

33 Cu-Si Alloys

34 Cu-Ni Alloys

41 Nickel

51 Titanium

61 Zirconnium

Welding Defects

Cold Lap
Cold Lap is a condition where the weld filler metal does
not properly with the base metal or the previous weld
pass material (interpass cold lap). The arc does not melt
the base metal sufficiently and causes the slightly molten
puddle to flow into the base material without bonding

Porosity
Porosity is the result of "gas entrapment" in the
solidifying metal. Porosity can take many shapes on a
radiograph but often appears as dark round or irregular
spots or specks appearing singularly, in clusters, or in
rows. Sometimes, porosity is elongated and may appear
to have a tail. This is the result of gas attempting to
escape while the metal is still in a liquid state and is
called "wormhole porosity" All porosity is a void in the
material and it will have a higher radiographic density
than the surrounding area.

Cluster Porosity
Cluster Porosity is caused when flux coated electrodes
are contaminated with moisture. The moisture turns into
gas when heated and becomes trapped in the weld
during the welding process. Cluster porosity appears just
like regular porosity in the radiograph but he indications
will be grouped close together.

Slag inclusion
Slag inclusions are non metallic solid material
entrapped in weld metal or between weld and base
metal. In a radiograph, dark, jagged asymmetrical shapes
within the weld or along the weld joints areas are
indicative of slag inclusions.

Incomplete Penetration (IP) or lack of penetration (LOP)


Incomplete Penetration (IP) or lack of penetration
(LOP) occurs when the weld metal fails to penetrate the
joint. It is one of the most objectionable weld
discontinuities. Lack of penetration allows a natural
stress riser from which a crack may propagate. The
appearance on a radiograph is a dark area with well
defined, straight edges that follows the land or root face
down the center of the weldment.

Incomplete fusion
Incomplete fusion is a condition where the weld filler
metal does not properly fuse with the base metal.
Appearance on radiograph is usually appears as a dark
line or lines oriented in the direction of the weld seam
along the weld preparation or joining area.

Internal Concavity or Suck Back


Internal concavity or suck back is a condition where
the weld metal has contracted as it cools and has been
drawn up into the root of the weld. On a radiograph it
looks similar to a lack of penetration but the line has
irregular edges and it is often quite wide in the center of
the weld image.

Internal or Root Undercut


Internal or Root Undercut is an erosion of the base
metal next to the root of the weld. In the radiographic
image it appears as a dark irregular line offset from the
centerline of ht weldment. Undercutting is not as straight
edged as LOP because it does not follow a ground edge.

External or Crown Undercut


External or Crown Undercut is an erosion of the base
metal next to the crown on the weld. In the radiograph, it
appears as a dark irregular line along the outside edge of
the weld area.

Offset or Mismatch
Offset or Mismatch are terms associated with a
condition where two pieces being welded together are
not properly aligned. The radiographic image shows a
noticeable difference in density between the two pieces.
The difference in density is caused by the difference in
material thickness. The dark, straight line is caused by
the failure of the weld metal to fuse with the land area.

Inadequate Weld Reinforcement


Inadequate Weld Reinforcement is an area of a weld
where the thickness of weld metal deposited is less than
the thickness of the base metal. It is very easy to
determine by radiograph if the weld has inadequate
reinforcement, because the image density in the area of
suspected inadequacy will be higher (darker) than the
image density of the surrounding base material.

Excess Weld Reinforcement


Excess Weld Reinforcement is an area of a weld that
has a weld metal added in excess of that specified by
engineering drawings and codes. The appearance on a
radiograph is a localized, lighter area in the weld. A visual
inspection will easily determine if the weld reinforcement
is in excess of that specified by the engineering
requirements.

Cracks
Cracks can be detected in a radiograph only when they
are propagating in a direction that produces a change in
thickness that is parallel to the x-ray beam. Cracks can
appear as jagged and often very faint irregular lines.
Cracks can sometimes appear as "tails" on inclusions or
porosity.

Discontinuities in TIG Welds


Tungsten Inclusion
Tungsten inclusion: Tungsten is a brittle and inherently
dense material used in the electrode in tungsten inert gas
welding. If improper welding procedures are used,
tungsten may be entrapped in the weld. Radio
graphically, tungsten is more dense than aluminum or
steel, therefore it shows up as a lighter area with a
distinct outline on the radiograph

Oxide inclusions
Oxide Inclusions are usually visible on the surface of
material being welded (especially aluminum). Oxide
inclusions are less dense than the surrounding material,
and, therefore appear as dark irregularly shaped
discontinuities in the radiograph

Discontinuities in Gas Metal Arc Welds (GMAW)


Whiskers are short lengths of weld electrode wire, visible on the top or bottom su6rface of the weld or contained
within the weld. On a radiograph they appear as light, "wire like" indications.

Burn Through
Burn Through results when too much heat causes
excessive weld metal to penetrate the weld zone. Often
lumps of metal sag through the weld, creating a thick
globular condition on the back of the weld. These globs
of metal are referred to as icicles. On the radiograph,
burn through appears as dark sports, which are often
surrounded by light globular areas (icicles).

Hands on Quality Control Weld Defects


PIPING MATERIAL COLOUR CODE
WELDING METHOD STATEMENT

FLOW CHART OF PIPING PROCESS IN THE FABRICATION SHOP


DESIGN CODE ANSI B 31.3 & ASME SECTION IX

QA/QC Job Descriptions (overview)


QA job description / QC job description

Validate your job descriptions by completing due dilegence - use quality control
checksheets, available to purchase and download.

QC Inspection Inspection Construction


Check Sheets Packages (NEW) Inspection & Test
Plans

Project (QC Audit Question Health & Safety


Procedures Check Sheets Environment
Template) Checklist

Quality Assurance
Check Sheets

Job descriptions  Quality Assurance Manager


 Quality Assurance Quality Control Procurement Manager
 Quality Assurance Quality Control Construction Manager (Site)
 Quality Control Turn Over Engineer
 Quality Control Senior Welding Inspector
 Quality Control Site Discipline Inspectors
 Certification Engineer
 Audit Leader

Quality Assurance Manager


The company Quality Assurance Manager is the representative of the project and has the responsibility for the
implementation and maintenance of the quality management system.

 The preparation of the companies QA manual control and supervision of all amendments and revisions
 Control and the distribution of all the companies quality documentation
 Monitor all quality related activities on the project
 Perform all internal and external audits on behalf of the companies management
 Verify contractor quality requirements are specified to vendors and contractor documentation submittals.
 Attend all pre-bid meetings and coordinate all project requirements with the project bidders.
 Attend client quality management meetings
 The preparation and control of project quality system management documentation prior to project commencement.
 Review quality inspection personnel qualifications and training requirements
 Monitor the disposition of all issued nonconformance reports.
 Monitor the progress and effectiveness of the project quality management system. Recommend and implement
improvements when required.
 Coordinate all QA/QC activities with the site QC manager
 Coordinate all QA/QC activities with the site QA/QC procurement manager
 Coordinate all quality related correspondence with the customers representatives.
 Monitor statistical method reporting.
 Action and close all customer complaints
 Control all achieve documentation upon the completion of the project.

Quality Assurance Quality Control Procurement Management


The quality control procurement manager has the responsibility for the coordination and inspection of all procured
items for site. He is responsibility to the projects QA manager.

 The reviewing of site purchase orders to ensure that the applicable requirements are met
 The control of on site and off site vendor inspectors
 The compilation of vendor inspection assignments packages
 The coordination and resolution of any nonconforming product Reviewing vendors QA/QC systems in accordance
with contractual requirements
 The attendance at site and inspection procurement meetings
 Coordination of vendor quality approvals when required
 Ensure the verification of documentation and certificates for materials purchased by vendors
 Review of suppler quality plans against contract requirements
 Review procurement documents to ensure that quality requirement have been correctly translated into purchase
requisitions and design documents
 Review supplier inspection procedures and personnel qualifications
 Review supplier material certificates
 Take part in supplier audit and surveillances
 Coordinate with the companies discipline engineers for the resolution of technical discrepancies
 Coordinate with management for quality improvements
 Issue of nonconformance reports
 Track all nonconformance reports
 Coordinate with the owners representative on all procurement issues
 Monitor progress of all purchase requisitions

Quality Assurance Quality Control Manager (Site)


The company site Quality Control Manager reports to the company QA Manager. He ensures the quality of the site
installations is consistent with the company's policy requirements together with national and international standards
and the customers specifications.

 Implement the QA/QC management system at site


 Coordinate with quality inspections with all the site sub contractors and vendors coordinate all non destructive testing
on site
 Coordinate with the customers representative on all quality matters
 Coordinate all receipt inspections
 Distribute relevant QA/QC documentation to site subcontractors
 Verify that the quality related site activities are in accordance with the applicable codes and standards
 Participate in the site internal and external site audits
 Coordinate all the quality site inspections through the site QC inspectors
 Ensure all quality control documentation is complied and competed for as-built hand over through the QC turnover
engineer
 Control all nonconformance reports and undertake remedial action
 Compete site quality control instructions and action remedial responses
 Review the customers specification and undertake relevant training to the site QC inspector
 Monitor the implementation of the approved site QC Plan
 Complete and coordinate the approval of the sites QC technical submittals to the customer
 Coordinate with the site construction manager on all quality issues Coordinate and chair the QA/QC site weekly
meetings with the projects subcontractors QC personnel
 Elaborating inspection and test programs
 Ensure the safety is adhered to at site
 Assure all technical documents relative to site quality control are current status

Quality Control Turn Over Engineer


The QA/QC Turnover engineer reports to the site QA/QC manager. He is responsible for the following.

 Ensures the quality records, acceptance certificates, mechanical completion certificates and the documentation for
specific systems and buildings/areas are prepared and collated in accordance with project requirements
 Coordinate with the planning and scheduling department to ensure milestone dates are understood for each turn over
area
 Coordinate with the site QC manager for the completion of as-built turnover documentation
 Resolve any discrepancies between the completed milestone and quality documentation
 Review suppliers inspection and test plans against the milestone scope of work
 Coordinate with the commissioning department to define the scope of work
 Assist the site subcontractors to compile turnover dossiers
 Provide progress information for incorporation into project reports
 Monitor hydrostatic test packs for incorporation into as-built dossiers
 Consider the implications of delays in QC as-built turnover documentation and bring to the attention of the site QC
manager
 Monitor and control the status of punch list and exception lists relevant to quality dossiers
 Attend the weekly QA/QC, and commissioning meetings
 Coordinate any inconsistencies with test packages with the field QC site inspectors
 Provide progress data to the planning and scheduling department

QC Senior Welding Inspector


The QC senior welding inspector reports to the site QC manager. He is responsible for the following.

 Elaborating and coordinating the welding specifications, and codes/standards


 Coordination with the field subcontractors for all welding procedure specifications and procedures qualifications
reports
 Review course and effects of welding defects and take remedial actions
 Coordination with the field subcontractors and the Third Party NDT Inspection Company
 Review of the radiographic film and all NDT reports on a daily basis
 Auditing of the approved Third Party NDT Inspection Company
 Reviewing the inspection and testing methods and procedures for Radiographic, Dye Penetrant, Magnetic Particle,
and Ultrasonic inspections
 Witnessing of welder qualifications testing and procedures qualification testing
 Witnessing any remedial repair welding
 Reviewing of the welding summery reports
 Checking the hydrostatic test packages for NDT compliance prior to testing
 Advising the site subcontractors with regards to welding and testing
 Monitor any Post Weld Heat Treatment on site and review the completed test reporting
 Selection of welds for non destructive testing
 Recording and listing of defective welds
 Monitor the control and issue of welding electrodes
 Control the QC site welding inspectors
 Actively monitor site radiation safety
 Review day to day applications for x-raying of welds
 Coordinate the issue of nonconformance reports through the site QC manager
 Compete site quality instructions to sub contractors when required

Quality Control Discipline Site Welding, Mechanical, Piping, Painting, Electrical, Instrumentation; Civil
Inspectors & Structural)
The site QC inspectors reports to the site QC manager

 Witnessing and sentencing of all site inspections within their disciplines


 Coordinate all site inspections with the site subcontractors
 Ensure that all inspection reports are accurate and that all attached documents are current status
 Ensure all work is correctly prepared prior to any inspection being undertaken
 Review all inspection reports for compliance
 Assist the site QC manager in the organisation, maintenance and control of the quality system
 Liase with the site construction engineers and provide assistance when requested
 Prepare nonconformance reports to the QA manager and assist in developing corrective actions
 Assist the QC manager and construction manager in resolving any discrepancies and ambiguities
 Coordinate with the customers QC inspectors for the resolution of site problems
 Coordinate with the site subcontractors to ensure that communications exist and are maintained
 Assist the site subcontractors in the resolution of drawing interpretation
 Attend the weekly QC meetings
 Review work procedures and method statements for compliance with good work practices and the customers
contract specializations
 The issuance of nonconformance reports in conjunction with the site QC manager
 The completion of QC site instructions and coordinate their closure The review of inspection test packages during the
course of construction activities
 Compliance with the site's health and safety regulations

Certification Engineer

 Facilitate the coordination of required verification information between the Client Representative, Client and project
personnel.
 Ensure the integrity and legal compliance of the product by engaging, and working with, Client Representative, Client
and project personnel..
 Provide advice and guidance to the project delivery team on all matters of verification and regulatory compliance
 Work with the Location Quality Manager and the Project Management Team to ensure:
 Project Verification Plan and dependent systems and procedures are developed and implemented in compliance with
the requirements of the Quality Management System (QMS) and Project Management System (PMS) consistent with
specific location, regulatory and contractual requirements.
 Project personnel are suitably trained in Project Verification Plan requirements and to access and apply dependent
systems, procedures and reference materials via the Project Web Site, QMS, PMS and the Knowledge Communities
as applicable. Facilitate regular meetings with all interested parties to ensure alignment of understanding and
direction.
 Co-ordinate the implementation of certification assurance processes within the project for regulatory compliance
 Review and approve Supplier/Subcontractor Quality Control Plans/Inspection Test plans and procedures.
 Be familiar with the requisition requirements and equipment/material specifications.
 Be fully familiar with the verification and inspection release processes and ensure their compliance.
 Ensure all certification requirements are clearly identified, understood and included with the requisition and PO.
 Attend Pre-production kick-off meetings with Supplier/Subcontractor (as appropriate).
 Review Supplier/Subcontractor Fabrication/Certification Dossiers (as appropriate).
 To participate (as necessary) in management visits/audits to Suppliers and Sub-contractors.
 Report promptly to the Project Quality Manager all matters related to verification scheme performance and regulatory
compliance.
 Ensure that all necessary quality records are identified and retained in accordance with client and regulatory
requirements.

Audit Leader
The Audit leader will ensure the implementation and effectiveness of quality processes and procedures that are
required to assure integrity of the company assets throughout their Asset Lifecycle, FEED (Front End Engineering &
Design) EPC (Engineering Procurement & Construction) Precommissioning, Commissioning and Project Handover.

 Overview
 Fiber Glass Reinforced Piping
 Structural Steel
 Piling Work
 Earth Work
 Civil Work
 Fabrication Shop
 Welding - Power Piping
 Welding - Pipe Lines
 Post Weld Heat Treatment
 Nondestructive Testing
 Coating Work
 Electrical Work
 Instrumentation Work
 Static Equipment
 Boilers
 Storage Tanks
 HVAC

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QA/QC organisation Chart (overview)
The Audit leader will assist the Asset Integrity Manager with the following:

 Confirm that all the necessary strategies and controls are demonstrably in place to assure the integrity of the assets
in the operations/production phase of the full lifecycle.
 Confirm project processes and procedures have been implemented to demonstrate full compliance with the
governmental integrity related laws
 Confirm that the impact of the rapidly evolving governmental legislative framework on the (Production) Integrity
Assurance Strategy is properly managed
 Confirm that the facilities under development, designed and built by the Project teams, are managed in such a way
that integrity (and hence safety and economic performance) can be maintained during the full asset lifecycle
 Confirm that the Project teams have made adequate integrity assumptions in the development of the basis of project
design, operational strategies and maintenance strategies
 Provide guidance in the development of Integrity Assurance processes and procedures of related projects as required
 Provide discipline driven input to the development of the overall asset integrity assurance plan for the onshore and
offshore assets
 Translate discipline focussed systems and management processes within the asset integrity assurance plan into
actionable procedures and work instructions for independent audit teams
 Foster and mentor a regionalisation programme for the integrity assurance function, building sustainable competency
and a sustainable integrity assurance & safety culture among newly recruited project staff

Accountabilities and Responsibilities:

The Audit Leader is responsible for:

 Assisting the Asset Integrity Assurance Manager by acting as audit leader of assigned audits (the audit leader will
preferably be assigned to audits of his own technical expertise)
 Managing exercises and audits to ensure the necessary strategies and controls are demonstrably in place to assure
the integrity of the assets in all phases of the project lifecycle
 Contributing to the assurance that the facilities under development by the Company are designed and built in such a
way that integrity (and hence safety and economic performance) can be maintained during all phases of the lifecycle
 Contributing to the preparation of look ahead plans for audits to be held
 Managing external resources in the execution of audits
 Coordinating with other auditing teams to prevent unnecessary disturbance of running projects
 Reviewing agendas and terms of reference to ensure clarity of purpose
 Preparing external parties of the auditing team for the audit
 Compiling and issuing report and support interpretation of its contents; follow-up and monitor closure of actions
 Coordinating reporting of external parties

HSE Responsibilities:

 Assuring technical integrity forms the basis of the company's health, safety and environmental performance.
 Audit Leader will interface with the on- and offshore Construction and Commissioning-, to plan and organise audits.
 Audit Leader will interface with representatives of the non-operating partners with regards to performing the auditing
functions
 Audit Leader will interface with representatives of integrity related contractors performing auditing tasks for the Asset
Integrity Assurance Group.
Control of Hydrogen Removal in 11/4 Cr. ½ Mo low alloy steel for the prevention
of weld cracking
The above specification was reviewed and a comment made advising a 60 minute minimum soak at 300-400C on
completion or partial completion of weldments in Cr. Mo. Material. The Specification tabulated 15minutes for
materials 10inch SCH 80 and below (15mm and below) and 30 minutes for 12 inch SCH 80 and above (above15mm
to 40 mm.).
The following notes are intended to give some additional information and should be taken into account.

The presence of hydrogen depends on a number of factors as follows:

1. Joint cleanliness (removal of surface contaminants, scale, rust oil,grease,paint etc)


2. Presence of moisture in the fluxes used in welding (controlled by baking and the use of low hydrogen consumables,
typically 5ml hydrogen/100 gms weld metal maximum. Control and issue of electrodes is also crucial after baking.
3. Preheat controls (adequate in Chiyoda's specification)
4. Microstructure susceptibility (high in this alloy)
5. Stress levels (greater in thicker joints).
6. Temperature limits on cooling. (the greatest risk occurs when near ambient temperatures are reached and cracking
can occur several hours or sometimes up to three days after welding is completed.

Most Fabricators/Contractors are aware of these causes and take measures to reduce the risk where possible. The
common additional technique to remove/reduce hydrogen levels is by introducing the post weld heating cycle.
Cracking is unlikely to occur when adequate soak times above 250C are used immediately on completion or partial
completion of welds. Removal rates are dependant on soak time and temperature. The table overleaf gives some
details for the amount of hydrogen removal based on different soak times and temperatures for the SMAW process
using low hydrogen electrodes, stored, baked, issued to the welder and controlled in accordance with the
manufacturer's recommendations.

Material Soak Temperature % Original


Thickness (Centigrade) Soak Time Hydrogen Remaining
(Minutes)

7mm 300 60 0

7mm 300 15 20

15mm 300 60 20

15mm 300 15 70

15mm 400 15 65

30mm 300 60 75

40mm 300 30 90

40mm 400 30 85

These figures were calculated by the Welding Institute who emphasised that although the technique for calculation is
considered conservative they have been shown to produce satisfactory results over a two year period. They take
account of the potential hydrogen which is a laboratory measurement of the moisture or hydrogen of any consumable
and a diffusivity (of hydrogen) factor for Cr/Mo material of 4 x 10-5 cms/sec.

Assuming low hydrogen electrodes are used and taking account of the potential hydrogen factor, the average
deposited weld metal hydrogen would be 5ml hydrogen/100gms weld metal. Hydrogen cracking has been
encountered in forgings as low as 2-5 ml hydrogen /100 gms weld metal. Based on all information above i.e
Chiyoda's experience and the Welding Institute (conservative) recommendations our advice is as follows:
 For material up to 15mm thick soak at 350C minimum for 15 minutes minimum
 For material over 15mm to 40 mm soak at 350C min for 45 minutes minimum
 The other precautionary measures listed in 1, to 6 must also be followed where applicable.
 We believe these recommendations are a responsible alternative to adequately reduce the hydrogen levels to
acceptable levels and offer a practice which is not far removed from current practice.

 Quality Control Inspection Check Sheets


1 - Material Control 10 - Structural Steel For 20.5 - Instrumentation 98 - ALL QC Construction
2 - Surveys Buildings Calibration Check Sheets
3 - Building Installation 11 - Welding 21 - Gas Removal System
4 - H.V.A.C 12 - NDE Special 22 - Overhead Crane
5 - Earthwork Processes 23 - Generator
5.1 - Road Construction 13 - Pipe Cleaning Blow 24 - Hotwell Pump
6 - Concrete Work Down 25 - Cooling Tower
7 - Piping Work 14 - Pressure Testing 26 - Turbine
8 - Piling 15 - Coating 27 - Condenser
9 - Structural 16 - Insulation 28 - General Construction
17 - Static Equipment Punchlist Report
18 - Rotating Equipment 29 - Milestone Completion
19 - Electrical Equipment Certificate
20 - Instrumentation 30 - Application for
Inspection


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 Select a category of inspection sheet:
1 - Material Control Material
Receiving
Report
INSPE
Over CT
Shortage
Damage
Report

Material
Inspection
Report

Storage
Report

Handling
Report

Material
Request
Issue Slip

Stock Card

Material
Return Slip

Material
Surplus List
Material
Accepted
Label

Material
Rejected
Label

Material
Hold Label

Conditional
Release
Label

Material
Release
Label

Material
Transfer
Report

Inspection
Release
Certificate

Conditional
Release
Certificate

Equipment
Preservatio
n Record

Equipment
Preservatio
n Log

Equipment
Preservatio
n Tag

Equipment
Preservatio
n Matrix

2 - Surveys Final
Inspection
of
Intersection INSPE
Points, Pipe CT
Support &
Crossfalls

Survey
Report Pad
and
Equipment
Area

Final
Inspection
of Pipe
Column

Final
Inspection
of Pipe
Column,
Head, Shoe

Final
Inspection
of Pipe
Anchor

Final
Inspection
of Road
Crossing

Final
Inspection
of Road

Equipment
Test

Final
Inspection
of
Secondary
Pipe

Fencing
Inspection

Survey
Report

3 - Building Installation Asphalt


Water
Proofing
Work INSPE
CT
Water
Proofing
Protection

Damproofin
g Water
Repellent
Work

Caulking
and Joint
Filler
Installation

Tile Work

Wood Work

Roofing
Insulation,
Roofing and
Siding Work

Down
Spouts and
Roof Drain
Work

Steel
Framing
Work

Miscellaneo
us Metals
Installation

Inspection
of Plaster
Wall & Floor
Finish

Fixtures &
Hardware
Installation

Glass and
Glazing
Installation

Vinyl Floor
Tile Work

Gypsum
Board
Installation

Acoustic
Board
Installation

Piping
Installation (
part 1 )

Piping
Installation (
part 2 )

Sanitary
Equipment
Installation

Miscellaneo
us
Equipment
Installation

Pressure
Test

Leakage
Test

Fire
Protection
Equipment
Installation

Test Record
of Piping
and Ducting

Building
Inspection
Record

Acceptance
of Builing
Externals

Acceptance
of Builing
Internals

4 - H.V.A.C Air Handling


Unit & Fans

HVAC INSPE
System CT
Function
Check

HVAC
System
Noise
Measureme
nt

Acceptance
Certificate
of Building
Equipment

HVAC
Installation
Check List
5 - Earthwork Sewer
Piping Work

Open Ditch INSPE


CT
Water
Leakage
and Sewer
Line

Installation
of Main
Sewer

Pond Lining

Gabions

Rock
Masonry
Work

Constructio
n Using
Culvert

Placement
of Base
Course

Placement
of Structural
Fill

Placement
of Structural
Fill
Foundation

New Roads
Finishing
Work

Compaction
of Structural
Fill

Clearing of
New Land

Compaction
Test of
Sand
Bedding by
Clegg
Hammer (
part 1 )

Compaction
Test of
Sand
Bedding by
Clegg
Hammer (
part 2 )

Inspection
of
Landscapin
g

Inspection
of
Landscapin
g
Equipment

QC
Geotextile
Check
Sheets

QC
Membraine
s Liners Hot
Shoe
Calibration

QC
Membraine
s & Liners
Leak Test

5.1 - Road Construction Proctor Test

Release For
Backfill INSPE
CT
Re-use Of
Excavated
Materials

Grading
Chart For
Sub-Base

Grading For
Base
Course

Aggregate
Test Report
6 - Concrete Work Trial Mix
Test of
Concrete
INSPE
Compress CT
Strength
Test of
Concrete

Record of
Anchor Bolts
for Steel
Structure

Concrete
Pour Record

Tank
Foundation
Record

Pre-
Concrete
Inspection
Record

Earth &
Concrete
Work
Foundation

Proctor Test

Concrete
Aggregates
( Table &
Test Results
)

Cable Pull
Pits Pre
Pouring

Cable Pull
Pits Post
Pouring

Inspection of
Reinforcing
Bar
Installation

Cement
Test Sheet

Concrete
Structure
Checks
Report
Before
Casting
Pre-grouting
Inspection
Check List

Aggregate
Test Report

Comprehen
sive
Strength
Test for
Concrete

Concrete
Delivery For
Ticket

Grouting
Inspection
Record

Backfilling
Embankmen
t Material
Inspection
and
compaction
Report

Soil Testing
Request

Sieve
Grading
Report

Soil Density
Test Report

Compaction
Test Report

Undergroun
d Gravity
Sewers
Leakage
Test
Checklist

Field Steel
Work
Grouting
Checklist

Asphalt
Concrete
Check
Report

Grout
Release
Form

Aggregate
Summary
Sheet For
Sundry Test

Geotextile
Check
Sheet

HDPE
Studliner/Ge
omembrane
Checks and
Test
Reports

Air Pressure
Test Form
Check And
Test
Reports

Release for
Liner/Membr
ane Laying

Column and
Tower
Inspection
Checklist

7 - Piping Work Pipework


Pre-Test
Checklist
INSPE
Hydrostatic CT
Test
Results Part
1

Hydrostatic
Test Report
Part 2

Flush Blow
and
Chemical
Clean
Acceptance
Certificate

Flushing
and
Cleaning
Report

Piping
Works
Installation
Checklist

Buried FRP
Pipe
Installation

Mechanical
Completion
of Pipework

Pipework
Post Test
Check List

GRP/FRP
Butt & Wrap
Lamination
(each Joint)

GRP/FRP
Adhesive
Joint
Preparation

Hydrolic
Actuated
Valve

Butterfly
Valve

Fire Hydrant

Manually
Operated
Valve

Mechanicall
y Diverter

Pneumatical
ly Actuated
Valve

Motorized
Valve

Reciprocati
ng
Compressor

Solenoid
Operated
Valve

Safety
Valve
8 - Piling Survey
Report
Piling
INSPE
Test Pile CT
Data

Pile Driving
Log Sheet

Pile
Extension
Record
Sheet

9 - Structural Steel Work


Fabrication
Check List
INSPE
Steel Work CT
Installation
Check List

Structure
Installation
Check List

QC Steel
Structure
Inspect
Check List

QC
Structural
Checklist
Report

QC
Structural
Release

QC
Inspection
Structural
Steel
Buildings

Inspection
Of
Structural
Steel
Erection

None
Destructive
Testing
Report
Structural
Cutting &
Drilling
Structural

10 - Structural Steel For Buildings Inspection


of Structural
Steel
Fabrication INSPE
CT
Inspection
of Structural
Steel
Erection

11 - Welding Welder
Qualificatio
n Test
INSPE
Procedure CT
Qualificatio
n Record (
part 1 )

Procedure
Qualificatio
n Record (
part 2 )

Welding
Procedure
Specificatio
n

Welders
Qualificatio
n Log

Welders
Performanc
e Chart

Daily Field
Weld
Report

Weld Travel
Sheet

Heat
Treatment
Instruction
Sheet
Consumeab
le Checklist
for Welding
Work

Welding
Repair
Record

Daily Field
Weld
Report

WTD
Attendance
Sheet

Structural
Weld Travel
Sheet SS2

Structural
Weld Travel
Sheet SS2

Weekly
Welders RT
Control
Sheet

12 - NDE Special Processes Radiographi


c
Examination
Log INSPE
CT
Magnetic
Particle
Examination
Log

Liquid
Penetrant
Examination
Log

Ultrasonic
Examination
Log

Radiographi
c
Examination
Report

Liquid
Penetrant
Examination
Report
Hardness
Testing
Report

NDT
Qualification
log

Contractors
Notice for
RT Works

RT
Examination
Report

Welders
Control
Sheet
Weekly

Local Post
Weld Heat
Treatment

Daily
Dosemeter
record

Radiographi
c Record

Calibration
intervals

Material List
For Positive
Material
Inspection

QA Pre-job
RT
Checklist

Positive
Material
Inspection(
PMI)

Radioactive
Isotope
Movement
Record

NDE
Clearance
QC
Checklist
13 - Pipe Cleaning Blow Down Pipework
Pre-test
Checklist
INSPE
Hydrostatic CT
Test Report

Flushing,
Blowing and
Chemical
Cleaning
Acceptance
Certificate

Post Pipe
Cleaning /
Blow Down
Check List

Mechanical
Completion
of Pipe
Work

Preparation
Check for
Pipe
Cleaning /
Blow Down

14 - Pressure Testing Pipework


Pre Test
Checklist
INSPE
Hydrostatic CT
Test Report

Pipework
Post Test
Check List

15 - Coating Daily
Report on
Paint
Operations INSPE
CT
In-process
Paint
Inspection

Accept
Inspection
of Paint
System

16 - Insulation Insulation
Inspection
Record
INSPE
Equipment CT
Piping
Release for
Insulation

Field Lining
Inspection

17 - Static Equipment Shop


Fabricated
Tank &
Vessel INSPE
Installation CT

Heat
Exchanger
Installation
Inspection

Final Vessel
Closure

Special
Equipment
Inspection

Auxiliary
Equipment
Index
Miscellaneo
us Items

Fired
Heater
Installation
Inspection

Fired Boiler
Inspection

Storage
Tank
Inspection

Heat
Exchanger
Installation
Inspection

18 - Rotating Equipment Equipment


Protection,
Preservatio
n& INSPE
Equipment CT

Alignment
Inspection

Equipment
Flange
Alignment

Compressor
Inspection

Pump
Inspection

Fan &
Blower
Inspection

Electrical
Motor
Inspection

Centrifugal
Compressor

Gear Box

Pump Motor
Running
Test

Centrifugal
Seperator
Static Test

Compressor
Running

Coupling
Alignment

Centrifugal
Seperator
19 - Electrical Equipment Visual
Inspection
of Cadweld
Connection INSPE
CT
Oil
Dialectric
Strength
Test

Constructio
n Drawings
Earthing
Grid

Cable Tray
Inspection
Check List

Visual
Inspection
of Earthing
Risers
Installation

Cable
Pulling
Inspection
Check List

Overall
Completion
of Earthing
Grid

Megger
Reading
Power
Control
Wire &
Cable

Visual
Inspection
of Earthing
Wire Layout

Meggar
Reading
Electrical
Equipment
inc Motors

Cadweld
Connection
Earth Wire

High
Voltage DC
Test Record
1kv Cable
Insulation
Resistance

Ground
Well
Resistance
Readings

Switchgear
Inspection

Megger
Reading
Transformer

Switchgear
Inspection
Record (
part 1 )

Switchgear
Inspection
Record (
part 2 )

480v Switch
Rack
Inspection
Record

Motor
Control (
part 1 )

Motor
Control (
part 2 )

Liquid Filled
Transformer

Pre
Commisioni
ng of Power
Transformer
s( part 1 )

Pre
Commisioni
ng of Power
Transformer
s( part 2 )

Neutral
Grounding
Resistor
Inspection
Record

Battery &
Battery
Charger
Inspection
Record
Replaceme
nt of Field
Control
Station Test
Record

Connection
of Existing
Loads to
New MCC'c
T

Internal
Lighting
Check
Sheet

Small
Power
Inspection
Check List

Distribution
Boards
Panel
Inspection
Check List

Telephone
System
Inspection
Check
Sheet

Undergroun
d Conduit
Inspection
Check List

Above
ground
Conduit
Inspection
Check List

Diesel
Generator
Installation
Check List

DCS-
Console
Desk
Installation
Check List

Control
Pane
Installation
Check List

LV Bus
Duct
Connection
Check List

Local Pane
& Box
Installation
Check List

Lighting
Protection
Installation

OA System
Installation

20 - Instrumentation Site
Inspection
Certificate
for Local INSPE
Mounted CT
Instruments

Instrument
Power
Supply
Inspection
Record

Alarm
Annunciator
Test Record

Control
System
Punch List
Record

Control
Systems
Test
Equipment
Calibration

Calibration
Form ( part
1)

Calibration
Form ( part
2)

Installation
and Loop
Check
Record

Megger
Reading
Instrument
Wires Cable

Instruments
Installation
Check List

20.5 - Instrumentation Calibration Control


Valves

Differential INSPE
Pressure CT
Transmitter

Transmitter
Remote
Diaph. Seal

Level
Switch With
Displacer

Level
Transmitter
With
Displacer

Motorized
Valve

On/Off
Valve Fail
Closed

On/Off
Valve Fail
open

Oriface
Plate

Pressure
Gauge

Safety and
Relief Valve

Pressure
Switch

Pressure
Transmitter

Temperatur
e Gauge

Temperatur
e Switch
Temperatur
e
Transmitter

I/P
Transducer

I
Transducer

Controller

Temperatur
e Element

21 - Gas Removal System Gas


Removal
System
Check List INSPE
Support CT
Structure

Gas
removal
System
Check List
Ejector,
Condenser
& Separator
Installation

Gas
Removal
System
Check List
Vacuum
Pump
Installation

22 - Overhead Crane Overhead


Crane
Installation
Check List INSPE
CT
23 - Generator Generator
Installation
Check List (
part 1 ) INSPE
CT
Generator
Installation
Check List (
part 2 )

Generator
Installation
Check List (
part 3 )

24 - Hotwell Pump Hotwell


Pump
Installation
Check List INSPE
CT

25 - Cooling Tower Cooling


Tower
Installation
Check List INSPE
CT
Cooling
Tower
Installation
Check List (
part 2 )

26 - Turbine
Turbine
Installation
Check List ( INSPE
part 1 ) CT
Turbine
Installation
Check List (
part 2 )

Turbine
Installation
Check List (
part 3 )

27 - Condenser Condesner
Check
Sheet ( part
1) INSPE
CT
Condenser
Check
Sheet ( part
1)

28 - General Construction Punchlist Report General


Constructio
n Punchlist
Report ( INSPE
part 1 ) CT

General
Constructio
n Punchlist
Report (
part 2 )

29 - Milestone Completion Certificate Milestone


Completion
Clearance
INSPE
CT
30 - Application for Inspection Application
for
Inspection
INSPE
CT

98 - ALL QC Construction Check Sheets ALL QC


Cheek
Sheets
Consisting INSPE
of 332 QC CT
check
sheets

QC Inspection Packages (NEW)


 01a Pi 01a Piping Hydrostatic Test Package02a Site Welding Documentation
 03a QC NDT Testing Check Sheets
 04a Construction (Storage of Site Isotope Bunker)
 05a QC Site Coordination Inspection Package
 06a QC Vendor Inspection Package
 07a Audit Documentation

 ping Hydrostatic Test Package


 02a Site Welding Documentation
 03a QC NDT Testing Check Sheets
 04a Construction (Storage of Site Isotope Bunker)
 05a QC Site Coordination Inspection Package
 06a QC Vendor Inspection Package
 07a Audit Documentation

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01a Piping Hydrostatic Test Package  01a Hydro Test
Package
~ Test Pack
Cover Sheet INSPECT
~ Completion
Acceptance
~ Punch List a
~ Punch List b
~ Equipment
Check List
~ Pipe Work Pre-
test List
~ Hydro Test &
Data Record
~ Monitoring
Data Record
~ Pressure Test
Diagram
~ Hydro Test
Report
~ Weld Travel
Sheet
~ Heat Treatment
Record
~ Hardness
Report
~ Test Routing
Slio
~ Chemical
Cleaning
~ Status Test
Pack
~ Test Pack Log
~ Piping Spool
List
~ Equipment List
~ Bill of Material
~ Summary of
Material

02a Site Welding Documentation  02a QC Welding


Check Sheets
~ NDT Welding
Classes INSPECT
~ Pipe Welding
Method
~ Welding
Procedure Spec
~ Procedures
Qualification
~ Welder
Evaluation
~ NDT Clearance
~ Pipe Welding
Travel Sheets
~ Daily Welding
Report
~ Welding Repair
Report
~ Welding S/S
Brackets
~ Welding
Structural Steel
~ Welding NDT
Report
~ Welder Testing
 02b QC Welding
Repair Piping
 03c Welding
Repair Structural
 04d Weld-inch
Diameter Chart

03a QC NDT Testing Check Sheets  03a NDT Testing


~ NDT
Technicians Log
~ Contractors RT INSPECT
Work
~ NDT Matrix
~ RT Repair
Report
 03b NDT Audit
Report

 04a Site RT
04a Construction (Storage of Site Isotope Bunker)
Storage Bunker
Drawing
 04b Request for INSPECT
Temporary RT
Source Storage
Permit
 04c Source Pit
Inspection Report

05a QC Site Coordination Inspection Package  05a QC Site


Coordination
~ QC Application
for Inspection INSPECT
~ Construction
QC Memo
~ QC Inspection
Schedule
~ Suppliers
Release
Certificate
~ RT
Examination
Report
~ QC Minutes of
Meeting
~ QC Application
for Inspection
~ Completion
Punch List
~ Completion
Payment Chart
~ QC Minutes of
Meeting List
~ QC
Construction
Memo Log
~ QC Distribution
Matrix - India
~ ISO
Subcontractor
Evaluation
 05b QC Meeting
Agenda
 05d Site
Temporary
Isotope Storage
Facility Permit

06a QC Vendor Inspection Package  06a QC Purchasing


(Inspection
Package)
~ Cover Letter INSPECT
~ Inspect
Assignment
~ Inspection
Items
~ Inspection
Report
~ Purchase
Order
 06b QC Purchasing
Inspection
Meeting
~ Pre-inspection
Meeting
 06e Construction
Work Notification
 06f Risk
Assessment RT
Work

07a Audit Documentation  07a Audit


Documentation
~ Audit
Notification INSPECT
~ Audit Report a
~ Audit Report b
~ Audit Report
Log
~ Non-
conformance
Report
~ Non-
conformance Log
~ Corrective
Action Request
~ Corrective
Action Log
 07b Audit PLAN
Schedule

QC Inspection & Test Plans (Construction


Phase)
100 - QC Inspection & Test Plans (Construction Phase)
101 - Project Quality Plan - PENDING

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100 - QC Inspection & Test Plans  "Part 1" (QCITP) Introduction
(Construction Phase)
 "Part 2" (QCITP) Test Plan
Construction Activities INSPECT

 00 - Construction Inspection
eTest Plant inspection points
 01 - QC application for
inspection
 02 - Non-conformance
 03 - Project quality audits
 04 - Demolition and salvage
 05 - Material control
 06 - Earthwork
 07 - Piling work
 08 - Concrete works
 09 - Piping works
 10 - Piping tie-ins
 11 - Structural
 12 - Welding/brazing
 13 - NDE special processes
 14 - Pressure testing
 15 - Coatings
 16 - Insulation/refractory
 17 - Static equipment
 18 - Rotating equipment
 19 - Equipment refurbishment
 20 - HVAC
 21 - Electrical
 22 - Instrumentation
 23 - Fireproofing

  "Part 3" (QCITP) Test Plan


Deliverables

101 - Project Quality Plan - PENDING

Project - QC Procedures Template


204 - QC PIPING 206 - QC ELECTRICAL PROCEDURES
PROCEDURES 207 - QC INSTRUMENTATION PROCEDURES
200 - QC CIVIL- 208 - QC WELDING PROCEDURES
PROCEDURES 209 - QC MECHANICAL PROCEDURES
201 - QC BUILDING 210 - QC ROTATING EQUIPMENT
PROCEDURES 280 - ALL Project Procedures
202 - QC STRUCTURAL
PROCEDURES
203 - QC COATING
PROCEDURES
205 - QC INSULATION
PROCEDUES

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204 - QC PIPING PROCEDURES PIPING DEMOLITION

BOLTING
INSPECT
DISINFECTION
PORTABLE WATER

PIPING FABRICATION

PIPING INSTALLATION

PRESSURE PIPE
TESTING

HOT - TAPS

TIE - INS

FLUSHING

BLINDING OF PIPING
EQUIPMENT

SOCKET SPACER
INSERTS

SOLVENT JOINTING PVC


PIPE

200 - QC CIVIL- PROCEDURES SURVAYING

SITE HANDLING - CIVIL


MATERIALS INSPECT
CIVIL DEMOLITION

DISPOSAL OF WASTE
MATERIAL

EXCAVATION

DEWATERING

BACK FILLING
FORMWORKS

CONCRETE
REINFORCEMENT

CONCRETE POURING

CONCRETE COURING

GROUTING

CONCRETE REPAIR

ASPHALTING

201 - QC BUILDING PROCEDURES CONCRETE FLOOR


CONSTRUCTION

BUILDING & MASONARY INSPECT


WALL

DRY WALL INSTALLATION

BUILDING ROOF
INSTALLATION

BUILDING CELILING
INSTALLATION

PRECAST BUILDING
INSTALLATION

DOORS & WINDOWS


INSTALLATION

BUILDING INSULATION

WATER PROOFING

WALL & FLOOR FINISHES

RAISED FLOOR
INSTALLATION
202 - QC STRUCTURAL PROCEDURES SITE HANDLING
STRUCTURAL

STRUCTURAL INSPECT
INSTALLATION

STRUCTURAL
FABRICATION

STRUCTURAL
DEMOLITION

203 - QC COATING PROCEDURES COATING

COATING MATERIAL
INSPECT

205 - QC INSULATION PROCEDUES SURFACE PREP


INSULATION

APPLICATION OF INSPECT
INSULATION

CLADDING

HEAT SLEEVE PIPE

TAPE WRAPPING PIPING

CONCRETE FIRE
PROOFING

REFRACTORY
206 - QC ELECTRICAL PROCEDURES CONDUIT INSTALLATION

DEMOLITION OF
ELECTICAL EQIPMENT INSPECT
STORAGE HANDLING
ELECTRICAL

CABLE TRAY
INSTALLATION

CATHODIC PROTECTION

CABLE PULLING

GROUNDING SYSTEMS

DUCTBANK
INSTALLATION

ELECTRONIC MOTOR

GENERATOR
INSTALLATION

SWITCH GEAR
INSTALLATION

TRANSFORMER
INSTALLATION

BATTERY UPS

JUNCTION BOX
INSTALLATION

MOTOR CONTROL

LIGHTING SYSTEM

CONTROL PANEL

RELAY INSTALLATION

BREAKER INSTALLATION

CABLE TESTING

GROUNDING SYSTEMS

MOTOR TESTING

SWITCHGEAR TESTING

TRANSFORMER TESTING

BATTERY TESTING

CONDUIT SEAL POURING

MULTIWAY SWITCH

TERMINATION SPLICING

IN PLANT
COMMUNICATION
TERMINATION &
SPLICING

207 - QC INSTRUMENTATION SITE HANDLING


PROCEDURES INSTRUMENT

DEMOLITION OR INSPECT
INSTRUMENTS

INSTRUMENT
PREINSTALLATION
CALIBRATION

INSTALLATION -
TRANSMITTER

INSTALLATION -
CONTROL VALVE

INSTALLATION -
SWITCHES

INSTALLATION SAFETY
VALVES

INSTALLATION -
ANALYZERS

INSTALLATION -
INDICATORS

INSTALLATION -
MISCELLANEOUS INSTR.

FIELD PRESSURE TEST


INSTUMENT PIPE

INSTRUMENT LOOP
CHECK

FIRE ALARM

GAS DETECTION
208 - QC WELDING PROCEDURES SITE WELDING

PREHEAT & INTERPASS


HEAT INSPECT
HEAT TREATMENT

POST WELD HEAT


TREATMENT

209 - QC MECHANICAL PROCEDURES PRE-INSTALLTION MECH


EQUIPMENT

PROTECTION INSPECT
PRESERVATION & MAINT
OF EQUIPMENT

COLD CUTTING &


PREPERATION FOR HOT
WORK

SCAFFOLDING

CAR SEALING

RIGGING

PRESERVATION OF
EQUIPMENT

HANDLING &
IDENTIFICATION MECH
MATERIALS

INSTALLATION OF
MECHANICALEQUIPMENT

TUBE ROLLING

210 - QC ROTATING EQUIPMENT PREPARATION OF


ROTATING EQUIPMENT

ROTATING EQUIPMENT INSPECT


ALIGNMENT
280 - ALL Project Procedures All Project Procedures

INSPECT

Audit Questions Check Sheets


301 - Audit Question Check Sheets

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301 - Audit Question Check (QA)-Quality Management System
Sheets
(QA)-Management Responsibility
INSPECT
(QA)-Resource Management

(QA)-Product Realization

(QA)-Measurement Analysis &


Improvement

(QC)- Welding Audit Check Lists

(QC)-Structural Audit Check Lists


Quality Assurance Check Sheets
Quality Assurance Check Sheets

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01 - Engineering QA-01 Change Proposal Order Satus Log

QA-02 Document Archive index


INSPECT
QA-03 Change Order

QA-04 Change Proposal

QA-05 Consession log

QA-06 Concession request

QA-07 Document Provisional Approval Status


Stamp

QA-08 Insurance Checklist

QA-09 Comment Control Sheets

QA-10 Supplier Document Schedule

QA-11 Job description

QA-12 Quality Action Plan

QA-13 Document Provisional Approval Status


Log

QA-14 Document Relase Note

QA-15 Document Routing Slip

02 - Procurement QA-001 Archive Log

QA-002 Material Receipts Summery


INSPECT
QA-003 Quality System Questionnaire

QA-004 Engineerng Query Register

QA-005 Field Expiditing Instruction

QA-006 Field Expedediting Report

QA-007 General Inspection Report


QA-008 Inspection Notification Sheet

QA-009 Inspection Release Certificate

QA-010 Inspection Report

QA-011 Inspecton Waiver Notice

QA-012 Material Issue Summery

QA-013 Clean Marketing Client Survey

QA-014 Material Transfer Note

QA-015 Materials Reciving Report

QA-016 Over Shortage and Damage Report

QA-017 Pre Inspection Meeting Report

QA-018 Materials Expiditing Report

QA-019 Project Execution Plan Task Sheet

QA-020 Punch Lists

QA-021 Rejection Note

QA-022 Rejection Note Waiver Register

QA-024 Test Package Completion Status Log

QA-025Transport in out Log

QA-026 Vendor NCR Punch List Close Out


Form

QA-27 Packing Check Sheet

Health Safety & Environment (ISO14001)


Checksheets Shopping List
32 - HSE Construction Checklist
33 - (HSE) Pipeline Review Checklists
34 - (HSE) Project Audit Procedure
35 - (HSE) Design Phase Technical Integrity Reiview Checklists
36 - Design Phase Block Modeler 3D-CAD Model Checklist
37 - Project (HSE) Safety Plan
60 - ALL Health Safety and Environment (HSE) Documents and Test Plan

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32 - HSE Construction Checklist Housekeeping

Work Practice
INSPECT
Fire Protection &
Emergency
Response

Tools & Equipment

Welding & Burning

Pressure Systems
Air

Pressure Testing

Vehicles & Mobile


Equipment

Energy & Isolation

Working at Heights

Use of Ladders

Roof Work

False Work

Scaffolding

Tower &
Scaffolding

Confined Space
Entry

Excavation

Piling

Lifting Operations

Manual Handling

Gin Wheels

Electrical Safety

Overhead Power
Lines

Demolition

Waste
Management On
Site

Working Overhead
or Near Water

Hazardes
Substances

Hasbestos
Ionising Radiation

Painting

Shot Blasting

Erection &
Structures

Storage &
Laydown Areas

Buildings

Welfare Facilities
On Site

Office &
Accomadation On
Site

HSE GUIDANCE
ON METHOD
STATEMENTS

33 - (HSE) Pipeline Review Checklists (HSE) LOWERING


& LAYING PIPE
CHECKLIST
INSPECT
(HSE)
EXCAVATION &
TRENCHING

(HSE) STEEP
SLOPE WORKING

(HSE) GENERAL
WORK
PRACTICES

(HSE)
HYDROTESTING
CHECKLIST

(HSE) WELDING &


BURNING
CHECKLIST

(HSE)
HOUSEKEEPING
CHECKLIST

(HSE) RADIATION
CHECKLIST

(HSE)
SHOTBLASTING

(HSE) SIMOPS
RISK
ASSESMENT
CHECKLIST

(HSE) VEHICLES
HEAVY
EQUIPMENT

(HSE)
ELECTRICAL
SAFETY
CHECKLIST

34 - (HSE) Project Audit Procedure (HSE) Project


Audit Procedure

INSPECT

35 - (HSE) Design Phase Technical Integrity (HSE) General


Reiview Checklists
LOCATION
ORIENTATION INSPECT
LAYOUT

CLASSIFICATION
OF HAZARDOUS
AREAS

PROCESS PLANT
- Pressure Vessels
& Exchangers

PROCESS PLANT
- Pipelines & Pig
Traps

PROCESS PLANT
- Piping

Furnices & Fired


Heaters

PUMP AND
COMPRESSORS

TANKS
(HYDROCARBON
STORAGE)
LOADING
FACILITIES - Jetty
Pier Loading

LOADING
FACILITES - Road
Rail Loading

BUILDINGS

CIVIL &
STRUCTURAL
DESIGN Inc Roads

OVER PRESSURE
& RELIEF
PROTECTION

FIRE & GAS


DETECTION -
General

FIRE & GAS


DETECTION - Gas
Detection

FIRE & GAS


DETECTION - Fire
Detection

EMERGENCY
SHUT DOWN
(ESD) SYSTEMS

ACTIVE FIRE
PROTECTION

Passive Fire
Protection

Fire Protection
General

Drainage &
Sewage

Flaring & Venting

Isolation

MATERIAL
SELECTION

HVAC

Electrical System
design

LIFTING,
MECHANICAL
HANDLING

HAZARDOUS
MATERIALS
DEMOLITION &
REFURBISHMENT

CONSTRUCTION

EMERGENCY
EVACUATION &
ESCAPE

MAINTANENCE

COMMUNICATION

AUDIO & VISUAL


ALARMS

SAFETY
EQUIPMENT &
SIGNS

ENVIRONMENTAL
CONDITION

ENVIRONMENTAL
HYGEINE

SITE HAZARDS &


CODES &
STANDARDS

36 - Design Phase Block Modeler 3D-CAD Model General Layout


Checklist Considerations

PROCESS UNITS INSPECT

General Safety &


Operability

Fire Prevention &


Safety Equipment

Piping

Valves

Heat Exchangers &


Boilers

Pumps &
Compressors

Furnaces & Boilers

Vessels &
Columns

Relief Valves
Tankage Storage
Transfer

Environment

Occupational
Health & Hygiene

37 - Project (HSE) Safety Plan Project (HSE)


Safety Plan

INSPECT

60 - ALL Health Safety and Environment (HSE) ALL Health Safety


Documents and Test Plan and Environment
(HSE) Documents
and Test Plan INSPECT

Project Overview
Custom
Revi
er
ew
Review
Of
Terms & Definitions Of
Bid
Docum
Tend
entatio
ers
n

Turnov
In
er Of
Proc
QC As-
ess
built
QA/QC Kick Off Meeting Insp
Docum
ectio
entatio
n
n

Setup of Engineering Procurement and


Construction Projects

Terms & Definitions


Construction Phase QC
Examination/Inspection
Quality control functions performed by Contractor or its subcontractor
through:

 QC Inspection Check Sheets


 Inspection and Test Plans by construction activity
 project specifications
 code and standards.
 Application for Inspection

QC Documentation Turnover By Pay


Milestones
 Verification of a completed construction milestone through:
 The traceability of QC Inspection reports for payment and completion
status.
 The closure of Non-conformance Reports and outstanding Technical
Queries, Design Changes

Construction Punch-list Verification


 The identification and acceptance of categories of punch listed items by
system, sub-system.
 missing materials.
 Incorporation into Master Punch List.
 Coordination and closure of Punch listed items by QC Application for
Inspection Form.

As-Built Drawings
 An engineering drawing that has been revised to reflect actual field
conditions and facility modification after the completion of construction.
 Normally As-built drawings are red line marked up (modifications
highlighted in red ink).

Turnover Package
 Turnover package content and structure will vary depending on the type of
project and shall be defined during the construction phase of the project.
 Spare parts data and other non-material requirements to be furnished to
the Startup organisation for systems, project areas, facilities or portions of
the work ready for commissioning.
 Documentation, including:
 Hydrostatic Test Packages,
 as-built drawings,
 Radiographic Film, completed test records
 punch lists,
 startup and operating instruction or manuals

Mechanical Completion
 Completion status of construction at the point of turnover to the Startup
Organisation is normally defined in the contract with the Customer.
Typically, erection and assembly of facilities including installation off :
 equipment, sub-assemblies and parts
 performance of non-operating adjustments,
 leak, pressure testing
 other non-destructive tests
 cold alignment checks

Pre-commissioning Phase
Pre-commissioning
 performance of non-operating adjustments
 leak, pressure and other non destructive tests
 cold alignment checks
 instrument calibration and loop checks
 electrical continuity and motor rotation checks made by Contractor or its
subcontractors prior to mechanical completion
 instrument calibration and loop checks
 electrical continuity and motor rotation checks are completed and the
facilities are ready for commissioning.

Commissioning Phase
Ready for Commissioning
 The status of construction after Mechanical Completion and prior to
startup.
 Construction and clean-up activities are complete and the facilities are
made ready for initial operation by the Startup Organisation
 Typically control and logic systems are statically tested
 rotating equipment is prepared for operation
 additive and inhibitor systems are charged
 the facilities are made ready for process pressurisation
 removal of internal intermediate isolation blinds.

Commissioning
 removal of system battery blinds
 purging and pressurising systems with process mediums
 utility systems such as plant air, cooling water, steam, etc
 running of facilities, and on-stream verification of control system
 equipment component performance pumps, motors, analysers, etc

Startup Phase
Startup Organisation
 The Customers operating staff, or third party organisation responsible for
commissioning and startup of mechanically completed facilities.
Startup
 Activities associated with the running or operating of the facilities or
portions of the facilities following Pre-commissioning, Mechanical
Completion and Turnover. Operating adjustments to achieve performance
of the facilities are made during Startup.

Turnover
 The transfer of care, custody and control of completed project areas or
facilities to a designated Startup Organisation.

Standard Project Definitions For


Construction, Pre-commissioning,
Commissioning Activities

Notes
1. Construction QC Documentation for verification of completed Milestones
(identify category of punch lists).
The closure of Non-conformance reports, resolution of outstanding
Technical Queries and red line mark up of As built drawings.
2. Pre-commissioning activity can begin prior to the Mechanical Completion
of the system.
3. At the Turnover (System Ready for Commissioning) Care and Custody is
transferred from the Contractor to the Customer.
4. Final Acceptance – The end of Normal Warranty Period of 1 year after the
Provisional Acceptance.

Project Quality
International Standard Organization Quality
Management System Requirements

Constructio
n Project
Failure
Prevention
Systems

Manage
your
processes
and they
will protect
your
Company
and profit
margins.

 01
Managemen
t Process

 02
Organizatio
n Process

 03
Conformity
Process

 04
Documentat
ion Process

 05
Examinatio
n Procedure

 I. Organization
 II. Quality Assurance Program
 III. Design Control
 IV. Procurement Document Control
 V. Instructions, Procedures, and Drawings
 VI. Document Control
 VII. Control of Purchased Material, Equipment, and Services
 VIII. Identification and Control of Materials, Parts, and Components
 IX. Control of Special Processes
 X. Inspection
 XI. Test Control
 XII. Control of Measuring and Test Equipment
 XIII. Handling, Storage and Shipping
 XIV. Inspection, Test, and Operating Status
 XV. Nonconforming Materials, Parts, or Components
 XVI. Corrective Action
 XVII. Quality Assurance Records
 XVIII. Audits

International Standard Organization Quality


Management System Requirements

Constructio
n Project
Failure
Prevention
Systems

Manage
your
processes
and they
will protect
your
Company
and profit
margins.

 01
Managemen
t Process

 02
Organizatio
n Process

 03
Conformity
Process

 04
Documentat
ion Process

 05
Examinatio
n Procedure

 I. Organization
The applicant 1 shall be responsible for the establishment and execution
of the quality assurance program. The applicant may delegate to others,
such as contractors, agents, or consultants, the work of establishing and
executing the quality assurance program, or any part thereof, but shall
retain responsibility for the quality assurance program. The authority and
duties of persons and organizations performing activities affecting the
safety-related functions of structures, systems, and components shall be
clearly established and delineated in writing. These activities include both
the performing functions of attaining quality objectives and the quality
assurance functions. The quality assurance functions are those of (1)
assuring that an appropriate quality assurance program is established and
effectively executed; and (2) verifying, such as by checking, auditing, and
inspecting, that activities affecting the safety-related functions have been
correctly performed. The persons and organizations performing quality
assurance functions shall have sufficient authority and organizational
freedom to identify quality problems; to initiate, recommend, or provide
solutions; and to verify implementation of solutions. There persons and
organizations performing quality assurance functions shall report to a
management level so that the required authority and organizational
freedom, including sufficient independence from cost and schedule when
opposed to safety considerations, are provided. Because of the many
variables involved, such as the number of personnel, the type of activity
being performed, and the location or locations where activities are
performed, the organizational structure for executing the quality assurance
program may take various forms, provided that the persons and
organizations assigned the quality assurance functions have the required
authority and organizational freedom. Irrespective of the organizational
structure, the individual(s) assigned the responsibility for assuring effective
execution of any portion of the quality assurance program at any location
where activities subject to this appendix are being performed, shall have
direct access to the levels of management necessary to perform this
function.

 II. Quality Assurance Program

The applicant shall establish at the earliest practicable time, consistent


with the schedule for accomplishing the activities, a quality assurance
program which complies with the requirements of this appendix. This
program shall be documented by written policies, procedures, or
instructions and shall be carried out throughout plant life in accordance
with those policies, procedures, or instructions. The applicant shall identify
the structures, systems, and components to be covered by the quality
assurance program and the major organizations participating in the
program, together with the designated functions of these organizations.
The quality assurance program shall provide control over activities
affecting the quality of the identified structures, systems, and components,
to an extent consistent with their importance to safety. Activities affecting
quality shall be accomplished under suitably controlled conditions.
Controlled conditions include the use of appropriate equipment; suitable
environmental conditions for accomplishing the activity, such as adequate
cleanness; and assurance that all prerequisites for the given activity have
been satisfied. The program shall take into account the need for special
controls, processes, test equipment, tools, and skills to attain the required
quality, and the need for verification of quality by inspection and test. The
program shall provide for indoctrination and training of personnel
performing activities affecting quality as necessary to assure that suitable
proficiency is achieved and maintained. The applicant shall regularly
review the status and adequacy of the quality assurance program.
Management of other organizations participating in the quality assurance
program shall regularly review the status and adequacy of that part of the
quality assurance program which they are executing.

 III. Design Control

Measures shall be established to assure that applicable regulatory


requirements and the design basis, as defined in § 50.2 and as specified
in the license application, for those structures, systems, and components
to which this appendix applies are correctly translated into specifications,
drawings, procedures, and instructions. These measures shall include
provisions to assure that appropriate quality standards are specified and
included in design documents and that deviations from such standards are
controlled. Measures shall also be established for the selection and review
for suitability of application of materials, parts, equipment, and processes
that are essential to the safety-related functions of the structures, systems
and components.
Measures shall be established for the identification and control of design
interfaces and for coordination among participating design organizations.
These measures shall include the establishment of procedures among
participating design organizations for the review, approval, release,
distribution, and revision of documents involving design interfaces.

The design control measures shall provide for verifying or checking the
adequacy of design, such as by the performance of design reviews, by the
use of alternate or simplified calculational methods, or by the performance
of a suitable testing program. The verifying or checking process shall be
performed by individuals or groups other than those who performed the
original design, but who may be from the same organization. Where a test
program is used to verify the adequacy of a specific design feature in lieu
of other verifying or checking processes, it shall include suitable
qualifications testing of a prototype unit under the most adverse design
conditions. Design control measures shall be applied to items such as the
following: reactor physics, stress, thermal, hydraulic, and accident
analyses; compatibility of materials; accessibility for inservice inspection,
maintenance, and repair; and delineation of acceptance criteria for
inspections and tests.

Design changes, including field changes, shall be subject to design control


measures commensurate with those applied to the original design and be
approved by the organization that performed the original design unless the
applicant designates another responsible organization.

 IV. Procurement Document Control

Measures shall be established to assure that applicable regulatory


requirements, design bases, and other requirements which are necessary
to assure adequate quality are suitably included or referenced in the
documents for procurement of material, equipment, and services, whether
purchased by the applicant or by its contractors or subcontractors. To the
extent necessary, procurement documents shall require contractors or
subcontractors to provide a quality assurance program consistent with the
pertinent provisions of this appendix.

 V. Instructions, Procedures, and Drawings

Activities affecting quality shall be prescribed by documented instructions,


procedures, or drawings, of a type appropriate to the circumstances and
shall be accomplished in accordance with these instructions, procedures,
or drawings. Instructions, procedures, or drawings shall include
appropriate quantitative or qualitative acceptance criteria for determining
that important activities have been satisfactorily accomplished.

 VI. Document Control

Measures shall be established to control the issuance of documents, such


as instructions, procedures, and drawings, including changes thereto,
which prescribe all activities affecting quality. These measures shall
assure that documents, including changes, are reviewed for adequacy and
approved for release by authorized personnel and are distributed to and
used at the location where the prescribed activity is performed. Changes
to documents shall be reviewed and approved by the same organizations
that performed the original review and approval unless the applicant
designates another responsible organization.

 VII. Control of Purchased Material, Equipment, and Services

Measures shall be established to assure that purchased material,


equipment, and services, whether purchased directly or through
contractors and subcontractors, conform to the procurement documents.
These measures shall include provisions, as appropriate, for source
evaluation and selection, objective evidence of quality furnished by the
contractor or subcontractor, inspection at the contractor or subcontractor
source, and examination of products upon delivery. Documentary
evidence that material and equipment conform to the procurement
requirements shall be available at the nuclear powerplant or fuel
reprocessing plant site prior to installation or use of such material and
equipment. This documentary evidence shall be retained at the nuclear
powerplant or fuel reprocessing plant site and shall be sufficient to identify
the specific requirements, such as codes, standards, or specifications, met
by the purchased material and equipment. The effectiveness of the control
of quality by contractors and subcontractors shall be assessed by the
applicant or designee at intervals consistent with the importance,
complexity, and quantity of the product or services.

 VIII. Identification and Control of Materials, Parts, and Components

Measures shall be established for the identification and control of


materials, parts, and components, including partially fabricated
assemblies. These measures shall assure that identification of the item is
maintained by heat number, part number, serial number, or other
appropriate means, either on the item or on records traceable to the item,
as required throughout fabrication, erection, installation, and use of the
item. These identification and control measures shall be designed to
prevent the use of incorrect or defective material, parts, and components.

 IX. Control of Special Processes

Measures shall be established to assure that special processes, including


welding, heat treating, and nondestructive testing, are controlled and
accomplished by qualified personnel using qualified procedures in
accordance with applicable codes, standards, specifications, criteria, and
other special requirements.

 X. Inspection
A program for inspection of activities affecting quality shall be established
and executed by or for the organization performing the activity to verify
conformance with the documented instructions, procedures, and drawings
for accomplishing the activity. Such inspection shall be performed by
individuals other than those who performed the activity being inspected.
Examinations, measurements, or tests of material or products processed
shall be performed for each work operation where necessary to assure
quality. If inspection of processed material or products is impossible or
disadvantageous, indirect control by monitoring processing methods,
equipment, and personnel shall be provided. Both inspection and process
monitoring shall be provided when control is inadequate without both. If
mandatory inspection hold points, which require witnessing or inspecting
by the applicant's designated representative and beyond which work shall
not proceed without the consent of its designated representative are
required, the specific hold points shall be indicated in appropriate
documents.

 XI. Test Control

A test program shall be established to assure that all testing required to


demonstrate that structures, systems, and components will perform
satisfactorily in service is identified and performed in accordance with
written test procedures which incorporate the requirements and
acceptance limits contained in applicable design documents. The test
program shall include, as appropriate, proof tests prior to installation,
preoperational tests, and operational tests during nuclear power plant or
fuel reprocessing plant operation, of structures, systems, and
components. Test procedures shall include provisions for assuring that all
prerequisites for the given test have been met, that adequate test
instrumentation is available and used, and that the test is performed under
suitable environmental conditions. Test results shall be documented and
evaluated to assure that test requirements have been satisfied.

 XII. Control of Measuring and Test Equipment

Measures shall be established to assure that tools, gages, instruments,


and other measuring and testing devices used in activities affecting quality
are properly controlled, calibrated, and adjusted at specified periods to
maintain accuracy within necessary limits.

 XIII. Handling, Storage and Shipping

Measures shall be established to control the handling, storage, shipping,


cleaning and preservation of material and equipment in accordance with
work and inspection instructions to prevent damage or deterioration. When
necessary for particular products, special protective environments, such
as inert gas atmosphere, specific moisture content levels, and
temperature levels, shall be specified and provided.

 XIV. Inspection, Test, and Operating Status

Measures shall be established to indicate, by the use of markings such as


stamps, tags, labels, routing cards, or other suitable means, the status of
inspections and tests performed upon individual items of the nuclear
power plant or fuel reprocessing plant. These measures shall provide for
the identification of items which have satisfactorily passed required
inspections and tests, where necessary to preclude inadvertent bypassing
of such inspections and tests. Measures shall also be established for
indicating the operating status of structures, systems, and components of
the nuclear power plant or fuel reprocessing plant, such as by tagging
valves and switches, to prevent inadvertent operation.

 XV. Nonconforming Materials, Parts, or Components

Measures shall be established to control materials, parts, or components


which do not conform to requirements in order to prevent their inadvertent
use or installation. These measures shall include, as appropriate,
procedures for identification, documentation, segregation, disposition, and
notification to affected organizations. Nonconforming items shall be
reviewed and accepted, rejected, repaired or reworked in accordance with
documented procedures.

 XVI. Corrective Action

Measures shall be established to assure that conditions adverse to quality,


such as failures, malfunctions, deficiencies, deviations, defective material
and equipment, and nonconformances are promptly identified and
corrected. In the case of significant conditions adverse to quality, the
measures shall assure that the cause of the condition is determined and
corrective action taken to preclude repetition. The identification of the
significant condition adverse to quality, the cause of the condition, and the
corrective action taken shall be documented and reported to appropriate
levels of management.

 XVII. Quality Assurance Records

Sufficient records shall be maintained to furnish evidence of activities


affecting quality. The records shall include at least the following: Operating
logs and the results of reviews, inspections, tests, audits, monitoring of
work performance, and materials analyses. The records shall also include
closely-related data such as qualifications of personnel, procedures, and
equipment. Inspection and test records shall, as a minimum, identify the
inspector or data recorder, the type of observation, the results, the
acceptability, and the action taken in connection with any deficiencies
noted. Records shall be identifiable and retrievable. Consistent with
applicable regulatory requirements, the applicant shall establish
requirements concerning record retention, such as duration, location, and
assigned responsibility.

 XVIII. Audits

A comprehensive system of planned and periodic audits shall be carried


out to verify compliance with all aspects of the quality assurance program
and to determine the effectiveness of the program. The audits shall be
performed in accordance with the written procedures or check lists by
appropriately trained personnel not having direct responsibilities in the
areas being audited. Audit results shall be documented and reviewed by
management having responsibility in the area audited. Followup action,
including reaudit of deficient areas, shall be taken where indicated.

Review of Bid Tenders


Customers now require to know how the supplier or contractor plans to
meet the customers Technical Specifications. The customer normally
requires objective evidence that the Suppliers can verify quality. This is
completed by forwarding to the customer sample exhibits from the
Bid Tenders
suppliers Quality Management System and/or Quality presentation by the
supplier or contractor. Suppliers or Contractors are not only assessed on
their Bid price but on their ability to define and meet the customers
Quality objectives within a limited time period.

The supplier or contractor submits to


the customer their Company Quality
Policy Manual Prior to the tender bid
meeting. The meeting outlines the full
Bid Tender
scope of the project where questions
Meeting are responded to from the potential
bidders. The project does not always
go to the lowest bidder.

The supplier or contractors must


Review of assure himself that he and his
Project subcontractors have the required
Resources resources in place to meet the
customers technical requirements.

In order for The Prime Contractor to obtain confidence from their


Subcontractor suppliers or vendors it is essential that objective evidence be obtained.
Evaluation This is normally completed by completing Audits and sending out Quality
questionnaires.

How does a company measure customer satisfaction and provide that


confidence at a bid stage meeting? Reputation does not always work
Customer
today. The zero issuance of nonconformance reports. Meeting the quality
Satisfaction
objectives as contained in milestones and bringing the project in on time
and within budget. This would be a major plus factor.

Customer Review of QA/QC Documentation


QA Policy Normally submitted at Bid stage to the customer.
Manual

NDT Third Party Non Destructive Testing Procedures are normally requested
Procedures in the contract to be submitted to the customer for their review and/or
Submitted approval. This would include the subcontractors NDT safety procedures.

Welding Welding Procedures Specifications (WPS's) and Procedure Qualification


Procedures Reports (PQR's) are normally required to be submitted to the customer
WPS/PQR's for review and approval prior to the start of any on site welding works.

Concrete Mix Normally a customer review is required and/or approval prior to the start
Designs of any work.

Painting Normally a customer review is required and/or approval prior to the start
Specifications of any work.

Sub Contractors as a part of contract requirements are normally


Approved required to be submitted to the customer for approval prior to the start of
Subcontractors the work. This would include assessing information on the
subcontractors capabilities.

Quality Control The site Quality Control organisation Chart must be completed prior to
organisational the commencement of work even if all QC personnel names are not
Charts indicated on the chart.

Revisions to It is important for the supplier to ensure all revisions to the customers
Contracts Contract Technical Requirements are completed prior to the start of any
Specifications construction work on site.

Has all critical equipment been identified on the Preventative


Preventative
Maintenance Schedule that will have long lead times prior to
Maintenance
installation?
Schedule
Reviewed

QC Inspection Have all Inspection and Testing Plans been reviewed and submitted to
& Test Plans the customer for review and/or approval.

Project Are all the Project Construction Procedures in place and do they reflect
Construction the scope of the customers Technical Requirements.
Procedures

QA/QC Kick Off Meeting

Does the project understand the work scope of each site


Planning & subcontractor and has it been defined in the project scheduling.
Scheduling This is especially important for the completion of As-Built
Dossiers for project Turn Over Purposes.

Has the Project Identified major constructability site issues that


Constuctability Items will impact upon the completion of the site quality inspections
Identified and subsequently delay the turn over of Quality Dossiers to the
customer.

Has the Project Identified all sub contractors procured items that
Procurement might not conform to the customers Technical Specifications?
Inspection Activities Have these items been identified on a procurement matrix and
receipt inspections been coordinated prior to release for site use.

Does each subcontractor have a designated team of Quality


Control Inspectors with organisation freedom to reject and
QC organisation
accept nonconforming material? Do these inspectors have
Chart Defined
sufficient qualifications and experience to complete the scope of
work.
The Project QA/QC team must identify points of contacts with
Point of Contacts the customer ,Prime Contractor, Sub contractors and Third Party
Defined Inspection bodies on site to ensure timely completion of site
inspections.

All the site subcontractors must understand and implement their


QC Inspection Plan site approved Quality Control Inspection & Test Plan (QCIP) to
Reviewed ensure the inspection of the work is undertaken during process
and with out any schedule delays.

Health & Safety of All subcontractors that use radiactive sources must be aware of
Radioactive Sources the site safety procedures and emergency evacuation
Reviewed procedures.

In Process Inspection
Issued nonconformance reports can be generated form the
Closure of customer or to the supplier or vendor. It is important the control
nonconformance and action for closure purposes is coordinated through a sole
Reports point of contact.Ensuring that delays in the construction schedule
are kept to an absolute minimum.

It must be agreed with the customer if they are going to sign off
the inspection check sheets during their attendance at the place of
Client Sign off of
inspection or whether the customer will verify conformance by
Inspection Test
reviewing the As-Built Turn Over Dossiers.If this is not agreed at
Dossiers
the early stage of the project this could cause considerable delay
later on.

Prior to the completion of a Project Milestone all outstanding items


Punch-snag List should be identified through one point of source. Punchlisted
Items items should be agreed and coordinated with the customer prior to
final handover.

Out standing work lists that are identified in the Punch list that
Outstanding Work cannot be completed must be identified in a Project Exception
list Defined List, rework to be completed at a later time. All rework must be
agreed with the customer.

Copies of Project Quality Control and Quality Assurance


QA/QC documentation are normally required by contract to be held for
Documentation retention for a period of five years by the suppliers or Prime
Reconciliation Contractor. Where a component or section of the Project fails at a
later stage a warranty claim will be initiated by the customer.

The Customer and the Prime Contractors must ensure there is


QC Manpower
sufficient Quality Control manpower on resources for the scope of
Defined
the customer's Technical Specifications.
Turn Over of As-Built QC Documentation

It is normal for the Customer to specify how and in what format the
QA/QC
QA/QC Turnover Dossiers are to be presented. This is normally given
Documentation
to the supplier in the form of a Project Procedure documentation.

QA/QC
It is normal for Project QA/QC documentation to be retained by the
Documentation
supplier or contractor for a minimum period of five years.
Retention

Prior to the completion of a Project Milestone all punchlisted items


Punch Listed should be identified and coordinated through one point of
Items source.Punchlisted items should be agreed and coordinated with the
customer prior to final handover.

In such cases were there is a failure of the product, the QA/QC


Customers
Turnover Dossiers will be able to identify whether there is a product
Warranty Claims
manufacturing defect or if it was an installation construction failure.

FLOW CHART FOR COMPLETION OF OUTSTANDING


PUNCH LISTED ITEMS
Schedule
and expedite
work with
subcontracto
r

Verify work
complete
and is
acceptable
Application
for
Inspection to
Constructio Prime QC
n Manager Dept. or
expedite on
case by
Track case basis
Progress of
Completed
Punchlisted
Items and Prime QC Inspectors
resolve any
Change Verify Work is
Orders and Acceptable
extra work
scope Punch Coordinator

Expedite Punchlist
Closures

QC Technical clerk

Update QC File, QC
Punchlisted Items and
Sign off originals. Check
outstanding Non-
Conformance Reports.

Punch Coordinator

Update As-built files


Copy and store in
Document Room.

Punch Coordinator

Joint Inspection with


Customers Engineer
obtain closure of work

Note:
Punch Coordinator to complete weekly status report to Prime Construction Manager, relevant to
the following:
- New Punchlisted Items Raised
- Punchlisted Items Closed
- Total Outstanding Punchlisted Item

Setup of Engineering Procurement and


Construction Projects
The Consortium