quality control procedure sample[1]

Document No. :

Revision/Edition : Date :

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TECHNICAL IMPLEMENTATION MANUAL Page :

QUALITY CONTROL PROCEDURE

TABLE OF CONTENTS

PAGE

1. SCOPE 2

2. DIFINATION 2

3. REFERENCE 2

4. RAW MATERIAL PROCUREMENT 2

5. MATERIAL RECEIVING INSPECTION 3

6. MATERIAL CONTROL 3

7. QUALITY CONTROL INSPECTION PROGRAMS FOR

FABRICATION 4

8. ACCEPTANCE CRITERIA FOR DIMENSION CHECK 5


PAINTING 5


PAINTING 6

11. DOCUMENTATION 7

APPENDIXES 8

APPENDIX 1 DIMENSION TOLERANCE 8

APPENDIX 2 WELDING DIMENSION TOLERANCE. 9

12. ATTACHENT 11

ATTACHMENT 1 –Inspect ion Record For Incoming Mater ia l . 12

ATTACHMENT 2 – Dimension Inspect ion Report . 13

ATTACHMENT 3 – Weld ing Inspect ion Report . 14

ATTACHMENT 4 – Coat ing Inspect ion Report . 15

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QUALITY CONTROL PROCEDURE 1. SCOPE

a) Inspect ion and test of equipment sha l l be based on approved drawing and

approved appl icab le procedures.

b) The qual i ty Contro l Department sha l l respons ib le for the fo l lowing but not be

l imited:

• Cont inuous check for a l l product ion process dur ing the whole fabr icat ion

per iods.

• Conduct a l l required tests, checks, and inspect ion.

• Mainta in the record for a l l the qual i ty contro l document for

rev iew/reference at a l l t imes and f ina l MDR.

2. DEFINITIONS

The fo l lowing def in i t ions shal l apply throughout the spec i f icat ion:

a) The Contractor sha l l mean…………..PT…..

b) The Subcontractor sha l l mean PT …………

3. REFERENCE

• Mater ia l : ASTM: A36,ASME: SA 240, JIS: E3101:2004, SNI,

SII .

• Weld ing : AWS D1.1

• C l ient Spec i f icat ion : PT. …………….. Drawing Approval .

4. RAW MATERIAL PROCUREMENT

a) Al l raw mater ia l wi l l be suppl ied by Subcontractor sha l l be Backed up by and

conform to the ir re levant mi l l / test ’s cert i f icates.

b) when mater ia l received f rom the mi l l does not sat is fy the standard’s

to lerance for camber, prof i le , f latness or sweep correct ive work by the use of

contro l led heat ing, chemica l and mechanica l s t ra ightening, subject to the

l imitat ion of the standards, may be perform. I t could be done or sha l l be

replace with a new one and prec ise one.

c) Steel mater ia l for fabr icat ion sha l l not be heavi ly p i t ted or rusted.

d) Subcontractor shal l provide the fo l lowing documents for record and contro l

of mater ia l .

• Mater ia l L is t & Cutt ing Plan.

• Mater ia l Test Report/Mi l l Cert i f icate(from the suppl ier)

• Del ivery L ist

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QUALITY CONTROL PROCEDURE 5. MATERIAL RECEIVING INSPECTION

a) Upon arr iva l of the mater ia l at fabr icat ion yards, Warehouse Sect ion wi l l

inform QA-QC Department and Project Contro l to recheck the raw mater ia l .

Scope of the inspect ion sha l l inc lude v isual d imens ion, sharpness, th ickness,

heat no. or manufacturer no. , etc.

b) Ident i f icat ion marks of mater ia l grade shal l be c lear ly marked on a l l p ieces

of mater ia l inc luding those cut f rom stock or f rom the whole mater ia l i tse l f .

This ident i f icat ion marks shal l remain c lear ly v is ib le at a l l t imes.

Recommended type of medium for ident i f icat ion marking sha l l be stamp,

paint or crayons. Subcontractor sha l l propose to Contractor the method

inspect ion.

c) Any non-conformance between Cl ient document and mater ia l rece ived by PT.

………………, QA/QC Department wi l l in form with Qual i ty Assurance

Conf i rmat ion (QAC).

d) When some mater ia l are unacceptable, QA/QC Department marked the

mater ia l as “REJECTED”

e) Repair mater ia l shal l c l ient spec i f icat ion and repair procedure approved by

c l ient .

f ) Inspect ion resul t sha l l be reported in Mater ia l Rece iv ing Report .

6. MATERIAL CONTROL

a) After mater ia l rece ived inspect ion has been conducted and mater ia l been

accepted, the Warehouse Sect ion shal l s tore the mater ia l and issue to the

fabr icat ion sect ion upon instruct ion.

b) The mater ia l rece ived by Warehouse Sect ion and mater ia l issue for

fabr icat ion sha l l be cont inuous ly reported to Project Contro l of status the

Project ’s mater ia ls .

c) The excess raw mater ia l f rom the fabr icat ion sect ion sha l l c lear ly be

ident i f ied and returned to the Warehouse Sect ion for restore.

d) Stock mater ia l on warehouse shal l be checked for v isua l and Dimension by

qual i ty contro l . Mater ia l should be store in secure p lace to preserve the

accuracy and qual i ty before process fabr icat ion.

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QUALITY CONTROL PROCEDURE 7. QUALITY CONTROL INSPECTION PROGRAMS FOR FABRICATION

Al l fabr icated part sha l l be inspected to the fo l lowing i tems:

7.1. IDENTIFICATION MARKS

a) Transfer of ident i f icat ion marks ( inc lude heat no.) shal l be

check pr ior to cutt ing.

b) Mater ia l t raceabi l i ty report sha l l be made.

7.2. MARKING

a) Giv ing the mark OK, i f resu l t of mark is correct .

b) After g iv ing mark OK, we can do the next process.

7.3. DIMENSION

a) Checking the “ MAL “ according on the place.

b) MAL made the dupl icated equipment as same as one from

paper/p lywood.

c) Ident i ty that the MAL has been made and checked in accordance

to drawing approval .

d) Only approved MAL wi l l be used for fabr icat ion process (mark ing,

cutt ing, bending, ro l l ing, bevel ing)

e) Progress ive d imens ional check sha l l be conducted at stages

before, dur ing and after the manufactur ing process.

f ) Dimensional mark ing shal l be checked pr ior to cutt ing, bevel ing,

bending, and ro l l ing. After part or f ina l assembl ing, a l l d imensional

marks are to be reconf i rmed for accuracy pr ior to further works such as

reforming, etc . in which the dimensional inspect ion sha l l be conducted.

g) Al l measur ing Tools to be used for Measur ing and Inspect ions shal l be

ca l ibrated by an Author ized Agency. The Cal ibrat ion records shal l be

kept as a QA records.

h) Check with measur ing too ls a l l d imens ional of indiv idua l members/shop

assembl ies, with in the speci f ied to lerance.

i ) Inspect ion resul t shal l be reported in the from of Dimens ion

Inspect ion Report (Attachment – 2)

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QUALITY CONTROL PROCEDURE 8. ACCEPTANCE CRITERIA FOR DIMENSIONAL CHECK

a) Steel Structures :

Dimens ion to lerance for stee l s tructure fabr icat ion shal l be accordance with

Appendix – 1

9. QUALITY CONTROL INSPECTION PROGRAMS FOR WELDING

a) Pr ior to weld ing act iv i ty, weld ing procedure qual i f icat ion test , welding

procedure spec i f icat ion, welding map, welder performance test and welder

l i s t sha l l be rev iewed and approved by Contractor and Company.

b) Al l fabr icated parts shal l be inspected as to the fo l lowing :

• Visual Inspect ion.

- Welding inspect ion sha l l ensure a l l parameter and condit ion

- As per WPS/PQR and welder has been fu l l f i l led before weld ing, dur ing

weld ing and after welding.

- Al l weld ing wi l l be v isual ly inspected to check i f that there are defects

such as undercut , crack, b low hole, s lag inc lus ion, and fused spatter .

- Al l parts shal l be thoroughly c leaned.Al l d i r t , welding e lectrode stubs

and fore ign matter sha l l be removed.

- The leg s ize of f i l let should be in accordance with the des ign

st ipu lat ion.

- Formed corner of bracket shal l be v isual ly checked, and shal l be no

crack or harmful defects is produced.

- Welding to lerance shal l be accordance with Appendix – 2

• NDE

- Non destruct ive examinat ion (NDE) of pressure boundary Weld and

at tachment welds to pressure boundary sha l l be done in accordance

with the approved NDE Procedure.

c) When PWHT and hardness test is required, therefore Subcontractor sha l l

mainta in these act iv i t ies to comply with the approved procedures.

d) Inspect ion resul t sha l l be reported in the from Welding Inspect ion Report .

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QUALITY CONTROL PROCEDURE 10. QUALITY CONTROL INSPECTION PROGRAMS FOR PAINTING

e) Al l surfaces prepared for pa int ing are to be inspected and the surface

preparat ion standard and paint used shal l be rev iewed and approved by

Contractor pr ior to the start of the work.

f ) Contractor sha l l be not i f ied of any defects, improper mater ia l or

workmanship or any condit ions which affect the sat is factory performance

and permanency of work.

g) No work shal l proceed at any stage of the job unt i l the fo l lowing stage

inspect ions have been carr ied out and approved :

• Before b last ing :

- The surface sha l l c leaned from dir t , dust, and other fore ign matter .

- The surface have c leaned sha l l be dr ied.

• After blast ing :

- Grades surface preparat ion.

- Surface prof i le .

h) Improper procedures dur ing appl icat ion, even though the spec i f ied tota l dry

f i lm thickness has been achieved, sha l l be suf f ic ient cause for complete

removal of the appl ied mater ia l and re-appl icat ion us ing the spec i f ied

procedure.

i ) Inspect ion resul t shal l be reported in the form Coat ing Inspect ion Report

(Attachment – 3) .

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QUALITY CONTROL PROCEDURE 11. DOCUMENTATION

Inspect ion report shal l be mainta ined by Subcontractor and approved by the

invo lved part ies .

Table Content of MDR :

- Inspect ion Release Cert i f icate (IRC)

- Cert i f icate Of Compl iance for fabr icated for i tem

- Inspect ion Test and P lan

- Non Conformance Report (NCR)

- Welding Procedure Inc luding Product ion Test Resul t WPS/PQR.

- Welder L is t Qual i f icat ion Records

- Mater ia l Mi l l Cert i f icate.

- Fabr icat ion Procedure

- Paint ing Procedure

- Pack ing Procedure

- Inspect ion Report for Incoming Mater ia l

- Mater ia l Cert i f icate

- Inspect ion Report

- Dimension Report and Weld ing Report

- Paint ing Report

- Environment Condit ion

- Surface Preparat ion

- Coat ing Appl icat ion

- Fi lm Thickness (DFT)

- Shop Inspect ion Test

- NDE report

- NDE Personal Qual i f icat ions

- Deviat ion Contro l

- Leak Test Procedure

- Major Welds Repair

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No

Description

Figure

Tolerance

6

Excess Weld

Metal

(e2)

7

Under Cut

(e3)

e3 ≤ 1 mm

8

Over Lap

(e4)

e4 = Unacceptable

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QUALITY CONTROL PROCEDURE No Description Figure Tolerance

9

Porosity

(α )

1. α ≤ 1.5 mm

2. α ≤ 1.5 mm 3. Cluster is

unacceptable

Crack

Unacceptable

Sparter

Unacceptable

Excess

Cupping

B – b ≤ 5 per 150 mm

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b) Attachment – 2 : Dimension Inspection Report

c) Attachment – 3 : Welding Inspection Report

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quality control procedure sample[1]

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