Quality Control Procedure Sample[1]

Company TECHNICAL IMPLEMENTATION MANUAL

Document No.

:

Revision/Edition : Date : Page :

QUALITY CONTROL PROCEDURE TABLE OF CONTENTS PAGE

1.

SCOPE

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

2

FABRICATION

4

8.

ACCEPTANCE CRITERIA FOR DIMENSION CHECK

5

9.

QUALITY CONTROL INSPECTION PROGRAMS FOR PAINTING

5

10. QUALITY CONTROL INSPECTION PROGRAMS FOR PAINTING

6

11. DOCUMENTATION

7

APPENDIXES

8

APPENDIX 1 DIMENSION TOLERANCE

8

APPENDIX 2 WELDING DIMENSION TOLERANCE.

9

12. ATTACHENT

11

ATTACHMENT 1 –Inspection Record For Incoming Material.

12

ATTACHMENT 2 – Dimension Inspection Report.

13

ATTACHMENT 3 – Welding Inspection Report.

14

ATTACHMENT 4 – Coating Inspection Report.

15

Document No.

Company TECHNICAL IMPLEMENTATION MANUAL

:

Revision/Edition : Date : Page :

QUALITY CONTROL PROCEDURE 1. SCOPE a)

Inspection and test of equipment shall be based on approved drawing and approved applicable procedures.

b)

The quality Control Department shall responsible for the following but not be limited: • Continuous check for all production process during the whole fabrication periods. • Conduct all required tests, checks, and inspection. • Maintain

the

record

for

all

the

quality

control

document

for

review/reference at all times and final MDR. 2.

DEFINITIONS The following definitions shall apply throughout the specification: a) The Contractor shall mean…………..PT….. b) The Subcontractor shall mean PT …………

3.

REFERENCE • Material

: ASTM: A36,ASME: SA 240, JIS: E3101:2004, SNI, SII.

• Welding

: AWS D1.1

• Client Specification

: PT. …………….. Drawing Approval.

4.

RAW MATERIAL PROCUREMENT a)

A l l r a w m a t e r i a l w i l l b e s u p p l i e d b y S ub c o n t r a c t o r s h a l l b e B a c k e d u p b y a n d conform to their relevant mill/test’s certificates.

b)

when

material

received

from

the

mill

does

not

satisfy

the

standard’s

tolerance for camber, profile, flatness or sweep corrective work by the use of c o n t r o l l e d h e a t i n g , c h e m i c a l a n d m e c h a ni c a l s t r a i g h t e n i n g , s u b j e c t t o t h e limitation of the standards, may be perform. It could be done or shall be replace with a new one and precise one. c)

Steel material for fabrication shall not be heavily pitted or rusted.

d)

Subcontractor shall provide the following documents for record and control of material. • Material List & Cutting Plan. • Material Test Report/Mill Certificate(from the supplier) • Delivery List

Document No.

Company TECHNICAL IMPLEMENTATION MANUAL

:

Revision/Edition : Date : Page :

QUALITY CONTROL PROCEDURE 5.

MATERIAL RECEIVING INSPECTION a)

U p o n a r r i v a l o f t h e m a t e r i a l a t f a b ri c a t i o n y a r d s , W a r e h o u s e S e c t i o n w i l l inform QA-QC Department and Project Control to recheck the raw material. Scope of the inspection shall include visual dimension, sharpness, thickness, heat no. or manufacturer no., etc.

b)

Identification marks of material grade shall be clearly marked on all pieces of material including those cut from stock or from the whole material itself. This

identification

marks

shall

r e m ai n

clearly

visible

at

all

times.

Recommended type of medium for identification marking shall be stamp, paint or crayons. Subcontractor shall propose to Contractor the method inspection. c)

Any non-conformance between Client document and material received by PT. ………………,

QA/QC

Department

will

inform

with

Quality

Assurance

Confirmation (QAC). d)

When

some

material

are

unacceptable,

QA/QC

Department

marked

the

material as “REJECTED” e)

R e p a i r m a t e r i a l s h a l l c l i e n t s p e c i fi c a t i o n a n d r e p a i r p r o c e d u r e a p p r o v e d b y client.

f)

6.

Inspection result shall be reported in Material Receiving Report .

MATERIAL CONTROL a)

After material received inspection has been conducted and material been accepted, the Warehouse Section shall store the material and issue to the fabrication section upon instruction.

b)

The

material

received

by

Warehouse

Section

and

material

issue

for

fabrication shall be continuously reported to Project Control of status the Project’s materials. c)

The

excess

raw

material

from

the

fabrication

section

shall

clearly

be

identified and returned to the Warehouse Section for restore. d)

Stock material on warehouse shall be checked for visual and Dimension by quality control. Material should be store in secure place to preserve the accuracy and quality before process fabrication.

Document No.

Company

:

Revision/Edition : Date : Page :

TECHNICAL IMPLEMENTATION MANUAL

QUALITY CONTROL PROCEDURE 7.

QUALITY CONTROL INSPECTION PROGRAMS FOR FABRICATION A l l f a b r i c a t e d p a r t s h a l l b e i ns p e c t e d t o t h e f o l l o w i n g i t e m s : 7.1. IDENTIFICATION MARKS a) Transfer of identification marks (include heat no.) shall be check prior to cutting. b) Material traceability report shall be made. 7.2. MARKING a) Giving the mark OK, if result of mark is correct. b) After giving mark OK, we can do the next process. 7.3. DIMENSION a)

Checking the “ MAL “ according on the place.

b)

MAL

made

the

duplicated

equipment

as

same

as

one

from

paper/plywood. c)

Identity that the MAL has been made and checked in accordance to drawing approval.

d)

Only approved MAL will be used for fabrication process (marking, cutting, bending, rolling, beveling)

e)

Progressive

dimensional

check

shall

be

conducted

at

stages

before, during and after the manufacturing process. f)

Dimensional

marking

shall

be

c h e ck e d

prior

to

cutting,

beveling,

bending, and rolling. After part or final assembling, all dimensional marks are to be reconfirmed for accuracy prior to further works such as reforming, etc. in which the dimensional inspection shall be conducted. g)

All measuring Tools to be used for Measuring and Inspections shall be calibrated by an Authorized Agency. The Calibration records shall be kept as a QA records.

h)

Check with measuring tools all dimensional of individual members/shop assemblies, within the specified tolerance.

i)

Inspection result shall be reported in the from of Dimension Inspection Report (Attachment – 2)

Document No.

Company

:

Revision/Edition : Date : Page :

TECHNICAL IMPLEMENTATION MANUAL

QUALITY CONTROL PROCEDURE 8.

ACCEPTANCE CRITERIA FOR DIMENSIONAL CHECK a)

Steel Structures : Dimension tolerance for steel structure fabrication shall be accordance with Appendix – 1

9.

QUALITY CONTROL INSPECTION PROGRAMS FOR WELDING a)

Prior

to

welding

activity,

welding

p ro c e d u r e

qualification

test,

welding

procedure specification, welding map, welder performance test and welder list shall be reviewed and approved by Contractor and Company. b)

All fabricated parts shall be inspected as to the following : • Visual Inspection. -

Welding inspection shall ensure all parameter and condition

-

As per WPS/PQR and welder has been full filled before welding, during welding and after welding.

-

A l l w e l d i n g w i l l b e v i s u a l l y i n s p e c t ed t o c h e c k i f t h a t t h e r e a r e d e f e c t s such as undercut, crack, blow hole, slag inclusion, and fused spatter.

-

All parts shall be thoroughly cleaned.All dirt, welding electrode stubs and foreign matter shall be removed.

-

The

leg

size

of

fillet

should

be

in

accordance

with

the

design

stipulation. -

Formed corner of bracket shall be visually checked, and shall be no crack or harmful defects is produced.

-

Welding tolerance shall be accordance with Appendix – 2

• NDE -

Non destructive examination (NDE) of pressure boundary Weld and attachment welds to pressure boundary shall be done in accordance with the approved NDE Procedure.

c)

When PWHT and hardness test is required, therefore Subcontractor shall maintain these activities to comply with the approved procedures.

d)

Inspection result shall be reported in the from Welding Inspection Report.

Document No.

Company TECHNICAL IMPLEMENTATION MANUAL

:

Revision/Edition : Date : Page :

QUALITY CONTROL PROCEDURE 10. QUALITY CONTROL INSPECTION PROGRAMS FOR PAINTING e)

All surfaces prepared for painting are to be inspected and the surface preparation standard and paint used shall be reviewed and approved by Contractor prior to the start of the work.

f)

Contractor

shall

be

notified

of

any

defects,

improper

material

or

workmanship or any conditions which affect the satisfactory performance and permanency of work. g)

No work shall proceed at any stage of the job until the following stage inspections have been carried out and approved : • Before blasting : -

The surface shall cleaned from dirt, dust, and other foreign matter.

-

The surface have cleaned shall be dried.

• After blasting :

h)

-

Grades surface preparation.

-

Surface profile.

Improper procedures during application, even though the specified total dry film thickness has been achieved, shall be sufficient cause for complete removal of the applied material and re-application using the specified procedure.

i)

Inspection result shall be reported in the form Coating Inspection Report (Attachment – 3).

Company TECHNICAL IMPLEMENTATION MANUAL

Document No.

:

Revision/Edition : Date : Page :

QUALITY CONTROL PROCEDURE 11. DOCUMENTATION Inspection report shall be maintained by Subcontractor and approved by the involved parties. Table Content of MDR : -

Inspection Release Certificate (IRC)

-

Certificate Of Compliance for fabricated for item

-

Inspection Test and Plan

-

Non Conformance Report (NCR)

-

Welding Procedure Including Production Test Result WPS/PQR.

-

Welder List Qualification Records

-

Material Mill Certificate.

-

Fabrication Procedure

-

Painting Procedure

-

Packing Procedure

-

Inspection Report for Incoming Material

-

Material Certificate

-

Inspection Report

-

Dimension Report and Welding Report

-

Painting Report

-

Environment Condition

-

Surface Preparation

-

Coating Application

-

Film Thickness (DFT)

-

Shop Inspection Test

-

NDE report

-

NDE Personal Qualifications

-

Deviation Control

-

Leak Test Procedure

-

Major Welds Repair

Document No.

Company TECHNICAL IMPLEMENTATION MANUAL

:

Revision/Edition : Date : Page :

QUALITY CONTROL PROCEDURE

No

Description

Figure

Tolerance

Excess Weld 6

Metal (e2)

Under Cut 7

(e3)

8

Over Lap (e4)

e3 ≤ 1 mm

e4 = Unacceptable

Document No.

Company TECHNICAL IMPLEMENTATION MANUAL

:

Revision/Edition : Date : Page :

QUALITY CONTROL PROCEDURE No

Description

Figure

Tolerance

1. α ≤ 1.5 mm Porosity 9

(α )

2. α ≤ 1.5 mm 3. Cluster is unacceptable

Unacceptable Crack

Sparter

Unacceptable

Excess

B – b ≤ 5 per 150 mm

Cupping

Company TECHNICAL IMPLEMENTATION MANUAL

Document No.

:

Revision/Edition : Date : Page :

QUALITY CONTROL PROCEDURE

Document No.

Company TECHNICAL IMPLEMENTATION MANUAL

:

Revision/Edition : Date : Page :

QUALITY CONTROL PROCEDURE b) Attachment – 2

c) Attachment – 3

: Dimension Inspection Report

: Welding Inspection Report

Company TECHNICAL IMPLEMENTATION MANUAL

Document No.

:

Revision/Edition : Date : Page :

QUALITY CONTROL PROCEDURE