PURPOSE

This procedure outlines the process used in the company to:

  • To ensure relevant departments follow requirements for quality inspection service.
  • To set up an effective, efficient, and precise processes for resolving quality issues.

 

SCOPE

This procedure is applicable for monitoring and measurement productions.

 

ABRIVIATIONS

  • PO       : Purchase order
  • WI        : Work instruction
  • ITP       : Inspection and test plan
  • NDT     : Non-destructive testing
  • NCR     : Non-conformity Report
  • QA/QC : Quality control dept.
  • HSE     : Healthy – Safety and Environment Dept.
  • PRD     : Production Dept.
  • FM       : Facility and Maintenance dept.
  • QCI      : QC Inspector
  • QCE     : QC Engineer
  • QAM    : QA/QC Manager
  • RT       : Radiography test
  • UT       : Ultrasonic test
  • MT       : Magnetic test
  • PT        : Penetrant test
  • MDR    : Manufacturer Data Records
  • DRW    : Drawing
  • WPS    : Welding procedure specification
  • SSPC   : Steel structures painting council
  • DFT     : Dry film thickness
  • IFC       : Issued for construction
  • STORE : Store keeper

 

REFERENCE DOCUMENTS

  • Quality manual
  • ISO 9001

 

RESPONSIBILITIES

  • The QAM is responsible to ensure compliance with this procedure.

 

PROCEDURE

Inspection of Material

  • Upon receipt of purchased materials or Client’s free-issue items, QCI/QCE and/or STORE shall visually inspect as following:
    • Check status of incoming material, quantity, dimension and size.
    • Check whether certification conforms to specification or standards are required.
    • Upon acceptable a lot or partial material, QCI/QCE shall be signed on PO.
    • If any damaged items found, QCI/QCE shall identify by marking “HOLD” and quarantined these materials.
    • QCI/QCE shall be prepared and issued the MRIR [Form no. QHSE-F-02].
  • If any non-conforming materials are not compliance with the PO, these materials shall be treated follows non-conformance and corrective action management procedure.

 Quality Control Documents

  • Prior to commencing the fabrication, based on project requirement, QA/QC shall be firstly submitted suitable procedures to Client for approval. Control of document submission shall follow document control procedure.

InProcess Inspection

General

  • 6.3.1.1  Inspection bases on the job description or ITPs.
  • 6.3.1.2  All dimensions shall internally check by PROD before sending Request for Inspection to QHSE department.
  • 6.3.1.3  The acceptance criteria shall be based on the specifications or standards/codes whichever is more stringent.
  • 6.3.1.4  QCI/QCE shall responsible to verify the request and issue the inspection report.

 

Fit-up inspection

  • 6.3.2.1  Fit–up inspection shall follow approved IFC drawings, technical specifications, and approved welding procedures.
  • 6.3.2.2  The major dimensions may record as internal report.

 

Visual inspection

  • All weld products shall be visually inspected by inspector.
  • Quality product shall be evaluated in accordance with applied standards or project specification.
  • Visual inspection should control before, during and after welding.
  • Visual inspection report shall record.
  • All welding defects shall be repaired according to weld repair procedure.
  • The major dimensions shall be re-checked and recorded.

 

NDT Examination

  • All NDT procedures and NDT plans shall prepare by QCE, essential variables are based on the approved IFC drawings and applicable specification.
  • NDT request form will be raised by QCI/QCE or PROD.
  • In case of the welding defects found after testing. The defects shall be repaired according to weld repair procedure.

 

Welding tractable

  • QCE shall prepare the welding maps and NDE maps to identify the weld joint or part number.
  • During fabrication, QCI/QCE shall be followed up for inspection and recorded all information of weld joint such as: Joint No., Welder ID, WPS, NDT required, date of fitting-up, date of visual inspection and results, … into the weld summary report.

Pressure test for pressure equipment

  • After fabricating completion, all piping spools will be identified the spool no. or tag name by paint marker or suitable traceability.
  • Pressure test shall be performed in accordance with the approved drawing or specifications.
  • The pressure test activities shall be in accordance with hydrostatic and pneumatic testing procedure.
  • Upon completion, the spools shall be drained out all the test medium and drying out the internal pipe.
  • All testing records shall be recorded in the pressure test certificates.

 

Surface treatment and coating inspection

  • After completing fabrication or pressure test, the product may prepare for coating accordance with surface treatment and painting.
  • All sharp edges will be rounded approximately 2mm.
  • Edges, corners and weld beads may be stripe coated prior to apply coating.
  • Prior to blasting all steel surfaces should free from oils/grease.
  • After blasting and before painting all steel surfaces will be checked by QCI.
  • DFT (Dry film thickness) inspection will be checked by QCI/QCE and reported.

 

MEASUREMENT CALIBRATION

  • In-house calibration, welding machine and heat quiver will internally calibrated in-house and certified by electrical technician.
  • External Calibration, QA/QC department shall monitor the master log sheet of all equipment. The Original certificates of calibration shall be verified and approved by QAM and it is retained in QA/QC department. Hard copies may issue for operator or for verification.
  • Master Log, Calibration log shall be prepared and updated by QA/QC department for easy tracing when required.

 

INSPECTION AND TEST STATUS IDENTIFICATION

Inspection and test status of semi-finished / finished products shall be identified as follows:

 

Non-conforming items

  • Mark “HOLD’’ or “REJECTED” in English and/or Vietnamese with QCI’s signature on the item and treat it according to non-conformance and corrective action management procedure.

 

Conforming items

  • For material, equipment and free issues from Client, QC will sign-off on the P.O for acceptance and Store will receive and keep properly.
  • For In-process product, inspection traveler or ITP will be attached to the fabrication items to indicate inspection status. Foremen/PROD supervisor and QCI will inspect as following Section 6.

FLOW CHART

Inspection flow chart is divided into 02 parts

  • Inspection flow chart for incoming material inspection.

(Figure 1: Inspection flow chart for incoming material inspection)

  • Inspection flow chart for in-process inspection.

(Figure 2: Inspection flow chart for in-process inspection)

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