3.0 Inspection & Test Plan

C : B11LQ /Sec.1.4.3 Inspection And Test Plan (ITP) Procedure Page 1 OF 10

QUALITY MANAGEMENT SYSTEM DOCUMENT

QUALITY DETAIL PROCEDURE

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THIS DOCUMENT PRESCRIBES COMPANY PRACTICE AND IS FOR INTERNAL USE ONLY. IT SHALL NOT BE REPRODUCED IN WHOLE OR IN PARTS OR RELEASED TO A THIRD PARTY WITHOUT

PRIOR CONSENT FROM THE HEAD OF RESPONSIBLE DEPARTMENT.

PREPARED BY : COMMISSIONING ENGINEER CONTROLLED COPY REVIEWED BY : MANAGER, COMMISSIONING NO. : APPROVED BY : PROJECT MANAGER UNCONTROLLED COPY RESPONSIBLE DEPARTMENT: HOOK-UP & COMMISSIONING

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QUALITY MANAGEMENT SYSTEM DOCUMENT

QUALITY DETAIL PROCEDURE

DOC. NO DATE REV. NO

: EJ/SSB/B11LQ/1.4.3/08 : 13/04/10 : 0

REVISION PURPOSE OF ISSUE DATE ISSUE ISSUED BY

A Issued for review 31/03/2008 Hook-up and Commissioning B Re-issued for approval 06/06/2008 Hook-Up and Commissioning 0 Issued for Construction 07/06/2008 Hook-Up and Commissioning

AGREED BY SSB AUTHORISED REPRESENTATIVE

................................................................... (SIGNATURE)

................................... (DATE)

NOTE : Please return approved copy to :

BROOKE DOCKYARD ENGINEERING & WORKS CORPORATION HOOK-UP AND COMMISSIONING DEPARTMENT

ENGINEERING DIVISION SEJINGKAT, JALAN BAKO

93050 KUCHING, SARAWAK


B11 LIVING QUARTERS MODULE AND HELIDECK

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 PURPOSE 4 OF 10

2.0 SCOPE 4 OF 10 3.0 REFERENCE 4 OF 10 3.1 Procedure 3.2 Guideline 4.0 RESPONSIBILITIES 5 OF 10 5.0 DEFINITION 5 OF 10 6.0 PROCEDURE FLOWCHART 6 OF 10 7.0 PROCEDURE DETAILS 7 OF 10 7.1 Identify the Inspection & Testing (IT) Requirement 7.2 Develop IT Checklist and Plan 7.3 Identify & Mobilize the Required Resources 7.4 Implement the IT Plan 8.0 RECORDS 9 OF 10 9.0 ATTACHMENTS 10 OF 10 10.0 PERFORMANCE MEASUREMENT 10 OF 10


1.0 PURPOSE

This procedure defines the necessary measures to ensure that adequate inspection & test plans is in place, that activities for the construction materials, equipment and services are monitored, and that essential controls during the fabrication, construction, installation, and commissioning phases of the project are in conformance to the quality requirements.

2.0 SCOPES

This procedure applies to the entire duration of the contract, each individual project, and subcontractors or suppliers hired to supply services to perform the inspection & testing works.

3.0 REFERENCE

3.1 Procedures:

1. Procedure Q.P.03-0 - Corrective Action 2. Procedure Q.P.05-0 - Control of Monitoring & Measuring Devices 3. Procedure Q.P.07-0 - Control of Non-Conforming Materials/ Works 4. Procedure Q.P.08-0 - Material handling, storage, packing & delivery 5. Procedure .E.P.01-0 - Preliminary Project planing- Workpack Preparation

3.2 Guidelines:

1. Guideline Q.G.2-1 - Guidelines on Radiography Testing 2. Guideline Q.G.2-2 - Guidelines on Hydrostatic Testing 3. Guideline Q.G.2-3 - Guidelines on MPI Testing 4. Guideline Q.G.2-4 - Guidelines on Ultra- Sonic Testing 5. Guideline Q.G.2-5 - Guidelines on Visual Inspection 6. Guideline Q.G.2-6 - Guidelines on Mechanical Equipment Testing 7. Guideline Q.G.2-7 - Guidelines on Electrical Equipment Testing 8. Guideline Q.G.2-8 - Guidelines on DCS Testing 9. Guideline Q.G.2-9 - Guidelines on Alarm & Shutdown System Testing 10. Guideline Q.G.2-10 - Guidelines on Fire & Gas Detection System Testing


4.0 RESPONSIBILITIES 1. Head of Project (HOP) / Project

Manager

To be responsible for overall control, direction and management of the project

2. Quality Management Representative (QMR)

To oversee the controls and implementation of ITP and records

3. QC/QA Engineer

To implement the Company quality system , ITP , quality procedures, and identify non-conformity and determine corrective action

4. QA/QC Inspector To implement the ITP , monitoring adherence to project procedures, maintain quality records, and compile project final documentation

4. Commissioning Engineer To implement the ITP as part of the commissioning and hand-over activities.

5.0 DEFINITIONS

1 Inspection Conformity evaluation by observation and judgement

accompanied as appropriate by measurement, testing or gauging

2 Test Determination of one or more characteristics according

to procedure


6.0 PROCEDURE FLOWCHART The detail procedure in section 7 must read referring to this Flowchart

NO YES

RESPONSIBILITY Head of project (HOP) QA/QC Engineer & Commissioning Engineer (CE) QA/QC Engineer & Commissioning Engineer (CE) QA/QC Engineer & HRD QA/QC Inspector/ Commissioning Engineer QA/QC Inspector/ Commissioning Engineer HOD & Client Rep.

ACTION 1. Identify IT

requirements during Workpack development

1. Develop IT checklist

& plans for the project

1. Identify &mobilize the

resources 1. Record and evaluate

results 2. Rectify any NCR ASAP 1. Approve record &

reports

1. Review & approve report final

APPROVE IT RECORDS

FIND REVIEW & APPROVE IT REPORTS

END

OK

START

IMPLEMENT IT PLAN

DEVELOP IT CHECKLIST & PLAN

IDENTIFY & MOBILIZE RESOURCES

IDENTIFY INSPECTION & TEST (IT) REQUIREMENTS

EVALUATE ITP RECORDS RE-DO


7.0 PROCEDURE DETAILS

7.1 Identify the inspection & testing (IT) requirements

All the inspections and testing required in the project must be identified during the preliminary quality planning or "Workpack" preparation phase and the IT requirements varies from project to project. Discipline Engineers (QA/QC, E & I and Mechanical) who are assigned to the project for the Workpack preparation and subsequent execution phases need to review the work scopes, drawings, and identify the inspection, testing and commissioning requirements.

7.2 Develop IT checklist and plan

7.2.1 Discipline Engineers to develop the acceptance criteria and checklist as per clients desired format for all the IT and commissioning requirements.

7.2.2 QA/QC Engineer to consolidate the planning for all the IT and commissioning

activities in the project IT plan together with procedures that describe the quality objectives, the extent of inspection, witness point and frequency, and the acceptance criteria including the method for disposition of non-conforming materials/ works.

7.3 Identify & mobilize the required resources 7.3.1 QA/QC Engineer to identify the necessary resources required to execute all the

IT and commissioning activities. The resources include manpower, tools and equipment such as the monitoring & measuring devices, and out sources services from a third party Inspection Company for all the Non- Destructive Test (NDT) works such as the Radiography Testing (RT) and MPI testing.

7.3.2 Head of Operations and Site Logistics Supports Team coordinate mobilisation

of all the resources for IT and commissioning works to project site as per the project execution schedule.

All monitoring & measuring devices that are vulnerable to damages must be properly protected, handled and transported under acceptable operational condition.


7.4 Implement the IT Plan.

7.4.1 Characteristic of IT

The QA/QC Engineer Inspector shall perform periodically the IT activities at appropriate stages to permit inspection such as dimension, NDT, visual, performance test among other tasks in accordance with documented procedures and guidelines describes in the IT plan. There shall be no random IT allowed.

7.4.2 Receiving Inspection

7.4.2.1 All incoming materials must be inspected jointly by Suppliers, QC

Inspector and Material Coordinator (MC) to ensure conformity to the required specification before being incorporated into the process or use in the construction or installation at project site.

7.4.2.2 The inspection must be documented and performed in conformance

with the IT plan and must not be limited to physical defects, quantity count, verification of quantity records, storage, handling and proper disposition of non-conforming materials.

7.4.2.3 In urgent cases, doubtful materials received may be permitted for

use in the construction provided that proper documents and identifications are performed. In the event of confirmed non-conformity, this will permit immediate recall and replacement of the materials and re-works if necessary.

7.4.3 In-process IT

7.4.3.1 The In-process IT shall be documented and performed to prevent

non-conformities. Reworks in the earlier and subsequent manufacturing/ prefabrication process, constructions and commissioning phases whenever in-house it is applicable will be determined by QA/QC Engineer/ QC Inspector and Commissioning Engineer as appropriate.

7.4.3.2 Users of all IT equipment will be responsible to check the

certification or verify the calibration prior to using them for the IT works.


7.4.4 Evaluate IT Record

7.4.4.1 All the IT performed shall be recorded, evaluated and reviewed in

accordance with the IT plan to ensure that all the quality requirement are complied satisfactorily prior to acceptance of products, works & services performed

7.4.4.2 Any non-conformity products must be promptly rectified either by

repairing the defects or re-doing the whole works, and repeat relevant IT activities until the results are satisfactory and acceptable by all interested parties.

7.4.5 Approval of IT Records

7.4.5.1 A consolidated report summarizing all products with acceptance and non-conformity IT records shall be submitted in phases to the Clients Representative and Asset Holder for approval.

7.4.5.2 The accepted IT records shall form part of the acceptance criteria of

subsystem and system hand-over in phases until the final hand-over to the Asset holder of the whole facilities upon completion of the project.

7.4.6 Final review and approval of IT records and Reports*

7.4.6.1 QA/QC Engineer to ensure a complete complication of the IT records

and summary reports to be submitted to Head of Project (HOP) for his review and approval

7.4.6.2 HOP to submit the approved IT report to the clients Focal point for

their further review and final approval.

P/N: *Clients term also known as the Final Documentation

8.0 RECORDS

Records of Inspection & Testing Log shall be maintained by QMR for a period of 3 years


9.0 ATTACHMENTS:

Attachment 1 : ITP for Mechanical, Piping & Pipeline Work of Material Receiving, Storage & Issuing Work

Attachment 2 : ITP for Welding Procedure Specification, Procedure Qualification and Welder Qualification

Attachment 3 : ITP for Mechanical, Piping & Pipeline Work of Piping Fabrication & Installation Work

Attachment 4 : ITP for Mechanical, Piping & Pipeline Work of Blasting, Painting, Wrapping & Insulation Work

Attachment 5 : ITP for Mechanical, Piping & Pipeline Work of Mechanical Equipment Installation

Attachment 6 : ITP for Mechanical, Piping & Pipeline Work of Pipe Laying Work Attachment 7 : ITP for Instrument & Electrical Work of Above Ground Cable Laying Work Attachment 8 : ITP for Instrument & Electrical Work of Underground Cable Laying Work Attachment 9 : ITP for Instrument & Electrical Work of Termination of Cable Attachment 10 : ITP for Instrument & Electrical Work of Equipment Installation Attachment 11 : ITP for Instrument & Electrical Work of Loop Check & Precommissioning

Work Attachment 12 : ITP for Instrument & Electrical Work of Calibration Work Attachment 13 : ITP for Instrument & Electrical Work of Impulse Line and Air Tubing Work Attachment 14 : ITP for Duplex Welding

10.0 PERFORMANCE MEASUREMENT

1. Zero rejection of all inspected & tested work scope 2. Reoccurrence of Non-Conformities after corrective action taken

-END-

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