Quality Control Procedure Sample[1]
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Transcript of Quality Control Procedure Sample[1]
Document No. :
Revision/Edition : Date :
Company
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
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 –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
Document No. :
Revision/Edition : Date :
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TECHNICAL IMPLEMENTATION MANUAL Page :
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
Document No. :
Revision/Edition : Date :
Company
TECHNICAL IMPLEMENTATION MANUAL Page :
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.
Document No. :
Revision/Edition : Date :
Company
TECHNICAL IMPLEMENTATION MANUAL Page :
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)
Document No. :
Revision/Edition : Date :
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TECHNICAL IMPLEMENTATION MANUAL Page :
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 .
Document No. :
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TECHNICAL IMPLEMENTATION MANUAL Page :
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) .
Document No. :
Revision/Edition : Date :
Company
TECHNICAL IMPLEMENTATION MANUAL Page :
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
Document No. :
Revision/Edition : Date :
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TECHNICAL IMPLEMENTATION MANUAL Page :
QUALITY CONTROL PROCEDURE
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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TECHNICAL IMPLEMENTATION MANUAL Page :
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
Document No. :
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TECHNICAL IMPLEMENTATION MANUAL Page :
QUALITY CONTROL PROCEDURE
Document No. :
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TECHNICAL IMPLEMENTATION MANUAL Page :
QUALITY CONTROL PROCEDURE
b) Attachment – 2 : Dimension Inspection Report
c) Attachment – 3 : Welding Inspection Report
Document No. :
Revision/Edition : Date :
Company
TECHNICAL IMPLEMENTATION MANUAL Page :
QUALITY CONTROL PROCEDURE