pr-qc-001,quality plan , rev 2.0

8/10/2019 PR-QC-001,Quality Plan , Rev 2.0

http://slidepdf.com/reader/full/pr-qc-001quality-plan-rev-20 1/21

Revision Number 2.0 Reference Number PR/QC/001

Amendment 0 Date 12-Jan-10

Document Title QUALITY PLANAl-Yusr Townsend & Bottum Co., Ltd.

u!"#l Industr#"l C#t$ %1'1Kingdom of Saudi Arabia

R()I(* AN+ APPR)AL INATUR( R(CR+

RL( TITL( INATUR( +AT(

riginator !A"!# $ngineer 12-Jan-10

Revie%er 1 Sr. !A"!# $ngineer 12-Jan-10

A&&roved b' !A"!# (anager 12-Jan-10

R(CR+ R()IIN

R()IIN N. +(CRIPTIN +AT(

2.0 )ncor&orated )S *001+200, reuirements 12-Jan-10

1.0 re&ared in ne% format and u&dated /0-(ar-0*



AYTB Co. Ltd. Qu"l#t$ Pl"n

TABL( CNT(NT

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2.0 S#$

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3.0 D$)N)T)N

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4.0 A5T !6A7)T5 7)#5

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11.0 )NS$#T)N AND T$ST

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12.0 #NTR7 )NS$#T)N= ($AS6R)N9 : T$ST $!6)($NT

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+CU(NT N. R()IIN +AT( PA(

R"!#"001 2.0 12-Jan-10 2 of 1




1/.0 #NTR7 NN-#NR(AN#$S

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1.0 B(CTI)(

1.1 To identif' and establis@ t@e &rocesses and controls to be im&lemented b' t@eaffected organiation to ensure t@at all items %it@in t@e sco&e of BRK meet t@es&ecified reuirements. T@ese ualit' reuirements s@all be follo%ed b' A5T= itssubcontractors= and su&&liers and s@all be a&&lied to an' direct or indirect&urc@ase orders= sub-orders= or services agreements.

1.2 To assure t@at t@e facilities built are safe= reliable= efficient= %ill satisf' t@eir intended

&ur&ose according to Job S&ecifications= and are built economicall' %it@ aminimum amount of re%orC and re&air.

.0 CP(

T@is !ualit' lan addresses A5T general ualit' assurance and ualit' controlreuirements t@at are a&&licable to all A5T subcontractors %@o &erform construction=installation= fabrication= @ooC-u& of electrical= instruments= structural= &i&ing andmec@anical items for A5T abrication and #onstruction activities.

This Quality Plan is prepared based on AYTB’s ISO 9001-200 !erti"i!ation s!ope and re#uire$ents


R"!#"001 2.0 12-Jan-10 / of 1




%.0 R((R(NC(

/.1 )S *001+200, !ualit' (anagement S'stems Reuirements/.2 A5T S("!A"001 #or&orate !ualit' Assurance (anual

2.0 +(INITIN

3.1 !ualit' Total of features and c@aracteristics of an entit' t@at bear onits abilit' to satisf' stated and im&lied needs Ei.e. fitness for use= meets intended &ur&ose and &erforms satisfactoril' for a s&ecified timeF.

3.2 !ualit' Assurance lanned and documented measures Erevie%= surveillanceand"or auditF designed to &rovide t@e desired level of confidence t@e BRK is &erformed satisfactoril' and inaccordance %it@ t@e reuirements and Gob s&ecifications.

3./ !ualit' #ontrol T@ose actions t@at &rovide a means to control and measure

t@e c@aracteristics of an item= &rocesses= or facilit' toestablis@ed reuirements.

3.3 !ualit' rogram T@e documented &lanEsF for im&lementing t@e ualit's'stem b' t@e affected organiation for t@e s&ecific sco&e of su&&l' for t@e &articular inuir' or &urc@ase documents.

3.4 !ualit' S'stem T@e organiational structure= &rocedures= &rocesses andresources needed to im&lement ualit' management.

3.8 #ontrol rocedures Britten &rocedures t@at formall' document t@e detailedactions to be undertaCen to control t@e %orC and assureualit'.

3.< )ns&ection : Test lan A documented &lan t@at identifies t@e ins&ection and testingactivities in a s'stematic flo% in accordance %it@ t@econstruction &rocess usuall' &rovided in t@e form of a matriHor table.

3., A5T A7-5usr To%nsend : ottum #o. 7td.

3.* Subcontractor A5T or #lient a&&roved &erson= com&an'= or grou& t@at=

t@roug@ contractual agreement= &erforms a service for #ontractor.

3.10 Su&&lier EendorF An' A5T"#lient a&&roved &erson= com&an'= manufacturer=subcontractor= vendor or subcontractor t@at &ro&oses to&rovide= or &rovides materials= eui&ment= or services inconnection %it@ t@e fabrication= installation and testing of=mec@anical eui&ment= &i&ing s'stems= steel%orC=miscellaneous foundations= etc.

3.11 Bitness oint A s&ecificall' identified critical ste& in manufacturing andtesting at %@ic@ #lient re&resentative must ins&ect BRK.

T@e su&&lier is obligated to notif' t@e designated


R"!#"001 2.0 12-Jan-10 3 of 1




ins&ectorEsF at a reasonable time in advance of suc@ ste&s.T@e su&&lier ma' &roceed %it@ t@e BRK= &ass a %itness&oint &rovided t@at t@e designated ins&ectionre&resentativeEsF agreeI @o%ever= normall' a subseuentsimilar o&eration is %itnessed at t@e earliest o&&ortunit'.

3.12 >old oint T@e same as %itness &oint eHce&t t@at t@e su&&lier ma' not&roceed %it@ t@e BRK until #lient re&resentative @aveins&ected it.

3.1/ Non-conformance Non-fulfillment of s&ecified reuirements= i.e. t@e absence of one or more ualit' s'stem elements from s&ecifiedreuirements.

3.13 (et@od Statement A met@od statement serve as a guidelines for t@e actualeHecution of %orCs a&&licable for t@e abrication and"or #onstruction roGect

3.14 roGect )nstruction An instruction given to site o&eration in order to com&leteassigned tasC for an' given reuirements as a&&licable tot@e &roGect.

3.0 AYTB QUALITY PLICY

4.1 T@e im&lementation of A5Ts !ualit' olic' s@all be t@e res&onsibilit' of t@e roGect(anagement Team and its staff.

4.2 All em&lo'ees s@all be informed of t@e &ro&er &rocedure for t@e fabrication=installation= ins&ection and t@e reuired safet' to ensure %orC is carried out inaccordance %it@ t@e &roGect s&ecifications= standards and dra%ings.

4./ Safe s'stem of %orCed develo&ed and in o&eration to &rotect &ersons= eui&ment=&ro&ert' and environment from being eH&osed to assessed @aards andassociated risC &otential in t@e course of o&eration being carried out.

4.3 A5T !ualit' olic' @as been formulated and can be found as an $H@ibit to t@is!ualit' lan. )t is also &rominentl' dis&la'ed at man' strategic locationst@roug@out A5T &roGect site offices.

4.4 $m&lo'ees at all levels of t@e organiation are eH&ected to fulfill= understand andmaintain t@e reuirements of t@is &olic' in all of t@eir %orC-related efforts anddecisions.

'.0 ANA((NT R(PNIBILITY AN+ RANI4ATIN


R"!#"001 2.0 12-Jan-10 4 of 1




'.1 r5"n#6"t#on

A5T @as an establis@ed organiational structure. T@is structure enforces t@eualit' s'stem efficienc' in t@e overall site organiation and %orC facilities. T@isstructure indicates lines of Res&onsibilit' and )nter-relation among de&artments

and ot@er organiational structure E$H@ibit - DF.

'. Aut7or#6ed Re8resent"t#9e

T@e !A"!# (anager is t@e aut@oried re&resentative of A5T. >e re&resents t@ecom&an' on all ualit' matters &ertinent to t@e ualit' Assurance and #ontrol asestablis@ed b' t@e &roGect s&ecifications and &rocedures. >e is res&onsible for t@efollo%ing+

8.2.1 #oordination of t@e entire com&an' effort in terms of ualit' to ensure t@att@e &roGect ualit' is ac@ieved.

8.2.2 $nsuring t@at all &roGect s&ecification reuirements are maintained and t@att@e com&an's ualit' s'stem is com&atible %it@ t@e foregoing.

8.2./ (aintaining liaison %it@ t@e #lient !ualit' De&artment on all mattersconcerning ualit' and t@eir common interest.

8.2.3 rganiing and conducting audits on construction= fabrication= &ainting andinstallation activities of A5T and its subcontractors.

8.2.4 )nvestigating &roblems and #lient com&laints on ualit' and initiatingcorrective actions.

'.% Res8ons#!#l#t#es And Aut7or#t#es

8./.1 roGect (anager

T@e roGect (anager is accountable for t@e to&-level management actionson t@e im&lementation of t@is &lan. >e is res&onsible in &roviding @is&roGect team %it@ t@e a&&ro&riate resources to ensure t@at %orCs are donein accordance %it@ t@e &roGect ualit' reuirements.

8./.2 roGect Su&erintendent

T@e roGect Su&erintendent is directl' res&onsible to t@e roGect (anager for all t@e activities related to t@e roGect. )t s@all be @is res&onsibilit' toensure t@at t@e roGect !ualit' lan is effectivel' develo&ed in accordance%it@ t@e contract reuirements and t@at t@e ualit' obGectives are ac@ieved.>e s@all revie% and communicate t@e reuirements to all assigned&ersonnel involved in t@e im&lementation of t@e &roGect to ensure t@at allassigned &ersonnel @ave t@e information reuired to &erform t@e %orC andt@at t@e information is correct and current. >e is res&onsible for &lanning&roGect eHecution and coordinates %it@ all de&artments to ensure t@at t@edesign interfaces bet%een disci&lines and subcontractors are identified

and a&&ro&riatel' managed.


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8././ (aterial #ontrol Su&ervisor

T@e (aterial #ontrol Su&ervisor re&orts to t@e roGect (anager. >e @ast@e overall res&onsibilit' in t@e im&lementation of materialcontrol"%are@ousing= &olicies and &rocedures to ensure t@e &ro&er records

Cee&ing= material @andling= receiving= storage= inventor' and issuance of items. >e s@all ensure availabilit' of ualit' materials and im&lement aneffective s'stem for tracCing and monitoring of &roGect-intended items toensure timel' serving of t@e &roGect material reuirements and its &ro&er traceabilit'. >e is res&onsible for &lanning and sc@eduling of overallinventor' control and %are@ousing o&eration. >e s@all coordinate %it@ield $ngineering 9rou&= roGect Su&erintendent= urc@asing )n-c@argeand !A"!# (anager in t@e im&lementation of t@e &roGects ualit' s'stem

8./.3 7ead ield $ngineer

T@e 7ead ield $ngineer re&orts to t@e roGect (anager. >e defines t@e

engineering and &rocurement activities t@at s@all start %it@ t@e revie% of reuisition &acCages to ensure t@at t@e' are in conformance %it@ #lientreuirementsI standards and &roGect &rocedures are in &lace at t@euotation stage. >e is res&onsible in coordinating t@e ualit' assuranceand control on &rocurement %it@ t@e !A"!# (anager. >e s@all coordinatet@e assessment of vendors Esu&&liers and subcontractorsF. >e s@all alsoorganie engineering &rocurement and verification of &urc@ased materials.

8./.4 !A"!# (anager

T@e !A"!# (anager s@all re&ort o&erationall' to t@e roGect (anager. >e@as t@e overall res&onsibilit' to organie= im&lement= coordinate= conductand manage t@e !ualit' Assurance and #ontrol rogram. )t s@all be @isres&onsibilit' to re&ort an' deficiencies in t@e ualit' of %orC to t@e roGect(anager. >e @as t@e aut@orit' to sto& %orC in an' area %@erediscre&ancies remain uncorrected and s@all cancel t@e sto& %orC order and non-conformance re&ort u&on satisfactor' correction of noteddeficiencies. T@e !A"!# (anager s@all coordinate %it@ t@e ield$ngineering 9rou&= roGect Su&erintendent= !# )ns&ectors andsubcontractors to ensure t@at t@e (et@od Statement " )ns&ection Test lanE)TF are &ro&erl' im&lemented.

8./.8 !# )ns&ector

T@e !# )ns&ectors s@all be under t@e direct su&ervision of t@e !A"!#(anager. T@e' s@all conduct &reliminar' ins&ections &rior to Gointins&ections %it@ t@e client. T@e' s@all monitor t@e reuired tests and recordins&ections and tests made. T@e' s@all ensure t@at all material andeui&ment to be incor&orated into t@e &ermanent installation in com&liance%it@ t@e contracts= &lans= s&ecifications and %it@ clients a&&roval. T@e !#)ns&ectors s@all @ave t@e rig@t to reGect %orC t@at does not com&l' %it@= or %@ic@ %as not ins&ected= tested or eHamined in full com&liance %it@ t@ereuirement of t@e dra%ings and &roGect s&ecifications.

8./.< ND$ #oordinator


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T@e ND$ #oordinator s@all be under t@e direct su&ervision of t@e !A"!#(anager. >e s@all coordinate %it@ !# )ns&ectors for Beld ND$ selection.>e s@all coordinate %it@ Subcontractor for ND$ activities. >e s@allcoordinate %it@ !# )ns&ectors and Subcontractors for outstanding RT%elding Goints due to an' re&airs or re-s@ooting reuired im&lementing !#release on a timel' manner.

:.0 +CU(NT AN+ +ATA CNTRL

:.1 ener"l

<.1.1 #ontrol measures s@all be establis@ed to assure t@at documents affectingualit' are &ro&erl' accom&lis@ed. Revie%ed and a&&roved b' aut@oried&ersonnel and &rom&tl' distributed to areas %@ere t@e' are to be used.

:. Control e"sures ;or Qu"l#t$ +o<uments

<.2.1 )nstructions are alread' im&lemented to delineate res&onsibilities and

&rovisions regarding document related activities= suc@ as+

aF re&arationbF Revie% and A&&rovalcF DistributiondF Transmittal= retrieval and dis&osaleF #oding and numberingfF )ndeHing and filinggF $ntr' %riting and corrections

<.2.2 A Document #ontroller s@all be assigned for distribution and maintenanceof documents generated at roGect Site.

<.2./ oid and Su&erseded documents s@all be surrendered to t@e Document#ontroller for burning or s@redding eHce&t for original co&' at Document#ontroller= %@ic@ %ill be stam&ed oidL= or Su&ersededL.

<.2.3 Document revisions or c@anges s@all be controlled in t@e same manner ast@e originals.

<.2.4 Records s@all be maintained b' t@e Document #ontroller and s@all beaudited &eriodicall' b' t@e !A"!# (anager or @is designee to ensureissuance and use of u&dated co&ies.

:.% Controlled +o<uments

<./.1 T@e follo%ing s@all be controlled and maintained a register as &er &roGectreuirements+

aF roGect !ualit' lan and its im&lementing &roceduresbF ersonnel ualifications and training recordscF roGect #ontract S&ecificationsdF Dra%ing and revisionseF )ns&ection and test re&ortsfF Audit and surveillance re&orts

gF Non-conformance Re&orts and corrective Action Reuests


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@F #ontractor client interface documents regarding ualit'= design or orders

iF endor ualification records GF (aterial and eui&ment control recordsCF roGect corres&ondencelF #alibration records

:.2 +o<uments "#nten"n<e

<.3.1 Site general &roGect documents s@all be controlled and maintained b' asite document controller u& to &roGect com&letion and"or turnover of documents to t@e client.

=.0 CNTRL PRCUR((NT

=.1 ener"l

#riteria s@all be establis@ed for t@e control of material= eui&ment and services

&urc@ased for use in &roGect. rocurement s@all be t@roug@ ualified su&&liers toensure t@at t@ese items com&l' %it@ t@e s&ecifications and"or a&&licable codesand standards.

=. Re>u#rements ;or Pro<urement

,.2.1 (aterials= eui&ments and services to be &rocured s@all be selected basedon a&&roved &roGect s&ecifications= eHce&t for t@ose materials andsubcontracted services t@at %ill be &rocured u&on a&&roval of t@e &ro&er aut@orities.

,.2.2 Reuisitions and &urc@ase &lacements for materials= eui&ment andservices s@all be made t@roug@ dul' a&&roved and controlled &rocurementdocuments.

,.2./ rocurement documents s@all be &ro&erl' accom&lis@ed and s@alladeuatel' describe t@e ualit' and documentation reuirements.

,.2.3 urc@ase documents s@all be revie%ed and a&&roved b' t@e 9eneral(anager &rior to actual &urc@ase.

=.% Control o; Pur<7"se "ter#"ls, (>u#8ments "nd er9#<es

,./.1 ro&osal submitted b' su&&liers and subcontractors s@all be revie%ed b' A5T to ensure t@at t@ose firms selected are listed in sco&e of %orC= A&&roved endors and Subcontractors and"or a&&roved b' #lient and t@e'@ave t@e reuisite resources= tools and &rocedures to &artici&ate in t@eestablis@ed Gob reuirements.

,./.2 Documents for &rocurement of materials= eui&ment and services %@et@er &urc@ased b' A5T or b' its subcontractors= s@all include but not limited tot@e follo%ing+

aF Reference to a&&licable &roGect codes and standards and designs&ecification reuirements referenced in &rocurement reuisition.


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bF 7isting of endor documents suc@ as instructions= &rocedures=dra%ings= s&ecifications= vendor ins&ection &lans= ins&ection and testrecords and vendor !A records to be &re&ared= submitted= or madeavailable for A5T and #lient revie% and a&&roval.

cF 7isting of ins&ections t@at s@all be eHercised over t@e sub su&&liers and

sub vendors b' t@e vendor.

dF T@e reuirement t@at t@e events defined in t@e )ns&ection and Testlan include a&&ro&riate @old and %itness &oints and ot@er s&ecialins&ections t@at ma' be eHercised over t@e endors Su&&liers andsub-vendors b' A5T or #lient must be incor&orated &rior to use or installation of t@e &rocured item.

eF )dentification of t@ose records t@at s@all be retained= controlled=maintained= or delivered to #lient and"or A5T &rior to use or installation of t@e &rocured item.

fF Documented satisfactor' eH&erience in su&&l'ing similar materials=eui&ment= services to t@e &etroleum"c@emical"&o%er industries= etc.and"or &@'sical surve' of t@e su&&liers manufacturing facilitiescom&liance to #lient A&&roved endors : Subcontractors 7ist.

gF $vidence of t@e !ualit' Assurance rogram= satisfactor' to A5Tand"or #lient.

,././ A5T s@all maintain receiving ins&ection to ensure t@at arriving materialsand eui&ment are &ro&erl' identified and conform to t@e reuirements of t@e &urc@ase documents.

,./.3 #learl' identif'ing and segregating t@em into a uarantined area until&ro&er dis&osition is made to control all non-conforming items.

,./.4 Documentation s@all be maintained confirming t@at services &urc@aseddirectl' or t@roug@ subcontractors conform to &rocurement reuirements.

=.2 u!<ontr"<tor?s *or@

,.3.1 $ac@ subcontractor s@all be reuired to develo& a ualit' control &lan t@atconforms to #lient contractual ualit' reuirements. T@e ualit' control&lan s@all contain organiational c@arts s@o%ing t@e subcontractor totalorganiation res&onsible for &erforming its %orC and clearl' s@o%ing t@e

assignments and members of &ersonnel res&onsible for t@e ualit' controlactivities.

,.3.2 Subcontractors &erforming %orC s@all im&lement a ualit' control &lan&ertinent to t@e %orC t@e' %ill be &erforming. T@e &lan s@all list t@eindividual ins&ection"testing activities t@at %ill be &erformed= s@o%ing &artof t@e &lan t@e subcontractor %ill eHecute directl'= s@o%ing &art eHecutedb' t@ird &art' ins&ection"testing agencies and s@o%ing %@at oversig@t t@esubcontractor %ill eHercise over suc@ agencies.

,.3./ A5T s@all develo& t@is &lan and reac@ an agreement %it@ itssubcontractorEsF and s@all submit suc@ &lan for #lient revie% and a&&roval


R"!#"001 2.0 12-Jan-10 10 of 1




as a&&licable. T@ereafter= A5T s@all conduct surveillance and audits of &lanned activities.

.0 PR+UCT I+(NTIICATIN AN+ TRAC(ABILITY

.1 ener"l

*.1.1 )dentification of items &urc@ased= stocC or com&an's su&&lied materialsduring initial storage= issue to A5T and in all stages of fabrication=construction and ins&ection s@all be done as &er &roGect reuirements.

*.1.2 All materials received s@all be identified b' means of deliver' notes=&urc@ase order and (ill Test #ertificates or (aterial #ertificate or #ertificate of #om&liance.

*.1./ Non-conforming material s@all be segregated and identified from ot@er material= until suc@ non-conformance conditions @ave been corrected or ot@er%ise action as &er t@e dis&osition given in t@e N#R.

. Ident#;#<"t#on Control

*.2.1 Tagged )tems

aF A5T s@all maintain identit' of t@e number on t@e eui&ments=instruments and ot@er tagged &roducts from t@e initial recei&t u& to t@efinal installation and to mec@anical com&letion.

9.2.1 i&ing (aterial )dentification

aF A5T s@all maintain marCings and"or color code on t@e &i&ing bulCmaterials and &rotect t@ese marCings from deterioration from t@e initialrecei&t from #lient and t@roug@out s&ool fabrication= u& to andincluding installation and assembl' of &i&ing s'stem at site.

bF All &i&ing materials s@all be controlled" identified b' &roGect number=&i&ing code number or @eat number= &i&ing material s&ecification andsie marCing i.e. T/187= 2L= [email protected].

cF B@en cutting &i&es= &i&ing code number or @eat number and"or ot@er euivalent marCing s@all be transferred and identified so t@at eac@&ressure retaining &i&ing material s@all @ave t@e traceabilit' to t@ematerial s&ecification= grade= sie and sc@edule"rating after assembl'.

dF A5T !A"!# s@all control t@e off-site and s@o& fabrication to assurecorrect &i&ing code or @eat number t@roug@out= fabrication= assembl'=and installation activities in accordance %it@ &roGect reuirement.

.% et7od o; "r@#n5

9.3.1 (arCing is to be identical on all &i&es b' a&&l'ing &aint marCing on t@e

eHternal surface of t@e &i&e= at bot@ ends.


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9.3.2 )n case it is &@'sicall' im&ossible to a&&l' t@e reuired marCing Ee.g. smallsieF= marCing s@all be marCed on a durable= securel' affiHed metal tag or to t@e internal circumferential surface of t@e item.

9.3.3 Above traceabilit' marCing is to be identical on all &i&es ,L and above b'

a&&l'ing &aint marCing on t@e eHternal circumferential surface of t@e &i&e=at bot@ ends.

10.0 PRC( CNTRL

10.1 T@e follo%ing %orCs are defined as s&ecial &rocesses+

aF BeldingbF ost Beld >eat Treatment EB>TFcF Non-Destructive Testing ENDTFdF ositive (aterial )dentification E()FeF #leaning

fF ainting and #oating

10.2 or %elding= in general= %elding &rocedures s@all be documented in t@e form of Belding rocedure S&ecification EBSF and s@all be ualified in accordance %it@ AS($ Section )?. Belding &arameters of t@e ualification test s@all bedocumented as rocedure !ualification Record E!RF= inclusive of t@emec@anical tests results. Belders and Belding &erators s@all be ualified inaccordance %it@ AS($ )?.

10./ or structural %elding= BS= %elders and %elding o&erators s@all be ualified inaccordance %it@ ABS D.1.

10.3 )ns&ection &ersonnel %@o &erform NDT of %elds s@all be ualified in ABS-!#-1and ASNT-SNT-T#-1A or euivalent.

10.4 ersonnel %@o &erform &ost %eld @eat treatment EB>TF and &ositive materialidentification E()F s@all be ualified based u&on t@eir Gob eH&erience= before t@e'commence t@e %orC.

10.8 rocedures and &ersonnel of t@e above s&ecial &rocesses s@all be ualified b' A5T and a&&roved b' t@e #lient.

10.< !ualification of s&ecial &rocesses= &ersonnel &erforming s&ecial &rocesses and

eui&ment s@all be Ce&t current and record files t@ereof s@all be maintained.

10., S&ecial &rocesses testing control s@all identif' t@e %oC &erformed ins&ected ands@all be acce&ted " reGected using re&orts= c@ecClist= or ot@er suitabledocumentation.

10.* rocesses @aving a direct effect on ualit' s@all be carried out under controlledconditions in accordance %it@ t@e %ritten &rocedures= dra%ings and s&ecifications.(et@ods of installation s@all be defined in documented %orC &rocedures.

10.10 rocesses s@all be monitored and controlled to ensure com&liance %it@ t@e&roGect s&ecifications and reuirements.


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11.0 INP(CTIN AN+ T(T

11.1 Pre-Ins8e<t#on eet#n5

A5T s@all attend t@e &re-ins&ection meeting conducted b' t@e #lient beforestarting an' ne% ins&ection= eHamination and test items to establis@ detail

sc@edule= &rocedure= &re-reuisite= conditions of ins&ection= eHamination or testand communication to &erform effectivel' reuired ins&ection= eHamination andtest.

11.1.1 S'stematic met@od for communicating ins&ection= eHamination and testinformation to be eHc@anged among #lient= A5T and subcontractors asconstruction &rogresses.

11.1.2 Ke' &ersonnel communication c@annel.

11.1./ Res&onsibilities of Ce' &ersonnel for conducting ins&ection= eHaminationand test and for solving &roblems during ins&ection eHamination and test.

11.1.3 T@e latest revision of a&&licable documents.

11.1.4 Sc@edule of construction= installation and @ooC-u& including ins&ection andtest.

11.1.8 #lassification of t@e ins&ection reuirements= c@aracteristics= met@ods=conditions= acce&tance criteria= and documentation of records to be taCen.

11.1.< )ns&ection items and t@eir @old= %itness or document revie% &oints.

11. Qu"l#t$ Control eet#n5

A5T s@all attend regular ualit' control meetings conducted b' #lient to solve or discuss t@e follo%ing items+

11.2.1 Ambiguous= dubious= conflicting= inconsistent or uestionable matters int@e ins&ection= eHamination= or test reuirements or acce&tance criteria.

11.2.2 An' &roblems found out during t@e ins&ection= eHamination or test.

11.2./ #larification on t@e ins&ection= eHamination or test &rocedures.

11.2.3 Acce&tance or reGection of ualified &ersonnel.

11.2.4 $valuation of ins&ection= eHamination or test results.

11.2.8 Acce&tance or reGection of ins&ection= measuring and test eui&ment.

11.2.< Dis&osition measures for non-conforming items.

11.% Qu"l#;#<"t#on o; Ins8e<t#on Personnel

11./.1 A5T s@all em&lo' t@e services of a / rd &art' contractor %@o @as been

ualified ND$ &ersonnel %@o &erform radiogra&@ic testing ERTF= magnetic


R"!#"001 2.0 12-Jan-10 1/ of 1




&article E(TF and liuid &enetrant ETF= ultra sonic testingE6TF inaccordance %it@ t@e American Societ' of Nondestructive TestingRecommended ractice no. SNT-T#-1A= )S"D)N *<12= ND)S J001= or euivalent standards. )n case of euivalent standards= ualification or certificate s@all be submitted to #lient for revie% and a&&roval. A5T&ersonnel in accordance %it@ above ualifications s@all also carr' out T.

11./.2 A5T s@all ualif' in-@ouse services of ualified () &ersonnel andeui&ment in accordance %it@ t@e eui&ment manufacturers standardsand recommendations.

11././ A5T s@all ualif' in-@ouse services of ualified B>T and >ardnesseHaminer in accordance %it@ t@e eui&ment manufacturers standards andrecommendations.

11.2 Cl"ss#;#<"t#on o; Ins8e<t#on "nd Test

All @old and %itness &oints reuired= t@e reuest s@all be submitted a minimum of

23 @ours in advance to t@e #lient.

11.3.1 >old oints

aF A5T s@all ins&ect or test a &roduct mandator' under t@e %itness of #lient.

bF A5T s@all not &roceed furt@er %it@ t@e subseuent &rocesses be'ondt@ese &oints until receiving acce&tance from #lient.

cF A5T s@all submit t@e ins&ection and test records to #lient for revie%.

11.3.2 Bitness oints

aF A5T s@all ins&ect or test a &roduct under t@e %itness of #lient.

bF A5T ma' &roceed furt@er %it@ t@e subseuent &rocesses %it@out t@e%ritten consent after 14 minutes of no s@o% of re&resentatives= but A5T s@all confirm %@et@er %aiver or %itness %@en #lient does not%itness t@e start of an ins&ection or test.

cF A5T s@all submit t@e ins&ection and test records to #lient for revie%and acce&tance.

11.3./ Document Revie% oints

A5T s@all submit t@e ins&ection and test records to #lient for revie% andacce&tance.

11.3 P#8e "!r#<"t#on "nd *eld#n5 Control

11.4.1 A5T s@all use t@e )so-$H&ress Soft%are better Cno%n as A#RNsoft%are an eas' to use stand aloneL com&uter drafting s'stem for dra%ing and fabrication of &i&ing s&ools. T@e A#RN s@all &rovide t@efollo%ing features+


R"!#"001 2.0 12-Jan-10 13 of 1




>ig@ ualit' dra%ings %it@ accurate information

S&ecification driven= automaticall' %rites bill of materials

roduce %eld ma&s= %eld t'&es and ins&ection information

rovides material summaries= inventor'= cut lists and material searc@es

rovides surface area for &ainting and insulation and s&ool %eig@ts for

s@i&&ing

rovides s&ool status= %elder and ins&ector records using t@e arcode

TracCing S'stem rovides a re&ort of all %elds b' individual %elder

11.' Ins8e<t#on "nd Test Pl"n ITP

roGect ualit' &lan reuires fabrication"field ins&ections and testing activities=%@ic@ s@all be &erformed in controlled and s'stematic manner to meet t@e &roGectreuirements and verif' construction= %orCs or services for com&liance to t@es&ecified &roGect s&ecifications and dra%ing reuirements and resultsdocumented. Suc@ &lans s@all describe t@e met@ods and &rocedures to be

em&lo'ed to ensure and verif' conformance of ualit' of t@e item during receiving=construction and final ins&ection and testing.

11.8.1 )ns&ection

aF T@e )ns&ection and Test lan E)TF s@all consist a narrative descri&tionof t@e seuence of activities or o&erations to be &erformed andc@aracteristics to be measured. T@e met@od of eHamination= t@ea&&licable acce&tance criteria and t@e documentation reuirementss@all also be included in t@e )T.

bF T@e )ns&ection and Test lan E)TF s@all establis@ t@ose ins&ections=

tests and @old &oints from ra% materials t@roug@ fabrication= erection or construction at %@ic@ conformance to reuirements s@all be verified.>old &oints and t@ose ins&ections rendered inaccessible b'subseuent o&erations s@all be verified before start of neHt o&erations.

cF Record of t@e ins&ection s@all= as a minimum identif'+

Relevant ins&ection " test

#onfirmation to t@e a&&licable &roGect s&ecification= codes=

standards and dra%ing reuirementsI T'&e of test eui&ment used and valid traceabilit' certificate

%@ere a&&licableI Acce&tance criteriaI and

Results

dF )ns&ection s@all be &erformed in conGunction %it@ t@e latest revision of t@e &roGect s&ecifications.

eF )ns&ection re&orts s@all be signed and dated b' A5T !#re&resentative.

fF B@ere ins&ection record forms are &rovided b' engineerings&ecifications= t@ese forms s@all be used. >o%ever= A5T s@all revie%

and acce&t t@em for com&liance to t@e &roGect ualit' &rogram. T@e


R"!#"001 2.0 12-Jan-10 14 of 1




forms s@all be su&&lemented= reformatted or modified as needed to becom&atible %it@ t@e A5Ts ualit' s'stem= but a&&licable verification of t@ese forms s@all be retained as a minimum.

11.8.2 Testing

aF Testing &rocedures suc@ as ND$= >'drostatic and neumatic Test=s@all @ave s&ecific reuirements and acce&tance criteria to meeta&&licable &roGect s&ecifications= standards and ot@er designdocuments. Test control &re-reuisites s@all include at least+

#alibrated )nstrumentsI

Adeuate and a&&ro&riate eui&mentI

Trained= ualified and"or a&&ro&riatel' licensed and"or certified

&ersonnelI re&aration= condition and com&leteness of items to be testedI

Suitable and controlled environmental conditionsI

(andator' ins&ections @old &oints %@ere a&&licable for %itnessb' t@e #lient.

bF Test results s@all be documented= evaluated and acce&tance status

identified b' ualified individual.

cF Testing s@all be &erformed in accordance %it@ t@e latest revision of &roGect s&ecifications and &rocedures.

11.: Re>uest ;or Ins8e<t#on RI

11.<.1 or t@e @old and %itness &oints= A5T s@all submit t@e Reuest for

)ns&ection ER)F of a &roduct to t@e #lient at least 23 @ours in advance of an ins&ection and test date.

11.= Ins8e<t#on "nd Test Re<ords

11.,.1 or t@e ins&ection and test records s&ecified in t@e )T= A5T s@all submitt@em to #lient for revie%.

11.,.2 A5T s@all @ave #lient signature and date t@e ins&ection test records.

11.,./ nl' for unacce&table &roduct= #lient %ill clearl' fill t@e reason of un-acce&tance in t@e ins&ection and test records. A5T s@all ins&ect=

eHamine or test again after solving causes of un-acce&tance.

11.,.3 A5T s@all also @ave t@e client revie%ed signature in t@e ins&ection andtest records t@roug@ #lient= %@ere so s&ecified in t@e )T.

1.0 CNTRL INP(CTIN, (AURIN AN+ T(T (QUIP(NT

12.1 A5T s@all im&lement a s'stem for control of measuring and testing eui&ment.S&ecified tools and eui&ments s@all be identified to maCe and &erform tests int@e field %it@ instructions of t@eir use= calibration and storage.


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12.2 A5T s@all identif'= maintain= control= adGust and calibrate tools gauges=instruments and ot@er measuring and testing devices used for activities controllingualit'.

12./ A5T s@all select t@e a&&ro&riate ins&ection= measuring and test eui&ment t@atare ca&able of t@e necessar' accurac' and &recision reuired for accom&lis@ing

t@e function of determining conformance to s&ecified reuirements.

12.3 #alibration s@all be &erformed at establis@ed &eriods against certified eui&mentor reverences= or valid material standards %@ere t@ese eHist. B@ere no suc@standard eHists= t@e basis used for calibration s@all be documented.

aF $ui&ment to be calibrated at &rescribed intervals against certified eui&mentin accordance %it@ t@e a&&licable codes and standards or t@e manufacturersinstruction+

ressure gauges for &neumatic or @'drostatic testing

T@eodolite

Surve'or level

Tem&erature controller for B>T

bF $ui&ment to be calibrated or adGusted &rior to use+ () eui&mentI c@ecC and adGust %it@ standards s&ecimen before and

after use Densitometer for RT inter&retationI c@ecC and adGust %it@ standard

s&ecimen before use errite meterI c@ecC and adGust %it@ standard s&ecimen before and

after use ortable t'&e Arc-$mission S&ectrometer Anal'er

Tem&erature gauge for &re-@eat and &ost @eat treatment Dial gauge

(icrometer

oltmeter

Ammeter

ernier cali&er

t@er s&ecial eui&ment= calibrate according to t@e manufacturers

instruction

cF $ui&ment to be log onl'

Ta&e measure (agnetic article $Hamination eui&ment

Telbrineller E@ardness testF

Beld gauge

t@er eui&ment as euivalent or similar

12.4 T@e calibration test certificate s@all be easil' traceable to t@e device and s@all bemaintained at t@e %orC site. #alibration record log of eui&ment bearing t@e serialnumber= range= certificate number= date eui&ment calibrated= neHt calibrationdate and validit' date s@all be made for correction of ins&ection= measuring andtest eui&ment found to be out of calibration. iles s@all be establis@ed containing


R"!#"001 2.0 12-Jan-10 1< of 1




t@e calibration records of all calibrated eui&ment and s@all be made available to#lient.

1%.0 CNTRL NN-CNRANC(

1%.1 ener"l

Non-conformances to establis@ed reuirements s@ould be &ro&erl' identified=documented= dis&ositioned and corrected.

1%. T$8es o; Non-Con;orm"n<es

1/.2.1 (aterials= eui&ment and &rocessed items t@at do not meet t@e design=s&ecifications= and"or dra%ing reuirements.

1/.2.2 )ncom&lete information or missing documents t@at maCe t@e item"s'stemsualit' status or attributes indeterminate.

1/.2./ rocedural non-conformances and non-conforming &rocesses %@ic@ affectt@e ualit' of an item"s'stem.

1%.% Ident#;#<"t#on

1/./.1 Non-conforming items s@all be &ro&erl' identified via tagging or marCing as>7DL. T@is s@all onl' be removed after t@e nonconformit' is corrected or &ro&erl' dis&osition for release and its res&ective N#R closed.

1/./.2 )dentification of all non-conforming item s@all be traceable to t@enonconformance re&ort.

1/././ Non-conforming items s@all be segregated from conforming items. B@eresegregation is not &ossible= a notification s@all be issued and"or &ostedsuc@ t@at t@e location and eHtent of t@e non-conformance is clearl'identified.

1/./.3 indings t@at are considered nonconformities as a result of ins&ection=audit= surveillances and"or customer com&laints s@all be t@oroug@l'revie%ed b' t@e concerned action &art' and s@all be committed to ans%er and initiate corrective and &reventive action.

1/./.4 A non-conformance log s@all be &rovided for t@e N#Rs generated to

&ro&erl' monitor its issuances and im&lementation= %@ic@ s@all be under control of !A"!# de&artment.

1%.2 +o<ument"t#on

1/.3.1 Non-conformances s@all be documented on t@e official N#R form andnoted b' t@e !A"!# (anager.

1/.3.2 N#R s@all be generated b' t@e !# )ns&ector and s@all be controlled b'!A"!# (anager.

1/.3./ Document #ontrol section s@all be res&onsible for transmitting t@e original

N#R to t@e action &art' and filing t@e original closed N#R.


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1%.3 NCR +#s8os#t#on "nd Control

1/.4.1 T@e follo%ing dis&osition s@all be used for non-conformances+

a% &e'e!t - (hen the non-!on"or$an!e renders the ite$)syste$

unsuitable "or its intended purpose*s%+

b% &e(or, - (hen the non-!on"or$an!e !an be eli$inated throuh additional pro!essin+

1/.4.2 Suc@ dis&osition s@all be revie%ed and acce&ted b' A5T !A"!#(anager. t@er%ise= reGect= remove and re&lace.

1/.4./ Re%orC items s@all be subGect to re-ins&ection at t@e &oints %@ere t@e non-conformances %ere discovered.

1/.4.3 Res&onses of all action &art' as soon as nonconformit' %as determined or

N#R issued s@all be %it@in siH E8F %orCing da's u&on recei&t of re&ort tofacilitate immediate resolution of t@e nonconformities.

1/.4.4 #oncerned grou& or disci&line s@all also be res&onsible in monitoringstatus of corrective action &lan %it@in t@eir res&onsibilit' to ensure &ro&er im&lementation.

12.0 AT(RIAL AN+LIN, TRA( AN+ PR((R)ATIN

12.1 ener"l

13.1.1 #ontrol measures s@all be establis@ed for t@e follo%ing activities+

aF (aterial identification and traceabilit'bF >andlingcF Storage and &reservation

12. Ident#;#<"t#on "nd Tr"<e"!#l#t$

13.2.1 (aterials and eui&ment= %@enever a&&licable= s@all be identified in ana&&ro&riate manner to &reclude in advertent use.

13.2.2 T@e means of identification s@all ensure t@e items traceabilit'= %it@out

affecting t@e function of t@e item t@us identified.

13.2./ Non-conforming material s@all be segregated and identified from ot@er material= until suc@ non-conformance conditions @ave been corrected or ot@er%ise action as &er t@e dis&osition given in t@e N#R.

12.% "ndl#n5

13./.1 (aterials and eui&ment s@all be @andled suc@ t@at t@eir intended functionor use is not im&aired.

13./.2 >andling s@all be in accordance %it@ t@e a&&licable codes= standards=

&rocedures= or manufacturers recommendations.


R"!#"001 2.0 12-Jan-10 1* of 1




7ogging Re&ort " #@art

Non Destructive Test Re&orts

)ns&ection Re&orts

#oating Re&orts

Dimensional )ns&ection Re&orts

Baiver or Acce&tance Record

ressure Test Record

14.4 !ualit' Records

14.4.1 !ualit' records= %@ic@ &rovide obGective evidence of t@e effectiveim&lementation of t@e !ualit' S'stem= are retained in t@e file in t@eDocument #ontrol section and"or at !A"!# De&artment %it@ t@e follo%ing@eading+

Audit Re&orts

#orrective Action Reuests

Non #onformance Re&orts Sto& BorC rder

Su&&lier Records

#alibration Records

Revision and #@ange rder Record

#ustomer #om&laints

!ualit' Assurance rocedure and Standard orm Registers

Document )ssue " Records " Transmittals

Training and !ualification Records

14.4.2 )ns&ection and Test Records or !# Records s@all be given to #lient at

com&letion of t@e &roGect.

14.8 Access and Securit'

14.8.1 All records are readil' retrievable and are stored in suc@ a manner as tominimie deterioration= damage or &ossible loss.

1' (DIBIT

.A’ - AYTB ISO 9001/200 erti"i!ate !opy

.B’ - AYTB Sa"ety Poli!y

.’ - AYTB Quality Poli!y

.’ - AYTB QA)Q Oraniation !hart *Typi!al%


R"!#"001 2.0 12-Jan-10 21 of 1