FPA-G-0001/A

FREMANTLE PORTS KWINANA BULK TERMINAL GRAB SHIP UNLOADER PROJECT

Guidelines for the Preparation of Inspection and Test Plans. FPA-G-0001/A
MARCH 2004

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FPA-G-0001/A

Contents 1.0 2.0 3.0 4.0 4.1 4.2 4.3 4.4 INTRODUCTION AND SCOPE CODES, STANDARDS, PROJECT SPECIFICATIONS AND REFERENCES DEFINITIONS REQUIREMENTS General ITP Review ITP Intervention Points Inspection And Test Performance Minimum Requirements for ITPs Use of Inspection & Surveillance Points

Page 1 1 1 1 1 2 2 2 A1-A2 B1-B4

Appendix A Appendix B

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1.0

INTRODUCTION AND SCOPE These Guidelines are issued to advise Contractors/Subcontractors of the requirements for Inspection and Test plans and the inspection and testing of equipment/materials provided to Fremantle Ports (FPs) for the Kwinana Bulk Terminal KBB2 Grab Ship Unloader Project.

2.0

CODES, STANDARDS, PROJECT SPECIFICATIONS AND REFERENCES The requirements of AS/NZS ISO 9001/2/3 (as appropriate): 1994 Quality Systems Model for quality assurance in production, installation and servicing or an equivalent standard shall be complied with.

3.0

DEFINITIONS These shall be as outlined in the General Conditions of Contract, plus the following: AINDT means the Australian Institute of Non-Destructive Testing Manufacturer's Data Report (MDR) means a volume or number of volumes compiled by Suppliers, containing records, certification and objective evidence of compliance with requirements appertaining to material or equipment for the Project.

4.0

REQUIREMENTS For each separable fabrication or construction portion of the Work, the Contractor shall provide an Inspection Test Plan (ITP) in accordance with the Contract Document Requirements. ITP format shall be in accordance with that shown in Attachment 1 (Page 1) ITP Cover Sheet and Attachment 2 (Page 2) ITP Continuation/Activity Sheet and shall contain the minimum requirements identified in Appendix A.

4.1

General ITPs shall identify, in Contract detail schedule sequence, those activities where formal intervention is deemed necessary to prevent the Work progressing beyond a point where failure to implement such control may prejudice the integrity of the Work. ITPs shall contain provision for the Principal and Certifying Authority to nominate inspection and surveillance points such as Hold, Monitor, Witness, Dimension, Visual, Review, Send against activities. These inspection and surveillance point activities are defined in Appendix B. The ITPs shall identify:

Project Identification (project name, PO/Contract job number) Work scope description Activity Number Verification Activity (e.g. Test, Inspection, Review)

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4.2

Applicable Standards Codes and Specifications Acceptance Criteria Verifying Document (e.g. Certificate, Report, Chart) Extent of intervention by Principal/Contractor and/or its Agents Type of intervention by each party (e.g. Hold, Witness, Review, Approve) Sign-off for each activity

ITP Review The Contractor shall submit ITPs to the Principal for review and approval prior to the commencement of affected Work and shall ensure that the Principals review comments, including Principal and Certifying Authority intervention points, are incorporated in the ITPs re-submitted to the Principal for acceptance.

4.3

ITP Intervention Points The Contractor/Subcontractor shall not progress affected Work beyond ITP intervention points without Principal approval nor without due notification of an impending ITP activity which requires Principal/Contractor and/or Certifying Authority attendance.

4.4

Inspection And Test Performance The Contractor shall ensure that all the inspection, test and verification requirements nominated in the Contract specifications (including destructive and non-destructive testing) are: addressed in Contractors ITPs; conducted in accordance with all Contract Specification requirements, in number, type and form; recorded, documented, authorized and established in the Manufacturers Data Report.

The Contractor shall also ensure that work is not undertaken without the required intervention and/or without timely notification to the Principal, or its Agents. Non-destructive testing personnel shall be currently qualified under the AINDT certification scheme, or under a comparable scheme acceptable to the Principal, for the category of non-destructive examination being undertaken.

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FPA-G-0001/A Appendix A Page Number A.1

APPENDIX A MINIMUM REQUIREMENTS FOR ITPs

ITPs are required to show (in steps), all the stages of development of goods or service from start to completion and follows progression of the planning schedule for the work. Each step should identify: The various checks or tests that are planned to take place; The in-house control procedures that will be used; The applicable codes and standards used; The documents that will be provided to verify fulfillment of requirements.

FORMAT A typical format for an ITP is provided in Attachments 1 and 2 to this Specification. A different format is acceptable, provided it contains the following: Cover Sheet The front page of the ITP containing: Project name, PO or Contract number; Contractors/Subcontractors name and location; Unique ITP number and revision status; Description of work; Acceptance criteria (applicable codes, standards, specifications and other documents); Legend to show the interpretation of any abbreviations used; Approvals

Continuation/Activity Sheet(s) A page or series of pages containing a description of all activities required from start to completion of work, listed and numbered in steps. Each step to have space provided to identify: location of activity, e.g. Office, Workshop or Sub-contractors;

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FPA-G-0001/A Appendix A Page Number A.2

the controlling document reference, e.g. standard, specification or procedure; acceptance Criteria to be used, e.g. ASME V or API 6D etc; the certifying or verification document reference, (usually the document which will be included in a Manufacturers Data Report); Inspection/Surveillance Activity (witness, monitor or hold points) by the Contractor, Principal and Certification Authority, with space for verification.

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FPA-G-0001/A Appendix B Page Number B.1

APPENDIX B USE OF INSPECTION AND SURVEILLANCE POINTS Hold (H): Sufficient holds must be used to ensure that product or service does not progress beyond a point where further work (without the required inspection/surveillance) may render the produce or service unacceptable. Hold points are: only used when it is imperative that specified inspection takes place: always accompanied by the required inspection activity(s), e.g. V, R, D, or W or a combination of several; instructions to the contractor that work cannot proceed until inspection takes place or the Principal grants a concession.

Monitor (M): Only used when a repetitious process or multiple similar materials are being inspected. Provides a guide to the inspector on the extent of inspection required and is always accompanied by the: inspection activity(s) required, e.g. V, R, or D or a combination; percentage (%) of the process or materials to be inspected, e.g. 50%

Witness (W): Used to identify specific tests or inspections desired to be witnessed by the Principal, an approved third party or Certifying Authority. Used to secure an opportunity for the inspector to watch or inspect a stage of the process or work for which it may be difficult to obtain timely, conclusive evidence of conformance to specifications. A witness point requires the Contractor to advise the time and location for inspection but does not require a hold to the process or production until the Principal inspector is present. Dimension (D): Instructs the inspector to physically check the dimensions of a product. A percentage accompanying the D, e.g. D 25% means: for multiple products - the number of items to be dimensionally checked; for a single product - the extent of dimensional checks required. Visual (V): Instructs the inspector to visually inspect the Product or process. A percentage accompanying the V applies to either single or multiple products in the same manner as for dimensional inspection. Review (R): Instructs the inspector to physically examine all quality records that are applicable to the inspection or test detailed and to endorse the records with his/her personal stamp or signature. Send (S): Identifies for the Contractor and inspector that verification documentation is required by the Principal for the test or inspection that has been identified. Such documentation is always required as part of the MDR.

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FPA-G-0001/A Appendix B Page Number B.3

ATTACHMENT 1 PURCHASER: PO/CONTRACT NO: DOCUMENT NO: __________________________________________ __________________________________________ __________________________________________ INSPECTION AND TEST PLAN PROJECT/LOCATION: DESCRIPTION OF WORK: REVISION:

Page 1 of 2 ________________________________________ ________________________________________ ________________________________________ REVISION STATUS REV DATE APPROVAL

INSPECTION/SURVEILLANCE KEY INSPECTION ACTIVITY DEFINITION

APPLICABLE CODES/STANDARDS All Codes & Standards are the latest Editions unless otherwise noted example: AS-1210, ASTM A 193, AS/NZS ISO9001

ABBREVIATIONS/DEFINITIONS Abbreviations used to describe control/verifying document example: MC P PO WPQ

(H)

Hold

Work must not proceed unless inspection activity is carried out. Always accompanied by V,R,D or W Monitor on a random basis always accompanied by V,R or D Witness by: Principal/Contractor, Third Party or Certifying Authority Dimensional check required Visual Inspection Examine/Endorse records Send verifying documents for approval

Material Certificates Procedure Purchase Order Weld Procedure Qual.

(M)

Monitor

(W)

Witness

(D) (V) (R) (S)

Dimension Visual Review Send

APPROVALS Prepared By:

Date: / /Approved By:

Date: / /

Principal Approval

Date: / /

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FPA-G-0001/A Appendix B Page Number B.4

ATTACHMENT 2 Page 2 of 2 INSPECTION AND TEST PLAN Document No: Revision No: Controlling Document Activity No. Activity Description Location Standard/Drg Specification Reference Clause or Section Acceptance Criteria Certifying Verifying Document Contractor Initial Inspection/Surveillance Activity Principal Initial Certifying Authority Initial

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