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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Contents

Page

1.0

INTRODUCTION AND SCOPE

2.0

CODES, STANDARDS, PROJECT SPECIFICATIONS AND

REFERENCES

3.0

DEFINITIONS

4.0

REQUIREMENTS

4.1

General

4.2

ITP Review

4.3

ITP Intervention Points

4.4

Inspection And Test Performance

Appendix A

Minimum Requirements for ITPs

Appendix B

Use of Inspection & Surveillance Points

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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:

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Project Identification (project name, PO/Contract job number)

Work scope description

Activity Number

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4.2

Verification Activity (e.g. Test, Inspection, Review)

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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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:

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Appendix A
Page Number A.2

location of activity, e.g. Office, Workshop or Sub-contractors;

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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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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Appendix B
Page Number B.3

ATTACHMENT 1
PURCHASER:
PO/CONTRACT NO:
DOCUMENT NO:

Page 1 of 2
__________________________________________
__________________________________________
__________________________________________

INSPECTION/SURVEILLANCE KEY

INSPECTION AND TEST PLAN

PROJECT/LOCATION:
DESCRIPTION OF WORK:
REVISION:

APPLICABLE CODES/STANDARDS

ABBREVIATIONS/DEFINITIONS

INSPECTION ACTIVITY

DEFINITION

All Codes & Standards are the latest Editions

unless otherwise noted

Abbreviations used to describe

control/verifying document

(H)

Work must not proceed unless

inspection activity is carried out.
Always accompanied by V,R,D or
W

example:
AS-1210,
ASTM A 193,
AS/NZS ISO9001

example:
MC
P
PO
WPQ

Hold

(M)

Monitor

Monitor on a random basis

always accompanied by V,R or D

(W)

Witness

Witness by: Principal/Contractor,

Third Party or Certifying
Authority

(D)

Dimension

Dimensional check required

(V)

Visual

Visual Inspection

(R)

Review

Examine/Endorse records

(S)

Send

Send verifying documents for

approval

APPROVALS
Prepared By:

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Date: / /Approved By:

________________________________________
________________________________________
________________________________________

Date: / /

REVISION STATUS
REV

DATE

Material Certificates
Procedure
Purchase Order
Weld Procedure Qual.

Principal Approval

Date: / /

APPROVAL

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Appendix B
Page Number B.4

ATTACHMENT 2
Page 2 of 2
INSPECTION AND TEST PLAN
Document No:
Revision No:
Controlling Document
Activity
No.

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Activity
Description

Location

Standard/Drg
Specification

Reference
Clause or
Section

Inspection/Surveillance Activity
Acceptance
Criteria

Certifying
Verifying
Document

Contractor

Initial

Principal

Initial

Certifying
Authority

Initial