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QUALITY MANAGEMENT

SYSTEM DOCUMENT
QUALITY DETAIL PROCEDURE

DOC. NO : EJ/SSB/B11LQ/1.4.3/08
DATE

: 13/04/10

REV. NO

: 0

SAMPLE
INSPECTION AND TEST PLAN (ITP) PROCEDURE

PROVISION OF HOOK-UP AND COMMISSIONING SERVICES FOR B11 LIVING


QUARTERS MODULE AND HELIDECK

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

REVIEWED BY

MANAGER, COMMISSIONING

NO. :

APPROVED BY

PROJECT MANAGER

UNCONTROLLED
COPY

CONTROLLED COPY

RESPONSIBLE DEPARTMENT: HOOK-UP & COMMISSIONING


C : B11LQ /Sec.1.4.3 Inspection And Test Plan (ITP) Procedure

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QUALITY MANAGEMENT
SYSTEM DOCUMENT
QUALITY DETAIL PROCEDURE

DOC. NO : EJ/SSB/B11LQ/1.4.3/08
DATE

: 13/04/10

REV. NO

: 0

REVISION

PURPOSE OF ISSUE

DATE ISSUE

ISSUED BY

A
B
0

Issued for review


Re-issued for approval
Issued for Construction

31/03/2008
06/06/2008
07/06/2008

Hook-up and Commissioning


Hook-Up and Commissioning
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

C : B11LQ /Sec.1.4.3 Inspection And Test Plan (ITP) Procedure

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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
3.1
Procedure
3.2
Guideline

4 OF 10

4.0

RESPONSIBILITIES

5 OF 10

5.0

DEFINITION

5 OF 10

6.0

PROCEDURE FLOWCHART

6 OF 10

7.0

PROCEDURE DETAILS
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

7 OF 10

8.0

RECORDS

9 OF 10

9.0

ATTACHMENTS

10 OF 10

PERFORMANCE MEASUREMENT

10 OF 10

10.0

C : B11LQ /Sec.1.4.3 Inspection And Test Plan (ITP) Procedure

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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.
2.
3.
4.
5.

3.2

Procedure
Procedure
Procedure
Procedure
Procedure

Q.P.03-0
Q.P.05-0
Q.P.07-0
Q.P.08-0
.E.P.01-0

Corrective Action
Control of Monitoring & Measuring Devices
Control of Non-Conforming Materials/ Works
Material handling, storage, packing & delivery
Preliminary Project planing- Workpack Preparation

Guidelines
Guidelines
Guidelines
Guidelines
Guidelines
Guidelines
Guidelines
Guidelines
Guidelines
Guidelines

Guidelines:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Guideline
Guideline
Guideline
Guideline
Guideline
Guideline
Guideline
Guideline
Guideline
Guideline

Q.G.2-1
Q.G.2-2
Q.G.2-3
Q.G.2-4
Q.G.2-5
Q.G.2-6
Q.G.2-7
Q.G.2-8
Q.G.2-9
Q.G.2-10

C : B11LQ /Sec.1.4.3 Inspection And Test Plan (ITP) Procedure

on
on
on
on
on
on
on
on
on
on

Radiography Testing
Hydrostatic Testing
MPI Testing
Ultra- Sonic Testing
Visual Inspection
Mechanical Equipment Testing
Electrical Equipment Testing
DCS Testing
Alarm & Shutdown System Testing
Fire & Gas Detection System Testing

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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
To implement the ITP , monitoring adherence to
project procedures, maintain quality records, and
compile project final documentation

4. QA/QC Inspector

4. Commissioning Engineer

5.0

To implement the ITP as part of the commissioning


and hand-over activities.

DEFINITIONS
1

Inspection

Conformity evaluation by observation and judgement


accompanied as appropriate by measurement, testing or
gauging

Test

Determination of one or more characteristics according


to procedure

C : B11LQ /Sec.1.4.3 Inspection And Test Plan (ITP) Procedure

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6.0

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

START

RESPONSIBILITY

IDENTIFY INSPECTION & TEST


(IT) REQUIREMENTS

ACTION

Head of project (HOP)


QA/QC Engineer &
Commissioning Engineer
(CE)

1. Identify IT
requirements during
Workpack
development

QA/QC Engineer &


Commissioning Engineer
(CE)

1. Develop IT checklist
& plans for the
project

QA/QC Engineer & HRD

1. Identify &mobilize the


resources

QA/QC Inspector/
Commissioning Engineer

1. Record and evaluate


results
2. Rectify any NCR ASAP

QA/QC Inspector/
Commissioning Engineer

1. Approve record &


reports

HOD & Client Rep.

1. Review & approve


report final

DEVELOP IT CHECKLIST & PLAN

IDENTIFY & MOBILIZE


RESOURCES

IMPLEMENT IT PLAN

EVALUATE ITP RECORDS

OK

RE-DO

NO

YES
APPROVE IT RECORDS

FIND REVIEW & APPROVE


IT REPORTS

END

C : B11LQ /Sec.1.4.3 Inspection And Test Plan (ITP) Procedure

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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

7.3

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.

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.

C : B11LQ /Sec.1.4.3 Inspection And Test Plan (ITP) Procedure

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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

7.4.3

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 nonconformity, this will permit immediate recall and replacement of the
materials and re-works if necessary.

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.

C : B11LQ /Sec.1.4.3 Inspection And Test Plan (ITP) Procedure

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7.4.4

7.4.5

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.

Approval of IT Records
7.4.5.1

7.4.5.2

7.4.6

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.
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.

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:

8.0

*Clients term also known as the Final Documentation

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

C : B11LQ /Sec.1.4.3 Inspection And Test Plan (ITP) Procedure

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9.0

ATTACHMENTS:
Attachment 1

Attachment 2

Attachment 3

Attachment 4

Attachment 5

Attachment
Attachment
Attachment
Attachment
Attachment
Attachment

:
:
:
:
:
:

6
7
8
9
10
11

Attachment 12 :
Attachment 13 :
Attachment 14 :

ITP for Mechanical, Piping & Pipeline Work of Material Receiving, Storage
& Issuing Work
ITP for Welding Procedure Specification, Procedure Qualification and
Welder Qualification
ITP for Mechanical, Piping & Pipeline Work of Piping Fabrication &
Installation Work
ITP for Mechanical, Piping & Pipeline Work of Blasting, Painting, Wrapping
& Insulation Work
ITP for Mechanical, Piping & Pipeline Work of Mechanical Equipment
Installation
ITP for Mechanical, Piping & Pipeline Work of Pipe Laying Work
ITP for Instrument & Electrical Work of Above Ground Cable Laying Work
ITP for Instrument & Electrical Work of Underground Cable Laying Work
ITP for Instrument & Electrical Work of Termination of Cable
ITP for Instrument & Electrical Work of Equipment Installation
ITP for Instrument & Electrical Work of Loop Check & Precommissioning
Work
ITP for Instrument & Electrical Work of Calibration Work
ITP for Instrument & Electrical Work of Impulse Line and Air Tubing Work
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-

C : B11LQ /Sec.1.4.3 Inspection And Test Plan (ITP) Procedure

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