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1. PURPOSE
This documented procedure has been established and maintained by the organization
also refers to the work instruction and testing activities in order to verify that the specified
requirements for the product are met.
2. SCOPE
This procedure applies to (i) receiving inspection of raw materials/ consumables and
sub contracted products (ii) in-process inspection and (iii) final inspection of the product
manufactured by the unit.
3. RESPONSIBILITY
The quality control department is primary responsible for implementing this
procedure, while the production and maintenance departments have secondary responsibility.
4. GENERAL
The raw materials and consumables are ordered on reputed suppliers who are
inducted as per procedure QP-12. As per the industry practice, only the critical raw materials
are subject to inspection at the unit. The raw material test certificates are reviewed for
acceptance, where applicable. The conditions of packing and external damages, if any, are
verified at the receipt stage by the designated sections. If there is any problem while using
any raw materials and consumable during production, the same will be taken up with the
suppliers and the problem resolved.
The acceptance criteria and the person authorizing the release of product for
delivery to the customer are maintained
5. PROCEDURE
SI.NO
1
2
3
4
ACTIVITY
Receiving inspection of all raw materials as per incoming
material inspection plan QC/IP-01
In process inspection and testing as per in process
inspection plan QC/IP-02
Final Inspection and testing as per final inspection plan
QC/IP-03
Maintenance of inspection records for the above
6. RECORDS
Records relating to receiving, in- process, final inspection
RESPONSIBILITY
Quality Control
Quality Control/Production
Quality Control
Quality Control/ production
1.
PURPOSE
This documented procedure has been established and maintained for the identification,
verification, storage, protection, issue and maintenance of customer property.
2.
SCOPE
3.
RESPONSIBILITY
The stores and planning in-charge have primary responsibility in implementing this
procedure. The Engineering,marketing and production department have secondary
responsibility.
4.
SYSTEM DETAILS
ACTIVITY
RESPONSIBILITY
i)Assessment of the quality of customer property at the receipt Planning, QC & Stores
stage.
5)
Planning, QC ,Marketing
& Stores
Marketing, Planning, QC
& Stores
RECORDS
Receipt, issue & balance status of customer property
PURPOSE
This documented procedure has been established and maintained for identification of the
product.
2.
SCOPE
This procedure covers all drawings, materials & product during all the stages of
production
and finished product.
3.
RESPONSIBILITY
Engineering, quality control, stores, production and maintenance
4.
PROCEDURE
a, For identification and traceablity
ACTIVITY
RESPONSIBILITY
i)
Marketing
ii)
Identification of drawing no
Engineering
ii)
Quality Control/stores
iii)
Production
iv)
Production / QC / stores
v)
QC / Production / Despatch
vi)
Maintenance /Stores
5.
6.
RESPONSIBILITY
NATURE OF IDENTIFICATION
i.
Stores in-charge
ii.
Conforming product
raw materials
QC / Stores
QC
iv.
Work-in-Progress
Production
Tags, boards
v.
Quality Control
FORMS:
RECORDS:
Nil
Nil
1. PURPOSE
This documented procedure has been established and maintained to preserve the conformity
of product during internal processing and up to delivery to intended destination
2. SCOPE
This procedure applies to the preservation of all the products handled in stores, production
and dispatch area as applicable
3. RESPONSIBILITY
The production supervisors, quality control in charge and stores in-charge are responsible for
handling the product, for storage and preservation, quality control in- charge and stores incharge are responsible. Production in- charge is responsible for packaging and stores in-charge is
responsible for the delivery of the product.
4. SYSTEM DETAILS
Sl.No
RESPONSIBILTY
QC / Stores in-charge
Stores in-charge
Stores in-charge
4
5
5.
6.
ACTIVITY
FORMS:
RECORDS:
Nil
Registers maintained in various areas
B
1
RESPONSIBILITY
Concerned Section
/ QC
Concerned Section /
QC
Concerned Section /
M.R
QC/Production
QC/Production
QC/Production
Concerned Section
Head
2
3
6. FORMS
Nil
7.RECORDS
a) Corrective Actions taken on Non conformities
b) Preventive actions taken
Concerned Section
Head
Concerned Section
Head
M.R
M.R
b)
c)
e)
f)
g)
h)
i)
j)
k)
5.
ACTIVITY
Servicing is usually receiving service calls from customer through
e-mail, ,fax telephone ,letter etc. Enter the details in service register.
Assign the work to service personnel or service providers depending
upon the availability of service engineers, location of site, duration of
work to be carried out and priority.
Conduct monthly review meetings to assess the pending calls and
action taken.
Preparation of guide line erection check list and carry out erection of
ventilation system, dust extraction system at site as per the check list.
Preparation of guide line commissioning check list and carry out
commissioning of ventilation system, dust extraction system at site as
per the check list.
Monitor the service progress made at site through service log sheet
Consult Engineering/ head- technical in the event of complicated
problems.
Ensure the usage of calibrated monitoring and measuring equipment at
site.
Ensure the completeness of work as planned and obtain the completion
report from customer. If not agreed by customer record the shortfalls.
Take appropriate corrective/preventive action for such cases.
Prepare and maintain service report for every site indicating the nature
of problems, service carried out, availability of spares at site including
any follow up action required.
FORMS/DOCUMENTS
1. Guide line manuals for erection, commissioning and checking
2. Activity chart
6. RECORDS:
RESPONSI
BILTY
Servicing
Servicing
Servicing
Servicing
Servicing
Servicing
Servicing/Headengineering
Servicing
Servicing
Servicing
Flow Chart
Flow Chart for T & C Procedure
START
Approval
Approval
Approval
N
Inspection passed
Y
Request for witness (RFWT) shall be submitted by (T&C to be
carried out and draft record to be attached with the relevant RFWT.)
T&C Works
- witnessed
N
T & C passed
Y
(E) T & C certificate and test record
shall be submitted.
-
to be issued
END
Page 1 of 9
WATER SYSTEM
iii) Pressure Tests of piped water at pressure specified in the contract documents/agreed and
same shall be recorded in appropriate format. All Safety valves/gauges etc shall have to be
effectively isolated/removed for this procedure. Unless otherwise specified /agreed, the
duration of hydro test shall be 12 hours. Any fault discovered during such tests shall be at once
remedied and the test reapplied until the section under test is considered sound.
Page 3 of 9
iv) All safety equipment shall be tested at their own design working pressure.
v) All Water Tanks to be filled with water and shall remain filled for at least 24 hours during which
all joints shall be carefully examined. Any defect shall be rectified immediately and the test
repeated.
vi) Charge the system with water by filling from the bottom upwards forcing the air to high points
for venting to atmosphere
AIR DISTRIBUTION SYSTEM
vii) Temporary filter media shall be used where building work is still in progress during T & C, and
replaced with clean filters for final measurements of flow rates;
viii) Extraction systems should not be run whilst building work is in progress and dirt is present .
ix) The following to be checked for cleanliness
(a) air intake screens and louvres;
(b) fan and other equipment chambers;
(c) f1oor gulley and all drainage traps;
(d) fan internals;
(e) washer tanks;
(f) eliminators;
(g) dampers and linkages;
(h) ducting and other airways;
(i) sensing elements; and
(j) terminal units.
x) Check:
(a) that turning vanes, thermal insulation, acoustic linings, and sensing elements have been fitted
and are undamaged;
(b) filters, silencers, fire dampers, volume control dampers etc., are installed correctly in relation
to air flow;
(c) the damper free-movement, clearances seating pinning to damper spindles, position of blades
with respect to quadrant indication, relative positions of blades in multi-leaf dampers;
(d) the control linkages on motorized dampers for alignment, rigidity, lubrication and free
movement without slackness;
(e) that dampers throughout the system are secured in open/close position, as desired, with
damper actuators locked;
(f) the free movement of fire dampers together with the location of, access to and fitting of
fusible link assembly; all fire dampers are finally secured in open position;
(g) that all adjustable louvers are set without deflection, i.e. normal to face of grille. Adjustable
cones on diffusers are set either all in the fully up or all in the fully down position; and
(h) that test holes are provided at strategic points for the measurement of branch and total air
volume flow.
xi) Visual Checks for Air tightness
Check:
(a) the builder's work for ducts and shafts, if applicable, are sealed;
(b) access doors to plant equipment are sealed around the whole periphery;
(c) ductwork joints, including flexible couplings are air tight;
(d) inspection covers are fitted;
(e) plugs or covers for test holes are fitted.
Page 4 of 9
;
(b) check that the bearings and motor temperature remain steady, that no noise or vibration
develops and that no bolts or fixing works is loose;
(c) vent all high points from time to time. When possible the medium should be heated to
maximum permissible levels to assist in removing air from the heating system;
(d) adjust the gland nuts of the pump glands to give the correct drip rate; (not applicable to
mechanical seals.)
iv) Water circuit to be balanced to obtain the correct flows as required by means of regulating
valves provided.
II) Air-distribution system
i)
Initial running of Electrically driven Fan set
(a) wherever possible the first start of any motor should be on light load;
(b) with centrifugal fan sets this will normally be achieved by limiting the mass flow by operation of
the main damper
ii)On activating the motor starter, check :
(a) that the direction and speed of rotation of motor shaft are correct;
(b) that the motor, drive and fan are free from vibration or undue noise;
(c) the motor starting current;
(d) the motor running current on all phases;
(e) that there is no sparking at commutator or slip rings;
(f) that there is no overheating of motor
(g) that there is no seepage of lubricant from the housing;
(h) that there is no overheating of the bearings;
(i) that oil rings are running freely;
(j) note the reduced speed rev/s and the motor running current on multi-speed motors;
(k) the rev/s of fan and motor; and
(l) visually / audibly check the performance of fan belts in case of abnormal vibration
Motor should run on light load until above-mentioned conditions are satisfied
ii)
Running in period
(a) after a short run at normal load (a few minutes run will normally suffice) flexible
connections to terminal units, etc., and terminal filters shall be restored to position;
(b) subsequently a running-in period shall be sustained until the fan set is in a reliable
continuous running condition; and
(c) the regulation of the air distribution system shall be delayed until the running-in period
(which may last for a few days) is completed satisfactorily.
iii)
The air flows to be balanced as per specified /agreed procedure.
III) Accoustic Tests
Site ambient noise levels shall be recorded prior to the commencement of tests. In order to minimise
background noise, external noise levels shall be taken at night or at an agreed time.
Checking Procedures
Page 7 of 9
Before noise level checks are undertaken, the following checks shall be carried out:(a) All systems are dynamically tested and balanced as per contract specification (check balancing
certificates)
(b) All building works are completed and areas under test are vacated or under control for carrying
out the noise test;
(c) All other noise generating activities and equipment are stopped.
Where circumstances require certain equipment to be kept operational, then this shall be
clearly indicated on the final test data sheets;
Sound meter tests of the system shall include sound pressure readings relating to the NC levels in
each room where stated in the Contract Drawings or in the Particular Specification.
In cases where measured noise levels are in excess of the specified criteria, additional checks shall be
carried out to identify the sources of excessive noise generation.
IV) Energy efficiency Equipment & system
T & C should be carried out before the handover of projects in order to verify that the energy
efficiency performance of the equipment and system, based on approved technical documents and
calculations , can be adequately achieved.
Minimum working efficiency of fans, pumps and motors to be checked;
Full set of calibrated instruments should be provided for taking record on design temperature,
volumetric and mass flowrate and pressure of air and water at relevant locations, air relative
humidity, equipment operating current and voltage and overall power input to the HVAC system;
Measure relevant system performance parameters such as air and water temperature, flowrate,
pressure, relative humidity, on/off position of dampers and valves and so on. Based on those
measured data and valid scientific equations to verify if the attained energy efficiency performance
of the equipment and system is acceptable according to the Particular Specification;
Record the operating speeds of the equipment (i.e. driving speed of motor and driven speed of fan
wheel, rotor or impeller) indicated on the nameplates, drawings or measured by speed-measuring
device
Page 8 of 9
Perform visual and audible checks for any apparent rough operation of the equipment or any
defective bearings, misalignment
Measure and record vibration at bearings of driving and driven components in horizontal, vertical
and, if possible, axial directions. There should be at least one axial measurement for each rotating
component (fan motor, pump motor)
Page 9 of 9