INSPODE PHILIPPINES, INC.

QUALITY ASSURANCE MANUAL

Date Issued:

March 11, 2014

Prepared By:

___________________________________________________

Approved By:

__________________________________________________

Table of Contents
Section
1.0
2.0
3.0
3.1
3.2
4.0
5.0 A / B
6.0 A / B
7.0 A / B
8.0 A / B
9.0 A / B
10.0 A / B
11.0 A / B
12.0 A / B
13.0 A / B
14.0 A / B
15.0 A / B
16.0 A / B
17.0 A / B
18.0
19.0

Element
Quality Policy.
Organizational Structure.
Quality Program.
Inspode Organizational Chart.
Inspode Contract Flow Chart.
Instructions, Procedures and Drawings.
Welders Trade Tests Procedures.
Pipefitters Trade Tests Procedures.
Insulators Trade Tests Procedures.
Millwrights Trade Tests Procedures.
Structural Steel Erectors Trade Tests Procedures.
Riggers Trade Tests Procedures.
Scaffolders Trade Tests Procedures.
Plumbers Trade Tests Procedures.
Low Voltage / High Voltage Electricians Trade Tests Procedures.
Instrument Technicians' Trade Tests Procedures.
Heavy Equipment Operators' Trade Tests Procedures.
Crane Operators' Trade Tests Procedures.
Blasters / Painters' Trade Tests Procedures.
Self-Audit Checklist.
Corrective and Preventive Action.

Appendix
A.
B.
C.
D
E.
F.

Welders Trade Test Checklist.

WR-1 CS 3 XXS SMAW.
WR-1 CS 3 XXS GTAW.
WR-1 SS 2 Sch 80 GTAW.
Radiographic Testing Report.
Inspode Philippines Trade Test Certificate ( Sample Only ).

QUALITY ASSURANCE MANUAL OF INSPODE PHILIPPINES, INC. TRADE TEST FACILITY

FOR WELDERS AND OTHER SKILLED CRAFTS CANDIDATES MOBILIZED
FOR CLIENTS OVERSEAS PROJECTS.
This Quality Assurance Manual shall establish the minimum requirements of the Inspode Philippines, Inc.
Trade Test Facility to test and qualify Welders and other Skilled Crafts Candidates mobilized for Clients
Overseas Projects.
1.0. QUALITY POLICY.
The purpose of this manual is to document the Inspode Philippines, Inc. quality system, to instruct and
guide employees whose actions affect product and service quality and to inform the Inspode Philippines,
Inc. Clients what controls are implemented to assure consistent delivery of product and service quality.
The Quality Policy of Inspode Philippines, Inc. is founded on the basis that we will meet all agreed
Clients requirement.
We strive for continuous improvement in our quality systems and will continuously and consistently meet
the objectives of Inspode Philippines, Inc., by:

Supplying products and services that will meet or exceed our Clients requirements.
Providing products and services that will result in Clients satisfaction.
Continuously training and upgrading of all our Staff.
Developing a dependable vendor base assessment, qualification and monitoring in terms of prompt and
quality deliveries.
Periodically reviewing and assessing this Quality Assurance Manual to assure its suitability and
relevance to meet the requirements of Inspode Philippines, Inc.
By meeting our objectives defined within this Quality Assurance Manual we will be able to:
Consistently provide defect-free products and services.
Extend Client satisfaction by:
a.
b.
c.
d.

On-time deliveries.
Meeting all contract requirements.
Providing consistent product quality.
Exceptional service quality.

2.0. ORGANIZATIONAL STRUCTURE.

The BOARD OF DIRECTORS of Inspode Philippines, Inc. aunthorzes the Implementation of the
Policies and Procedures contained in this Quality Assurance Manual.
The President:

Formulates / implements strategic plans to guide / oversee complete operation of the business.

Forms / recruits / sets goals / leads / guides / directs / motivates / evaluates work of Staff.

Creates marketing strategies researches / develops current and new strategies.

Adheres to strict quality assurance and Client satisfaction.

Manages procurement process and supply base efficiently and effectively.

Ensures continuous generation of revenues.

Reviews performance to ensure wiorking within budget and success of business.

Performs public relations functions / liaises with government agencies / technical organiztions.

 The Quality Assurance Officer:

Delegated with the authority and responsibility to establish, document and administer the
necessary guidelines, requirements, and controls to assure compliance to and effective
implementation of the intent of this Quality Assurance Manual.

Reviews and initials Trade Test Certificates for the Presidents approval.

The Marketing Officer:

Sources and communicates directly with potential Clients to understand and to determine their
requirements, specifications and Standards for Skilled Crafts Technical Testing services.

Coordinates with Clients on the correct interpretation of specifications, whether verbal or written, for
purposes of contract review by the General Management to insure that Clients requirements are
adequately defined and documented and have been understood.

Receives instructions from the President on contract pricing.

Monitors Client satisfaction.

The Purchasing Officer:

Develops and assesses its vendors and purchases only from those which satisfies Inspode
Philippines Inc. requirements in terms of quality, costs and delivery schedules.

Prepares all the purchasing documents completely describing ordered products,reference

applicable standards and quality requirements.
The President reviews and approves all purchasing documents before release.

Upon arrival of the purchased items, the Purchasing Officer shall advise immediately the President
or the Operations Manager, the latter two having sole authority to sign for the receipt of any
incoming purchased items.

Collects all Delivery Documents, including Mill Certificates, and submits these to the Accountant, for
payment / document filing.

Establishes inventory leadtimes and monitors vendors' quality performance.

The Accountant:
The functions are:

Payroll.
General Ledger.
Cash / Bank Reconciliation.
Account Receivables / Payables.
BIR Compliance / Payment of Taxes.
Remittances to SSS / Philhealth / Pag-Ibig.
Government Reportorial / Securing Business Permits / SEC

The Secretary:
The functions are:

Information Technology.
Human Resources / Administration.

Prepares Trade Test Certificates.

Handles Confidential / Sensitive Documents.

The Operations Manager:

Shall have all the special and pertinent updated information necessary to Trade Test a Clients
Skilled Crafts, such as special processes, dimensional requirements, special materials or specific
blueprint requirements

Reviews information prior to new and duplicate job order acceptance.

Coordinates all efforts in Trade Testing, safely, productively and profitably, within schedule,
complying to all applicable standards and Client requirements.

Ensures all equipment, consumables, materials and tools are be clearly identified at all times.

Gages Assessors' expertise, and if required, conducts skills training.

Ensures that every Trade Test Candidate understands what is expected.

Reviews and initials all Trade Tests Checklist ( see Appendix A ), Trade Test Certificates prior to
approval by the President.

Prepared and carries out a schedule of periodic inspection, repair and maintenance of tools and
equipment

Closely monitors quality and inventory level of all consummables and triggers action for any
deviation observed.

3.0. QUALITY PROGRAM.

Documentation.
The Quality Program is documented within this manual and may be supported at any point by desk or
work instructions that may be selected to increase control of a quality function. Desk or work instructions
can originate from any Stafff:

From the Quality Assurance Officer, for rectification of observed deviation from accepted standard.
From the Marketing Officer, for any revision on the Trade Test Module as instructed by the Client.
From the Purchasing Officer, for alteration or substitution to non-available procured items
From the Operations Manager, for changes in Trade Test Modules due to abnormalities in the
operations.
From the Accountant, for items not meeting the budget.

All desk or work instructions shall be approved by the President.

Planning.
The Quality Program is planned to control products and services from the requirements of a Clients
order to include procurement practices, receipt / inspection of vendor material, Trade Test procedure and
storage to the eventual shipment of an article to our customer.
Education and Training.
Employees are educated and trained, as necessary, to assure that suitable proficiency is achieved and
maintained throughout our Quality Assurance systems.
There are two categories of education and training.

Training is performed as "On the Job Training", the technical aspect, to specifically target competency on
the job under the direct supervision of the President. Procedural changes are implemented by training of
any individual(s) affected by the change.
The focus of the general education and training to inculcate all our staff on the philosophy of Inspode; our
vision, mission, beliefs, the high level guiding principles of Inspode Philippines, Inc.
Everything else will operate under these high fundations for a system of belief of Inspode Philippines,
Inc.

4.0. INSTRUCTIONS, PROCEDURES AND DRAWINGS

A. The Facility shall operate an internal Quality Assurance System.
1. The Facility shall have a well-defined Organizational Structure, stating the operational and functional
duties and responsibilities, and job descriptions.
2. The Facility shall have a Quality Assurance System that shall enable it to maintain the capability to
perform satisfactorily the technical functions for Trade Testing of Welders and other Skilled Crafts.
3. A documented Quality Assurance Manual shall be available for use by the Facilitys Staff for the purpose
of maintaining quality control.
4. Arrangements for timely feedback and corrective actions, whenever non-conformances are detected,
shall be in place.
5. Procedures for dealing with technical complaints shall be included.
B. The Facility shall have the Personnel with the necessary education, training, technical knowledge
and experience for their functions.
1. The Welding Assessors shall be Certified Welding Inspectors capable of administering and assessing
the required Welders Qualification Tests. They shall also be full-time employees of the Facility.
2. The Staff shall not be under undue inducement that might influence their judgment or results of their
work.
3. The Staff shall be aware of both the extent and limitations of their areas of responsibility for the technical
operation of the Facility.
4. An Operations Manager shall be designated who has the over-all responsibility for the technical
operations of the Facility.
5. There shall be provisions for verifiable compliance to the quality control requirements by the
Radiographic Testing Company. These shall include, among others, qualification and certification of the
RT Companys personnel according to ASNT SNT-TC-1A, RT Level II.
C. The Facility shall have sufficient welding equipment, to adequately and successfully Trade Test and
qualify Welders and other Skilled Crafts.
1. The welding equipment to be used for qualification of Welders shall be designed for the process to be
used and be capable of providing the full range of parameters specified in the Welding Procedure
Specifications.

For GTAW and SMAW 300 AMP, DC, Constant Current,

100% Duty Cycle

2. All equipment shall be maintained regularly to provide steady electrical and mechanical characteristics
required for successful welding of the Test Coupons.
3. Machine controls or functions to change or adjust parameters shall be fully operational.
4. All equipment shall be properly maintained to ensure protection of the coil / capacitors / transformers /
rectifiers from corrosion due to grinding dust and other causes of deterioration.
5. Welding cables to be used for the grounds and electrode holders shall be size 2/0 minimum.
6. Splice / joint in the welding cables shall not be allowed.

7. The Facility shall have all items of measuring and testing tools for the correct performance of the welding
equipment.
8. Welding power supply systems shall be calibrated monthly to show correlation of volt-amp meter
readings vs. actual test meter values by a discrepancy of 5% maximum.
9. Any item of the equipment which has been subject to overloading or mishandling, or which gives suspect
results, or has been shown by calibration, or otherwise to be defective, shall be taken out of service and
clearly labeled until it has been repaired and then shown by test or calibration to be performing its
functions satisfactorily.
10. A red tag indicating the date of the last calibration shall be attached to the equipment requiring
calibration, and shall not be used.
11. When necessary, welding equipment shall be subjected to in-service checks between regular recalibrations, if the equipment shows signs of malfunctioning.
12. Records shall be maintained of the equipment, which shall include:

The name of the equipment.

Manufacturers name, type identification and serial number.
Date of last calibration and calibration records.
Details of maintenance.
Manufacturers operating manuals.
Date of next scheduled calibration.

D. All Base Metals used for qualification testing shall be obtained and maintained with rigid Quality
Control.
1. Certified Mill Reports shall be obtained and kept on file representing all Test Coupons Base Metal.
2. Base Metal Test Coupons shall be permanently marked with metal punch to allow traceability to the
Welders and Mill Test Reports.
3. Test Coupons shall be prepared in accordance with all the requirements of the Welding Procedure
Specifications and test requirements.
4. Upon completion and passing the VT, the Test Coupons shall be sent for RT, not later than the following
working day.
5. The radiographs and RT results shall be submitted to Client for review the next following working day,
after receipt of the Test Coupons by the RT Company. .
6. Upon completion of all testing, the Test Coupons shall be stored by the Facility for 1 month, in such a
manner that they will be free from contamination.
7. At all stages of handling, preparation, welding, testing and storing, the system for identification shall be
applied, through documentation and metal punch marking, to ensure that there can be no confusion
regarding the identity of the Test Coupons and the results of the tests made.
8. At all stages, precautions shall be taken to prevent damage to the Test Coupons, which would invalidate
the results contamination, corrosion and stress.
9. There shall be clear documentations for receipt, retention and disposal of Test Coupons.
10. The Facility shall retain on record, all original documents, data, calibration logs, and final test reports,
and shall contain sufficient information to permit satisfactory repetition of the tests.

E. Welding Electrodes and Filler Wires shall conform to the test requirements.
1.

The Facility shall furnish certification that all the Welding Electrodes and Filler Wires conform to the
requirements of classification and size.

2.

All Welding Electrodes and Filler Wires that have been removed from the package shall be protected
and stored so that the welding properties are not affected.

3.

Welding Electrodes and Filler Wires shall be dry and in suitable condition for use.

4.

ER70S-2 Filler Wires showing any sign of deterioration shall not be used.

5.

All 6010 Welding Electrodes shall not be preheated.

6.

All 7018 Welding Electrodes shall be purchased in hermetically sealed containers. Immediately after
opening, the Welding Electrodes shall be stored in ovens held at a temperature of at least 120C.

7.

All Welding Electrodes and ER70S-2 Filler Wires that have been wet shall not be used.

8.

All Welding Electrodes exposed to the atmosphere or stored in the ovens shall not be used the next day.

F. The Welding Environment in which the Trade Tests are undertaken shall not be such as to invalidate
or adversely affect the test results.
1. The Welding Booths shall have adequate ventilation / illumination and shall be protected from conditions
such as excessive dust, moisture, draft, vibration and wind velocity.
2. There shall be sufficient space in each Welding Booth, of 2 meters x 1.5 meters, to allow the Welders
sufficient access to perform the Trade Test comfortably and safely.
3. A separate grinding space with Benches and Bench Vises, far from the Welding Booth, shall be provided
for Test Coupons preparation.
4. Each Welding Booth shall have a workable Test Stand for the Welder to position the Test Coupon at
least effort.
5. Adequate measures shall be taken to ensure good housekeeping in the Facility.
G. The Facility shall have adequate Welding Gages and Measuring Tools for correct performance of the
Trade Tests.
1. The Facility shall have the following Welding Gages and Measuring tools:

Vernier Caliper
Letter Metal Punch
Hi-Lo Gage
Telescopic Inspection Mirror
Illumination Light
Temperature Crayons
150-mm Machinistss Rule
Precision Tape
Magnifying Lens
Bridgecam Welding Gage
Radiograph Viewer

2. The Facilitys Welding Assessor shall frequently perform inspection using these tools.

H. The Facility shall have adequate Tools and Supplies to achieve uninterrupted Trade Tests.
1. The Facility shall have adequate Tools and Supplies of the following:

Welding Aprons
Welding Masks
Welding Gloves, long
Dark Lens, Shade 12
Clear Lens
Argon Gas
6010 Welding Electrodes 2.4 / 3.2 mm
7018 Welding Electrodes 2.4 / 3.2 / 4.0 mm
ER70S-2 Filler Wires 2.4 / 3.2 / 4.0 mm
ER 309 Filler Wires 2.4 / 3.2 mm
Tungsten Electrodes 2.4 mm
Electrode Holder Assemblies
Ground Clamp Assemblies
TIG Torch Assemblies
Argon Gas Flowmeters, Hoses and Clamps
Ceramic Cups Size 12
Collets and Collet Bodies 2.4 mm
Portable Disc Grinders / Cutters with Guards
Cutting / Grinding Discs, 4
Tri-Squares 300mm
Steel Squares 300mm
Steel Brushes
Ballpeen Hammers
Pliers / Tongs
Files Bastard Cut
Files Half-Round
Files Round
Chipping Hammers
Soft Stones

2. The Welding Assessor shall ensure usability of the Tools and Supplies.
I. The Facility shall follow appropriate Safety and Health practices.
1. Safety regulations and workplace hazards / risks control practices and procedures, according to OHSA
standards, shall be monitored and complied with.
2. Use of PPE at all times Welding Masks / Welding Aprons / Welding Gloves / Safety Shoes shall be
strictly enforced.
3. Face masks shall be required in stainless steel welding which causes Hexavalent Chromium.
J. On-Site Assessment of the Trade Test Facility shall be conducted to demonstrate the capacity and
capability to conduct the required testing and qualification functions.
1. Assessment Guide and Checklist shall be used in performing an Assessment. These documents shall
ensure that Assessments are conducted as uniformly and completely as possible.
2. The Assessment shall involve:
a. An entry briefing with Operations Management
b. Review of Quality Assurance System Manual
c. Interviews with the Staff

d. Observations of selected Tests

e. Examination of Equipment and Calibration Records
f. An exit briefing of Examiner findings
3. The objective of an Assessment shall be to establish whether the Facility complies with the requirements
set forth in this procedure.
4. The Examiners may provide advice in response to questions or on the basis of observations to provide
help to improve the Facilitys potential of being in compliance.
5. At the conclusion of the Assessment, the Examiner shall prepare a report of findings, identifying
deficiencies ( i.e., deviations from the criteria in this procedure ), which, in the opinion of the Examiners,
the Facility must correct.
6. After the exit briefing with the Facility Operations Manager, the Facility Operations Manager shall sign
the Deficiency Report.
7. The Facility shall be requested to rectify the deficiency within one month of the date of the exit briefing.
5.0 - A. CLIENTS WELDERS WRITTEN EXAMINATIONS.
To be finished in two ( 2 ) hours.
1. Enumerate welding safety practices ( List at least 10 ).
2. Enumerate Pipe Welder specific duties ( List at least 10 ).
3. What is P-1 base metal?
4. What is P-8 base metal?
5. Explain the meaning of SMAW.
6. What is the meaning of 70 and 18 in AWS E-7018?
7. What P-1 steel electrodes are not preheated?
8. What is the current type / polarity for AWS E-7018?
9. Explain the meaning of GTAW.
10. What GTAW filler wire is used to weld P-1 Carbon Steel to P-8 316 Stainless Steel?
11. Explain and enumerate base metal preparation before conducting welding.
12. Explain how root pass is performed.
13. Explain how to perform hot pass and capping.
14. Explain what are the causes of porosity.
15. Explain what are the causes of undercut.
16. Explain and enumerate welding defects ( List at least 5 ).
17. What is fillet weld?
18. What is socket weld?
19. What is 6-G?
20. What is 4-G?
21. What welding positions in pipes will qualify welder for all positions?
22. What pipe thickness based on ASME IX will qualify welder for unlimited thickness?
23. What plate thickness based on AWS D1.1 will qualify welder for unlimited thickness?
24. What welding positions in pipes will qualify welder for all positions?
25. What is WPS?
5.0 B. CLIENTS WELDERS TRADE TEST COUPONS SPECIFICATIONS .
The following shall be the Test Coupons Specifications adopted for all Clients Projects.
To be finished in total six ( 6 ) hours, including preparation.

TEST COUPONS

SPECIFICATIONS
3 pipe CS, P-No. 1
Sch DBLE. E.H., 0.600
6G position up
SMAW E6010 root, 1/8
SMAW E7018 fill and cap, 3/32 & 1/8
VT + RT
3 pipe CS, P-No. 1
Sch DBLE. E.H., 0.600
6G position up
GTAW ER 70S2 root / fill / cap
VT + RT
2 pipe CS, P-No. 1

Sch 80, 0.218

6G position up
GTAW ER309L root / fill / cap
VT + RT

VISUAL TESTING.
The entire 3 Welders Test Coupons shall pass Visual Testing. The following items / indications are considered
rejectable and will result in the failure of a Welder test:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Welding the test coupon using an electrode other than that specified.
Welding the test coupon with weld sequence or weld progression other than that specified.
Arc strikes outside the weld groove.
Excessive penetration in the root bead or weld cap build-up, exceeding 1/8.
Any incomplete penetration, including burn-throughs or craters.
Concave bead shall not be below base material.
Pinholes in the root.
Cold lap in the weld.
Undercut in root or cap.
Rough appearance in the completed weld.
Test welds are to have a complete, uniform root and full, even cap.
The weld shall not have any type of cracks.
Thorough fusion shall exist between adjacent layers of weld metal and between weld metal and base
metal.
14. Weld profiles shall not have reinforcement not blending smoothly into the base metal surface.
15. No visible porosity.
The entire 3 VT-passed Welders Test Coupons shall pass Radiographic Testing.
RADIOGRAPHIC METHOD.
The Radiographic Testing Parameters shall be as follows:
1. Radioactive Source shall be Iridium 192.
2. Radiographic Films shall be AGFA Structurix D7, or equivalent.
3. IQI Wire Designations shall be:
a. For Test Coupons # 1 & 2 ASTM Set 1B, with 0.016 wire shall be visible on all the
Radiographs ( 4 wires visible ).
b. For Test Coupon # 3 ASTM Set 1A, with 0.008 wire shall be visible on all the Radiographs
( 2 wires visible ).
4. Source to Film Distance shall be 10 20.
5. Image Quality Indicator shall be on the Source Side.
6. Radiographs shall be two exposures per Test Coupon at 0 and 90.

7.
8.
9.
10.

Radiograph Technique shall be DWE / DWV ( Double Wall Exposure / Double Wall Viewing ) Ellipse.
Radiographic Density shall be 2.0 3.0.
Geometrical Unsharpness ( Ug ) shall not be greater than 0.02.
Minimum thickness of Lead Intensifying Screens shall be:
a. For Front Lead Screens, 0.005.
b. For Back Lead Screens, 0.006.
11. Letter B Lead Marker shall be used to monitor Back Scatter Radiation.
12. The Identification Image shall be as follows:
a. Welders Name.
b. Date of Radiograph.
c. Pipe Diameter.
d. Welding Process.
e. Weld Location.
f. Radiographers Company Name.
g. Radiographers Company Name
RADIOGRAPHIC TESTING CRITERIA.
Test Coupons shall all pass Radiographic Testing. Radiographic Acceptance criteria shall be in accordance to
ASME IX, QW-191.2:
1. Any type of crack or zone of incomplete fusion or penetration shall be unacceptable.
2. For rounded indications, acceptance criteria shall be in accordance with ASME IX, Paragraph
QW-191.2.2 B.
STORAGE OF RADIOGRAPHS.
1. Radiographs shall have inter-leafing paper between films.
2. Radiographs shall be stored vertically in a cabinet and shall be kept for one year, after which, they shall
be disposed.
RETEST AND RENEWAL OF QUALIFICATION.
1. If a Welder fails on any one of the 3 Test Coupons, an immediate retest on the failed Test Coupon shall
be given. If the Welder still fails on the retest, he shall be disqualified.
2. As a procedure, a 3-month validity period for these Qualifications shall be adopted. The Welder shall be
given a requalification test on all the 3 Test Coupons, if the Candidate has not done welding, within the
3-month period, prior to the expiration of qualification.

COMPARION CHART FOR ALL TEST COUPONS.

CLIENT'S WELDERS WARM-UP.

All Welders, after they pass their Trade Tests, and 3 days before their anticipated travel, shall have to undergo
Warm-Up, based on the Test Coupon below:
TEST COUPONS

2
3

SPECIFICATIONS
6 pipe, P-No.1
Sch. 80, 0.432
6G position up
SMAW E6010 root, 1/8
SMAW E7018 fill and cap, 3/32 & 1/8
VT only
Bead on Plate, GTAW CS
GTAW ER 70S2, 2.4mm
8 Run
Bead on Plate, GTAW SS
GTAW ER309L, 2.4mm
8 Run

6.0 A. CLIENTS PIPEFITTERS WRITTEN EXAMINATIONS.

To be finished in two ( 2 ) hours.
1. Enumerate pipefitting / fabrication safety practices ( List at least 10 ).
2. Enumerate pipefitter / fabricator specific duties ( List at least 10 ).
3. Explain how to interpret isometric drawing.
4. Explain how to execute piping layout.
5. Explain how to install pipe supports.
6. Explain how to conduct testing on pressurize pipe.
7. Explain how to use basic scaffolding and ladders.
8. Explain how to properly use oxygen-acetylene flame cutting equipment.
9. Explain the procedure on how to install above ground pipe.
10. Explain the procedure on how to install underground pipe.
11. Enumerate different kinds of valves usually used in pipe fabrication and erection.
12. Enumerate kinds of flanges used in pipe fabrication and erection.
13. Determine the take-off of 90 degrees and 45 degrees elbow for 4" and 6" pipe.
14. What is a pipe schedule?
15. What is the standard bevel angle on an open V groove weld?
16. What is a DTI?
17. What are the two types of gaskets used in piping system?
18. What is a large bore?
19. Enumerate the cleaning and flushing methods of a piping system.
20. Explain and enumerate tools used in pipe fabrication.
6.0 B. CLIENTS PIPEFITTERS TRADE TEST COUPONS SPECIFICATIONS.
Any one of the Test Modules A or B or C.

NOTE :

a. 3 pipe schedule 20, 600 mm length.

b. All joints tack welded.
c. To be finished in two ( 2 ) hours, each pipe diagram.

7.0 A. CLIENTS INSULATORS WRITTEN EXAMINATIONS.

To be finished in two ( 2 ) hours.
1.
2.
3.
4.
5.

Explain and enumerate Insulator specific duties ( List at least 10 ).

Explain how to participate and attend daily tool box meeting.
Explain how to interpret isometric drawing.
Explain how to install cold and hot insulation system for pipe, flanges and vessels.
Explain how to install cold and hot insulation system for columns, tanks, valves, transition pieces and
other industrial LNG production devices.
6. Explain how to install insulator materials such as urethane and cellular glass composite system.
7. Explain how to install insulator materials such as rigid and semi-rigid mineral wool / hard set cement
systems.
8. Explain how to install inner / outer vapor barriers, tape expansion, and contraction joints.
9. Explain, how to install aluminum and stainless steel metal jackets or cladding systems.
10. Explain the procedure on how to apply vapor barrier tape, foil laminate tape, vapor stops and beveled
flanges.
11. Explain the procedure on how to apply SS bands, SS wire, hydraulic cement, high solid butyl sealants and
SS panhead screw.
12. Explain what a U-shaped fitting with a removable round pin is.
13. Explain what a packing puller.
14. Explain how to set a straight line around a piece of pipe.
15. Explain how bolt length is measured.
16. Explain what are short pieces of pipes threaded on both ends and used to make connections between
fittings.
17. Explain the standard for tightening a bolt-up flange with a gasket.
18. Explain the procedure on how to install basic scaffolding and how to climb in a scaffolding.
19. Explain the procedure on how to use running shears, sheet metal break and sheet rolling machines.
20. Explain and enumerate tools use in insulation.

7.0 B. CLIENTS INSULATORS PRACTICAL TESTS.

To be finished in three ( 3 ) hours.

1. Fabrication of insulation materials

a. Rockwool blanket, for hot insulation,
b. Polyurethane foam, for cold insulation.
2. Use of SS wires, SS bands and cement.
3. Insulation securement.
4. Metal strapping.
5. Tie wire and support.
8.0 A. CLIENTS MILLWRIGHTS WRITTEN EXAMINATIONS.
To be finished in two ( 2 ) hours.
1. Enumerate millwright safety practices ( List at least 10 ).
2. Explain and enumerate millwright specific duties ( List at least 10 ).
3. Explain, how to perform mechanical equipment installation. ( List at least 5 ).
4. Explain how to properly align rotating equipments ( List at least 5 ).
5. Explain how to interpret drawings.
6. Explain how to use torque wrench to pre-determined measurements.
7. Explain how to use rigger winch.
8. Discuss and explain the purpose of: a) micrometer b) dial indicator.
9. Discuss and explain the use of shims for final alignment of motors?
10. Explain what is a grout?
11. Explain how to use basic scaffolding and ladders.
12. Explain how to apply effective fire prevention practices.
12. Explain how to use barriers and barricades.
13. Explain the purpose of rim and face alignments.
14. Explain process for conveyor systems assembly.
15. What are the three (3) types of centrifugal fans?
16. What is the first step in setting up a pump and motor?
17. When aligning a motor, what would you use to set the gap between the couplings?

18. Which is the best method to check the accuracy of a precision level?
19. What is the coupling gap?
20. What is theodolite?
21. Identify 3 types of fasteners.
22. Describe oxy-acetylene cutting, welding and heating practices.
23. Describe how to level, align and secure equipment.
24. Describe power transmission theory.
25. Explain prime mover theory.
26. Describe power turbines.
27. Explain pneumatic theory.
28. Explain hydraulic theory.
29. Describe vacuum systems.
30. Explain pump theory.
31. Explain compressor theory.
32. Identify types of pumps.
32. Explain how to identify and select hand and power tools.
8.0 B. CLIENTS MILLWRIGHTS PRACTICAL TESTS.
To be finished in three ( 3 ) hours.
The Candidate will demonstrate the ability to remove, inspect, disassemble, rebuild, install and align a
pump and record necessary information.

1. Familiarization with various precision measuring instruments, dial indicators, inside and outside
micrometers, engineering levels, vernier calipers.
2. Fabrication of millwright items.
a. Prepare materials as per drawings and instructions.

b. Marking, cutting and welding using different cutting and welding methods.
c. Process materials using different machining and fitting methods.
3. Installation of equipment.
a... Move equipment using manual methods and moving equipment safely.
b. Install equipment and auxiliary connections.
c. Bolt down and level equipment.
d. Test equipment.
4. Tasks to perform.
a. Remove pump from casing.
Check impeller condition.
Check shaft and seal.
b. Remove impeller backplate and seal.
Check shaft run-out.
Check for seal failure.
Inspect backplate.
c. Disassemble bearing housing.
Inspect shaft.
Check for proper fit.
Inspect backplate.
d. Install shaft and bearings into housings.
Check and verify proper fit.
Ensure all secondary seals, O-rings, etc., are in place.
e. Install pump in casing.
Verify impeller clearance.
Verify seal setting after impeller clearance.
Proper specifications met during installation.
9.0 A. CLIENTS STRUCTURAL STEEL ERECTORS WRITTEN EXAMINATIONS.
To be finished in two ( 2 ) hours.
1.
2.
3.
4.
5.

Enumerate structural steel erection safety practices ( List at least 10 ).

Enumerate structural steel erector specific duties (List at least 10).
What is structural steel construction?
Explain sequence of structural steel erection procedures.
Perform the following hand signals: a) Raise the boom and lower the load b) Lower the boom and
raise the load c) Dog everything d) Travel, and e) Stop.
6. Explain the procedure on how to bolt aligned members to keep them in position until they can be
permanently bolted or welded into place.
7. Explain the procedure on how to guide a member using tag line (rope) in order to guide it into
position.
8. Explain how to set up hoisting equipment for raising and placing structural steel members.
9. Explain the procedure on how to cut and weld steel members to make alterations using
oxyacetylene welding equipment.
10. Explain the procedure on how to clean and maintain tools, equipment and work area and restock
supplies and materials as necessary.
11. Explain the procedure on how to force members into final position using turnbuckles, crowbars,
jacks and hand tools.
12. Explain the procedure on how to load, transport and unload materials, tools, equipment and
supplies.
13. Explain the procedure on how to align holes in members with corresponding holes in previously
placed members by drafting drift pins or handle of wrench through holes.

14. Explain the procedure on how to verify vertical and horizontal alignment of members using plumb
bob or level.
15. Explain the procedure on how to fasten steel members to cable hoist using chain cable or sling.
16. What are EWPs?
17. What are DTIs?
18. Explain how to use basic scaffolding and ladders.
19. What is OSHA?
20. What is AISC?
9.0 B. CLIENTS STRUCTURAL STEEL ERECTORS PRACTICAL TESTS.

NOTE: a. 25 Trainees to assemble in 5 hours.

b Assembly by bolt connection.
10.0 A. CLIENTS RIGGERS WRITTEN EXAMINATIONS
To be finished in two ( 2 ) hours.
1. Enumerate rigging safety practices ( List at least 10 ).
2. Explain and enumerate rigger specific duties ( List at least 10 ).
3. Perform the following hand signals: a) Emergency stop b) move slowly c) raise boom d) lower boom
e) hoist f) lower g) use main hoist h) use whip.
4. Explain while lifting what are the safety measures.
5. Explain how to calculate the load sizes and the lifting capacities of the rigging gears.
6. Explain how to inspect hooks, shackles and chains.
7. Explain how to communicate with the crane operator.
8. Explain how to tie slings and chokes.
9. Explain how to maintain wire ropes.
10. Explain the causes and prevention of damages in wire ropes.
11. Explain what the different types of rope knots.
12. Explain and discuss the following miscellaneous rigging gears: a) synthetic web slings b) ropes
c) wire ropes d) hooks e) shackles f) tuggers

13. Explain the procedure on how to seize wire ropes.

14. Explain the causes of wire rope failure.
15. Explain the proper installation of ropes sockets.
16. What are the strands in a wire rope wound around?
17. What is the first thing to determine before beginning any rigging operation?
18. Wire ropes should only be cut after what preparation?
19. Shake-out hooks are best suited for what equipment?
20. What method is used when transferring wire ropes from a reel to the drum of a crane?

10.0 B. CLIENTS RIGGERS PRACTICAL TESTS.

1. Inspect snatch blocks, fittings, slings ( Wire rope / chain / synthetic m) and fasteners for excessive
wear, visual damages and modification.
2. Install latches, bearings, locking devices, wire rope clips, wedge sockets.
3. Identify sizes, grades, rated capacities and manufacturer.
4. Demonstrate understanding of the workload limit of the slings / blocks / fittings.

5. Demonstrate understanding of the condition of rigging gear.

6. Demonstrate understanding of proper handling and storage of rigging gears.
7. Demonstrate knowledge of controlled risk procedures.
8. Demonstrate knowledge of various load factors.
9. Demonstrate knowledge of limitations of slings, blocks and fittings.
10. Identify and demonstrate usage of specific rigging gears.
11. Evaluate load determine center of gravity, load weight and lifting point.
12. Select and connect slings and hatches.
13. Determine and observe load limits of rigging gears.
14. Determine and achieve load control ability.
15. Demonstrate correct procedures in installing rigging gears.
16. Interpreting correctly the rigging chart.
17. Ability in using various combinations of rigging gears.
18. Establish appropriate communication signals with crane operator by using radio or hand signals.
19. Guide crane operator in handling the load.
20. Unusual loading or environmental condition is anticipated and communicated with the crane
operator.
21. Distances, heights and clearances in the work areas are assessed and communicated with the
crane operator.
22. Providing tagline to achieve loads stability.
23. Total lift of load is communicated to the crane operator.
24. Traveling path of load is directed based on the assessed environmental hazards.
25. Demonstrate understanding of rick-control procedures.
11.0 A. CLIENTS SCAFFOLDERS WRITTEN EXAMINATIONS.
To be finished in two ( 2 ) hours.
1.
2.
3.
4.
5.
6.
7.
8.

Explain how to comply with the OHSA requirements on scaffolding erection.

Explain how to Identify and confirm site access and emergency routes.
Explain how to determine and plan to erect and dismantle of scaffolding.
Explain how to inspect damage scaffolding components and isolate, label, tag and reject.
Explain and describe the scaffolding procedure in general.
Explain and enumerate scaffolder specific duties ( List at least 10 ).
Explain the usage of working drawings.
Explain use of load tables, following limits, standard, specification, design loading on scaffolding
support structures.
9. Explain how to properly identify, maintain and use hand and power tools?

10. Explain how to use and install barriers and barricades?

11. Explain how to prepare footings.
12. Explain the procedure how to assemble tubular type scaffoldings.
13. Explain the procedure how to dismantle tubular type scaffoldings.
14. Explain the procedure how to assemble hanging scaffold.
15. Explain how to install fall protection devices.
16. Explain the procedure how to assemble H-frame scaffoldings.
17. Explain the procedure how to assemble socket type scaffoldings.
18. Explain the usage of the following: a) base jack b) jack head c) cross brace.
19. Explain the usage of the following: a) coupler b) clamp.
20. Explain how to accomplish scaffolding checklist report.
11.0 B. CLIENTS SCAFFOLDERS PRACTICAL TESTS.

NOTE: a.
b.
c.
d.
e.
f.

Erection of 8-legged staircase towers to give a quick and easy personnel

passage to any working level.
Plan area: 1.8m x 4.4m.
Height: 8m.
Two 1.3m bays.
Center bay of 1.8m.
Broad 1.3m wide landing platforms with timber or steel battens.

g.
h.
i.

Rigid 0.8m wide stairways to provide a firm non-slip thread.

Full handrailing with double handrails.
To be finished in 3 hours by a crew of 5 Scaffolders.

NOTE; a. Erection of 8-legged staircase towers having a base lift of 2.0m,

using 1.5m stairway unit at the base of the tower.
b. Plan area: 1.8m x 4.4m.
c. Height: 8m.
d. An extra 1.8m ledger as a guardrail is erected.
e. Full double guardrails to the landing platform.
f. Batten toeboard along the outer edge of the platform.
g. To be finished in 3 hours by a crew of 5 Scaffolders.

NOTE: a.
b.
c.
d.
e.
f.
g.
h.

Erection of mobile tower.

Plan area: 4.9m x 4.9m.
Height: 12m.
Erected with 4 castor wheels.
Working platform formed either with board or batten type decking.
When by means of scaffold boards, intermediate transoms are used.
To ensure the tower is rigid and stable, the tower is tied to a secure structure.
To be finished in 3 hours by a crew of 5 Scaffolders.

12.0 A. CLIENTS PLUMBERS WRITTEN EXAMINATIONS;

To be finished in two ( 2 ) hours.
1.
2.
3.
4.
5.
6.
7.
8.
9.

Enumerate plumbing safety practices ( List at least 10 ).

Explain and enumerate plumber specific duties ( List at least 10 ).
Explain the procedure on how to install ceramic shower and wash basins.
Explain how to interpret isometric drawing.
Explain how to execute domestic piping layout.
Explain how to install domestic pipe supports.
Explain how to conduct system test applicable to buildings.
Explain, how to use basic scaffolding and ladders.
Explain, how to install toilet bowl and urinals including fixtures.

11. Explain the procedure on how to install underground domestic pipe.

12. Explain and enumerate different kinds of valves usually used in domestic pipe fabrication.
13. In plumbing system, what are the materials used for sealing joints connection for sanitary and
water lines.
14. Explain the procedure on how to determine the take-off of 90 and 45 elbow for 4" and 6"
domestic pipe.
15. Explain and enumerate tools used in plumbing works.
16. Explain the procedure on how to install ceramic shower and wash basins.
17. What tool is used for laying out a sockolet on a pipe?
18. What fittings are used to connect between pipes?
19. What fittings are used for a reducing branch on long and short radius elbows?
20. What is the device that catches and holds a quantity of water to form a seal?

12.0 B. CLIENTS PLUMNERS PRACTICAL TESTS.

1. Prepare pipes for installation.

Identify materials, tools and equipment.
Cut / thread pipes.
a.
b.
c.
d.
e.

Plastic pipe and fittings.

Copper pipe and fittings.
Cast iron pipe and fittings.
Carbon steel pipe and fittings.
Corrugated stainless steel tubing.

2. Make piping joints and connections.

Fit-up joint and fitting.
Perform threaded pipe joints and connections.
3. Perform construction works.
Perform piping layouts.
Cut pipes through walls and floors.
4. Perform plumbing installation and assemblies.

Prepare materials, tools and equipment for plumbing works.

Prepare plumbing work.
Install pipes and fittings.
Install hot and cold water supply.
Install / assemble plumbing fixtures.
Install drainage / waste / vent piping system.

5. Conduct pipe leak testing.

Prepare for conducting pipe leak testing.
Perform pipe leak testing.
6. Perform plumbing repair and maintenance work.
Repair defective pipes, fittings and plumbing fixtur
Clear clogged pipes and drains.

13.0 A. CLIENTS LOW VOLTAGE / HIGH VOLTAGE ELECTRICIANS WRITTEN EXAMINATIONS.

1. Enumerate LV / HV electrician safety practices ( List at least 10 ).
2. Enumerate LV / HV electrician specific duties ( List at least 10 ).
3. Explain how to identify and state the function of the following switches: a) single-pole b) doublepole c) three way switch d) four-way switch e) safety switches.
4. Explain how to identify and connect common type of electrical services: a) single-phase,
3 wire 120 / 240 V b) three-phase 4 wire, 120-208 V c) three-phase, 4 wire 120-240 V.
5. Explain how to identify / install conduit raceway, boxes and fittings ( List at least 5 ).
6. Explain, how to identify / install anchors and supports.
7. Explain, how to calculate spacing for high voltage cables.
8. Explain the procedure on how to set and test transformers.
9. Explain the procedure on how to set and test high voltages cables by megger test.
10. Explain how to calculate the bending and training radius on high voltage cables.
11. Explain, how to take care of tools and special devices or instrument.
12. Explain the preparatory procedure on how terminate and splice HV cables.
13. Explain the preparatory procedure on how to terminate cable using termination kit.
14. Explain, how to identify, install / connect electrical distribution equipment: a) distribution voltage
b) Electrical conductors ( feeders ) c) Panel boards / switch gear d) motor control center
e) transformer.
15. Explain the procedure on how to install switch gear and control panel.
16. Explain the procedure on how to pull high voltage cables.
17. Explain the procedure on how to set and test high voltage switch gear.
18. Explain the procedure on how to pull high voltage cables.
19. Explain the procedure on how to pull high voltage cables.
20. Explain the procedure on how to set and test high voltage switch gear.
13.0 B. CLIENTS LOW VOLTAGE / HIGH VOLTAGE ELECTRICIANS PRACTICAL TESTS.
NOTE: Separate courses for LV and HV electricians.

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

Cable pulling.
Cable splicing.
Cable termination and jointing.
Cable glanding.
Cable tray.
Construction of power cables.
Conduit pipe bending.
Testing.
Commissioning.
Maintenance.

14.0 A. CLIENTS INSTRUMENT TECHNICIANS WRITTEN EXAMINATIONS.

1. Explain how to perform commissioning and simulation of instrument loop.
2. Explain and enumerate Instrument technician specific duties ( List at least 10 ).
3. Explain how to properly select and operate test equipment to calibrate the following Instrument control
saystem a) temperature transmitter, controllers, transducer and recorder b) flow transmitter c) level
transmitter d) pressure transmitter.
4. Explain how to install valve manifolds.
5. Explain how to install / connect relays.
6. Explain how to install/connect timers.
7. Explain how to install/connect various type of switches.
8. Explain how to install and connect instrument wiring and cables.
9. Explain and discuss how to identify, select, fabricate, and install gaskets and O-ring for a given instrument.
10. Explain the proper procedure on how to terminate, ground, and shield instrument cables and conductors.
11, Explain how to operate the equipment used in testing and calibrating control valves.
12. Explain and discuss how to perform continuity check to verify installation.
13. Explain how to install fasteners.
14. Explain how to identify, select hand and power tools.
15. Explain what calibration is.
16. Explain how to reduce pressure for an instrument.
17. Explain the type of tubing material used in high pressure and corrosive environments.
18. Explain the purpose of a swedgelok gap inspection gauge?
19. Explain how man ferrels does a flare fitting use.
20. Explain the tube cutters made for use in tight places.

14.0 B. CLIENTS INSTRUMENT TECHNICIANS PRACTICAL TESTS.

PROCESS AND INSTRUMENTATION DIAGRAM

HVAC APPLICATION

INSTRUMENT HOOK-UP DIAPHRAGM

TEMPERATURE TRANSMITTER HOOK-UP DETAIL PIPE

1.
2.
3.
4.
5.
6.
7.
8.

Basic PLC ( Omron or Siemens S7-300 )

Basic configurator / calibration ( Honeywell / Yamatake or Hart
communicator ).
Application symbols and diagrams exercises.
Application pressure / level / flow / temperature / electronics circuit /
controllers exercises.
Field testing / calibration exercises.
Tube bending / fitting.
Instrument installation.
Loop checking.

15.0 A. CLIENTS HEAVY EQUIPMENT OPERATORS WRITTEN EXAMINATIONS.

1. Enumerate heavy equipment operator safety practices ( List at least 10 ).
2. Enumerate heavy equipment operator specific duties ( List at least 10 ).
3. What is the primary task of a loader?
4. Which are the two major categories of dump trucks?
5. What are backhoe cabs that are fully enclosed?
6. What is the term to shallowly loosen the road surface?
7. Bulldozers are able to operate on irregular terrain and steep slopes due to what?
8. What is the attachment used to break boulders and other solid objects?
9. A crawler loader is similar to what type of equipment?
10. Which type of standard dump truck has three rear axles?
11. What is the comparison of a backhoe to an excavator?
12. What is common name of a bulldozer?
13. Why are excavators often referred to as hoes?
14. What is a ridge of loose dirt?
15. What bucket is / are one of the primary operating component of a loader?
16. What are the most commonly used dump trucks?
17. What is the mechanical latch that secures the backhoe in the closed position?
18. What is the common attachment on a bulldozer?
19. The upper carriage of an excavator can rotate how many degrees?
20. What component of the motor grader is used to push material forward and to the side?
21. Wheel type loaders are usually steered with what?
22. On what type of off-road dump truck is the cab and body built on the same frame?
23. There are how many different attachments available for the backhoe loaders?
24. What are the basic categories of blades on a bulldozer?
25. What can the grapple attachment on an excavator be used for?
26. What are the six basic steps for operating a motor grader?
27. What should you always do when leaving your wheel loader?
28. What is the main purpose of operating a dump truck?
29. How many degrees can a backhoe loader arm swing?
30. What are the three characteristics that will affect bulldozer performance?
31. What will determine the minimum safe working distance between power lines and operating
heavy equipment?
32. For finish grading, the blade of the motor grader is usually in what position?
33. What is one of the attachments of a loader?
34. What are the leading reasons for dump truck top heavy load tip over?
35. What controls the stabilizers, boom, stick and bucket of the backhoe loader?
36. Bulldozers can travel up to what speed?
37. Where is the ripper attachment of an excavator attached to?
38. What is used for placing and smoothing special material in a motor grader?
15.0 B. CLIENTS HEAVY EQUIPMENT OPERATORS PRACTICAL TESTS.
Must be able to perform pre- and post operation procedure, perform productive operation, and perform basic
preventive maintenance servicing on any of the following given heavy equipment:

BULLDOZERS

HYDRAULIC EXCAVATORS CRAWLER TYPE

HYDRAULIC EXCAVATORS WHEEL TYPE

MOTOR GRADERS

WHEEL LOADERS

ARTICULATED OFF-HIGHWAY DUMP TRUCK

BACKHOE LOADER

RIGID OFF-HIGHWAY DUMP TRUCK

PAVERS

ROAD ROLLERS

CONCRETE PUMP

TRANSIT MIXER

16.0 A. CLIENTS CRANE OPERATORS WRITTEN EXAMINATIONS.

1. Enumerate crane operator safety practices ( List at least 10 ).
2. Enumerate crane operator specific duties ( List at least 10 ).
3. Explain how to properly set up a crane ( List at least 3 ).
4. What are the types of lifts and their procedure ( List at least 4 types ).
5. What are the major causes of crane accidents ( List at least 4 ).
6. Explain how to inspect and maintain a crane.
7. Explain how to communicate with riggers.
8. Explain how to interpret and calculate crane loading chart.
9. Explain how to properly operate a crane.
10. Explain how cranes are overloaded.
11. Explain what is a pick and carry load chart. What precautions must be followed for such
operations?
12. Explain and discuss the following miscellaneous rigging equipments: a) synthetic web slings
b) ropes c) wire ropes d) hooks e) shackles f) tuggers
13. Discuss and explain the difference between manually-operated and computerized cranes.
Give and describe example of each type.
14. Explain the classification of cranes (stationary or movable), booms ( telescopic or fixed ) and
tracking ( track mounted or crawler ). What is the purpose of each class?
15. Explain how to interpret hand signals.
16. What type of sling is easily subject to cutting or slicing from sharp edges?
17. What are the acceptable methods for load line tieback?
18. Slings are designed and rated in what configuration?
19. What must be the rating of the fire extinguisher that must be placed in the crane cab?
20. The center of rotation of the crane to the center of gravity of the load is called what?
21. Rough terrain cranes capacities are generally greater over at what part?
22. Truck cranes generally have no lifting capacity over which area?

16.0 A. CLIENTS CRANE OPERATORS PRACTICAL TESTS.

Must be able to perform pre- and post operation procedure, perform productive operation, and perform basic
preventive maintenance servicing on any of the following given crane:
TELESCOPING CRANES WHEEL- MOUNTED ( SINGLE / MULTIPLE CONTROL STATION ).

TRUCK-MOUNTED.

CRAWLER.

LATTICE BOOM CRANES WHEEL-MOUNTED ( SINGLE / MULTIPLE CONTROL STATION ).

TRUCK-MOUNTED.

CRAWLER.

LOCOMOTIVE.

17.0 A. CLIENTS BLASTERS / PAINTERS WRITTEN EXAMINATIONS.

1. Explain safety precautions in sandblasting operations.
2. Explain safety precautions before, during and after painting.
3. Explain how to select and wear protective equipment for blasting and painting.
4. Explain and describe the blaster / painter procedure in general.
5. Explain and enumerate blaster / painter specific duties ( List at least 10 ).
6. Explain how to properly identify, maintain, and use hand and power tools?
7. Explain how to use and install barriers and barricades?
8. Explain how to use basic scaffolding and ladders?
9. Explain the procedure on preparation of surfaces to be painted (pipe and steel).
10. Explain the two basic types of blast pots used for blasting steel.
11. How much pressure is commonly used to blast rust or mill scales from steel?
12. Explain how to treat the surface of bright galvanized surfaces before painting.
13. Explain the procedure on how to set-up airless spray equipment .
14. Explain the procedure on how to adjust fluid and air pressure in paint spray.
15. What is the material that gives paint its color called?
16. Explain the procedure on how to mix epoxy paint.
17. Explain how to adjust the consistency of paint.
18. Explain when and how is the thinning of a two part paint done.
19. Explain the proper procedure in handling, storing and disposing of paints.
20. What causes paint blistering? Cracking? Flaking?
17.0 B. CLIENTS BLASTERS / PAINTERS PRACTICAL TESTS.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.

Airless spray paint equipment spraying technique.

Choice of the right spraying equipment.
Airless pump ( function / manner of operation ).
Daily maintenance of the spray equipment.
Spraying technique ( viscosity and spray pattern ).
Right choice of filter / nozzle for the paint to be used.
Safety before and during the painting.
Practical use of sandblasting equipment.
Heavy duty blasters.
Sandblasting with water injection.
Alternative grinding and cleaning equipment
Safety in sandblasting operations.
Practical use of spraying equipment.
Mixing of two component paint before use.
Spray technique.
Cleaning of the equipment after use.
Practical servicing of airless spray equipment.
Disassemble the pump suction on the airless pump.
Clean and inspect the different pumps.
20. Assemble the pump section on the airless pump.
21. Disassemble / inspect / clean and assemble the spray gun.
22. Testing the equipment.

18.0. ON-SITE SELF-AUDIT CHECKLIST OF INSPODE PHILIPPINES, INC, WELDERS AND OTHER
SKILLED CRAFTS TRADE TEST FACILITY
TRADE TEST FACILITY
FACILITY OPERATIONS MANAGER
ADDRESS
TELEPHONE NO.
E-MAIL
EXAMINER
DATE

CELLPHONE NO,

1.PART I PROCEDURES
Personnel interviewed
A

Describe the procedure for procurement

of materials including filler metals.

1
2
3
4
5

Is there a written procedure?

Does it include a sample purchase order?
Does the P.O. require test reports and mill certificates?
Are the materials and certifications checked on receipts?
Are the test reports and mill certificates on file?

Describe discussions with Welder

Candidates.

1
2
3

Is a sample application available?

Is it filled out so it may be used as a sample?
Is the Welder advised of safety rules and testing requirements?

Describe the procedure for traceability of

materials, from certifications, to welding,
inspection, testing and documentations.

1
2
3
4
5

YES

NO

YES

NO

YES

NO

YES

NO

Is the Welder assigned an identification code?

Is the identification code recorded on the Test Coupons and documents?
Does the Assessor verify that certified materials are used?
Are the test materials identification recorded on the test records?
Is the Welder identification code recorded on the radiographs?
2.PART II PERSONNEL

Personnel interviewed

1
2
3
4
5
6

Is the Facility under the authority of the Operations Manager?

Does the Operations Manager have at least 5 years welding experience?
Are the Welding Assessors employees or Contractors?
Are they currently certified as CWIs?
Are the RT Personnel employees or contractors?
Are the RT Personnel ASNT SNT-TC-1A, RT Level II certified?

Are Job Descriptions available and the Organizational Chart?

3.PART III OPERATIONS

Personnel interviewed

1
2
3
4
5
6
7

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

Are Welding Procedures available for use by the Welder?

Is the fit-up inspected prior to welding?
Are RT Acceptance Criteria available to the RT Interpreter?
Are the RT results recorded on the Test Records?
Is the Welders file complete?
Are there written procedures for non-conformance?
Are there written procedures for dealing with technical complaints?
4.PART IV REFERENCE DOCUMENTS

Personnel Interviewed

1
2

Does the Facility maintain a library?

Are there current copies of Welder Qualification Codes and Standards?
5.PART V GENERAL

Personnel Interviewed

1
2

Are there Training Programs to upgrade skills?

Does Management review QA Program on a routine basis?
6.PART VI WELDING TESTS

1
2
3
4
5
6

Does the Welding Assessor have a checklist for the Trade Test?
Is the WPS available to the Welder during Testing?
Is Safety Equipment verified?
Is material checked?
Is fit-up verified?
Are Test Positions verified?
7.PART VII TEST COUPONS HANDLING

1
2
3

Are written procedures available to define VT acceptance criteria?

Are RT methods controlled by written procedures?
Is there proper documentation as to the disposal of Test Coupons?
8.PART VIII FINAL DISPOSITION

1
2

Is the Welders file complete?

Are records forwarded to Clients complete?

PART IX WELDING EQUIPMENT AND CONTROLS

NUMBER
1
A
B
C
D

SMAW
Number of Units
Number of AC
Number of DC
Number of AC / DC

2
A
B
C
D

GTAW
Number of Units
Number of AC HF
Number of DC
Number of AC / DC
9.PART X CUTTING EQUIPMENT

1
A
B

OFC
Number of Sets
Type Fuel Gas Used
10.PART XI MEASURING AND TESTING EQUIPMENT

1
2
3
4
5
6
7
8
9
10
11

YES

NO

YES

NO

Is a Maintenance Procedure or Schedule established?

Is Maintenance Log up to date?
Does Equipment appear abused?
Are proper Equipment Records maintained?
Are Calibration Methods defined?
Are Welding Gages and Measuring Tools complete?
Does the Facility perform Tensile Strength Testing?
Does the Facility perform Impact Testing?
Does the Facility perform Vickers Hardness Testing?
Does the Facility perform Bend Testing?
Does the Facility perform Chemical Analysis?
11.PART XII RECORDS AND TEST REPORTS

12.
1
2
3

Are Written Procedures on file for Record Retention?

Are Records retained for the 5-year requirement?
Are Records secure?

19.0. CORRECTIVE AND PREVENTIVE ACTION

14.1. Corrective action is taken to help assure nonconformances are resolved, permanent solutions are
implemented and continuous improvement efforts are achieved. Corrective and preventative actions
are issued, recorded and verified in accordance with documented procedures.
14.2. Everyone in the organization is responsible for instituting, monitoring, or requesting corrective /
preventive actions. Problems are evaluated for potential impact on operations, safety, quality,
performance, reliability and Client satisfaction. Sources of data and information used in the
evaluation may come from failure analysis results, operations, or Client feedback.
14.3. After the cause of the problem has been identified, measures are taken to prevent its recurrence.
Nonconforming items are properly corrected. The effects of these measures are audited to assure
the desired goals are met and the permanent changes are in place, documented and
communicated.

APPENDIX A