INSPECTION AND TEST PLAN (ITP) STRUCTURAL STEEL WORKS FABRICATION

This page is a record of all revisions of this document. All previous issues are hereby superseded and are to be destroyed.

REV	DATE	DESCRIPTION	PRPD	CHKD	REVD	APPRD	COMPANY
0	11 June 2014	Issue For Construction
C	03 June 2014	Issue For Approval
B	10 Apr 2014	Issue For Approval
A	10 Mar 2014	For Review & Comment
SIGNED (Initials)

                                                           

QA Review (PQM) Sign: ___________________    Date: ________________

               NOTES:

a)   Revision bar (vertical line) shall be placed in the right hand margin to indicate where the change has been made.

b)   PRPD = Prepared by, CHKD = Checked by, REVD = Reviewed by

      APPRD = Approved by

c)   In case of conflict between any requirements stipulated in this document with the contractual requirements, the contractual requirements shall prevail.

REVISION LOG
REV. No.	REV. DATE	REV. PAGE	REVISION DESCRIPTION
A	10-Mar-14		First Issue
B	10-Apr-14	All	Second Issue
C	03-Jun-14	All	Third Issue
0	11-Jun-14		Issue For Construction

TABLE OF CONTENTS

Section            Description

A.              Inspection Categories

B.              Notice (Request) of Inspection

1.0            Material Receiving Inspection  / Quality of Structural Steel

2.0            Welding/ Welders Qualifications

3.0            Release for Painting / Erection

4.0            Foundation Preparation

5.0            Inspection of Fabricated Items

6.0            Steel Works Erection

7.0            Field Welding

8.0            Grouting

9.0             Final Inspection

10.0                   Repair/ Adjustment / Re-Fabrication

11.0           Attachments

               Attachment 1 –   ITR  -QGI-001           Notification (Request) for Inspection

Attachment 2 –   ITR -QGI-002          Release Note

Attachment 3 –   ITR -QMI-001         Receiving Inspection Report

Attachment 4 –   ITR -QCI-011          Structural Steel Works Checklist

Attachment 5 –   ITR -QCI-016          Steel Structure Fabrication

Attachment 6 –   ITR -QCI-017          Bolt Torque Record for Structural Steel

Attachment 7 –   ITR -QCI-018          Installation Record for Structural Steel

 Attachment 8–    ITR -QCI-019          Welding Inspection Record

 Attachment 9–    ITR -QCI-020          Foundation Pad Inspection Report

 Attachment 10–  ITR -QCI-023          Paint Inspection Report

Attachment 11–  ITR -QCI-025          Final Inspection for Structure Steel

A.    Inspection Categories

The following inspection categories shall be used to identify the extent of inspection for each inspection activity within the ITP

I      Inspection items:

       It is the primary responsibility of Subcontractor and/or CONTRACTOR’s Quality Department to carry out the necessary inspection and test to assure conformance to the Contract requirements, drawings, specification and related codes and standards.

S     Surveillance

Monitor the status of work and materials and analyses of records on a periodical basis to ensure that specified requirements are being fulfilled. 

W    Witness

   As mandatory items of inspection, examination, or test this stage shall be notified in advance by the Subcontractor or CONTRACTOR’s construction department and shall be performed under witness of the relevant Inspection Authority. However, work may proceed if the relevant authority is not available at the required time.

H    HOLD

Hold point (H) means a point, designated by prior stated agreement in the inspection and test plan(s), at which the performance of an activity must be stopped and put an hold until specified actions are completed.

R     Review

       Review results of inspection, examination or test.

B.     Notice (Request) of Inspection

Definition of terms:

Ø  Contractor, refers to Hyundai HEC-JV organization or individual that contracts with another organization or individual (the owner) for the construction of a building, road or other facility

Ø  Subcontractor, an individual or business that signs a contract to perform part or all of the obligations of another’s contract from Hyundai HEC-JV as Contractor

The Subcontractor shall submit to CONTRACTOR a ‘Notice of Inspection Request one (1) day before the inspection is to be carried out. The request shall contain information as follows:

·         Inspection item(s).

·         Responsibility Category. (as defined within the ITP)

·         Date, place and time of inspection.

·         Requirement for third party inspection (if any).

·         Any other relevant information.

The Subcontractor may proceed with the inspection activity at the specified time without the presence of CONTRACTOR or COMPANY for witness inspection unless a delay has been previously advised and agreed by either party.

·         The Notice of Inspection shall be sequentially numbered by the subcontractor in accordance with SUT1-Z05-G-00-4-016‘Numbering Procedure for Project Quality Documents’.

·         The Site Inspection and Test Procedure (SUT1-Z05-Q 00-4-022) shall be implemented for the Structural Steel Works (Fabrication & Erection).

·         Site Receiving Procedure (SUT1-Z05-Q 00-4-023) shall govern fort the proper handling of materials and its components.  This procedure is to assign responsibility and describe the methods of performing receiving inspection on Equipements & Materials arriving at the site to ensure that thet comply with the purchase order and project requirements

·         Welder & Welding Operator Qualification Procedure (SUT1-Z05-Q 00-4-030) will also be implemented. This procedure is to establish the requirements and control measures for Performance Tests of Welder and Welding Operator Qualification Tests for EfW Project @ Sakra at Jurong Island Singapore. It is intended to apply to qualifications in construction sites.

 

·         Welding materials Control Procedure (SUT-Z05-Q 00-4- 029). This procedure will describes the general requirements for welding consumable of storing, handling,distributing and issuing welding consumables on the construction site

No.	Activity and Characteristic to be Checked	Reference Documents (Codes/ Std/ Spec. / Proc.)	Acceptance Criteria	Verifying Document	Inspection Points
					Subcon	CONTR.	RE/RTO	SCC	Lab
1.0	Material Receiving Inspection
1.1	- Receiving Inspection of Materials - Confirm material storage condition	SUT1-Z05-Q 00-4-023 Site Receiving Inspectiin Procedure	Approved Construction Drawing – Issued for Construction (IFC) & Mill Certificates & Factory Production Control Certificates (FPC), No physical defects, Safeguards against adverse environment	ITR-QMI-001-Receiving Inspection Report	I	W/R	W/R	S
1.2	Receipt inspection of welding consumables	SUT1-Z05-Q 00-4-023- Site Receiving Inspection Procedure	Low hydrogen/min. Tensile strength 480N/mm². As per manufacturers recommendations. Storage-Temp. & Humidity control environment	ITR-QMI-001- Receiving Inspection Report	I	R	S	S
2.0	Welding/ Welders Qualifications
2.1	Confirmed Welding Procedure Specification	SUT1-Z05-Q00-4-005 WPS (AWS D1.1 Prequalified)	Approved WPS & PQR Approved Construction Drawing – Issued for Construction (IFC)	ITR-QCI-011 Structural Steel Checklist(para. 2 & 4) ITR-QCI-016- Steel Structure Fabrication	I	R	R	R
2.2	Cofirmed Welders(Welders Qualification Test & Contro)	SUT1-Z05-Q00-4-030   Welder & Welding Operator qualification Procedure SUT1-Z05-Q00-4-021 General Welding Procedure	Conforming the AWS D1.1, Approved WPS & PQR	ITR-QCI-0011 Structural Steel Checklist- para. 2 & 4) Welder or Welding Operator Performance Qualification Record	I	W/R	W	R
3.0	Foundation Preparation
3.1	Confirmation acceptance of foundation	Approved Construction Drawing - (IFC)	Signed “Release Form” from Concrete casting subcontractor/contractor	QGI-002  Release Note	I	R	R	R
3.2	Control foundation level pad elevation & location	Approved Construction Drawing - (IFC)	Elevation tolerance EL. ± 2mm., As per specification	ITR-QCI-020- Foundation Pad Inspection Report	I	W/R	W/R	R
4.0	Inspection of Fabricated Items
4.1	Confirm Dimension Verification,(Before Erection)	SUTO-ALL-C08-4-004	Approved Construction Drawing – Issued for Construction (IFC)AWS D1.1/ D1.1M	ITR-QCI-0011- Structural Steel Checklist- para. 2 & 4)	I	W	R	S
4.2	Visual inspection of workmanship including weld quality	SUTO-ALL-C08-4-004	Approved Construction Drawing – Issued for Construction (IFC)AWS D1.1/ D1.1M	ITR-QCI-0011 Structural Steel Checklist- para. 2 & 4)	I	W	S	S
5.0	Steel Works Erection
5.1	Confirm column plumbness	SUTO-ALL-C08-4-004	Approved Construction Drawing – Issued for Construction (IFC)	ITR-QCI-0018 Installation Record For Structural Steel	I	W/R	W/R	S
5.2	Confirm bracings are properly insta SUT0-All-C08-4-004lled	SUTO-ALL-C08-4-004	Approved Construction Drawing – Issued for Construction (IFC)	ITR-QCI-011 Structural Steel Checklist(para. 5)	I	S	S	S
5.3	Confirm handrails, gratings, & stairways are correctly installed	SUTO-ALL-C08-4-004	Approved Construction Drawing – Issued for Construction (IFC)	ITR-QCI-011 Structural Steel Checklist(para. 5)	I	S	S	S
6.0	Bolting
6.1	Confirm all nuts, bolts & washers have been fitted.	SUTO-ALL-C08-4-004	Approved Construction Drawing – Issued for Construction (IFC)	ITR-QCI-011 Structural Steel Checklist(para. 3)	I	S/W	S	S
6.2	Confirm erection bolts have been replaced with high strength bolts(where applicable)	SUTO-ALL-C08-4-004	Approved Construction Drawing – Issued for Construction (IFC)	ITR-QCI-011 Structural Steel Checklist(para. 3)	I	S/R	S/R	S
6.3	Confirm bolt torque	SUTO-ALL-C08-4-004	Approved Construction Drawing – Issued for Construction (IFC)	ITR-QCI-0017  Bolt Torque Inspection record for Structural Steel	I	W/R	W/R	R
7.0	Field Welding (As per Drawing- Field Points)
7.1	Confirm welding works is carried out in  accordance with approved procedures	SUT1-Z05-Q00-4-006 WPS  & PQR procedure	Conforming the AWS D1.1 Approved WPS & PQR	ITR-QCI-0019 Welding Inspection Record	I	S/R	S/R	S
7.2	Visual Inspection of welding	SUT1-Z05-Q00-4-006  - WPS & PQR Pprocedure	Conforming the AWS D1.1 Approved WPS & PQR	ITR-QCI-0011 Structural Steel Checklist(para 4)	I	W/R	W/R	S
7.3	Non Destructive Testing (NDT) of welding works    (As per 11.0 NDE)	SUT1-Z05-Q00-4-006 - WPS & PQR Procedure SUT0-All-C08-4-004	Approved Construction Drawing – Issued for Construction (IFC)	ITR-QCI-0019 Welding Inspection Record	I	W/R	W/R	S/R
8.0	Grouting
8.1	Confirm grouting is complete	Approved Construction Drawing – Issued for Construction (IFC)	Grouting must be done after column verticality is plumbed	Grout Inspection & Test reports	I	W	S	S
8.2	Confirm final anchor bolt torque after grouting	Approved Construction Drawing – Issued for Construction (IFC)	Approved Construction Drawing – Issued for Construction (IFC)	ITR-QCI-025- Final inspection for Structure Steel	I	W	R	S
9.0	Final Inspection
9.1	Carry out Final inspection of the structure	Approved Construction Drawings	Approved Construction Drawing – Issued for Construction (IFC)	ITR-QCI-025- Final inspection for Structure Steel	I	W	R	W
10.0	Repair/ Adjustment  & Re-fabrication
10.1	Confirmed material - Receiving Inspection of Materials	Site Receiving Procedure (SUT1-Z05-Q 00-4-023)	Approved Construction Drawing – Issued for Construction (IFC) & Mill Certificates & Factory Production Control Certificates (FPC), No physical defects, Safeguards against adverse environment	ITR-QMI-001- Receiving Inspection Report	I	W/R	W/R	S
10.2	Marking & Cutting	SUT1-Z05-Q00-4-005 WPS (AWS D1.1 Prequalified)	Approved Construction Drawing – Issued for Construction (IFC), Approved tolerance – ASCI specification for Structural Steel Buildings	ITR-QCI-016- Steel Structure Fabrication	I	W	S	S
10.3	Fit up Check	SUT1-Z05-Q00-4-005 WPS (AWS D1.1 Prequalified)	Approved joint detail As per WPS.	ITR-QCI-016- Steel Structure Fabrication	I	W	S	S
10.4	Confirm Final Dimension Check	SUTO-ALL-C08-4-004	Approved Construction Drawing – Issued for Construction (IFC)	ITR-QCI-016- Steel Structure Fabrication	I	W	S	S
10.5	Welding Visual Inspection - Full Penetration welds 100% - Partial penetration welds 50% - Fillet welds 25%	SUT1-Z05-Q00-4-005 (WPS) (AWS D1.1 Prequalified)	AWS D1.1 Tabl;e 6.1 & 6.2 All lifting lugs 100% MPI Test - Verify NDT % has been completed	ITR-QCI-016- Steel Structure Fabrication	I	W/R	W/R	S
11.0	NDE
11.1	RT or  UT - Full penetration Butt Welds  50 % and Magnetic(MT) or Dye penetrant testing (PT) 50%  (for site welds the above will be 100%) UT  or M/ PT - Partial penetration Butt Welds Min.25% & MT/PT  25% (for site welds the above will be 50%) MT  or PT - Fillet Welds  Min 20% (for site welds the above will be 50%)	SUTO-ALL-C08-4-004	AWS D1.1 Tabl;e 6.1 & 6.2	NDE Report	I	W/R	W/R	S
11.2	Re-Painting/ Galvanizing  (Touch up - Cold ) - Surface preparation - Thickness of Zinc Coating/ Painting Cointing Dry film	Approved MS for Painting Works	Approved Materials Specification ,  Material Brochure  & Catalogue Specification	ITR-QCI-023 Painting Inspection Report	I	S/R	S/R	S/R
11.3	Adhesion Test(If necessary –Random sample Test)	SUTO-ALL-C08-4-004 SUTO-ALL-P08-4-008	As per ASTM D-3359/ISO 2409 (Type Type) or As per ASTM D-4541/ISO 2624 ( Dolly pull-off))	ITR-QCI-023 Painting Inspection Report	I	W/R	W/R	S

LEGEND:        ITL: Independent Testing Laboratory   I: Execution of Inspection and Test      R: Review    S: Surveillance     W: Witness    H : Hold

11.0 Attachments

              Attachment 1 –   ITR  -QGI-001           Notification (Request) for Inspection

Attachment 2 –   ITR -QGI-002          Release Note

Attachment 3 –   ITR -QMI-001         Receiving Inspection Report

Attachment 4 –   ITR -QCI-011          Structural Steel Works Checklist

Attachment 5 –   ITR -QCI-016          Steel Structure Fabrication

Attachment 6 –   ITR -QCI-017          Bolt Torque Record for Structural Steel

Attachment 7 –   ITR -QCI-018          Installation Record for Structural Steel

 Attachment 8–    ITR -QCI-019          Welding Inspection Record

 Attachment 9–    ITR -QCI-020          Foundation Pad Inspection Report

 Attachment 10–  ITR -QCI-023          Paint Inspection Report

Attachment 11–  ITR -QCI-025          Final Inspection for Structure Steel