This page is a record of all revisions of this document. All previous issues are hereby superseded and are to be destroyed.
REV
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DATE
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DESCRIPTION
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PRPD
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CHKD
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REVD
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APPRD
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COMPANY
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0
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11 June 2014
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Issue For Construction
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C
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03 June 2014
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Issue For Approval
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B
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10 Apr 2014
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Issue For Approval
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A
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10 Mar 2014
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For Review & Comment
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SIGNED (Initials)
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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
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REV. No.
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REV. DATE
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REV. PAGE
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REVISION DESCRIPTION
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A
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10-Mar-14
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First Issue
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B
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10-Apr-14
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All
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Second Issue
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C
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03-Jun-14
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All
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Third Issue
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0
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11-Jun-14
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Issue For Construction
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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.
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Activity and Characteristic to be Checked
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Reference Documents (Codes/ Std/ Spec. / Proc.)
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Acceptance Criteria
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Verifying Document
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Inspection Points
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Subcon
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CONTR.
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RE/RTO
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SCC
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Lab
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1.0
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Material Receiving Inspection
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1.1
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- Receiving Inspection of Materials
- Confirm material storage condition
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SUT1-Z05-Q 00-4-023
Site Receiving Inspectiin Procedure
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Approved Construction Drawing – Issued for Construction (IFC) & Mill Certificates & Factory Production Control Certificates (FPC), No physical defects, Safeguards against adverse environment
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ITR-QMI-001-Receiving Inspection Report
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I
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W/R
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W/R
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S
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1.2
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Receipt inspection of welding consumables
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SUT1-Z05-Q 00-4-023-
Site Receiving Inspection Procedure
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Low hydrogen/min. Tensile strength 480N/mm². As per manufacturers recommendations. Storage-Temp. & Humidity control environment
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ITR-QMI-001- Receiving Inspection Report
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I
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R
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S
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S
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2.0
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Welding/ Welders Qualifications
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2.1
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Confirmed Welding Procedure Specification
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SUT1-Z05-Q00-4-005 WPS (AWS D1.1 Prequalified)
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Approved WPS & PQR
Approved Construction Drawing – Issued for Construction (IFC)
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ITR-QCI-011 Structural Steel Checklist(para. 2 & 4)
ITR-QCI-016- Steel Structure Fabrication
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I
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R
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R
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R
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2.2
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Cofirmed Welders(Welders Qualification Test & Contro)
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SUT1-Z05-Q00-4-030 Welder & Welding Operator qualification Procedure
SUT1-Z05-Q00-4-021 General Welding Procedure
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Conforming the AWS D1.1, Approved WPS & PQR
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ITR-QCI-0011 Structural Steel Checklist- para. 2 & 4)
Welder or Welding Operator Performance Qualification Record
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I
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W/R
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W
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R
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3.0
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Foundation Preparation
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3.1
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Confirmation acceptance of foundation
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Approved Construction
Drawing - (IFC)
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Signed “Release Form” from Concrete casting subcontractor/contractor
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QGI-002 Release Note
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I
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R
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R
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R
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3.2
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Control foundation level pad elevation & location
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Approved Construction
Drawing - (IFC)
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Elevation tolerance EL. ± 2mm., As per specification
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ITR-QCI-020- Foundation Pad Inspection Report
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I
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W/R
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W/R
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R
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4.0
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Inspection of Fabricated Items
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4.1
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Confirm Dimension Verification,(Before Erection)
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SUTO-ALL-C08-4-004
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Approved Construction Drawing – Issued for Construction (IFC)AWS D1.1/ D1.1M
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ITR-QCI-0011- Structural Steel Checklist- para. 2 & 4)
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I
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W
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R
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S
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4.2
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Visual inspection of workmanship including weld quality
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SUTO-ALL-C08-4-004
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Approved Construction Drawing – Issued for Construction (IFC)AWS D1.1/ D1.1M
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ITR-QCI-0011 Structural Steel Checklist- para. 2 & 4)
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I
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W
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S
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S
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5.0
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Steel Works Erection
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5.1
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Confirm column plumbness
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SUTO-ALL-C08-4-004
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Approved Construction Drawing – Issued for Construction (IFC)
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ITR-QCI-0018 Installation Record For Structural Steel
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I
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W/R
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W/R
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S
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5.2
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Confirm bracings are properly insta SUT0-All-C08-4-004lled
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SUTO-ALL-C08-4-004
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Approved Construction Drawing – Issued for Construction (IFC)
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ITR-QCI-011 Structural Steel Checklist(para. 5)
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I
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S
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S
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S
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5.3
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Confirm handrails, gratings, & stairways are correctly installed
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SUTO-ALL-C08-4-004
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Approved Construction Drawing – Issued for Construction (IFC)
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ITR-QCI-011 Structural Steel Checklist(para. 5)
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I
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S
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S
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S
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6.0
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Bolting
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6.1
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Confirm all nuts, bolts & washers have been fitted.
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SUTO-ALL-C08-4-004
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Approved Construction Drawing – Issued for Construction (IFC)
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ITR-QCI-011 Structural Steel Checklist(para. 3)
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I
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S/W
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S
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S
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6.2
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Confirm erection bolts have been replaced with high strength bolts(where applicable)
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SUTO-ALL-C08-4-004
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Approved Construction Drawing – Issued for Construction (IFC)
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ITR-QCI-011 Structural Steel Checklist(para. 3)
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I
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S/R
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S/R
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S
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6.3
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Confirm bolt torque
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SUTO-ALL-C08-4-004
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Approved Construction Drawing – Issued for Construction (IFC)
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ITR-QCI-0017 Bolt Torque
Inspection record for Structural Steel
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I
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W/R
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W/R
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R
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7.0
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Field Welding (As per Drawing- Field Points)
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7.1
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Confirm welding works is carried out in
accordance with approved procedures
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SUT1-Z05-Q00-4-006 WPS & PQR procedure
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Conforming the AWS D1.1
Approved WPS & PQR
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ITR-QCI-0019 Welding Inspection Record
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I
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S/R
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S/R
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S
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7.2
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Visual Inspection of welding
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SUT1-Z05-Q00-4-006 - WPS & PQR Pprocedure
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Conforming the AWS D1.1
Approved WPS & PQR
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ITR-QCI-0011 Structural Steel Checklist(para 4)
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I
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W/R
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W/R
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S
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7.3
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Non Destructive Testing (NDT) of welding works
(As per 11.0 NDE)
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SUT1-Z05-Q00-4-006 - WPS & PQR Procedure
SUT0-All-C08-4-004
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Approved Construction Drawing – Issued for Construction (IFC)
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ITR-QCI-0019 Welding Inspection Record
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I
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W/R
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W/R
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S/R
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8.0
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Grouting
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8.1
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Confirm grouting is complete
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Approved Construction Drawing – Issued for Construction (IFC)
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Grouting must be done after column verticality is plumbed
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Grout Inspection & Test reports
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I
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W
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S
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S
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8.2
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Confirm final anchor bolt torque after grouting
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Approved Construction Drawing – Issued for Construction (IFC)
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Approved Construction Drawing – Issued for Construction (IFC)
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ITR-QCI-025- Final inspection for Structure Steel
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I
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W
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R
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S
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9.0
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Final Inspection
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9.1
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Carry out Final inspection of the structure
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Approved Construction Drawings
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Approved Construction Drawing – Issued for Construction (IFC)
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I
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W
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R
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W
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10.0
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Repair/ Adjustment & Re-fabrication
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10.1
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Confirmed material
- Receiving Inspection of Materials
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Site Receiving Procedure (SUT1-Z05-Q 00-4-023)
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Approved Construction Drawing – Issued for Construction (IFC) & Mill Certificates & Factory Production Control Certificates (FPC), No physical defects, Safeguards against adverse environment
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ITR-QMI-001- Receiving Inspection Report
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I
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W/R
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W/R
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S
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10.2
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Marking & Cutting
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SUT1-Z05-Q00-4-005 WPS (AWS D1.1 Prequalified)
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Approved Construction Drawing – Issued for Construction (IFC), Approved tolerance – ASCI specification for Structural Steel Buildings
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ITR-QCI-016- Steel Structure Fabrication
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I
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W
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S
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S
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10.3
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Fit up Check
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SUT1-Z05-Q00-4-005 WPS (AWS D1.1 Prequalified)
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Approved joint detail As per WPS.
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ITR-QCI-016- Steel Structure Fabrication
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I
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W
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S
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S
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10.4
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Confirm Final Dimension Check
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SUTO-ALL-C08-4-004
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Approved Construction Drawing – Issued for Construction (IFC)
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ITR-QCI-016- Steel Structure Fabrication
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I
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W
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S
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S
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10.5
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Welding Visual Inspection
- Full Penetration welds 100%
- Partial penetration welds 50%
- Fillet welds 25%
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SUT1-Z05-Q00-4-005 (WPS)
(AWS D1.1 Prequalified)
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AWS D1.1 Tabl;e 6.1 & 6.2
All lifting lugs 100% MPI Test
- Verify NDT % has been completed
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ITR-QCI-016- Steel Structure Fabrication
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I
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W/R
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W/R
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S
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11.0
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NDE
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11.1
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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%)
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SUTO-ALL-C08-4-004
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AWS D1.1 Tabl;e 6.1 & 6.2
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NDE Report
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I
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W/R
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W/R
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S
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11.2
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Re-Painting/ Galvanizing (Touch up - Cold )
- Surface preparation
- Thickness of Zinc Coating/ Painting Cointing Dry film
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Approved MS for Painting Works
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Approved Materials Specification , Material Brochure & Catalogue Specification
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ITR-QCI-023 Painting Inspection Report
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I
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S/R
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S/R
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S/R
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11.3
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Adhesion Test(If necessary –Random sample Test)
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SUTO-ALL-C08-4-004
SUTO-ALL-P08-4-008
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As per ASTM D-3359/ISO 2409 (Type Type) or
As per ASTM D-4541/ISO 2624 ( Dolly pull-off))
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ITR-QCI-023 Painting Inspection Report
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I
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W/R
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W/R
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S
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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
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