Professional Documents
Culture Documents
Gip 1
Gip 1
Gip 1
Inspection
Plan
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1- GENERAL ......................................................................................................................................................... 2
1.1- Scope............................................................................................................................................................ 2
1.2- Definitions ................................................................................................................................................... 2
1.3- Language ..................................................................................................................................................... 2
1.4-Codes & Standard ....................................................................................................................................... 2
1.5- Client's rights for access to the site ........................................................................................................... 2
2- Reporting........................................................................................................................................................... 3
3- CATEGORIES OF MATERIAL AND EQUIPMENT'S ................................................................................ 3
3.1. Level Definitions: ........................................................................................................................................ 3
3.2. INSPECTION VISIT FREQUENCY ........................................................................................................ 5
3.2.1 SUBMITTION OF SUPPLY LIST ............................................................................................................ 6
4. Announcing Client for Inspection .....................................................................................................................12
5. Quality Control Plan and testing Plan (QCP) ...................................................................................................19
6. Final Book .........................................................................................................................................................20
7. Inspection Type and Extension..........................................................................................................................23
8. Inspection Documents ........................................................................................................................................25
9. Inspection at sub-supplier's workshop .............................................................................................................27
10. Documentation required for the issuance of Quality Test Certificate (QTC) ...............................................28
11. Test pieces for destructive testing ..................................................................................................................28
12. Repairs .............................................................................................................................................................28
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1- GENERAL
1.1- Scope
General inspection procedure (GIP) covers all procedure of quality control,
inspection and testing to be applied for local equipments supply
1.2- Definitions
The following words and expressions shall have the meanings hereby assigned to them
except where the Context otherwise requires:
- Client or buyer:
- Client Inspector: Means Client representative that nominated for inspection
and quality control activities(BARSOO)
- Local Supplier:
- Local Suppliers Inspector:
work
- Sub Supplier &/or manufacturer: Means the firm or company for local
supply employed by local Supplier
- Plant:
1.3- Language
All drawings, design, information's, documentations, erection, operation &
maintenance manuals & Instructions shall be in English &or Persian. The language
used during inspection as well as all correspondences shall be in English &/or
Persian
2- Reporting
Supplier shall furnish, with reference to the Plant it's implementing of updated
inspection and testing schedules during manufacturing based on updated project
progress report. Supplier also should provide permanent or temporary possibilities for
attending Client Inspector as required.
LEVEL A
Inspection Level A : is defined as a full stage inspection carried out
progressively from commencement of manufacturing to final acceptance, and
should be required on occasions where work program demands regular
attendance.
The scope shall include:
• Review/witnessing of source material's chemical and physical
properties- including metallurgical enhancement and traceability to approved
certification level.
• Verify the use of qualified welders and qualified welding procedures monitor
manufacturers'
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Level B
Inspection Level B is defined as specific stage inspection of equipment and final
inspection of equipment prior to shipment. Stages of inspection shall be agreed upon
during a pre-inspection meeting to be held with the Vendors after purchase award and
shall include:
• Scrutinize material test certificates
• Check at random of materials, dimensions, and finishes monitor
specific tests and stage
inspections
• Witness specific tests and stage inspection
• Auditing of the Vendors quality control program
• Witnessing final pressure and workshop performance testing on and
offload tests as applicable simulation of automatism and followed by inspection of
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each equipment item. Such frequencies are intended to cover inspection visits by
professional Inspectors only. The Contractor shall not combine inspection and expediting
functions, nor have them performed by the same individual.
The table of hot briquette plant equipment with considering level of inspection
shall be considered as table 1. The following table is as an example of DRI
equipment for information.
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Table 1
7 Structural
7.1 Special category steel *
7.2 First and Secondary category steel *
special equipment
8.1 Process and utilities filter and strainers *
8.2 Effluent treatment units *
8
8.3 Chlorine production and Chlorine package *
8.4 Nitrogen generation and Air separation unit *
8.5 Magnetic separator *
8.6 Refrigeration units(HVAC) *
8.7 Water treatment units *
8.8 Incinerators and solid disposal unit *
8.9 Exhaust stacks *
8.10 Lubricants, chemicals, resins, Catalysts *
8.11 Overhead cranes, hoists *
8.12 Lifting and Mobile Vehicles *
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11 Communication systems
Telecommunication equipment
- PA Systems *
- Intercommunication system *
-CCTV *
*
- Others
Instrumentation
12.1 Safety system PLC's(ESD,PSS,FG) *
12.12 Cables *
13 Miscellaneous
13.1 Equipment, materials or components not *
listed
above
2.3 Types of Inspection
The types of inspection are defined as follows:
- Visual - Each item is visually checked for compliance with the purchase order.
- Random - Where 10 to 15% of a batch of items, as selected by the authorized
inspector, are fully checked.
- Full - This is a visual check, plus a full test for each item of Category A and, where
specified, for Category B. In some case a complete test may have to be carried out in
few stages of construction at the factory.
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Warning:
If, during the random inspection, failures occur in the batch of selected items, the authorized
inspector may decide to increase the level of inspection to 100%
2.4 Spare Parts
When specified in the purchase order, spare parts for the above instruments or
instrument systems, comprising either part or complete systems, shall be inspected and
tested by the same factory inspection and testing procedures. However, spare components
for systems, such as printed circuit boards, etc. need only a 10 to 15% random inspection
by the authorized inspector
3. FACTORY INSPECTION AND TESTING
3.1 General
The purpose of ‘factory inspection and testing’ is to check that the instruments and instrument
systems to be supplied comply with the requirements stated in the purchase order.
Before attempting to carry out the inspection and especially the checking of calibrations, the
authorized inspector shall check that the factory test equipment, as supplied by the
manufacturer/supplier, is suitable for testing the instruments included in the purchase order.
The factory shall provide a Calibration Certificate with the Calibration carried out against
primary test equipment.
The manufacturer shall be able to prove that equipment used for calibration is traceable back to
national standards, with certificates issued by approved independent laboratories, institutes or
other bodies.
The following documents should form the basis of the manufacturer’s production system in the
order of priority as listed.
1) The purchase order and any subsequent variations.
2) Data/requisition sheets and drawings.
3) The Company’s standards.
4) The manufacturer’s quotation.
5) The manufacturer’s standard specifications.
6) The manufacturer’s standard quality control procedures.
Deviations from the above requirements will be allowed only with the written approval of the
Company.
Factory inspection shall be witnessed by:
- The Company; for ’in-house’ projects.
- The designer; for turn-key projects, either alone or (at the Company’s discretion)
accompanied by a representative of the Company.
- The designer/Company for other projects, as applicable.
Note:
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If, for any reason, the Purchaser waives inspection, this shall not relieve the supplier from
the responsibility of repairing at his own cost any defects found.
The Company’s and/or the Company’s third-party inspector or specialist shall have free entry
and access during normal working hours, to those parts of the manufacturer’s and/or
submanufacturer’s premises which are involved in the manufacturing and testing of
instruments and instrument systems applicable to the purchase order.
3.2 The Scope of Inspection
The basic scope of inspection will be defined by written notes giving the following information:
- The inspection agency.
- The engineer co-ordinating inspection activity.
- Pre-manufacturing/inspection meeting to be held (if any).
- Type of inspection i.e. running, intermediate, final.
- Requirement for a document review.
- Requirement for an inspection report.
- Any additional information.
Where other disciplines are involved in instrument inspection, the nominated instrument
inspector shall have overall responsibility for the release note.
The above instructions will be further clarified by the final inspection plan
4. THE INSPECTION PLAN
4.1 General
The manufacturer shall provide (with the quotation) a basic document entitled inspection Plan
for instrumentation this shall include all instruments and instrument systems which are subject
to inspection.
Objectives of the Inspection Plan:
- Establish the inspection activities specified in the purchase order.
- Finalise and agree all inspection and testing procedures by collating the purchaser’s
and manufacturer’s requirements.
- Allow the Purchaser to plan his inspection activities.
-Determine which inspections and tests at manufacturer’s/submanufacturer’s may or
will be attended and by whom.
- Define the activities which will be co-ordinated by the instrument, electrical or
mechanical inspectors.
- Establish a yardstick if payment is to be made in installments.
4.2 Types of Inspection Plan
Plan a - The Standard Inspection Plan - the manufacturer’s standard inspection and test
procedure, as approved by the Purchaser.
Plan b - The Amended Inspection Plan - the manufacturer’s standard inspection plan, but with
additional requirements of the Purchaser incorporated.
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For standard instrumentation, the manufacturers functional testing procedures should be added
to the inspection plan.
5. FACTORY INSPECTION DOCUMENTS
The basic document shall be The Instrument Inspection Report as described below.
This document shall be completed, signed and issued by the authorized inspector within 10
working days after the completion of inspection.
All sheets shall contain Company’s purchase order number.
5.1 The Instrument Inspection Report
The instrument inspection report shall cover all the stages of inspection given in the final
inspection plan, and the format should be as follows:
5.1.1 A cover sheet
The cover sheet shall contain:
- The type and title of the report.
- Name and address of the manufacturer/subsupplier.
- User’s complete purchase order number.
- Requisition number and revision letter.
- Inspection order number.
- Manufacturer’s reference.
- Date of report.
- Name and signature of the authorized inspector.
- Approval of the report by the inspectors management.
- Summary.
- Cross-references to other reports.
5.1.2 Table of contents
The following gives a typical example of the table of contents of an inspection report:
- Inspection reference data.
- Statement of Compliance.
- Scope of Inspection.
- Inspection Reference Documents.
- List of Subsuppliers.
-Test and calibration equipments used, test facilities, manufacturer personnel involved.
- Inspection activities/results, (all deficiencies and deviations even if rectified during
inspection should be listed).
- Review of manufacturer’s documentation.
- NONA/NCR (Notes of None Acceptance/None Conformance Report).
- Attachments.
5.1.3 Inspection reference data
This shall contain
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- Calibration/test notes.
- Inspection sheets if applicable.
- Certificate of conformance (electrical area classification).
-Letters and/or telexes approving deviations or granting concessions from specifications
and or requisitions.
-Minutes of meetings held before and/or during inspection stages.
- Release notes, NONA, NCR’s.
5.2 Completion of the Report
If so requested in the order for inspection, a factory Instrument Inspection Report shall be
completed by the authorized inspector.
A report may also be issued on final acceptance of sub-orders to the main purchase order.
However, this report shall be considered as intermediate and it shall be re-issued as part of the
final report. This is particularly applicable in the context of packaged units.
The Instrument Inspection Report shall be completed in five original sets and presented to the
Company.
5.3 The Non-Conformance Report
The non-conformance report is a quality assurance related document, for reporting all serious
deficiencies in a manufacturer/ supplier’s capabilities to supply manufactured items of the
required quality, for whatever reason, e.g. quality of work factory organization, test equipment
and assistance rendered, etc.
5.4 The Release Note/Note of Non-Acceptance
When the authorized inspector or inspection agency are satisfied that the instruments and or
instrument systems comply with the technical requirements and conditions of the purchase
order, a release note shall be issued.
The release note is an official contractual document and shall be completed carefully and
accurately. The purchase order number shall be clearly readable and the release note shall apply
to one purchase order only.
The release note shall be given to the manufacturer/supplier with copies to the user as indicated
on the form itself.
and Esfahan and 7 days for other city in advance necessary for traveling and
providing requirements due to plane and kind of tests.
• Any deviation in time of test activities shall be informed in reasonable time
to the client to avoid excess cost to him.
In items that is necessary to submit QCP , during sending document until approved by
client, the QCP was submitted is the criteria for construction and inspection.
If client presented a note on the documents, notes and documents provided
criteria for manufacturing and inspection .
For each item/equipment a Quality Control and testing Plan (Q.C.P) will prepare
that includes the Inspection references, method of inspection, Quality Plan, supplier's
inspector and client representative's responsibilities, acceptance criteria and type of
record/report Issued correspondence to the inspection and control conducted on
items. Any exceptional deviation has to be discussed between the client and the
supplier during manufacturing and before the start of inspection. Quality Control Plan
will include:
• Reference Specifications (includes project specifications, Drawings,
International standards, common practices or acceptable standards)
• Definitions
• Subprojects Name
• The name of Sub-supplier or Manufacturer of the subproject
• Scope
• List of drawings (Client DWG No.)
• List Of units
• Inspection Test Plan (ITP)
• NDT Map (plans)
• Level II time schedule of proceed
• Contractual number
• Inspection Class
• Weld Map (plan)
• Painting cycle and color coding
• Instruction of tests
• Appendixes (include specifications, Guidance for Inspection and QC forms
if there is)
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6. Final Book
Final Book is final quality documents for each item and includes a collection of inspection
documents and it will be completed gradually during the inspection activities.
Final book at the end of inspection and issue of certificate shall submit to the client
representative for final approval. One complete copy of each Final book will be delivered to the
client.
Final book shall include the following documents:
- Mechanical equipment and steel structures:
8- Bill of lading
9- Inspection Release of Equipment (IRE)
10- Inspection Release of packing (IRP)
11- Certificate of origin
12- Certificate of conformity
13- Invoice
14- IC
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ITEM DOCUMENT A B C
MI SI CI MI SI CI MI SI CI
1 Material Certificate (Major A A R A A R A A R
Items)
2 Welder Qualification A A R A A R A R R
3 Welding A A A A A A A A A*
Procedure_Qualification
12 Performance/Function Test H H H H H H H W W*
14 Type Test H W W H R R - - -
COMMENT:
1-R= REVIEW : Each of the Contractor's QC inspectors will summarize their daily
inspections in a daily report. The Department's Daily Report of Construction or a
similar form shall be used for maintaining a written record of inspection results.
Original records are to be maintained by the Contractor and available upon request
for review by the client or consultant.
H=HOLD : Hold Points are mandatory verification points identified by the Client
or consultant beyond which work may not proceed until the Contractor notifies the
Client or consultant and the Client or consultant performs mandatory verification
and gives notice to the Contractor to proceed.
A=APPROVE
2-performance and functional test= mechanical Run, vibration, noise, temperature & act
test; *: Except catalogue items
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8. Inspection Documents
LEVEL
ITEM DOC U M EN T
A B C
Material Certificate
1 2.3 2.3 2.3
(Major Items)
2 Material receiving control 3.1A 3.1A 3.1A
3 Welder Qualification 3.1A 3.1A 3.1A
Welding Procedure
4 3.2 3.2 3.1A
Qualification
9.4. Sub-suppliers, as the case may be, shall provide free of charge to supplier
& client adequate office space, secretarial assistance and telecommunication
services during the execution of inspection activities as per Contract.
9.5. Where the contract provides for tests on the premises of a supplier or of
any sub supplier, said sub supplier shall provide such assistance, labor,
materials, electricity, fuel, stores, apparatus and instruments as may be
required and as may be reasonably demanded to carry out such
test efficiently.
9.6. Safety: During test execution the safety regulations, in force in the country
where the inspection takes place, shall be fulfilled by the manufacturer. Safety
garments, whenever required, will be made at disposal of the client's inspectors
9.7. Sub-supplier should be selected from approved vendor list .If they are not in
vendor list, before starting the contract, it is essential that approval from client should
be taken.
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12. Repairs
In case of defect or deficiency which affects any critical item, sub supplier shall
submit to the supplier, before proceeding to make good the defect or deficiency, a
report explaining the measures they intend to adopt, and their consistency with
applicable Standards. All relevant reports should be submitted by supplier to Client.
13. Packing and Marking
The Packing and related marking will be provided in separate specification.