approach to inspection.pdf

7/26/2019 APPROACH TO INSPECTION.pdf

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SBU-Quality Services

Approach to Inspection

& Reporting

ByM. Bhoopathy


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The Process: Receipt of Inspection Notif ication from Client/Supplier/RIC

Preparation:

Establishing Contact with Supplier

Verification of Authenticity of the Inspection Notification

Awareness of the Material / Equipment to be inspected including

functional requirements

Verif ication of technical inputs available with office/ Supplier

Contract Code

Chargeability

Formats to be used

Verif ication of earlier Inspection Documents, if any


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At Suppliers Location:

Contact the concerned personnel

Verification of applicable (approved) documents like MR, PO,

Drawings, ITP, Specifications, Procedures, Data Sheets, WPS, PQR,

WPQR and/or any others

Verification of Vendors Internal Inspection Reports such asdimensional reports, NDT reports, Certified Material Test Reports

(CMTR), Pressure Test reports as per ITP

Availability of calibrated instruments/equipments with Supplier

Verify if the calibration certificates of the instruments / equipments

are traceable to National / International standards


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Sampling :

Sampling plan as per ITP/Customer Approved Document or

Applicable standard

Normally sampling is 100% or Random

Percentage of random sampling is to be specified in the approved

document. If not, the same should be clarif ied from Customer.

In case the Customer is not available/reachable, enquire with the

Supplier on what he intends to offer. Carryout inspection of the

offered materials and record in the report. Seek final decision offrom Customer

Identify the samples witnessed with Sr. No. / Identification No.


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Explanation of Hold, Witness, Review, Verification:

HOLD (H):

Hold points are defined as critical steps in manufacturing and

testing whereby SELLER is obligated to advise the

BUYER/BUYERS REPRESENTATIVE in advance of the operation

so that it can be witnessed.

The SELLER cannot proceed with work past the hold point without

witness by the BUYERS REPRESENTATIVE, except by prior

writ ten authorization of the waiver.


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Explanation of Hold, Witness, Review, Verification:

WITNESS (W):

Witness points are defined as critical steps in manufacturing and

testing whereby SELLER is obligated to advise the

BUYER/BUYERS REPRESENTATIVE in advance of the operation

so that it can be witnessed.

The SELLER may proceed with work past the witness point if the

BUYERS REPRESENTATIVE can not attend. Seller will keep

record of the inspection activity for review of Buyers

representative.


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Explanation of Hold, Witness, Review, Verification :

During the next visit, any similar activity may be witnessed and

reported.

REVIEW (R):

Inspection by review of documentation

Suppliers advance notification is not required.

VERIFICATION (V):

Not a standard term, though f inds use with many CustomersCare should be taken while interpreting the term

It can include physical verification of the job, like a joint, a dimension

before signing off the document.

Should be defined clearly before using the term V


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Inspection-Visual & Aesthetics:

Checking completeness with respect to BOM / Drawing / Part List/

P&ID

Cleanliness of the equipment / assembly / system

Weld Cleaning

Verification of bought-outs for Make, Model with respect to

Customer approved documentation


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Inspection-Visual & Aesthetics:

Matching of components, wherever possible, if the components are

assembled at Project Site

Match marking (Should be mentioned in the Inspection Report, if not

match marked)

Flatness, buckling, dents, scratch marks, temporary tacks & cleats,

finish

Preparation for shipment (if in scope of inspection)


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Dimensional Inspection:

Check:

Appropriate measuring instruments (accuracy,

least count etc)

Completeness

Orientation

ElevationVerticality

Straightness

Alignment

Water levelBase frame dimensions

Fitment dimensions


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Dimensional Inspection:

Check:

Keys & key-ways (with slip gauges)

End connections

Threads (with gauges)

Counter f langes

FlatnessTwist

Distortion

Staggering of nozzles / holes

Flange type & serration


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Non-Destructive Testing (NDT):

To be Witnessed for HOLD or WITNESS

To be reviewed for REVIEW

EXCEPTION: Normally Radiographs are reviewed for conformation

to specification. In such case, it should be recorded in the reportas Films Reviewed , Radiographs Reviewed while signing off

the RT report

Verify the calibration requirements of the equipment before

witnessing NDT

Verify approved makes/validity of consumables


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Pressure Test (Hydrostatic / Pneumatic):

Preferably to be carried out with an approved procedure

Minimum two pressure gauges should be used (difference in

reading between two gauges should be 2% of test pressure

maximum)

Range selection of the Gauge (1.5 to 4 times the test pressure)

Dial Size (minimum 2 required by some Customers)

Gauges should be calibrated

Calibration certificates should be traceable to National OR

International standards


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Location of Gauges on the job (one at the bottom and the other at

the top location)

Location of vent

Water analysis is available (for Stainless steel equipments)

Safety: Hydrostatic test location should be away from normal

work place, proper scaffolding should be available (if required)

Temperature Rise during test


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Circumference of vessel before, during and after hydrostatic test

Pressurizing; Should be done gradually. The Supplier should

carry out hydrostatic test internally before offering to Inspector

Hold Period: As per the approved procedure or standard

Visual Inspection: All area should be visually seen after the Hold

period. Inspector to take help of light to increase visibility.

Observe pressure drop, if any.


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Painting:

Surface Preparation: Roughness and finish

Painting system

Monitor Climatic conditions: Humidity, temperature, cleanliness

(painting booth)

Verify storage facil ities of paints

Verify Manufacturers batch No. of the paint (base and hardener)

and their expiry dates

Verify the interval between two coats of paint


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Painting:

Inspect:

Paint shade

Dry Film Thickness (DFT)-Minimum and Maximum Value

Wet Film Thickness (WFT) if required

Scratch test

Adhesion test


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Documentation:

Final Documentation / Inspection Record Book / Manufacturing record

Book / Manufacturers Data Record / Final Disposit ion Record

Documentation should be reviewed by Supplier for correctness before

submitt ing for Inspectors review

Check testing, if required, should be done for all the specifiedelements of the standard, including the TRACE elements

Verify Material Certification required

Documentation should be reviewed with respect to a specification(refer spec.)

Supplier to ensure any specific format requirements of Customer


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Documentation:

Documents should be prepared by Supplier as per approved ITP or

procedure

Documents should be compiled by Supplier with respect to an Index

All the sections of the final documentation should be traceable to

Main Index. The individual sections should have sub-index

All the sections of the final documentation should be traceable to

Main Index. The individual sections should have sub-index

All the pages of the Final Documentation should be progressivelynumbered

Documentation should be complete, legible


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Material Certification (BS EN 10204):

Types of Material Certification requirements:(Based on Crit icality of Service)

Type 2.1Type 2.2

Type 3.1

Type 3.2


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BS EN 10204-Type of documents

Non-specificinspectiondocuments

Name: Declaration of

compliance with the order

Content: statement of


(doesnt include test

results!)

Who validate it - the

manufacturer

Type 2.1Type 2.1 Type 2.2Type 2.2

Name: Test report



(include test results!)


manufacturer


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BS EN 10204-Type of documents

Specificinspectiondocuments

Name: Inspection certif icate 3.1



(include specific test results!)


manufacturer inspection

(independent of manufacturing

department!)

Type 3.1Type 3.1 Type 3.2Type 3.2

Name: Inspection certificate 3.2

Content: statement of compliance

with the order (include specific

test results!)

Who validate it - the manufacturer

inspection (independent of

manufacturing department!) +

purchasers/official designated

authorised inspector


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Conduct of Inspector:

Surveyor represents the Organization. Hence, conduct of the

Surveyor reflects the Organization's culture and value

Surveyor should be impartial, unbiased, honest and should

conduct himself with high dignity in any situation

Surveyor should not indulge in any sorts of unwarranted

argument with Suppliers personnel

Surveyor should not disclose information of one supplier/client to

other supplier/client


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Report writing

Reporting


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Report Writing

RememberYou are the one actually seeing the Equipment/item

Where asThe Customer is visualizing the Equipment/item through your

report


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Report Writing

Inspection Report


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Report Writing

What Do Customers look for in Inspection Report?

Simple

Legible

Complete

Decisive

Conclusive


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Report Writing

Simple Report

For Eg:

Visual-Satisfactory.

or

Visual: Undercuts noticed on CS1 between 90-180,

to be rectified. Other areas visually found ok.

Simple report does not mean insufficient information


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Report Writing

Legible Report

Use black pen 0.5 tip

Write in block letters

Use soft version maximum possible


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Report Writing

Completeness

Verify that all requirements are ensured as per P.O, Drawings,

Technical Specification, ITP as applicable.

Sequence the report, preferably as per the ITP Sl no/contents.

Mention all the documents referred including revision numbers.

Ensure that all the information are ticked/fil led as applicable.

Qty - inspected/accepted/rejected/hold are exactly f illed in

Reference to the previous reports and content, where applicable


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Report Writing

Decisive

Ensure that you are decisive in each stage

For eg: RT films reviewed and found acceptable.

or

Slag to a length of 19 mm observed in LS4 segment AB

against 12 mm as per code. Not acceptable.

If the requirements are clear, do not expect client to

clarify.


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Report Writing

Conclusive

Client may not have time to go through complete

report

Conclusion of your report is very important

If you seek customer clarification, elaborate and be

specific on what customer need to do. (seek

clarification only if you do not have the acceptance

norm)


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Report Writing

Expediting Report


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Report Writing

What do customer look for in your expediting report?

What is the expected delivery

What is the back up for your assessment

What are the constraints

What should I (customer) do

What should supplier/others do


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Report Writing

Make a Comprehensive Report

Your report should cover

Availability of P.O

Acknowledgement of P.O

Status of Engineering activities

No of drawings & size

under preparation

under approvalcommitment for submission


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Report Writing

Status of QAPs

Whether prepared

Submitted for approval

Commitment for submission


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Report Writing

Status of Materials

Consolidated list of materials/BOQ

Whether ordered

Verify proof of ordering

Verify delivery schedule as per sub p.o.

Check with sub supplier in case of critical materials

Whether received at shop

When expected


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Status of Bought Outs

Whether ordered

Verify sub P.O.

Check with sub supplier If necessary make a visit/recommend visit

Commitment for delivery

Report Writing


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Status of Manufacturing

Verify bar chart/mfg schedule

Verify availability of resources

Men

Machinery

Materials

Verify present load and shop commitments

Project the expected delivery based on your overallobservations

Report Writing

R t W iti


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Highlight where there are possibilities of slippages

Could be

Design

Resources

Client

Summarize action points

Identify responsibili ties

Get the time frame

Highlight

What Who

When

How

Report Writing

R t W iti


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Report Writing

Follow Up

Keep track of action points

Keep client informed of developments (over phone,mail etc if there is no immediate visit)

R t W iti


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Report Writing

Some Tips

Take notes of your findings

Sequence your findings

Verify all Points are addressed

Report Writing


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A Simple way is Self Audit

or

A re look at your report before signing

Report Writing

Report Writing


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Report Writing

Your report is the ultimate one which converts our

service into revenue

Each of our inspection visits are to be charged

correctly

Ensure that all columns are filled correctly QS No,

Report No, Date etc

Remember billing personnel are non technical and allyour entries are to be accurate.

Report Writing


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Report Writing

Doubts! Please Do Not Hesitate To Ask


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Thank you