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Guidelines for the Preparation of Inspection and Test Plans. FPA-G-0001/A
MARCH 2004


0 3.FPA-G-0001/A Contents 1.0 2.0 4.0 4.4 INTRODUCTION AND SCOPE CODES. PROJECT SPECIFICATIONS AND REFERENCES DEFINITIONS REQUIREMENTS General ITP Review ITP Intervention Points Inspection And Test Performance Minimum Requirements for ITP‟s Use of Inspection & Surveillance Points Page 1 1 1 1 1 2 2 2 A1-A2 B1-B4 Appendix A Appendix B C:/endi/FPAITP .3 4.1 4. STANDARDS.2 4.

0 REQUIREMENTS For each separable fabrication or construction portion of the Work. Review) C:/endi/FPAITP . the Contractor shall provide an Inspection Test Plan (ITP) in accordance with the Contract Document Requirements.0 INTRODUCTION AND SCOPE These Guidelines are issued to advise Contractors/Subcontractors‟ of the requirements for Inspection and Test plans and the inspection and testing of equipment/materials provided to Fremantle Ports (FP‟s) for the Kwinana Bulk Terminal KBB2 Grab Ship Unloader Project. 4. 4.0 CODES.g. Review. Inspection.1 General ITP‟s shall identify. installation and servicing‟ or an equivalent standard shall be complied with. The ITP‟s shall identify:     Project Identification (project name. Test. 3. 2.FPA-G-0001/A Page Number 1 1.0 DEFINITIONS These shall be as outlined in the General Conditions of Contract. ITP format shall be in accordance with that shown in Attachment 1 (Page 1) „ITP Cover Sheet‟ and Attachment 2 (Page 2) „ITP Continuation/Activity Sheet‟ and shall contain the minimum requirements identified in Appendix A. in Contract detail schedule sequence. Monitor. Witness. plus the following: “AINDT” means the Australian Institute of Non-Destructive Testing” “Manufacturer's Data Report” (MDR) means a volume or number of volumes compiled by Suppliers. certification and objective evidence of compliance with requirements appertaining to material or equipment for the Project. those activities where formal intervention is deemed necessary to prevent the Work progressing beyond a point where failure to implement such control may prejudice the integrity of the Work. Visual. Send against activities. These inspection and surveillance point activities are defined in Appendix B. Dimension. PROJECT SPECIFICATIONS AND REFERENCES The requirements of AS/NZS ISO 9001/2/3 (as appropriate): 1994 Quality Systems „Model for quality assurance in production. PO/Contract job number) Work scope description Activity Number Verification Activity (e. ITPs shall contain provision for the Principal and Certifying Authority to nominate inspection and surveillance points such as Hold. STANDARDS. containing records.

g.4 Inspection And Test Performance The Contractor shall ensure that all the inspection. or its Agents. Non-destructive testing personnel shall be currently qualified under the AINDT certification scheme. Review. C:/endi/FPAITP . or under a comparable scheme acceptable to the Principal. for the category of non-destructive examination being undertaken.g. are incorporated in the ITPs re-submitted to the Principal for acceptance. including Principal and Certifying Authority intervention points. Witness. recorded. conducted in accordance with all Contract Specification requirements. documented. in number. Report. 4.2 Applicable Standards Codes and Specifications Acceptance Criteria Verifying Document (e.FPA-G-0001/A Page Number 2       4. Chart) Extent of intervention by Principal/Contractor and/or its Agents Type of intervention by each party (e. authorized and established in the Manufacturer‟s Data Report. 4. The Contractor shall also ensure that work is not undertaken without the required intervention and/or without timely notification to the Principal.3 ITP Intervention Points The Contractor/Subcontractor shall not progress affected Work beyond ITP intervention points without Principal approval nor without due notification of an impending ITP activity which requires Principal/Contractor and/or Certifying Authority attendance. test and verification requirements nominated in the Contract specifications (including destructive and non-destructive testing) are:    addressed in Contractors ITPs. Hold. Certificate. type and form. Approve) Sign-off for each activity ITP Review The Contractor shall submit ITPs to the Principal for review and approval prior to the commencement of affected Work and shall ensure that the Principal‟s review comments.

Each step should identify:     The various checks or tests that are planned to take place. The applicable codes and standards used. The documents that will be provided to verify fulfillment of requirements. A different format is acceptable. PO or Contract number.g. The in-house control procedures that will be used. all the stages of development of goods or service from start to completion and follows progression of the planning schedule for the work. Acceptance criteria (applicable codes. C:/endi/FPAITP . Workshop or Sub-contractors. Description of work. listed and numbered in steps. provided it contains the following: Cover Sheet The front page of the ITP containing:        Project name. standards. specifications and other documents). Each step to have space provided to identify:  location of activity. Unique ITP number and revision status. e. FORMAT A typical format for an ITP is provided in Attachments 1 and 2 to this Specification. Office.1 APPENDIX A MINIMUM REQUIREMENTS FOR ITPs ITPs are required to show (in steps). Contractor‟s/Subcontractor‟s name and location. Legend to show the interpretation of any abbreviations used.FPA-G-0001/A Appendix A Page Number A. Approvals Continuation/Activity Sheet(s) A page or series of pages containing a description of all activities required from start to completion of work.

specification or procedure. Inspection/Surveillance Activity (witness.g. standard.2     the controlling document reference. e. acceptance Criteria to be used. ASME V or API 6D etc. (usually the document which will be included in a Manufacturers Data Report).FPA-G-0001/A Appendix A Page Number A. the certifying or verification document reference. with space for verification. monitor or hold points) by the Contractor. C:/endi/FPAITP .g. Principal and Certification Authority. e.

e.FPA-G-0001/A Appendix B Page Number B. Provides a guide to the inspector on the extent of inspection required and is always accompanied by the:   inspection activity(s) required. Visual (V): Instructs the inspector to visually inspect the Product or process.1 APPENDIX B USE OF INSPECTION AND SURVEILLANCE POINTS Hold (H): Sufficient „holds‟ must be used to ensure that product or service does not progress beyond a point where further work (without the required inspection/surveillance) may render the produce or service unacceptable. Review (R): Instructs the inspector to physically examine all quality records that are applicable to the inspection or test detailed and to endorse the records with his/her personal stamp or signature. V. an approved third party or Certifying Authority.g. R.  for a single product . Send (S): Identifies for the Contractor and inspector that verification documentation is required by the Principal for the test or inspection that has been identified. 50% Witness (W): Used to identify specific tests or inspections desired to be witnessed by the Principal. Hold points are:    only used when it is imperative that specified inspection takes place: always accompanied by the required inspection activity(s). R. A percentage accompanying the V applies to either single or multiple products in the same manner as for dimensional inspection. A witness point requires the Contractor to advise the time and location for inspection but does not require a hold to the process or production until the Principal inspector is present. V. conclusive evidence of conformance to specifications. or D or a combination. D.g.g. or W or a combination of several.the extent of dimensional checks required. e.g. e. Used to secure an opportunity for the inspector to watch or inspect a stage of the process or work for which it may be difficult to obtain timely. Dimension (D): Instructs the inspector to physically check the dimensions of a product. Monitor (M): Only used when a repetitious process or multiple similar materials are being inspected. Such documentation is always required as part of the MDR. A percentage accompanying the D.the number of items to be dimensionally checked. e. percentage (%) of the process or materials to be inspected. instructions to the contractor that work cannot proceed until inspection takes place or the Principal grants a concession. C:/endi/FPAITP . D 25% means:  for multiple products .

FPA-G-0001/A Appendix B Page Number B.3 ATTACHMENT 1 PURCHASER: PO/CONTRACT NO: DOCUMENT NO: __________________________________________ __________________________________________ __________________________________________ INSPECTION AND TEST PLAN PROJECT/LOCATION: DESCRIPTION OF WORK: REVISION: Page 1 of 2 ________________________________________ ________________________________________ ________________________________________ REVISION STATUS REV DATE APPROVAL INSPECTION/SURVEILLANCE KEY INSPECTION ACTIVITY DEFINITION APPLICABLE CODES/STANDARDS All Codes & Standards are the latest Editions unless otherwise noted example: AS-1210.D or W Monitor on a random basis always accompanied by V.R or D Witness by: Principal/Contractor. (M) Monitor (W) Witness (D) (V) (R) (S) Dimension Visual Review Send APPROVALS Prepared By: Date: / /Approved By: Date: / / Principal Approval Date: / / C:/endi/FPAITP . AS/NZS ISO9001 ABBREVIATIONS/DEFINITIONS Abbreviations used to describe control/verifying document example: MC P PO WPQ (H) Hold Work must not proceed unless inspection activity is carried out.R. Third Party or Certifying Authority Dimensional check required Visual Inspection Examine/Endorse records Send verifying documents for approval Material Certificates Procedure Purchase Order Weld Procedure Qual. Always accompanied by V. ASTM A 193.

FPA-G-0001/A Appendix B Page Number B. Activity Description Location Standard/Drg Specification Reference Clause or Section Acceptance Criteria Certifying Verifying Document Contractor Initial Inspection/Surveillance Activity Principal Initial Certifying Authority Initial C:/endi/FPAITP .4 ATTACHMENT 2 Page 2 of 2 INSPECTION AND TEST PLAN Document No: Revision No: Controlling Document Activity No.