Quality Control Plan

Client:

Project: All

Job No.:

Author Approved by Client Approval

Name
Title
Date

Key:

A Approve Activity
ICB Independent Competent Body
R Review. Compare data record with client specified acceptance criteria.
H Hold. Process / activity should cease until instructed by QC department.
W Witness. Process / activity to be witnessed, documented and maintained.
M Monitor. Review processes / activities periodically to ensure progress.

P.M Production Manager

Q.C Quality Control P.E Project Engineer
S/MC Stores / Material Control W.S Workshop Supervisor

1) Applies to Percentage Activity. Petrofac / ICB to be advised when activity is to commence.

2) Applies to Safety Critical Fabrications only.
 1- Document Approval

Acceptance Verification Inspection

Ref Process Activity QA / QC Activity QP Ref
Criteria Documents
Shahab Client ICB
P.E. Order Receipt-Review Contract Register-Allocate Unique Conformance to Contract Review
R
P.M. and Job Specifications. Job No. Original Quote. Documents

Acknowledge Receipt by
P.E. Receive Drawings and Client
Signing and Dating Client N/A R
P.M. Specification. Drawings/Specifications
Transmittal.

P.M. Review Drawing and Contract. Finalise Full Work scope. N/A Contract Documentation R

Register Drawings & Drawing

Check Approved for Construction
P.M. Documents. Identify N/A Register/Transmittal R
Drawings & Documentation
Issue & Revision Status. Sheets.

Prepare NDT Schedule From Client

Supplied AFC Drawings & Data. Check AFC Drawings Clients acceptance
Q.C AFC Drawings & Data. H/R
Prepare Material Traceability Issue/REV Status. criteria
sheets.

PM Submit Weld Procedures For Client Ensure Compliance with Weld Procedures
Approved procedures H/R H/A R (2)
Q.C Approval. Client Requirements. Approval Sheets.

Ensure Welders
Welder Qualifications
Q.C Review Welder Qualifications Qualified To Approved N/A H/R R R (2)
Matrix.
Weld Procedure.
 2- Material Control

Acceptance Verification Inspection

Ref Process Activity QA / QC Activity QP Ref
Criteria Documents
RFL Client ICB
Receive Client Free Issue Material
Identify Shortages,
& Check Shahab co. Supplied
Damage, Quantity &
Material. Perform Materials Material Material Receipt Sheets,
S/MC Report. Check
Receipt Inspection-Mark Specifications/ Test Certification, H/R R R (2)
Material/Test
Identification Numbers Against Certificates. Delivery Notes.
Certificates & Verify
Supplied Test Certificates &
Conformance to Specs.
Delivery Note.

S/MC Report Non-Conformances on Carry Out 2nd Inspection- Non-Conformance

Material Specifications H/R H/A
Material Damage Etc. Raise NCR Report.

Material & Goods To Be Stored In

S/MC Check Storage/Handling Client/Suppliers
Accordance With Clients Relevant Specification. H/R M
Of Goods & Materials. Specifications.
Requirements.

S/MC Issue Material/Items For

N/A AFC Drawings Material Control M M
Fabrication

S/MC Check Material

Material Allocation/Traceability Material Receipt Logs Material Control Sheets M M (2) M (2)
Index/Traceability Logs
 3- Fabrication

Acceptance Verification Inspection

Ref Process Activity QA / QC Activity QP Ref
Criteria Documents
RFL Client ICB
Check Structural/Piping Confirm all Structural
Q.C AFC Drawings AFC Drawings, Piping
Drwgs/Procedures Revision Status- /Piping Drwgs are R M
WS Procedures. Isometrics.
Issue for Fabrication. Current Status.
Check-Mark Out-
Draw Material From Stores &
Transfer Identification AFC Drawings AFC Drawings Piping
WP Return all Surplus Materials to Job Spec M M
No’s To All Off Cuts. Isometrics.
Stores
Check Material Type.
Check Prep Angles
Prep & Clean Weld Ends on Approved Weld
WP Against Relevant Weld Job Spec Weld/NDT Logs. H/M M (2) M (2)
Material. Procedure
Procedure.
AFC Drawings.
Sample Check Fit Up
WP Approved Weld
Assemble & Fit Up Components. Dimension-Root-Gap. Job Spec Weld/NDT Logs. M M (2) M (2)
QC Procedures.
Tack Welding.
Check Welders Qualified
- Ensure WPS Correct -
Consumables Comply
With WPS. Check Pre-
Job Spec, NDT
Heat Requirements,
WP Weld Components. Drawings, Piping Weld/NDT Logs. M M (2) M (2)
Weld Parameters,
Isometrics.
Consumables, Interpass
Temperature, Weld
Interruption & Record
Welder Indents.
 4- Fabrication cont.

Acceptance Verification Inspection

Ref Process Activity QA / QC Activity QP Ref
Criteria Documents
RFL Client ICB
Visual Examination Of
QC Check Completed Welds. Job Spec Weld/NDT Logs. H M (2) M (2)
Welds.

Carry Out Dimensional

QC Dimensional Control. Job Spec AFC Drawings M/R M M (2)
Survey.
Client Approval of NDT
WS Submit NDT Procedures. Approved Procedures NDT Procedures. H/R R R (2)
Procedures.

Check NDT
QC Carry out NDT On Welds Requirements. Raise PO Client spec NDT Reports/Radiographs H/R/M R R (2)
For NDT Sub Contractor.

Check Reports for

Accuracy & Legibility, NDT Reports/Radiographs
QC NDT Client spec H/R/M R R (2)
Identify Repairs/Area
Where Found.

Identify Non-Conforming
Welds, Place on Hold NDT Reports/Radiographs
WP Repair Welds As Required. Job Spec H/R/M R
Until Disposition
Actioned.

Check Loadtest
Requirements/Raise PO
QC Load testing Job spec Reports H/R/M R R (2)
for Loadtest Sub
Contractor
Check Reports for
QC Loadtest / Post load test ndt Client spec Reports H/R/M R R (2)
Accuracy
 5- Strength & Leak testing

Acceptance Verification Inspection

Ref Process Activity QA / QC Activity QP Ref
Criteria Documents
RFL Client ICB
Client Approval for Approved
WS Submit Testing Procedure Approved Procedure H/R/W R R
Testing Procedures Procedures
Check Welds
Complete Monitor
Test in Accordance
Clients Specs Hydrotest
QC Testing Items with Procedure. Carry W/R W (1) (2) W (1) (2)
Reports/Graphs
Out Final Visual. Carry
Out NDT where
required.

6- Coating

Sample Check On
Completion That
WS Submit Coating Requirements
Coating Is Per Client spec Coating Reports. R/W R/W
QC Procedure.
PO/Procedure. Carry
Out Visual.
 7- Final Inspection and Despatch

Acceptance Verification Inspection

Ref Process Activity QA / QC Activity QP Ref
Criteria Documents
RFL Client ICB
Final Visual Ensure compliance
WS
Final Inspection Inspection, Review with contract Contract requirements R/W H R (2)
QC
all Documentation requirements
Cleanliness, Flange Faces
& Machined Surfaces
are Protected, Items Are
QC Contract Release And Dispatch
Despatch Ready For Shipping Etc. H/M W
WS Requirements Notes.
Prepare: Release
Dispatch Notes. Ship To
Client.

8- Documentation

Check All QC
Documentation Is In
Order, Prepare Contract QC Documentation
QC Documentation H/R R/A R (2)
Completed Contract Requirements. Package
QC Pack. Submit To
Client For Acceptance.