QUALITY CONTROL REQUIREMENTS

FOR LARGE VOLUME BULK ORDERS

2. DEFINITIONS
2.1. Terms
Term Description
Acceptance Maximum reject number in a sample causing rejection of the
Number whole lot
Contractor Entity engaged by company to perform Work.
Corrective Action Action taken to eliminate the cause of a nonconformity or other
undesirable situation.
Criticality Rating A value assigned to systems and products based on established
criteria used to determine priorities for project team and contractor
activities.
Heat The total amount of metal produced which can be represented by
one analysis sample and one set of mechanical tests
Inspection Release A document indicating that required inspections have been
Certificate/Notice completed and the material or product is released to the next
activity.
Lot A particular group, collection or set of items with the same
specified requirements in an order, manufactured under the same
conditions and in the same continuous time period
Lot Size Number of items in a lot
Nonconformity The non-fulfillment of a requirement.
Order Size The total number of items in a PO having the same specified
requirements
Procurement Contracting and purchasing of materials, products, and services.
Quality The ability of a product, service, or activity to meet or exceed
requirements.
Sample Number of items from a lot to be tested
Reject An item containing one or more nonconformities worthy of
deeming the item as rejected under the purchase order
specifications
Subcontractor Entity engaged by contractor to perform all or portion of
contractor's work scope.
Vendor Manufacturer or distributor that provides products and/or
materials to a purchaser.
2.2. Acronyms
Acronym Description
ITP Inspection and testing plan
MTO Material takeoff
MTR Materials test report
NDE Nondestructive examination
PIM Pre-inspection meeting
PO Purchase order
RFQ Request for quotation
3. OBJECTIVES
Company expects that all materials and equipment purchased for installation in its facilities meet
specified project requirements. This PDS applies statistical QC sampling processes outlined in
ISO 2859-2 Plan A to increase confidence that POs for bulk materials which are not subject to
100% inspection meet project requirements.
It shall be noted that this PDS is not meant to replace current ITP or FATs, but rather to be
incorporated into the ITP and act as an independent verification method to provide project teams
assurance that the quality of bulk lot items received at site is acceptable.
4. CONTRACTOR REQUIREMENTS
1) Contractor shall provide the personnel required to implement the sampling program
including supervisory and coordination resources.
2) [A] Contractor shall manage the selection of random samples and witnessing of QC tests by
contractor inspectors. NDE Technicians shall be qualified in accordance with ASNT ACCP-
CP-1, ASNT CP-189, or other company approved standards. Contractor shall submit for
company approval the list of inspectors and NDE technicians together with qualifications
contractor proposes to use to implement this PDS.
3) Contractor shall manage its inspection personnel and resources to perform the random
sampling and witness the tests progressively as the materials are readied for inspection and
delivery, and in conjunction with Vendor inspection schedule, rather than at final shipment.
4) Contractor shall provide the necessary system to plan, track and report the status of the
sampling program requirements of this PDS including nonconforming items found and lots
rejected.
5) [A] Contractor shall develop and obtain company approval for a procedure to implement the
requirements of this PDS. Contractor shall ensure all appropriate procurement and quality
personnel are trained on this procedure.
6) Contractor shall include this PDS in all POs meeting the quantity thresholds noted in
Appendix A. Contractor shall also ensure vendors understand and support the sampling
requirements of this PDS.
5. VENDOR REQUIREMENTS
1) Vendor shall plan and execute production so that the PO materials can be sampled and
tested as specified in the PO while still meeting required delivery dates. Unless otherwise
noted in the PO all tests required under this PDS are to be performed by the vendor, in
conjunction with its standard sampling and tests program.
2) Sampling requirements, both for destructive and non-destructive tests, are to be conducted
progressively as the materials are readied for inspection and delivery, rather than at final
shipment.
3) Vendor shall ensure that persons performing the tests are qualified to ASNT SNT-TC-1A or
other contractor approved standard.
4) Vendor shall neither seek nor issue inspection release certificates / notices until all sampling
and testing requirements described in this PDS are completed and accepted by contractor.
5) Vendor shall rework any nonconforming item found during inspection. Nothing in this PDS
shall be assumed to grant the right to vendor to knowingly supply nonconforming products.
6. IMPLEMENTATION
1) Contractor shall review all RFQ preparation documentation for process pipe, fittings, flanges,
filters, gaskets, valves, piping bolts and fasteners, pipe hangers, cryogenic cold shoes, and
cables to determine whether any items in the order meet or exceed the threshold quantities
specified in Appendix A, with respect to the total quantity listed in the MTOs of referenced
items. In cases where Appendix A quantities are met or exceeded, contractor shall include
this PDS in the RFQ and PO specifications. Items which meet or exceed Appendix A
thresholds (based on MTOs) shall be deemed large volume items.
2) Contractor shall include a review of this PDS in all applicable PIMs held with vendors.
3) Contractor and vendor shall discuss:
a) Sampling unit (e.g. pieces, drums, etc.) and planned lot sizes for the order at the PIM
and determine the corresponding sample sizes for the items in the PO using Appendix
B.
b) Maximum number of rejects allowed in the sample before the lot is rejected. This
maximum number of rejects is listed in Appendix B under “Acceptance Number”. Note
that in case of conflict with the purchase order, or industry codes and standards the most
stringent requirements shall govern. For example, in the case of 100% inspection the
“Acceptance Number” shall be zero.
4) Vendor shall provide and maintain estimated completion schedule of each lot and notify
contractor so that contractor inspection personnel can be made available to perform random
sampling and witness QC tests from each particular lot.
5) QC tests are to be performed as follows:
a) All samples are subject to the non-destructive tests specified in the PO.
b) For process pipe, fittings, flanges, bolts, fasteners and cables a minimum of 10% of the
samples, rounded up to the next highest integer and taken at random from the total
samples, shall be destructively tested and witnessed by contractor personnel to confirm
the chemical and physical properties in the MTR.
c) When materials are subject to testing requirements from industry standards (e.g.,
ASME), the tests performed to fulfill those standards can be counted towards the tests
required by this PDS as long as they are witnessed by contractor’s inspection personnel.
6) Vendor shall segregate, store and present its products to contractor’s inspector in a way
suitable for the selection of random samples. Vendor shall make available any necessary
personnel and equipment to perform random selection and testing of the samples.
7) Contractor shall assign inspection personnel to randomly select samples from the PO lots
and to witness the QC tests specified in the PO. Contractor’s inspection personnel shall
witness and record the results of the QC tests.
8) A lot is accepted if all following conditions are met:
a) The total number of rejected units in the non-destructive test samples is at or below
the acceptance number for the corresponding lot size in Appendix B, and where such
rejected units are corrected per vendor’s non-conformance handling process.
b) There is no rejected unit in the destructive test samples.
9) A lot is rejected if;
a) The total number of rejected units in the non-destructive test samples exceed the
Acceptance Number for the corresponding lot size in Appendix B, or
b) There is one or more rejected units in the destructive test samples.
10) When a lot is rejected due to exceedance of the acceptance number in the non-destructive
test samples, the rejected lot may be proposed for acceptance if all units in the lot have
been re-examined or retested (100%) and witnessed by contractor inspection personnel,
and all nonconforming units have been corrected as per the nonconformance handling
process.
11) [A] When a lot is rejected due to one or more rejected items in the destructive test samples,
vendor may opt to perform an investigation – at contractor’s discretion - to demonstrate that
the cause of failure is isolated and does not impact other units within the same lot.
Contractor may consider accepting or rejecting the remaining units in the lot based on the
investigation result. In such case, the following shall apply:
a) Contractor shall provide notification to company prior to the start of the investigation.
b) Company retains the right to participate in the investigation, which includes a review
of the investigation plan and report, and/or to witness any inspection and test
performed during the investigation.
Appendix A
Minimum Order Quantities Triggering QC Sampling
A. PIPING

THRESHOLD
NO. BULK MATERIAL CATEGORY
UNIT

1.0 PIPE (≤ 10” NPS) Meter

1.1 Carbon Steel, Seamless 4,500

1,2 Carbon Steel, Welded 4,500
1.3 Low Chrome, Seamless (Up to 13% Cr) 4,500
1.4 Stainless Steel, Seamless 4,500
includes TP 304, 316, 321 and 347 material
Includes Low Carbon & Dual certified grades of Stainless
Steel
1.5 Stainless Steel, Welded 4,500
includes TP 304, 316, 321 and 347 material
Includes Low Carbon & Dual certified grades of Stainless
Steel
1.6 Super Austenitic Stainless Steel & Nickel Alloys, Seamless 1,800
1.7 Super Austenitic Stainless Steel & Nickel Alloys, Welded 1,800
Duplex, Seamless (review sourcing restrictions for Duplex
1.8 1,800
Materials)
1.9 Duplex, Welded (review sourcing restrictions for Duplex Materials) 1,800

Number of
2.0 PIPE FITTINGS (≤ 10” NPS)
Items

2.1 Butt-weld End Fittings - Carbon Steel 1500

2.2 Butt-weld End Fittings - Low Chrome (Up to 13% Chrome) 1000
Butt-weld End Fittings - Stainless Steel (includes TP 304, 316,321
2.3 750
& 347)
2.4 Butt-weld End Fittings - Alloy 20 & Other Nickel Alloys 750
Butt-weld End Fittings - DUPLEX (review sourcing restrictions for
2.5 750
Duplex)
 THRESHOLD
NO. BULK MATERIAL CATEGORY
UNIT

2.6 Branch Outlet Fittings (O'lets) 1500

2.7 Forged Steel Fittings - ASME B16.11 1500
2.8 Miscellaneous Non-Standard Fittings 750
2.9 Swage Nipples 5000

Number of
3.0 FLANGES (≤ 10” NPS)
Items

3.1 Carbon Steel Flanges 1500

3.2 Low Chrome Flanges (Up to 13% Cr) 1000
3.3 Stainless Steel Flanges 750
3.4 Alloy 20 & Other Nickel Alloy Flanges 750
3.5 Duplex Flanges 750
3.6 Long Weld Neck - Carbon Steel Flanges 1500

Number of
4.0 GASKETS (≤ 10” NPS)
Items

4.1 SPIRAL Wound Flexible Graphite Filled - ASME B16.20 2000

4.2 Corrugated Metal Flexible Graphite Covered (CMGC) 2000

Number of
5.0 FILTERS (≤ 10” NPS)
Items

5.1 Filters ALL

Number of
6.0 GATE / GLOBE / CHECK VALVES (≤ 10” NPS)
Items

6.1 API 602 – Forged 1000

API 594 / API 600 / API 623 - Cast C.S Class 150# & 300#
6.2 750
Includes gate, globe and swing check valves
API 594 / API 600 / API 623 - Cast C.S Class 600# and Above
6.3 350
Includes gate, globe and swing check valves
 THRESHOLD
NO. BULK MATERIAL CATEGORY
UNIT

API 594 / API 600 / API 623 - Cast Low Chrome (Up to 13% Cr)
6.4 Class 150 and 300# 750
Includes gate, globe and swing check valves
API 594 / API 600 / API 623 - Cast Low Chrome (Up to 13% Cr)
6.5 Class 600# and Above 350
Includes gate, globe and swing check valves
API 594 / API 600 / API 623 - Stainless Steel Class 150# & 300#
6.6 350
Includes gate, globe and swing check valves
API 594 / API 600 / API 623 - Stainless Steel Class 600#
6.7 and Above 350
Includes gate, globe and swing check valves
API 594 / API 600 / API 603 / API 623 and/or ASME B16.34 - Alloy
6.8 20 and Other Nickel Alloys 350
Includes gate, globe and swing check valves
6.9 Utility Service Valves - Brass & Bronze, IBBM 3000
6.10 Tilt Disc Check Valves - ASME B16.34 3000

Number of
7 BUTTERFLY VALVES (≤ 10” NPS)
Items

High Performance - Soft Seated

7.1 API 609 (Double Offset Type) 150
Specify API 607 when purchasing "fire-tested" valves.

Metal and Resilient Metal (Graphite Laminate) Seated

API 607, API 609 - Category B (Triple Offset Type)
7.2 - Warranted leakage rate is zero for resilient metal seated option 25
- Warranted leakage rate per API 598 for metal seated option in
preferred direction only

7.3 Cryogenic API 609 - Category B - Class 300 Stainless Steel 100

Number of
8 BALL VALVES (≤ 10” NPS)
Items

THD / SW and Flanged (NPS 2 and smaller) – API 607, API 608
8.1 1000
Soft / Graphite Seated - Floating Ball
Top Entry
 THRESHOLD
NO. BULK MATERIAL CATEGORY
UNIT
Two Piece (Seal welded for threaded body designs to avoid
accidental disassembly)
Three Piece (Bolted Body)
Flanged - Class 150 AND 300 – API 607, API 608
Soft or Graphite Seated - Floating Ball
Up to NPS 6 (full port) and up to NPS 8 (Std. or reduced port) in
8.2 750
Class 150, and up to NPS 4 (full port) and up to NPS 6 (Std. or
reduced port) in Class 300. Manufacturer certification to API 607 is
required.
Flanged - Class 150 and 300 - Fire Tested – API 607, API 608
8.3 Soft or Graphite Seated - Trunnion Mounted - Manufacturer 750
certification to API 607 is required.
Metal Seated – Floating Ball - ASME B16.34 / API 608
Up to NPS 6 (full port) and up to NPS 8 (std. or reduced port) in
8.4 750
Class 150, and up to NPS 4 (full port) and up to NPS 6 (std. or
reduced port) in Class 300.

Flanged, Soft or Metal Seated, Floating Ball - API 6D

Bi Directional, High Pressure. Two and three piece designs up to
8.5 350
NPS 3 in Class 600, up to NPS 2 in Class 900 and up to NPS 1½
in Class 2500
8.6 Metal Seated – Trunnion Mounted - ASME B16.34 / API 608 350
8.7 Cryogenic - Floating Ball 100
8.8 Cryogenic - Trunnion Ball - API 6D 100

Number of
9 PLUG VALVES (≤ 10” NPS)
Items
Expanding Seal Type (Non Lubricated)
9.1 350
API 599, API 607
9.2 Lubricated Type - API 599. Cast Steel And Low Chrome 350
Fully Lined Type / Sleeved Type. Carbon Steel And Stainless Steel
9.3 350
- Externally fire tested models
9.4 Wedge Type 350
 THRESHOLD
NO. BULK MATERIAL CATEGORY
UNIT

Number of
10 SPECIAL VALVES (≤ 10” NPS)
Items

10.1 Tank Vents 50

10.2 Pressure Relief Valves 50

Number of
11.0 BOLTS / FASTENERS (≤ 2” Φ)
Items
Alloy Bolts and Hex Nuts, all materials requiring impact testing for
11.1 5000
services below -50°F (-45°C) and all coated bolts
11.2 Stud bolts all materials and specifications 15000
11.3 Hex Fasteners all materials and specifications 30000

Number of
12.0 PIPE HANGERS
Items

12.1 Pipe Hangers (all types / sizes) 50

Number of
13.0 CRYOGENIC PIPE SHOES (≤ 10” NPS)
Items

13.1 Cryogenic Pipe Shoes 200

B. ELECTRICAL, INSTRUMENTATION AND TELECOMMUNICATION

THRESHOLD
NO. BULK MATERIAL CATEGORY
UNIT

Number of
1.0 CABLE
Drums (Meter)

Medium Voltage Power Cable 90 (36,000)

Appendix B
Lot, Sample Sizes and Acceptance Numbers
Lot Size
Acceptance
Sample Size
Number
Minimum Maximum

16 25 Inspect Every Item

26 50 28 0

51 90 34 0

91 150 38 0

151 280 42 0

281 500 50 0

501 1,200 80 1

1,201 3,200 125 3

3,201 10,000 200 5

10,001 35,000 315 10

35,001 150,000 500 18

150,001 500,000 500 18

>500000 500 18

Table has been extracted from ISO 2859-2 Table A for Limiting Quality (LQ) 5%
Attachment: Purpose Code Definitions
Code Description
A Assigned to paragraphs that require company endorsement before the work may
proceed or the design is finalized.