The main objective of the Quality Assurance & Control is to create awareness at all levels in the organization about the code requirements and the service of the products being manufactured
The quality requirements of the order is analyzed in consultation with engineering, procurement and quality control department and listed to form a plan. The Q.C Inspectors will be inspecting the equipment during its various stages and will ensure that the fabrication is in conformance with the code / approved quality plans. The QA & QC manager reports to the Director (Works) has the responsibility to control the quality of all equipment’s manufactured strictly adheres to the code / customer requirement.
The QA & QC dept shall ensure that the codes ASME,TEEMA, BS,BIS 2825,DIN etc.. used for the materials fabrication , testing etc. are of the latest edition. The Design calculations and fabrication drawings shall be submitted to the QA & QC dept. Internally before submitting the third party / Client. How ever the approvals from the third party / Client shall be done directly by the design department. The quality plan shall contain the description of sequence of operations that shall be carried out during the manufacture , the type and the quantum of check by internal QC inspector with the reference to the specification / code and a remark column. The inspection / witnessing done by the third party inspector shall be also shown separately
When the goods are purchased / received appropriate formats shall be used. The QA & QC shall check / instruct the material received using calibrated instruments with respect to the purchase requisition. Henceforth color coding / numbering of material shall be done easier identification and trace ability.
All instruments / Equipments shall be calibrated at approved testing laboratories. The calibration shall be with in the period due for next calibration .The instruments / equipment’s shall be kept in a dust free and temperature controlled environment
A step by step inspection stages required during the manufacturing of equipment’s shall be as defined in the approved quality plan. The range of operation shall be monitored thoroughly using specified testing equipments
Any deviation from the procedure approved by the QA plan met during the fabrication process will be dealt by the QA/QC Manager and Director (Works) and steps will be decided up on the correct the minor deviation. The item under the code deviation shall be replaced if it is not possible to correct however the code shall not be violated. The Customer shall be apprised of the remedy and the approval shall be obtained.
The Quality dept shall train personnel in the various welding categories like SMAW,MIG,TIG,SAW etc and make them quality under the external inspection agencies. The welder / welding operator shall be guided by the QA& QC dept. shall maintain a record all the welding Consumable. Containing the details specification electrodes , No. of electrodes ,batch no. etc before welding the baking temperature shall be in conformance with the code.
The selection of electrode for welding shall be depending on:-
A welding procedure specification WPS shall be prepared by the QA& QC Dept./ welding Engineer to ensure that the weldment proposed is capable of providing the requirement properties for its intended applications. This shall contain the variables both the essential and non essential ,such as the joined design ,base, filler materials, the weld Position and technique the electrical characteristics applicable ,during the specified welding and the acceptable range of these variables, base on this WPS , a procedure qualification test shall be carried out on the standard test specimen in the presence of the inspector and the actual conditions and the result of the non destructive tests applied via Visual ,liquid penetrate, radiography and ultrasonic shall also be recorded. The destructive test such as tensile and guided bend test (face root& side) where ever required, shall be carried out in the presence of the inspector and the results are duly appended in the PQR. This PQR shall then be certified by the inspection agency / client employed. The trained welders/ welding operators will be made to qualify individually using the approved procedures in the inspectors presence. A record of these welder /welding operators performance qualifications shall maintained and renewed periodically by the QA & QC Department.
Generally all welded pressure vessels or vessel parts shall be post weld heat treated as per the code requirement / client requirements. The heating and holding periods, the furnace atmosphere shall be so controlled avoid excessive oxidation of the surface of the vessel. No repair shall be carried after the post weld heat treatment.
All observations during the inspection stages shall be recorded in the prescribed format prepared by QA & QC Dept, and the counter signed by the external Inspector. Each report shall contain all the details like name, purchaser, code, specification ,material grade etc.. In the absence of any specification / direction by the customer , the inspection stages for the various standard equipment shall be as per the manufacturers standard format.
The records made during every stage of fabrication shall be kept and filled in chronological order .Every equipment shall be given a separate file and the stages of Fabrication ,inspection and rectification (if any) duly recorded and appended to the respective files .Along with dispatch of equipment ,the final documents containing copies ,in required number of all reports and charts shall be submitted to the client.
The internal inspection department , under the direct control of the QC & QC Manager, acts separately and makes the reports in person to the Director(Works).The production department with the engineering department shall take up the solutions to the problems Encountered during manufacturing for suitable design changes if any and obtain revisions to the quality plan. The engineering department shall ensure that the revisions are acceptable and get them approved from the customer through the quality department. Only after this the fabricated item shall be presented for inspection to the external inspection agency. The general functions of QC Engineer / Inspector is to examine all materials in constructing a pressure vessel shall be examined before fabrication for the purpose of detecting , as far as possible , defects ,which would affect the safety of the vessel.
The stage inspections shall be carried out strictly as per the quality plan approved and the Relevant code / Customer requirement .The Inspector shall witness all the tests ( Both destructive and non-destructive) whatever necessary. When conditions permit entry in to Vessel ,a through inspection of the interior parts shall be made before final closure.
At each and every stage wherever a hold point is specified in the approved quantity plan for the presence of the external inspection agency, the internal Q.C Engineer/ Inspector shall coordinate the manufacturing and inspection program to avoid the waiting time of any agency.
After the fabrication of the equipment ,Q.C Inspector shall make an external inspection of the completed vessel before final hydro test/ pneumatic test for the dimensional accuracy and workmanship. The inspector shall verify that the vessel confirms with the fabrication drawing and the applicable code and repair works, if any ,are already finished and approved before giving consent to carryout the final testing Through all stages of inspection ,the inspector shall correlate the stage inspection report data with the actual condition of the vessel , where relevant ,the external inspector after conducting the inspection and on finding it to be correct, shall countersign the inspection report.
The inspection agency for carrying out the inspection shall be as per customer intimation. The QA dept shall arrange for the external inspector to; have free access to such parts of all plant as are concerned with the supply of manufacture of material for the vessel , when so required. The inspector shall be permitted free access at all times while work on the vessel is being performed to al part of the manufacturers shop that concern the construction of the vessel and to the site of field erected vessels during the period of assembly and testing of the .He shall be kept informed of the progress of the work and notified reasonably in advance when vessel will be ready for any required tests or inspection stages. After the final inspection, the final clearance of the vessel shall be affected by approving and countersigning the final certificate, prepared and issued by the QA dept.
The manual is intended as a guiding tool for the organization and shall be periodically updated considering the additional requirements and procedure simplification, however, without any compromise on the specification requirements.