General

Inspection
Plan
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General Inspection Plan

1- GENERAL ......................................................................................................................................................... 2
1.1- Scope............................................................................................................................................................ 2
1.2- Definitions ................................................................................................................................................... 2
1.3- Language ..................................................................................................................................................... 2
1.4-Codes & Standard ....................................................................................................................................... 2
1.5- Client's rights for access to the site ........................................................................................................... 2
2- Reporting........................................................................................................................................................... 3
3- CATEGORIES OF MATERIAL AND EQUIPMENT'S ................................................................................ 3
3.1. Level Definitions: ........................................................................................................................................ 3
3.2. INSPECTION VISIT FREQUENCY ........................................................................................................ 5
3.2.1 SUBMITTION OF SUPPLY LIST ............................................................................................................ 6
4. Announcing Client for Inspection .....................................................................................................................12
5. Quality Control Plan and testing Plan (QCP) ...................................................................................................19
6. Final Book .........................................................................................................................................................20
7. Inspection Type and Extension..........................................................................................................................23
8. Inspection Documents ........................................................................................................................................25
9. Inspection at sub-supplier's workshop .............................................................................................................27
10. Documentation required for the issuance of Quality Test Certificate (QTC) ...............................................28
11. Test pieces for destructive testing ..................................................................................................................28
12. Repairs .............................................................................................................................................................28
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1- GENERAL
1.1- Scope
General inspection procedure (GIP) covers all procedure of quality control,
inspection and testing to be applied for local equipments supply

1.2- Definitions
The following words and expressions shall have the meanings hereby assigned to them
except where the Context otherwise requires:
- Client or buyer:
- Client Inspector: Means Client representative that nominated for inspection
and quality control activities(BARSOO)
- Local Supplier:
- Local Suppliers Inspector:
work
- Sub Supplier &/or manufacturer: Means the firm or company for local
supply employed by local Supplier
- Plant:

1.3- Language
All drawings, design, information's, documentations, erection, operation &
maintenance manuals & Instructions shall be in English &or Persian. The language
used during inspection as well as all correspondences shall be in English &/or
Persian

1.4-Codes & Standard

Acceptance standards for material and equipment shall be in accordance with
International/ European/ National standards.

1.5- Client's rights for access to the site

Client and Representatives of the client have right to inspect in offices and workshops,
packer shops, warehouses and storage areas and any other places of the
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manufacturers or Suppliers and/or Sub-suppliers while manufacturing, erection or

assembling is performed for quality control and tests.

2- Reporting
Supplier shall furnish, with reference to the Plant it's implementing of updated
inspection and testing schedules during manufacturing based on updated project
progress report. Supplier also should provide permanent or temporary possibilities for
attending Client Inspector as required.

3- CATEGORIES OF MATERIAL AND EQUIPMENT'S

The inspection of equipment and materials shall be classified in 3 levels as defined
in below described in table 1. This categorization and all consequences shall be
considered in QCTM and Quality Control and Testing plan.

3.1. Level Definitions:

The levels of equipment and material in regard of importance and quality control are
defined in below:
In each level QCP shall be submitted prior to construction and befor e
inspection and test.

LEVEL A
Inspection Level A : is defined as a full stage inspection carried out
progressively from commencement of manufacturing to final acceptance, and
should be required on occasions where work program demands regular
attendance.
The scope shall include:
• Review/witnessing of source material's chemical and physical
properties- including metallurgical enhancement and traceability to approved
certification level.
• Verify the use of qualified welders and qualified welding procedures monitor
manufacturers'
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Assembly, fabrication and erection and all prescribed tests.

• Check on materials, material traceability, dimensions and finishes.
• Monitor manufacturer's assembly, Fabrication and Erection and all
prescribed test
• Scrutinize manufacturer's quality assurance/quality control system.
• Review/Audit witness of non- destructive examinations including alloy
verification if required.
• Ensuring that personnel are qualified to perform these examinations
• Witness all pressure and performance tests followed by inspection of
disassembled equipment, if applicable
• Review/Witness all major tests required by approved QA/QC vendor
documents, including on And off load tests of machinery or type tests of
electrical equipment as required.
• Final visual and dimensional inspection of equipment.
• Review of final data book package in accordance with approved index.
• Verify packing and marking identification.
• Issue of QCP , ITP , I.C. and final release Certificate(s).

Level B
Inspection Level B is defined as specific stage inspection of equipment and final
inspection of equipment prior to shipment. Stages of inspection shall be agreed upon
during a pre-inspection meeting to be held with the Vendors after purchase award and
shall include:
• Scrutinize material test certificates
• Check at random of materials, dimensions, and finishes monitor
specific tests and stage
inspections
• Witness specific tests and stage inspection
• Auditing of the Vendors quality control program
• Witnessing final pressure and workshop performance testing on and
offload tests as applicable simulation of automatism and followed by inspection of
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disassembled equipment if required.

• Final visual and dimensional inspection and packing inspection
• Review data book package in accordance with approved index
• Verification of packing and marking
• Issue of QCP , ITP , I.C. and final release certification
Level C
Inspection level C is defined as the review and acceptance/endorsement of
manufacturer's attestation including data book requirements. Class C Equipment
can be included less important supplies, where failer of equipment will not be cause
a major production less or personalize injury and those applies to products which are
manufactured according to standard procedures ,are produced by the manufacturer
,are currently checked during production by manufacturer's routine procedure. Such
products are defined as "shelf materials" and/or "catalogue materials" .These
equipment should be provided from approved vendor list. If manufacture or supplier
of the parts or equipment is not in the vendor list, before providing them,
necessary approval from client should be taken. There is no need for issuing of QCP
for cataloge items. Data sheet of them should be submitted before inspection
.purchase order should be submitted before inspection for approved of client
.purchase orders should be according to client approved bill of materials. For
Equipment that are manufacturing by any approved supplier , QCP shall be
submitted.

3.2. INSPECTION VISIT FREQUENCY

For local supplier the Contractor shall perform inspection visits in Vendors shops, as
well as in their sub vendors shops, at specific stages of equipment, fabrication,
assembly, testing. Lining, painting and packing. Such specific inspection stages are
to be determined for each category of equipment in accordance with the finalized and
approved Test Plan which the stages of inspection, type of Inspection/Control (such as
witnessing of Dimensional, NDT, pressure test and other tests) and output documents,
applicable to all phases of fabrication, assembly and testing, shall be defined for
manufacturer/supplier, contractor Quality Control department and client representative.
In addition to specific inspection visits, for local manufacturing the contractor shall also
conduct regular inspection visits in accordance with the frequencies indicated hereafter
which are to be understood as minimum frequencies to be applied to each component of
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each equipment item. Such frequencies are intended to cover inspection visits by
professional Inspectors only. The Contractor shall not combine inspection and expediting
functions, nor have them performed by the same individual.

3.2.1 SUBMITTION OF SUPPLY LIST

For local supplier the Contractor shall be submitted the supplier list before purchase and
fabrication.
REACTORS, PRESSURE VESSELS, HEAT EXCHANGERS, BOILERS and
FURNACES
Level A: regular inspection visits shall be conducted at least once every month Level
B: regular inspection visits shall be conducted at least once every six weeks.
MAJOR MACHINERY EQUIPMENT
Level A: regular inspection visits shall be conducted at least once every other week
Level B: regular inspection visits shall be conducted at least once every month. Level
C: regular inspection visits shall be conducted at least once every six weeks
PACKAGES
Level A: regular inspection visits shall be conducted at least once every month. Level
B: regular inspection visits shall be conducted at least once every six weeks.
ELECTRICAL IINSTRUMANTATION EQUIPMENT
Level A: regular inspection visits shall be conducted at least once every month.
Level B: regular inspection visits shall be conducted at least once every six weeks
Level C: inspection visit as specific stages only
PIPING
Level A: regular inspection visits shall be conducted at least once every six weeks.
Level B/C: inspection visits at specific stages only
General Notes: Specific level I items shall require full time attendance by the
Contractor's resident representative(s), as identified in the attached list.
3.3. Allocation of inspection levels to equipment and materials:
Equipment and materials will be allocated to the A.B.C level of inspection Level
of inspection will be specified at the time that QCP was submitted.
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The table of hot briquette plant equipment with considering level of inspection
shall be considered as table 1. The following table is as an example of DRI
equipment for information.
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Table 1

ITEMS OF EQUIPMENT AND MATERIALS TO BE INSPECTED (DRI equipment)

Item Description Inspection levels
No. A B C
Pressure vessels
1.1 Process and pressurized storage
vessels (BSI 5500 and ASME VIII Div.2,
ASME
VIII Div.1) for design pressure and
temperature conditions
- 80 barg or greater *
- Less than 80 barg to 50 barg *
1
- Less "than 30 barg (except vacuum)and *
- Less than 350°C to 0°C *
- Less than 30 barg and above 340°C *
- Less than 30 barg and below 0°C *
- Under vacuum *
1.2 Reactor vessels, Dryers, Columns, *
1.3 Impact tested carbon and low *
alloy steels, high Ni steel and
austenitic stainless, Inconel lined
1.4 All services in low and cryogenic *
design Temperatures
1.5 Non-ferrous Alloy Vessels *
1.6 Caldded Vessels *

1.7 Lined Vessels, rubber or *

epoxy coating/FRP/refractory
/Lead
Atmospheric pressure storage tanks
2.1 Field fabricated carbon steel:
- 25 mm or greater
- Less than 25 mm *
- Impact tested carbon and low alloy *
steel , Hi Ni steel, S.S and non-ferrous *
alloys.
2

2.2 Shop fabricated

- Carbon steel *
- 35 mm or greater
- Less than 35 *
- Fiberglass lined, lead lined rubber or *
epoxy coated *
- alloy steels and non-ferrous alloys *
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3 Boilers, furnaces, burners /dryers *

3.1 Boilers, furnaces, burners, fired,
Heaters/Dryers
3.2 Flares and Burners *
3.3 Waste heat recovery boilers *
3.4 De-aerators and steam drums, ... *
Exchangers
4.1 Plate or Shell and tube for service:
- 40 barg or greater *
-1250 mm bundle Dia. or greater *
- less than 40 barg or 1250 mm bundle *
Dia. *
4 - Low temperature (less than 0°C)
- alloy or non-ferrous, *
4.2 Air coolers
- headers, tube bundles, fins *
- fans, motors, frame, spiral *

4.3 Double pipe, plate frame, spiral *

4.4 Plate fin ( core) exchangers *

4.5 Cold/Cryogenic exchangers *
Rotating equipment
5.1 Crushers, Mills, Magnetic Separators, *
Trammels
5.2 Pumps:
- Process pumps *
- Low and cryogenic temperatures *
- Fire water .Boiler feed *
5 - Auxiliary pumps *

5.3 Emergency generators *

5.4 Air compressors *

5.5 Miscellaneous
- Classifier / Separators / spirals *
- Blower, metering pumps, *
Mixers
- Manufacturer's standard Items *
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Piping and piping materials

6.1 Piping:
- impact tested carbon and low alloy steel, *
austenitic stainless steel and inconel steel an
inconel625/ incoloy825
- other piping *
6.2 Pipe flanges, fitting and valves:
- Impact tested carbon steel and low alloy steel, *
6 austenitic stainless steel an
inconel625/incoloy825
- other flanges, fitting and valves *

6.3 Pipe supports, saddles, etc

- cryogenic temperature *
- other services *

6.4 Metal bellows expansion

joints
- cryogenic temperature *
- other services *

6.5 Bimetallic transition joints *

6.6 Welding consumable/electrodes *

7 Structural
7.1 Special category steel *
7.2 First and Secondary category steel *
special equipment
8.1 Process and utilities filter and strainers *
8.2 Effluent treatment units *
8
8.3 Chlorine production and Chlorine package *
8.4 Nitrogen generation and Air separation unit *
8.5 Magnetic separator *
8.6 Refrigeration units(HVAC) *
8.7 Water treatment units *
8.8 Incinerators and solid disposal unit *
8.9 Exhaust stacks *
8.10 Lubricants, chemicals, resins, Catalysts *
8.11 Overhead cranes, hoists *
8.12 Lifting and Mobile Vehicles *
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8.13 Water maker (potable) *

8.14 Hydraulic power units *
9 Firefighting equipment
9.1 Deluge/sprinkler/C02/fixed skids *

9.2 F/F Portables *

9.3 Monitors *
9.4 Hydrants, and piping system *
Electrical
10.1 Switch Gear *
10.2 Motor control centers *
10.3 Transformers:
10
- 22KV and higher or 300 KVA and above *
capacity
10.4 Motors:
- Less than 300 KV A capacity (low voltage)
-150 KW and above rating *
- Less than 150 KW rating *

10.5 Un-interruptible power supplies *

10.6 Cables
- Power rated voltage 1 KV and above *
- Less than 1 KV rating *

10.7 Control Relay panels *

10.8 Lightning fittings junctions boxes *
lighting and small panels, etc

10.9 Batteries, chargers and distribution *

Boards
10.10 Power distribution Control system *
10.11 Emergency Generators *
10.12 Cable trays/cable ladders *
10.13 Bus bar trunking *
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11 Communication systems
Telecommunication equipment
- PA Systems *
- Intercommunication system *
-CCTV *
*
- Others

Instrumentation
12.1 Safety system PLC's(ESD,PSS,FG) *

12.2 Control Panels *

12.3 Analyzers *
12.4 Control valves/safety valves *
12.5 Controllers, transmitters, recorders etc *

12 12.6 Gauges, pressure switches *

12.7 Audio, Visual alarming skids *
12.8 Pressure control regulation skids *
12.9 Flow meters, indicators *
(mono-electrical)
12.10 DCS/Supervisory computer *
12.11 Gas Chromatograph, sample *
conditioning systems, prefab, shelters

12.12 Cables *
13 Miscellaneous
13.1 Equipment, materials or components not *
listed
above
2.3 Types of Inspection
The types of inspection are defined as follows:
- Visual - Each item is visually checked for compliance with the purchase order.
- Random - Where 10 to 15% of a batch of items, as selected by the authorized
inspector, are fully checked.
- Full - This is a visual check, plus a full test for each item of Category A and, where
specified, for Category B. In some case a complete test may have to be carried out in
few stages of construction at the factory.
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Warning:
If, during the random inspection, failures occur in the batch of selected items, the authorized
inspector may decide to increase the level of inspection to 100%
2.4 Spare Parts

When specified in the purchase order, spare parts for the above instruments or
instrument systems, comprising either part or complete systems, shall be inspected and
tested by the same factory inspection and testing procedures. However, spare components
for systems, such as printed circuit boards, etc. need only a 10 to 15% random inspection
by the authorized inspector
3. FACTORY INSPECTION AND TESTING
3.1 General
The purpose of ‘factory inspection and testing’ is to check that the instruments and instrument
systems to be supplied comply with the requirements stated in the purchase order.
Before attempting to carry out the inspection and especially the checking of calibrations, the
authorized inspector shall check that the factory test equipment, as supplied by the
manufacturer/supplier, is suitable for testing the instruments included in the purchase order.
The factory shall provide a Calibration Certificate with the Calibration carried out against
primary test equipment.
The manufacturer shall be able to prove that equipment used for calibration is traceable back to
national standards, with certificates issued by approved independent laboratories, institutes or
other bodies.
The following documents should form the basis of the manufacturer’s production system in the
order of priority as listed.
1) The purchase order and any subsequent variations.
2) Data/requisition sheets and drawings.
3) The Company’s standards.
4) The manufacturer’s quotation.
5) The manufacturer’s standard specifications.
6) The manufacturer’s standard quality control procedures.
Deviations from the above requirements will be allowed only with the written approval of the
Company.
Factory inspection shall be witnessed by:
- The Company; for ’in-house’ projects.
- The designer; for turn-key projects, either alone or (at the Company’s discretion)
accompanied by a representative of the Company.
- The designer/Company for other projects, as applicable.
Note:
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If, for any reason, the Purchaser waives inspection, this shall not relieve the supplier from
the responsibility of repairing at his own cost any defects found.
The Company’s and/or the Company’s third-party inspector or specialist shall have free entry
and access during normal working hours, to those parts of the manufacturer’s and/or
submanufacturer’s premises which are involved in the manufacturing and testing of
instruments and instrument systems applicable to the purchase order.
3.2 The Scope of Inspection
The basic scope of inspection will be defined by written notes giving the following information:
- The inspection agency.
- The engineer co-ordinating inspection activity.
- Pre-manufacturing/inspection meeting to be held (if any).
- Type of inspection i.e. running, intermediate, final.
- Requirement for a document review.
- Requirement for an inspection report.
- Any additional information.
Where other disciplines are involved in instrument inspection, the nominated instrument
inspector shall have overall responsibility for the release note.
The above instructions will be further clarified by the final inspection plan
4. THE INSPECTION PLAN
4.1 General
The manufacturer shall provide (with the quotation) a basic document entitled inspection Plan
for instrumentation this shall include all instruments and instrument systems which are subject
to inspection.
Objectives of the Inspection Plan:
- Establish the inspection activities specified in the purchase order.
- Finalise and agree all inspection and testing procedures by collating the purchaser’s
and manufacturer’s requirements.
- Allow the Purchaser to plan his inspection activities.
-Determine which inspections and tests at manufacturer’s/submanufacturer’s may or
will be attended and by whom.
- Define the activities which will be co-ordinated by the instrument, electrical or
mechanical inspectors.
- Establish a yardstick if payment is to be made in installments.
4.2 Types of Inspection Plan
Plan a - The Standard Inspection Plan - the manufacturer’s standard inspection and test
procedure, as approved by the Purchaser.
Plan b - The Amended Inspection Plan - the manufacturer’s standard inspection plan, but with
additional requirements of the Purchaser incorporated.
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4.3 The Authority and Content of the Inspection Plan

The finally agreed inspection plan, whether it is the standard or the amended plan, shall be
accepted as the basic inspection document and, in cases of conflict between documents of the
requisition, its requirements shall rule.
The inspection plan shall be signed by both parties, i.e. manufacturer and user and the document
shall not be amended without the written agreement of the user.
The inspection plan shall include all references to manufacturer’s documents and/or standards.
The inspection plan shall consider the following items as applicable:
a) A clarification or pre-manufacturing meeting.
b) Preparation of a Sub-orders list.
c) Subsuppliers visits.
d) Progress.
e) Inspection-visual and general.
f) Testing (pressure, and electrical insulation).
g) Calibration of instruments.
h) Process stream analysers and/or analyser modules.
i) Programmable Logic Controller (PLC) - function and system check.
j) Safeguarding systems check.
k) Distributed Control System (DCS) check.
l) Process computer system check.
m) Function/performance tests.
n) Control valves.
o) Special procedures (see 3.2).
p) Special documents.
q) Manufacturer’s documents.
r) Packing and preservation procedures: This item is also the responsibility of the
Materials Department.
For all complex systems such as:
- Equipment Packages.
- DCS.
- PLC (logic systems).
- Process stream analysers/analyser modules.
- Safeguarding systems.
- Blending.
- Tank gaging (computerized).
- Oil movement system (computerized).
- Process computer systems.
- Computer input, output equipment.
The inspection plan include specific functional test procedures, as agreed with the Company.
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For standard instrumentation, the manufacturers functional testing procedures should be added
to the inspection plan.
5. FACTORY INSPECTION DOCUMENTS
The basic document shall be The Instrument Inspection Report as described below.
This document shall be completed, signed and issued by the authorized inspector within 10
working days after the completion of inspection.
All sheets shall contain Company’s purchase order number.
5.1 The Instrument Inspection Report
The instrument inspection report shall cover all the stages of inspection given in the final
inspection plan, and the format should be as follows:
5.1.1 A cover sheet
The cover sheet shall contain:
- The type and title of the report.
- Name and address of the manufacturer/subsupplier.
- User’s complete purchase order number.
- Requisition number and revision letter.
- Inspection order number.
- Manufacturer’s reference.
- Date of report.
- Name and signature of the authorized inspector.
- Approval of the report by the inspectors management.
- Summary.
- Cross-references to other reports.
5.1.2 Table of contents
The following gives a typical example of the table of contents of an inspection report:
- Inspection reference data.
- Statement of Compliance.
- Scope of Inspection.
- Inspection Reference Documents.
- List of Subsuppliers.
-Test and calibration equipments used, test facilities, manufacturer personnel involved.
- Inspection activities/results, (all deficiencies and deviations even if rectified during
inspection should be listed).
- Review of manufacturer’s documentation.
- NONA/NCR (Notes of None Acceptance/None Conformance Report).
- Attachments.
5.1.3 Inspection reference data
This shall contain
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- Purchase order number.

- Manufacturer’s reference number.
- Commodity.
- Instrument tag numbers/identification.
- Quantity.
- Data and number of delegation telex.
- Scope of work indicated in delegation telex.
- Commodity shipment date.
- Original delivery date as stated on purchase order.
- Inspection agency.
5.1.4 Statement of compliance
Stating that the inspected goods meet all the requirements of the purchase order (and agreed
deviations) as could be verified by the inspection agency.
5.1.5 Scope of inspection
Summarize inspection activities giving dates of inspection with reference to the inspection
plan.
5.1.6 Inspection reference documents
This section shall make reference to all engineering standards drawings, etc. including revision
numbers on which final inspection was based.
5.1.7 List of sub-suppliers
This section shall list all subsuppliers and their scope of supply, date of release, report number
(if any).
5.1.8 List of calibration equipment
List all calibration equipment used, with serial numbers, personnel involved, etc.
5.1.9 Inspection results
This section shall report in detail all the results of the inspection activities.
5.1.10 Review of manufacturer’s documentation
This section shall state that the documentation presented by the manufacturer complies with the
purchase order.
5.1.11 Notes of non acceptance (NONA) and non conformance report (NCR)
List all NONA and NCR’s issued during the contract together with the resolution and clear
reference to the telex or letter.
5.1.12 Attachments to the inspection report
At the final Acceptance Release Inspection the following documents shall be attached to the
report.
- The inspection plan.
- Certificate of conformity (design/construction testing).
- Certificate of performance.
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- Calibration/test notes.
- Inspection sheets if applicable.
- Certificate of conformance (electrical area classification).
-Letters and/or telexes approving deviations or granting concessions from specifications
and or requisitions.
-Minutes of meetings held before and/or during inspection stages.
- Release notes, NONA, NCR’s.
5.2 Completion of the Report
If so requested in the order for inspection, a factory Instrument Inspection Report shall be
completed by the authorized inspector.
A report may also be issued on final acceptance of sub-orders to the main purchase order.
However, this report shall be considered as intermediate and it shall be re-issued as part of the
final report. This is particularly applicable in the context of packaged units.
The Instrument Inspection Report shall be completed in five original sets and presented to the
Company.
5.3 The Non-Conformance Report
The non-conformance report is a quality assurance related document, for reporting all serious
deficiencies in a manufacturer/ supplier’s capabilities to supply manufactured items of the
required quality, for whatever reason, e.g. quality of work factory organization, test equipment
and assistance rendered, etc.
5.4 The Release Note/Note of Non-Acceptance
When the authorized inspector or inspection agency are satisfied that the instruments and or
instrument systems comply with the technical requirements and conditions of the purchase
order, a release note shall be issued.
The release note is an official contractual document and shall be completed carefully and
accurately. The purchase order number shall be clearly readable and the release note shall apply
to one purchase order only.
The release note shall be given to the manufacturer/supplier with copies to the user as indicated
on the form itself.

4. Announcing Client for Inspection

The announcing/confirmation/waiving of inspection and tests will be ruled as

follows:
• Preliminary manufacturing time schedule and inspection/test time chart will be
submitted to client within 15 calendar days before the manufacturing.
• Preliminary announcement for test execution will be sent to Client Inspector
within 10 calendar days in advance.
• Official tests will be informed to Client Inspector 3 days for Tehran, Ahvaz
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and Esfahan and 7 days for other city in advance necessary for traveling and
providing requirements due to plane and kind of tests.
• Any deviation in time of test activities shall be informed in reasonable time
to the client to avoid excess cost to him.
In items that is necessary to submit QCP , during sending document until approved by
client, the QCP was submitted is the criteria for construction and inspection.
If client presented a note on the documents, notes and documents provided
criteria for manufacturing and inspection .

5. Quality Control Plan and testing Plan (QCP)

For each item/equipment a Quality Control and testing Plan (Q.C.P) will prepare
that includes the Inspection references, method of inspection, Quality Plan, supplier's
inspector and client representative's responsibilities, acceptance criteria and type of
record/report Issued correspondence to the inspection and control conducted on
items. Any exceptional deviation has to be discussed between the client and the
supplier during manufacturing and before the start of inspection. Quality Control Plan
will include:
• Reference Specifications (includes project specifications, Drawings,
International standards, common practices or acceptable standards)
• Definitions
• Subprojects Name
• The name of Sub-supplier or Manufacturer of the subproject
• Scope
• List of drawings (Client DWG No.)
• List Of units
• Inspection Test Plan (ITP)
• NDT Map (plans)
• Level II time schedule of proceed
• Contractual number
• Inspection Class
• Weld Map (plan)
• Painting cycle and color coding
• Instruction of tests
• Appendixes (include specifications, Guidance for Inspection and QC forms
if there is)
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• WPS & PQR

• Welder Qualification Certificate
• NDT Personnel Certificate
• paint supplier

6. Final Book
Final Book is final quality documents for each item and includes a collection of inspection
documents and it will be completed gradually during the inspection activities.
Final book at the end of inspection and issue of certificate shall submit to the client
representative for final approval. One complete copy of each Final book will be delivered to the
client.
Final book shall include the following documents:
- Mechanical equipment and steel structures:

1. Approved technical specification, Data sheet

2. Approved QCP (Quality Control Plan)
3. Reports & Records:
Equipment related Reports & Records considering bellow item but not limited to them
shall be issued.

-Material list & Material certificate

-Dimension and Visual test report
-NDT reports and other specified Test records
-Executed welding procedure (W.P.S.) for critical welding
-Heat treatment chart, stress relieving report
-Pressure test records and diagrams (including Hydro test, pneumatic test, leakage
Test)
- Mechanical running test, functional test, performance test, On/Off load Test, Type
Test, report etc as per approved ITP
- Factory Acceptance Test report (FAT)
- Surface preparation/painting inspection report
- Other test & inspection report and certificate based on ITP and client contract
- Non- Conformity formats (NCR) with removal procedures
- Engineering queries (TQ)
4. The latest signed progress report
5. MOM Inspection signed in factory or work shop
6. List of spare parts
7. List of sub vendors
8. All test procedure based on ITP
9. Packing procedure
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10. Weld and paint repair procedure(where applicable)

11. Final signed packing list

12. Signed Release note

13. IC (Inspection Certificate)

14. General drawing

15. Erection Manual

16. Maintenance and operational manual

17. Pre Commissioning & Commissioning Manual

18. Storage Instruction

- Electrical and Instrumentation document

1. Technical specification, Data sheet
2. Electrical manual
3. Maintenance Manual
4. List of catalogs
5. Approved QCP (Quality Control Plan).
6. Material certificate
7. Certificate of origin
8. List of spare parts
9. List of sub vendors
10. Routine test reports
11. Performance test reports
12. MOM Inspection signed in factory
13. Non- Conformity formats (NCR) with removal procedures.
14. General drawing

15. Final signed packing list

16. Signed Release note

17. IC (Inspection Certificate)

- Catalogue Items
1- Approved technical specification, Data sheet
2- All test reports
3- Certificate of origin
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4- Non- Conformity formats (NCR) with removal procedures.

5- Factory acceptance procedure
6- Final signed packing list
7- Signed Release note

8- Bill of lading
9- Inspection Release of Equipment (IRE)
10- Inspection Release of packing (IRP)
11- Certificate of origin
12- Certificate of conformity
13- Invoice
14- IC
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7. Inspection Type and Extension

Type of inspection will be carried out according to the table below. Specific
inspection or any exception will be indicated in individual QCP of equipments.
The extension of test shall be in according to that defined in Level definition in
clause3.1 (MI= Manufacturer Inspector, SI=Supplier Inspector, CI= Client
Inspector/Representative)

ITEM DOCUMENT A B C

MI SI CI MI SI CI MI SI CI
1 Material Certificate (Major A A R A A R A A R
Items)
2 Welder Qualification A A R A A R A R R

3 Welding A A A A A A A A A*
Procedure_Qualification

4 NDT personnel certificate A A A A R R R R R

5 Visual Inspection H H W H W W H R R*
6 UT H H W H W W H W* W*
7 RT H W W H W W H W* W*
8 MT.PT H H W H W W H R R*
9 Assembly and fit Up Control H H W H W W H R R*
10 Final Visual and Dimensional H H H H H H H W W*
Control
11 Pressure Test H H H H H H H W W*

12 Performance/Function Test H H H H H H H W W*

13 On/Off load Test H H W H W R H R R*

14 Type Test H W W H R R - - -

15 Sand Blast, Rust Prevention H H H H W W H R R*

and Painting
16 Packing and Marking H H R H W R H H R
Verification
17 Final Release Note H H H H H H H H H
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18 Final Data Book H H A H H A H H A

COMMENT:

1-R= REVIEW : Each of the Contractor's QC inspectors will summarize their daily
inspections in a daily report. The Department's Daily Report of Construction or a
similar form shall be used for maintaining a written record of inspection results.
Original records are to be maintained by the Contractor and available upon request
for review by the client or consultant.

H=HOLD : Hold Points are mandatory verification points identified by the Client
or consultant beyond which work may not proceed until the Contractor notifies the
Client or consultant and the Client or consultant performs mandatory verification
and gives notice to the Contractor to proceed.

W=WITNESS : Witness Points require notification of the client or consultant by

the Contractor. Upon properwritten notification by the Contractor to the Client or
consultant, work mayproceed beyond a Witness Point with or without action by the
Client or consultant.

A=APPROVE
2-performance and functional test= mechanical Run, vibration, noise, temperature & act
test; *: Except catalogue items
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8. Inspection Documents

Inspection documents and records will be provided according to DIN/EN 10204

and table below:

LEVEL
ITEM DOC U M EN T
A B C
Material Certificate
1 2.3 2.3 2.3
(Major Items)
2 Material receiving control 3.1A 3.1A 3.1A
3 Welder Qualification 3.1A 3.1A 3.1A
Welding Procedure
4 3.2 3.2 3.1A
Qualification

5 NDT personnel certificate 3.IB 3.IB 3.IB

6 Visual Inspection 3.2 3.1A 3.1A

7 UT RESULTS 3.IB 3.IB 3.1A
8 RT RESULTS 3.IB 3.IB 3.1A
9 MT.PT RESULTS 3.1A 3.1A 3.1A

Assembly and fit Up

10 3.2 3.1A 3.1A
Control

Final Visual and

11 3.2 3.2 3.1A
Dimensional Control
12 Pressure Test 3.2 3.2 3.1A
Performance/Function 3.2(if 3.2(if 3.2(if
13
Test applicable) applicable) applicable)
14 On/Off load Test 3.2 3.1A 3.1A
15 Type Test 3.IB 3.IB 3.IB
Sand Blast, Rust
16 3.2 3.1A 3.1A
Prevention and Painting
Packing and Marking
17 3.1A 3.1A 2.3
Verification
18 Final Release Note 3.2 3.2 3.2
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19 Final Data Book 2.3 2.3 2.3

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9. Inspection at sub-supplier's workshop

Supplier will instruct the Sub-suppliers of machinery and equipment ordered in
accordance with relevant contracts to comply with the following procedures
wherever applicable.
9.1. Each Sub-Supplier shall expedite the manufacturing and the delivery of
materials/or equipment of the Plant. Client shall be entitled at all reasonable
times during manufacturing, storage and packing, to inspect, examine and test
on each Supplier's or Sub- supplier's premises the qualities and workmanship
as well as progress of the works performed under the Contract (with supplier
coordination).
9.2. The pieces of machinery and equipment to be delivered will be examined
by client representative according to QCP. If a large number of pieces of the
same kind will be fabricated, the client representative will take samples for
examination in proportion to the quantities to be supplied, according to QCP.
9.3. Special tests discussed and agreed between the parties that can not be
performed with equipment at Supplier's/Sub-supplier's laboratories, shall be
performed by qualified institutions/inspector agreed upon.

9.4. Sub-suppliers, as the case may be, shall provide free of charge to supplier
& client adequate office space, secretarial assistance and telecommunication
services during the execution of inspection activities as per Contract.
9.5. Where the contract provides for tests on the premises of a supplier or of
any sub supplier, said sub supplier shall provide such assistance, labor,
materials, electricity, fuel, stores, apparatus and instruments as may be
required and as may be reasonably demanded to carry out such
test efficiently.
9.6. Safety: During test execution the safety regulations, in force in the country
where the inspection takes place, shall be fulfilled by the manufacturer. Safety
garments, whenever required, will be made at disposal of the client's inspectors
9.7. Sub-supplier should be selected from approved vendor list .If they are not in
vendor list, before starting the contract, it is essential that approval from client should
be taken.
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10. Documentation required for the issuance of Quality Test Certificate

(QTC)
Together with pertinent technical Specification the Supplier will make
available to the client the
following for client approval: (if the frame of QCP)
10.1. Reports on all test performed mentioned in QCP
10.2. Casting certificates
10.3. Pressure testing certificates
10.4. Certificates of pertinent testing laboratories
10.5. Result of any destructive test, together with pertinent sketches and
description
10.6. Reports on welder's qualification Certificate.
10.7. Reports of repairing
10.8. Certificate of purchased Items should be added to QTC
10.9. Any other report which assigned in QCP

11. Test pieces for destructive testing

Test pieces agreed between the parties shall be branded in the presence of Buyer
Representative for important forgings and castings. (If required by QCP) Vl/here
heat treatment of the casting or forging is necessary, the test piece shall not be
removed before the treatment is earned out.

12. Repairs
In case of defect or deficiency which affects any critical item, sub supplier shall
submit to the supplier, before proceeding to make good the defect or deficiency, a
report explaining the measures they intend to adopt, and their consistency with
applicable Standards. All relevant reports should be submitted by supplier to Client.
13. Packing and Marking
The Packing and related marking will be provided in separate specification.