“Quality is fitness for the purpose.

Reliability is the ability to continue to function to our accepted quality standard.”

PLEDGE:
 WACOM delegates the necessary responsibilities with authority and
organizational freedom to all its members under independent
departments performing QA/QC functions to ensure high quality
standards and identify quality related problems and to initiate,
recommend and provide solutions to maintain Quality Standard.

MOTTO:
 Establish and maintain the right level of the Quality Standard for all the
activities which may influence the quality of the services and
production rendered by WACOM and that quality will be planned and
built into a product/service, and verified by means of review,
inspection and testing, to satisfy the customer.
1. QUALITY ASSURANCE PROGRAMME

1.1 Quality Assurance

2. QA MANUAL

2.1 Manual Control

3. QA/QC PROCEDURES
3.1 QA General procedures

3.2 QA/QC Functional procedures

4. QUALITY CONTROL
4.1 Visual Inspection of plate works, structural Steel and piping

4.2 Non – Destructive Examinations (NDE)

4.3 Leak Testing / Hydrostatic testing

4.4 Inspection of Surface Treatment

4.5 Dimensional Control

5 DETAIL INSTRUCTIONS

In matters affecting quality Control, a Quality Control team shall carry out all
aspects of inspection as specified by the Quality Assurance Manager, which
would meet the specification and implied requirements of the customer.

This manual shall be the Bible for quality of all the activities of the Company.
This Manual is essentially set to meet the requirements of ISO 9000.

No deviations from the methods set forth herein are permitted, unless clearly
authorized by the quality Assurance Manager or the appropriate authority o
WACOM. Conflicts arising between Quality Assurance Engineer and other
departments in matters affecting Quality are resolved by the appropriate
authority without negating the requirements of the standards.
1.1 The Quality Assurance is divided into three parts :
- QA Manual (Part 1)

- QA/QC Procedures (Part 2)

- Instructions (Part 3)

Each Division/ Department head in the WACOM is responsible for ensuring that
the personnel in his section are familiar with the QA program and that his
Division/ Department complies with applicable procedures.

QA Manual is the overall document of the QA system that describes the

Quality requirement and their principal accomplishment.

2.1 Manual Control

This manual shall not be revised to meet client’s specifications. All
additional requirements imposed by the client shall be covered in the
QC plan for that particular project.

Distribution of QA Manual may be done as follows: -

- Controlled QA Manual
This Manual shall be distributed to individuals and departments
within WACOM for direct use in their work. Such copies shall be
subject to automatic revisions.

- Uncontrolled QA Manual
This Manual shall in its current status, be distributed to
individuals/ organizations outside WACOM for information and
review and will not be revised.
Request for changes and revisions to be directed to Quality
Assurance Department.

No changes will be made without approval of the management

of WACOM and the Quality Assurance Department.

Changes shall be indicated giving all pages of the chapter and a

new revision no. and date in the title block. Revised chapters /
pages will be distributed to the holders of the controlled QA
Manuals, who shall be responsible for exchanging the chapters
in the QA Manuals.
QA/QC procedures as part 2 comprise of general and functional procedures.

3.1.1 QA general procedures are needed to control administration of the

Quality Assurance activities within WACOM.
- Document preparation, review, distribution and control.
- Record retention
- Non conformity records
- Quality Audit & Management review

The above general procedures, which are required routinely in each

division / Department are described briefly as below:

3.1.2 Document preparation, Review, Distribution and Control:

These procedures provide the guidelines for preparation, Review,

distribution of documents, drawings Specifications, procedures,
correspondence handled by all the sections of the company. This also
covers the documents received from and sent to clients, vendors, sub-
contractors and others.

The Drawings/Documents (Specifications and procedures) shall be

checked by project, engineering, operations QA/QC and safety for
initial check for errors, omissions, interference and adequacy etc.
comments shall be passed on to clients for possible revision / response.
The revised drawings / documents approved by clients shall be
distributed to the above stated departments. All the obsolete drawings
shall be collected and stamped “VOID”/ “SUPERCEDED”.

The documents prepared by each department are to be checked before

issue within or outside the company.

The document shall have identifiable number for easy identification.

The documents generated by the company or received from outside

client, vendor, sub-contractor or others shall be distributed through a
nodal point, which is responsible for recording and distribution of the
documents. Every department is responsible for safe keeping of the
generated document and received documents.

The projects shall be solely responsible for maintaining the copies

issued to various departments.

The projects shall issue to the fabrication department details of cutting

lists, templates and shop fabrication drawings generated by the
 engineering department. The QA/QC personnel shall liaise with the
project, engineering, fabrication, and operation for NDT, fabrication
documentation and weld plans.

After fabrication, all construction drawings shall be updated and

stamped “as-built”.

All documents pertaining to the project shall be handled by the project

engineer and transmitted to engineering, fabrication and QC personnel
as required.
Records of revision in the fabrication procedures shall be maintained by
the project engineer.
All revisions shall be dully notified to the relevant personnel.

3.1.2 Record Retention:

This section provides guidelines for retention of documentation
completed / received after completion of the activity and maintaining
the records for future reference.

On completion of the job / project, copies of all reports, records and

documentation shall be submitted to the client.

The final documentation shall contain:

- Design Specification and Calculations
- Drawings
- QC Plan
- NDT & Heat Treatment procedures
- Welding procedure records
- Welding operator’s records
- Test certificates for materials and others
- NDT Reports
- Hydro test Records and Reports
- As-Built Drawings
- Spare parts details
- Operation & Maintenance Manuals
- Any other documents/ records related.

Company shall keep all correspondence, documentation for a period as

specified/requested by client. After this retention period, the client
shall be notified of disposal of any documents. Important and essential
documents are retained and safeguarded.

3.1.3 Non-Conformity Records :

Non-conformity is any condition of document, material or
 workmanship, which WACOM not comply with the governing code or
specification or requirement and requires correction or elimination for
acceptance.

Some of the examples for controlling the non-conformity are as follows:

Material not conforming to the requirement and cannot be rectified

shall be removed from location with an appropriate identification
record shall be made of the defective material rejected.

If the non-conformity falls within framework of an approved procedure

for rectification of the conditions, the fabrication shall rectify the
condition strictly as per the procedure, subject to the approval of the
concerned authority from the client.

3.1.4 Quality Audit and Management Review:

This section provides guidelines for ensuring that all the departments
of the company shall strictly follow the Quality procedures in order to
maintain the high quality expected in the output.

Quality audit for any particular activity is carried out by a team,

headed by appropriate authority from QA/QC department. The team
shall be aware of the operations of the department being audited. The
audited department shall co- operate with the team.

A joint review meeting is held by the head of QA/QC department,

relevant department heads and the appropriate authority from the
management. Any corrective actions for non-conformity shall be
prescribed. Any changes or updating of quality measures/procedures if
required is finalized and the same are incorporated in the quality
manual with approval from the appropriate authority.

3.2 QA/QC FUNCTIONAL PROCEDURES

These comprise of procedures, which describes the practical
accomplishment of the QA/QC requirements, related to the different
activities performed:

 Contract Review
 Planning & Engineering.
 Material Control
 Production Control
- ON-SHORE
- OFF-SHORE
 Inspection Program
  Equipment Check & Instrumentation Calibration
 Vendor & Contracts Evaluation.

3.2.1 CONTRACT REVIEW:

This procedure outlines briefly the activities to be carried out by

various departments for review of the contract

During the bid review stage, the client’s drawings, documents, and
other specifications and requirements are reviewed thoroughly for any
errors, omissions, contradictions, adequacy and sensibility.

Bidding section shall confer with projects, engineering, fabrications,

operations, QA, safety and other relevant departments in finalizing the
tender proposal and its meeting with various requirements of the
client. Any ambiguity or inadequacy in the design and contractual
documents shall be clarified with the client and documents.

3.2.2. PLANNING & ENGINEERING

This procedure describes the requirements to be followed for planning
and engineering during the bidding stage as well as project execution
stage.

A planned schedule is prepared during the bidding stage with all the
activities required for complete scope of work as per tender
information mile stones set by client.
A comprehensive program with the help of Bar Charts/CPM/PERT
TECNIQUES with project key dates are prepared and enclosed in
company proposal as per tender requirement engineering section
reviews the tender document or the technical scope of work,
specifications, procedures, drawings for various activities.

After award of the contract, the planning and engineering activities

are revised/modified/updated to suit the requirement of the
contract. Detail procedures, Bill of Materials, Scope of work with all
activities is laid down.

Certain guidelines are to be followed for the above activities. These

are summarized as follows:
- The Engineering Personnel shall prepare all drawings and
documents (planning, package, calculations, analysis, specifications,
procedures, reports etc.) files under separate names & numbers,
assigned as per established procedure and norms.
- These shall be issued to tender section of the Project as the case
may be for review and onward transmission to client.

- After the documents /drawings are approved by the client /clients

representative as per requirement, the engineering shall record the
approved and issue for distribution, these documents to all relevant
sections by the projects.

- The engineering personnel shall maintain a logging record off all

these copies made for distribution to various sections.

- The project shall distribute the required number of copies of the

approved drawings/document to relevant sections.

- Project shall maintain a strict record of number of copies distributed

and a list of personnel, copies were distributed to along with track
record of revisions made and issued.

- Based on the client approved drawings /document the engineering

shall raise the bill of materials along with detail specifications,
inspections/testing
- equipment’s as per contract requirements and inputs from
fabrication, QA and operation.

- The bill of materials shall specify the quantity, size and condition in
which the material shall be used for fabrication. Incase material is
not provided by the clients or is not available, the requisition is
raised for procurement.

- All incoming materials shall include relevant conformance

certificate, indicating the as-received condition, and expected
properties after completion of fabrication. This includes both the
purchased materials as well as the client supplied material.

- Details of additional testing or requirements shall be clearly

specified in the purchase requisition, by the engineering.

- During the course of fabrication, if the material is to undergo any

welding or heat treatment, the engineering shall indicate the
details.

- If the fabrication involves qualifying new welding procedure and

welder’s Procedures and welders’ performance qualification, the Bill
of Material shall include material required for the same. QA/QC
 shall review these procedures & release for client approval.

- Conformance certificate shall be verified by the project / fabrication

/ QA Engineers, prior to acceptance of the material.

- Once the material is received, the material controller takes charge

of all material during entire fabrication and subsequent activities.

- If the project involves fabrication/execution at site, (onshore or

offshore) the project &engineering personnel along with the
relevant personnel shall conduct a site survey, prior to bid as well as
before fabrication of assemblies to be installed on site. Based on
the site –survey input to be incorporated in the fabrication drawings
to engineering.
3.2.3. Material Control

This is the procedure for verification of receiving, quantity, storage and

traceability of material in use.

Engineering department will prepare the bill of materials, identify the

scope of supply of materials by client and WACOM and send to
projects/stores for verifying if any material with required specification
available in stock with relevant certificates.

Available materials shall be issued by stores on requisition and for

remaining materials as approved by the engineering department shall
be forwarded to purchase department.

Purchase department shall raise enquiries, get quotations, and do

necessary technical / commercial evaluation shall issue local purchase
order duly authorised by project. Before placing the order it is to be
ensured that the material and its documentation meet the job
specifications and the delivery meets the project schedule.

Receiving of Material
- Receiving ,inspection and storage of material shall be handled
by the material controller(MC)

- MC shall check the delivery notes against the requisition and

confirm that quantity supplied is in accordance with the
requisition.

- MC shall ensure that relevant mill/test certificate are

attached. Projects shall arrange for mill certificates from the
 client-supplied material.

- MC shall check that the markings on the material are genuine

and comply with mill/test certificates and material specifications

- MC shall ensure that the material satisfies the specification

as per the requirements of the customer/client.

- Inspection and Acceptance of Material

- Mills/test certificates shall be verified against the marking on

material.
-
- Thickness and other dimensions shall be checked to ensure that
they comply with the specifications and are within the tolerance
limits.
-
- Plate Inspection
- Visual inspection shall be conducted to examine for indications
of corrosion, pitting, surface laminations and damage during
handling etc.
-
- Pipe Inspection
- Visual inspection shall be conducted to examine externally and if
possible internally for indications of pitting, surface laminations,
mechanical damage etc.
-
- Structural Sections
- Visual inspection shall be conducted for corrosion, pitting,
surface laminations dimensional tolerances etc. Visual inspection
shall also incorporate measures to ensure that the flanges are at
right angles to the web.
-
- Fittings (Flanges, Elbows, Tees etc.) Inspection
- Visual inspection shall be conducted to check for indications of
corrosion, pitting, manufacturing defects, mating face distortions
etc.
- Valve Inspection
- Visual Inspection shall be conducted to check for corrosion,
pitting and manufacturing defects etc.

- Welding Consumable Inspection

- Consumable inspection shall be conducted to ensure that all
 welding consumables meet the specifications and classifications
as described on approved welding procedures. Consumables in
unsealed or damaged containers shall be rejected.
- Material Controller shall accept only those materials approved
by the QC Personnel and enter into the inventory. Only accepted
material shall be issued for fabrication.

- In case of defect in supplied items, the QC personnel shall make

a defective material report and forward to the projects through
the QA Engineers. Standard format shall be used to report
defective materials.

- Materials with equivalent specifications may be used subject to

the approval of the projects/ Engineering / QA / QC and the
client. Supplementary test reports or certificates of compliance
if required, shall be submitted to the clients to support the
equivalent material.

- Storage of Materials
- Material, equipment’s, packages etc. susceptible to
environmental damages and deterioration shall be protected
from any kind of damage.

- Flanges, bolts, gaskets, valves etc. shall be stored in the covered

areas.
-
- Bulk material like steel sections, plates, pipes etc. can be stored
in the open on timber bearers.
-
- Material is systematically arranged for easy identification.
-
- Marking of Material
- All material shall be marked with marker or hard stamped for
identification of applicable material specification and heat
number.

- Sectioning of material shall be done with each section duly

identified prior to sectioning.
- Process pipeline spools shall be marked with line and spool
numbers hard stamped on metal tags and tied around individual
spools with wire.
-
 - Material Traceability
- Each section of the material shall be marked and identified in
accordance with the documents at the time of acceptance. Such
markings shall be properly maintained during storage for
traceability.
• Production Control Onshore :
Scope :
This section describes the procedures, to be followed for onshore
construction for production control in translation of the raw material
into a finished product including fabrication, documentation etc.

Production Planning & Execution:

Material Controller shall make available all materials required for the
necessary operations according to the material take-off list, as
requested by the site and directed by the Engineering.

The site manager and the project / engineering department shall first
review the working drawings to determine the sequence and method
of fabrication. A detail job route sheet is developed. Copies of the Job
Route Sheet and QC plan Shall be available with the site, QA/QC,
Foreman` s and the project.

The drawings and documents are delivered to the site for the
operations to be started.

Site Supervisors / Foreman is responsible to ensure the correct usage of

material or equipment while operation. The combination of the work
shall be in accordance with the JRS. The QC shall work in parallel to
ensure the quality with respect to the specifications as per the
drawings and calculations.

The welding / Fabrication activities shall be notified of all major

discrepancies. They shall be handed as per procedure for non-
conformity.

Welding and fabrication inspection shall be handled by the QC

personnel after completion of the same, as per procedures for
examination and inspection.

The site supervisor/foreman after completion of the welding and

fabrication shall rise requisition to the QC personnel to conduct the
Non-destructive examination of the components as per QC plan.
After completion of the inspection, the components shall be
 dispatched/permitted for further operation if any.

In case of any defects observed the same shall be documented and

reported. Repairing or reworking done accordingly to comply with the
specifications given by the client.

Documentation
- All the documents pertaining to the release of the component
shall be prepared and signed by the project engineering
supported by the QA department.
- As built drawings are prepared by engineering/project
based on the records supplied by fabrication
supervisor/foreman and QC personnel.
- Consolidated inspection record for the project shall be compiled
by the QA Engineer and submitted to projects.
- The projects shall ensure that all documentation is completed in
due course and made available to the client after the completion
of the project.

Responsibility
- It shall be the responsibility of the projects to ensure that the
various members of the line management are fully conversant
with the relevant drawings and specifications that govern the
project.

- It shall be the responsibility of QC personnel to ensure the

quality control plan is adhered to during the entire course of the
project.

- Site foreman/supervisor shall be responsible for the

progress of the fabrication.

3.2.5 OFFSHORE CONSTRUCTION

Scope:
This section details procedures involved for offshore projects. Section
3.2.4 is applicable for all the activities of these offshore projects, which
are carried out in the fabrication site of the company.

The following are the guidelines and requirements to be adhered for

overall works to be carried out:
Planning & Execution:
The projects, engineering &offshore operations review the working
drawings to determine the scope, sequence & method of fabrication at
 yard and erection at site. QA

Engineer confers with projects on welding sequence &processes

required at the yard as well as at offshore site. A QC plan is prepared
&documented by the QA engineer. Copies of production &QC plan are
distributed to QA engineer. Project and job foreman, in yard as well as
site foreman.

As per material take off list, the material controller makes available all
materials as requested for by the yard &the barge.

Barge foreman is responsible to ensure material used as per working

drawings. Bevelled ends shall be cleaned prior to welding.

Barge fitter/fabrication foreman should ensure that the fits up of

components are in accordance to the applicable working drawings
before releasing components for welding. Also QC personnel shall have
to ensure compliance of components to working drawings in all
respect.

Barge welding foreman shall supervise the welding activities. He is

responsible for assigning the right welders, welding operators
&welding procedures for the relevant procedure.

After completion of welding &fabrication, barge based QC to conduct

NDE. After inspection the component shall be despatched for further
operations with a material identification list.

If queries regarding fabrication is not clarified at site, same shall be sent

to base office.

Incase if the project is related to the hook-up then the project

department should ensure the pre-fabricated and after fabrication
documents b received for the records and reference from the client.
Any queries can be passed to the client for clarification before the next
step for planning starts.

Documentation:
All documents pertaining to the release of the components shall be
prepared & signed by QA.

As-built drawings are prepared by engineering at base, based on the

records supplied by QA/QC from barge.
 A consolidated inspection record for the project shall be complied by
the QA engineer and submitted to the projects.

The projects shall be responsible for maintenance of all documents and

submission of documents to the client at the end of the project.

Responsibility
For every project, it shall be the responsibility of the projects to ensure
that the various members of the line management are fully conversant
with the relevant drawings and specifications that govern the projects.

It shall be the responsibility of the QA section to establish the quality

control for the project.

It shall be the responsibility of the QC personnel to ensure that during

the entire course of the project the quality control plan is adhered to.

Barge Foreman shall be responsible for the progress of the fabrication,

erection & installation at site. However, QC personnel shall ensure that
the component is cleared after inspection for further operation.

Quality Assurance Engineer shall monitor the performance quality of

the works carried out at site and of QC personnel.
3.2.6 INSPECTION PROGRAMME
This section outlines the procedures to be followed by the quality
control personnel during the course of fabrication, erection and
installation in fabrication yard or on the site in ensuring the conformity
to the quality plan.

Quality plan for the particular project shall be laid down and documented.

This shall be prepared by the QA/QC section, on the basis of the input
supplied by the project.

The personnel involved in quality control activities:

- Shall be suitably qualified to execute the responsibilities
entrusted upon him.
- Shall be supplied with suitable instruments to execute this work.
- Shall be properly informed of his scope of work as related to the
particular job. Information pertaining to a job may reach him
either through the project, barge/fabrication superintendents.
QA engineer or his immediate supervisor.
The QC plan shall form the basis for the inspection program for the
project. Any deviation from the QC plan shall obtain approval from the
QA/QC section and the client’s representatives, if required.
- non-destructive examination shall be carried out in line with QC
procedure under:

- QC personnel shall compile a consolidated report for the stage

wise inspection conducted on the job with the reports approved
by the client/client’s representative. After approval all original
documents and graphs are retained in archive and copies
submitted to the client.

• EQUIPMENT CHECKS & INSTRUMENT CALIBRATION

This section outlines the procedures to be followed by equipment
checks and calibration of the instruments used in quality control.

Measuring instrument and equipment shall be tested and calibrated by

using a standard reference. Typical measuring instruments &
equipment shall include
• Pressure Gauges
• Load Cells
• Ammeters / Volt Meters / Ampere meters
• Recorder Units
• Ultrasonic Testing Equipment
• Theodolite & Level Instruments
• Welding Machine

It is the responsibility of the foreman handling the project to get

equipment's checked for their required performance and the
instruments calibrated.

Calibration of instruments may be conducted by a recognized testing

agency. The agency shall issue certificates of calibration. The
certificates shall contain details of the instruments, model, serial
number, calibration, reference used for calibration, and date of
calibration.

Records of inspection/check/test of the equipment's and calibration

certificate shall be maintained by QA. QC personnel shall ensure proper
functioning of the equipments/instruments, and validity of calibration.
Records shall be available for client’s review.

Measuring tapes and level gauges shall be visually inspected for

damage and checked using a known reference.
 3.2.8 VENDOR /SUB-CONTRACTOR EVALUATION
This section describes the procedure to inspect and evaluate
vendor/sub- contractor for the supply of materials, equipments or
render services as a part of the project work.

Evaluation shall be conducted prior to the award of contract. This

procedure enables the vendor/sub-contractor to provide services
suitable to the work/specification supplied by the company.

Sub Contracting:
The evaluation shall be conducted by a team consisting of QA/QC,
projects and engineering, thorough inspection of the sub contractor’s
premises and facilities is done to ensure the suitability of equipment,
manpower and other facilities they have. The team should ensure that
the work force/personnel involved in carrying out the sub contract
work is suitably qualified. Documental evidence to be taken and if
necessary may individually interviews the personnel. The team shall
ensure that the equipments used are up to the reasonable standards of
serviceability for the work.

The team shall review the quality control program, storage facilities
and any others. After completion of the defined work, the project shall
receive the documentation accompanying the service rendered.

Material Supplier
The team shall carryout a detail inspection of the supplier facilities to
ensure that materials supplied for a particular project meet the
specifications as detailed by the engineering, and all the certificates
pertaining to the quality of the material is made available prior to
delivery.

All materials shall have relevant information pertaining to

identification, grade place of magnification, size, specifications,
schedules heat numbers colour coding and other necessary required
information as specified. The information shall be stamped or printed
on suitable location.

The material controller shall ensure that the material supplied have
correct documentation and all in accordance with the specifications
QC should ensure that subcontractor adheres to all check points to
maintain the required level of quality for the services / products
rendered.
SCOPE:
 This section describes methods and requirements for Quality Control.
The purpose of QC is to check for complying of requirements, and to
identify non-conformance and to ensure quality is achieved as per
specifications and requirements.

The different method for achieving the quality for different operations
shall be as explained below:

4.1 Visual Inspection of Structural Steel and Piping

Personnel performing visual inspection shall have available all relevant
codes and documents pertaining to the work, such as applicable codes,
specifications, welding procedures etc. It is the responsibility of each
inspector to ensure that the inspection is performed in accordance with
applicable codes, specifications and procedures.

The inspectors have the authority to stop work, which is not carried out
to the standards of relevant codes and specifications. The extent of the
inspection required is generally governed by contract requirements.
However this dWACOM not limit the inspector’s responsibility and he
shall attend and/or inspect all operations and completed work as
necessary to ensure specified quality.

Visual inspection can be divided into three main stages, i.e. preventive
inspection, follow-up inspection and final inspection. All structural
steel, piping material, welding repairs included, is subjected to
inspection in all three stages.

Upon visual acceptance of the welding it is the QC inspector’s

responsibility to schedule and initiate the required.

Non-Destructive Examinations. The “Request for NDE” prepared by the

QC inspector may serve as a visual inspection release.

When reporting before and during welding, the inspector determines

the extent of is report by his own judgement. Deviations, which might
affect product quality, shall be reported. This shall be done in writing to
the Inspection Engineer with copy to the production supervisor.

Reporting after final inspection shall provide a record of the structures

and items that have been inspected and approved. In case of non-
approval, a punch list shall be complied including all remarks
concerning unsatisfactory or unfinished work.
4.2 Non-Destructive Examinations (NDE)
It is the Inspection Engineer’s responsibility to ensure that
 a. NDE is carried out by adequately qualified personnel.
b. Necessary NDE procedure is prepared in accordance with
applicable codes and standards and the contract requirements.
c. NDE is performed according to approved procedures.
d. NDE results are recorded and reported on approved report forms.
e. A complete history and tractability record is prepared.

The method of examination to be used will be as specified in the

production documents in compliance with contract requirements.
Normally the following examination methods are used:
- Radiographic Testing (RT)
- Ultrasonic Testing (UT)
- Magnetic Particle Inspection (MPI)
- Liquid Dye-Penetrate Examination (DP)
Other methods may be applied as found appropriate by the QA
Engineer and clients representative.
Radiographic Testing Procedure:
The RT procedure will describe the method to be used for radiographic
testing specifying:
- Material type and thickness range
- Technique , i.e. single wall, double wall, panoramic
- Source of radiation and strength of source
- Maximum source-to-film distance
- Film brand and type
- Screens to be used
- Processing
- Identifying marking of films
- Reporting RT results
- Acceptance criteria

Ultrasonic Testing Procedure:

The UT procedures shall cover the following:
- Weld geometry, weld type and type of material
- The surfaces from which examination shall be carried out
- Surface conditions and type of couplet.
- Scanning technique
- Probe types, frequencies and transducer sizes
- Type of ultrasonic instrument
- Description of calibration
- Sensitivity level and acceptance criteria
- Limitations of examination
- Method and extent of reporting
- Acceptance criteria
Magnetic Particle Inspection Procedure:
The MPI procedures shall cover the following :
- Materials, shapes sizes to be examined
- Magnetization technique
- Equipment to be used for magnetization
- Surface preparations, finishing, cleaning
- Type of ferromagnetic particles to be used, manufacturer, color, wet or
dry etc.
- Magnetization currents
- Demagnetization
- Extent of examination
- Method of extent of reporting
- Acceptance criteria
Liquid Dye-Penetrate Examination Procedure:
The DP procedures shall cover the following:
- Materials, shapes and sizes to be examined, and the extent of
examination
- Type of penetrate, penetrate, remover, emulsifier and developer
- Cleaning materials used and time allowed for drying
- Dwell time and temperature of surface and penetrate during
examination
- Removal of excess penetrate and drying of surface before applying
developer
- Developing time before interpretation
- Post-examination cleaning
- Method and extent of reporting
- Acceptance criteria

4.3 Leak Testing / Hydrostatic Testing

Leak testing and hydrostatic testing of tanks, vessels and piping systems
will be performed according to written procedures, and in compliance
with code requirements and contract specifications. The test system
will be blinded and two calibrated pressure gauges will be fitted.

Normally water containing corrosion inhibitor, oxygen scavenger and

brocade if specified, will be used for testing. When all air pockets are
vented, the pressure will be raised slowly up to the design pressure and
all joints/connections will be inspected for leaks. Correction of any
leakage will be carried out and the pressure then raised to full
hydrostatic test pressure, which shall be maintained for a period,
specified in the test procedure. A visual inspection of all joints will be
performed. There should be no drop of pressure during testing.
Temperature of the test media will be recorded during the test and will
be compared with the pressure readings.
 If the test is found acceptable the pressure test report and other test
documents will be signed and approved by the QA/QC and client’s
representative.

4.4 Inspection of Surface Treatment

Inspection of surface treatment will be carried out according to written
procedures, covering all surface treatment processes.

It is the responsibility of the Engineer/Foreman in charge to ensure that

the work is carried out according to the valid procedures, that
equipment and consumables for surface preparation and coating are
used and stored as prescribed, and that the test logs stated in the
procedures are correctly maintained.

The Plant Inspector will ensure that approved procedures and

specifications are adhered to, by performing regular and random
inspections. He is responsible for reporting of the work.

The QAD is responsible for systematic filing of all reports point lists and
releases to be part of the final documentation.

4.5 Dimensional Control

The extent of dimensional control will be established by QA according
to contract requirements. QA is responsible for preparing the necessary
instructions and sketches, which will be subject to client’s approval.
Generally, the Project Engineer in charge, is responsible for adequate
dimensional control and for ensuring that piping or structural items are
assembled within specified tolerance.

5.1 Detail instructions as part 3 are made for each activity of the company
and describe in detail, how WACOM will comply with quality assurance
requirements of customers / contracts / order, Design specification,
Drawings, Processes, Fabrication, Inspection, Tests and Documentation
by records, from the acceptance of contract/order to final approval by
client’s / customers / authorities.

Note: These procedures may be amended for a particular project to

satisfy the specific requirements of the project with proper permission
from the management and QA department.
Assigning the authority with responsibility and accountability, allowing
for perfect involvement in the job to achieve the objectives by
informing beforehand the process and limitations gives the way for the
Quality and Reliability.

For any clarifications, please contact the QA/QC department.