DOCUMENT TITLE

INSPECTION AND TEST PROCEDURE

DOCUMENT NO.
PROJECT NAME
SITE LOCATION
GS E&C JOB NO.
CLIENT NAME
CONTRACTOR NAME
VENDOR NAME
P.O. NO. (GS)

DESCRIPTION

STEEL STRUCTURES

VENDOR DOCUMENT REVIEW

PROJ:

1 APPROVED

2 APPROVED WITH MINOR COMMENT.

INCORPORATE COMMENTS AND SUBMIT
AS FINAL

3 APPROVED WITH MAJOR COMMENT.

REVISE AND RE-SUBMIT FOR APPROVAL

4 NOT APPROVED.
APPROVAL

CUSTOMER:

MR

N:

PO

N:

ITEM:

U.O.:

VR Doc. CODE:

BY:

REV.

DATE

DESCRIPTION

RE-SUBMIT

FOR

DATE: XX/XX/XXXX

PREPD

CHKD

APPD

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TABLE OF CONTENTS
1.0

Scope

2.0

References

3.0

Control of inspection and test plan

4.0

Material Receiving inspection

5.0

Material Identification

6.0

Fit-up Inspection

7.0

Welding Inspection

8.0

Nondestructive Examination

9.0

Dimensional & Visual Inspection

10.0 Painting and Galvanizing Inspection

11.0 Final Inspection
12.0 Packing and shipping Inspection
13.0 Documentation
14.0 Attachments

INSPECTION AND TEST

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1.0

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Scope
This procedure establishes the instructions for preparation and control of Inspection and Test
Plan (ITP) which identifies the main activities (inspection, test) to be performed during
fabrication.

2.0

References
All of work shall be carried out according to this procedure and following references.
AISC : American Institute of steel construction
ASTM : American Society for Testing and material
AWS: American Welding Society
SSPC: Steel Structure Painting Council
JIS: Japanese Industrial Standards

3.0

Control of Inspection and Test Plan

3.1

The ITP (Inspection and Test Plan) shall be used for inspection and test during the
fabrication of structural steel.

3.2

Application of inspection as per "Inspection and Test Notification"

3.2.1

Inspection will be performed by QC and CONTRACTOR QC Inspector

3.2.2

The Application for Inspection shall be submitted to CONTRACTOR at least 2

weeks (14 working days) prior to the date of inspection, Changes weeks (14
working days) prior to the date of inspection, Changes thereto shall be
advised at least 5 working days prior to the date of inspection.

3.2.3

CONTRACTOR shall reply to vendor's inspection notification before 5 working

days of inspection date.

3.2.4

The Application for Inspection shall be submitted to CONTRACTOR QC Dept.

3.2.5
4.0

Persons in charge : CONTRACTOR resident QC inspector

Expediting : (Expediting Coordinator)

Vendor will submit Inspection completion Notice for Pre-Shipment Inspection.

Material Receiving Inspection

4.1

All materials used in the manufacture of structural steel should be covered by mill
certificates showing chemical analysis, mechanical test required by the applicable
specification. All the materials shall be bought from the Approved vendors and from
the listed countries.

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4.2

4.3

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Receiving inspection section of Q.C Dept. shall perform receiving inspection

according to applicable specification and codes for the following as a minimum.
-

Checking of material source from approved sub-vendor list.

Checking of handling damage, distortion and surface rust condition.

Checking of mill certificate, verification of mechanical and chemical properties.

Verification of Heat No./Batch No. available on material.

Checking of identification marking on the material or parts.

Visual checking for crack and other injurious defects.

Visual checking for steel plate lamination at all edge.

Details to be verified from a mill test certificate

Test Certificates shall be in original or copies of the original. Copies shall be endorsed
by the supplier as Certified True Copy of the Original. Copies shall be clear and
readable in full detail. Heat Number/Batch Number and Mill Identification shall match
with the markings on the material. Physical and Chemical properties in mill test
certificate shall meet the material specification requirements in the P.O. If the above
requirements are not met, the Test Certificates shall be rejected and an IRR shall be
raised.

4.4

5.0

In case of high strength bolts

-

Check test certificates for conformity with bolt specifications.

Dimension check.

Check class and grade of bolts as per requirements.

Material Identification
Material shall be identified as defined in the applicable industry specifications, such as
applicable manufacturing specification number (e.g., ASTM, JIS specification and grade)
and/or heat numbers, heat codes, or unique identifiers. Bolting is identified as per the
markings provided in the bolt manufacturing standards (AISI, JIS). Instrument bulks are
identified by manufacturer's markings. Material identification will be applied by the
manufacturer directly to the item, using low stress stamps or paint stencils. All of work shall
be carried out according to this procedure and following references.

6.0

Fit-up Inspection
6.1

Fit-up shall be checked in accordance with the relevant welding procedure

specification and shop fabrication drawings approved by CONTRACTOR.

6.2

Inspection shall be mainly made on the followings, but not limited to :

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7.0

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Root gap and beveled angle.

Cracks, notches, flaws and other injurious defects on the edges.

Tack welding and alignment of parts to be joined.

Material Identification
7.1

Welding shall be carried out only in accordance with approved WPS as per AWS
D.1.1 section 3.

7.2

Welding Procedure Specification shall be qualified for the production welding position
as per AWS D1.1 as per AWS D.1.1 section 3 and 4 and 7T04-CS-00-TS-009 section
2.4.

7.3

Welders and welding operators' performance shall be verified properly as per AWS
D1.1 section 4.

7.4

Welded products shall be visually checked for such features as dimensional accuracy
of the weldment and presence of surface porosity, slag inclusion, cracks, craters,
undercut, overlap and etc. as per AWS D1.1 5.24 of Table 6.1 and 7T04-CS-00-TS009 section 1.3.2.

7.5

Inspector shall ensure :

-

All welding is performed in conformance with AWS D1.1 or as agreed in

contract. Welding is carried out by qualified welders and welding operators as
per code and is allowed to weld only in the positions and processes they are
qualified.

Welders should have valid I.D cards and their certificates with QC file.

Approved welding procedures are followed and if not inform the QC

supervisor.

The welding consumables are approved ones and are in good storage
conditions.

Approved welding procedures are followed and if not inform the scale.

Tack welders are also qualified as per code.

All welded splicing are approved by production planning department.

Latest revision of shop drawings are issued for fabrication.

Welder# shall be hard stamped at 100mm from weld centerline for scale.

WPS/PQR will be displayed on the welding area.

Welder list also be displayed on the welding area.

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7.6

8.0

9.0

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Inspection to be done
-

All welds should be inspected visually.

Refer all requirements to the latest edition of AWS D1.1 or other codes and
standards specified by Customer.

Use proper inspection tools e.g., welding gage, inspection mirror, torch light
etc.

Check for proper fillet weld sizes, joint preparation and appearance.

Any non-conformance should be verbally informed to the Bay Foreman for

immediate rectification to the satisfaction of the Welding Inspector before the
shift ends. Non-Conformities which were not rectified before shift ends shall
be reported through IRR form. All acceptable items shall be reported through
form.

Non-destructive Testing (ALL NDE Procedure to be referred)

8.1

The acceptability of welds inspected by ultrasonic examination shall be as per AWS

D1.1 section 6.8 and 10 and 7T04-CS-00-TS-009 section 1.3.2 for high rise structure
(e.g. Compressor Shelter) and structures supporting heavy equipment. Ultrasonic
examination shall be performed and / or tested by magnetic particle inspection as per
AWS D1.1, ASTM E709

8.2

Ultrasonic examination shall be performed by only qualified employed.

Dimensional & Visual Inspection

9.1

All structural members shall be subject to 100% visual & dimensional inspection.

9.2

Dimensions & Visual Inspection shall be checked in accordance with the shop detail
drawing, specification requirement and drawings.

9.3

Dimensional & Visual inspection shall be performed before/after Galvanizing Painting

work.

9.4

Dimensional inspection records shall show specified dimensions, actual dimensions

errors and specified tolerance limits to facilitate review.

10.0 Painting & Galvanizing Inspection as per 7T04-PR-00-TS-001

10.1 For paint coatings, surface preparation shall be inspected to ensure the requirements
of section 4, 7T04-PR-00-TS-001 is complied with and the result recorded.
10.2 For galvanized coatings, testing and inspection shall be conducted in accordance with
7T04-PR-00-TS-001 section 8. The test and inspection report shall be reviewed, and
the results shall be verified as complying with the requirement.
11.0 Final Inspection

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The checks to be made at the Final Inspection shall include, but are not limited to the
following :
-

Straightness and twist

Item is hard-stamped correctly

Actual measurement shall be marked against the Approved DWG is attached to the
Dimension Report - Signed by VENDOR QC & CONTRACTOR RI.

Weld sizes are correct

N.D.T has been carried out

Appropriate dressing has been carried out

Members identification as per the Member identification Procedure.

CHECK Color coding as per the project requirement /as per approved drawing.

12.0 Packing and Shipping Inspection as per 7T04-PT-00-PC-002

All the completed structure and parts shall be checked against packing list to ensure the
conformance of the package number, quantity and identification markings as per
specification requirement. Bolt & Nut shall be done box packing with proper rust prevention
treatment.
13.0 Documentation

Inspection reports for submittal shall be included as follow.

-

These inspection records shall be compiled as one book (VDB).

Mill Certificates (Shapes , Plate, Grating, Bolt & Nuts with Washer, Weld-rod)

Summary for Dimension and Visual Inspection.

NDE Report for the nominated point with NDE control sheet.

Certificate for Inspection Release by form of CONTRACTOR

WPS and PQR

Dimension inspection report should be done 100% using drawing to show the
difference from drawing (For Main Member such as Column, Girder and etc.)

Certificate of Origin (COO)

Inspection Completion Notice / Inspection Release Certificate

Calibration Record for Equipment, Inspection tool. Etc

AQIS Requirement

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14.0 Attachments

14.1 Inspection and Test Flow Chart

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